3200-Plus 3200 Fuel Smart HydroStat Plus Instruction Manual
- June 13, 2024
- HYDROSTAT
Table of Contents
3200-Plus 3200 Fuel Smart HydroStat Plus
Product Information
The MODEL 3200-Plus Temp Limit / LWCO Control with Thermal
TargetingTM is designed for water boilers. It has a three-function
design, including temperature limit control, low water cut-off, and
boiler reset control. The control adjusts the boiler temperature
based on heating demand. It operates on 120 VAC input and has a 24
VAC burner circuit. The product is patented under patent numbers
8,931,708; 8,844,834; 7,891,572, with others pending. It also
supports the use of the Hydrolevel OS-100 Outdoor Sensor Kit (sold
separately) for outdoor reset and warm weather shut-down
functionality.
Installation of this control should be done by qualified
personnel in accordance with local codes and ordinances. It is
important to read the instructions completely before proceeding.
Safety precautions are advised, including disconnecting the power
supply before installing or servicing the control to prevent
electrical shock or equipment damage. Additionally, the boiler
should be thoroughly cooled before installing or servicing the
control to prevent serious burns.
In climates subject to sustained below-freezing temperatures,
freeze protection monitoring or other precautions are recommended
for unattended dwellings to prevent frozen pipes and water
damage.
Product Usage Instructions
-
1. IMMERSION WELLS
The Fuel Smart HydroStat control can be installed on a
Hydrolevel Electro-WellTM or an existing immersion well in the
boiler. When installed on an Electro-WellTM, the Low Water Cut-Off
function is automatically activated. Heat transfer grease should
not be used. Ensure there is 1/2 inch clearance between the copper
well tube and any surface within the boiler.
-
1. MOUNTING THE CONTROL
Make sure the immersion well or Electro-WellTM is installed in
the boiler manufacturer’s designated temperature limit control
tapping. If using an Electro-WellTM, pipe sealing compound should
be used instead of Teflon tape.
-
1. Two mounting positions are available on the back of thecontrol. Select the best position for the location of the control
and remove the knockout. -
Place the control on the well and tighten the well clamp screw
while holding the box against the well nut. -
Insert the sensor all the way into the well through the chosen
knockout.
Note: The Fuel Smart HydroStat control can be mounted
horizontally in case of space restrictions, but vertical mounting
is recommended for proper orientation of the LED display.
MODEL 3200-Plus Temp Limit / LWCO Control with Thermal TargetingTM for Water
Boilers
120 VAC Input / 24 VAC Burner Circuit PATENT NO. 8,931,708; 8,844,834;
7,891,572; others pending
Three Function Design
INSTALLATION INSTRUCTIONS and OPERATING MANUAL
· Saves Fuel Features Thermal TargetingTM technology and Thermal Pre-Purge
capability
· Outdoor Reset Ready Provides Outdoor Reset and Warm Weather Shut-Down
capability with the addition of Hydrolevel OS-100 Outdoor Sensor Kit (sold
separately)
· Universal Design Replaces common cold-start and triple-action Aquastats
· Operating Indicators LEDs, Dynamic Display and Test Button provide
continual and on-demand status checks
· Prioritizes Domestic Hot Water Gives priority to low limit setting or to
calls from indirect water heater
· Reduces Condensation Holds circulator off until boiler reaches 125°F
· Aquastat is a registered trademark of Honeywell International, Inc.
Temperature Limit Control Designed for cold start and tankless coil boilers.
Low Water Cut-Off Provides protection against potentially dangerous low water conditions when installed with the Hydrolevel Electro-WellTM (see page 2 for details).
Boiler Reset Control
· Thermal Targeting On-board micro-
processor adjusts boiler temperature based on heating demand.
· Outdoor Reset Ready Compatible with
Hydrolevel OS-100 Outdoor Sensor Kit (sold separately) for outdoor reset and
warm weather shut-down functionality.
WARNING Electrical shock hazard. To prevent electrical shock, death or equipment damage, disconnect power supply before installing orservicing control. Only qualified personnel may install or service this control in accordance with local codes and ordinances. Read instructions completely before proceeding.
CAUTION To prevent serious burns, boiler should be thoroughly cooled before installing or servicing control.
WARNING Frozen pipes/water damage. Central heating systems are prone to shut down as a result of power or fuel outages, safety related fault conditions or equipment failure. Installation of freeze protection monitoring or other precautions is recommended for unattended dwellings in climates subject to sustained below-freezing temperatures.
126 Bailey Road, North Haven, CT 06473 · Phone
203-776-0473 · FAX
203-764-1711 · www.hydrolevel.com
1
IMMERSION WELLS
Fuel Smart HydroStat can be installed on a Hydrolevel Electro-WellTM or on an
existing immersion well already in the boiler. IMPORTANT: The control will
only provide low water cut-off protection when installed on an Electro-WellTM.
Installing HydroStat with Hydrolevel Electro-WellTM
The Electro-Well can be identified by the black electrical insulator or, if
installed, by the groove cut into the hexnut.
When installed on an Electro-WellTM (sold separately), the Low Water Cut-Off
function is automatically activated. Heat transfer grease should not be used.
NOTE: For proper operation, there must be 1/2″ clearance between the copper
well tube and any surface within the boiler.
See Electro-WellTM models on page 15.
Installing HydroStat with Standard Immersion Well
NOTE: When installed on a standard immersion well, the “LWCO Active” LED will
not illuminate.
2
MOUNTING THE CONTROL
IMPORTANT Make sure that the immersion well or Electro-WellTM is installed in
the boiler manufacturer’s designated temperature limit control tapping.
NOTE: If installing an Electro-Well, pipe sealing compound should be used.
Teflon tape is not recommended.
STEP 1 Two mounting positions
are available on the back of the control (Fig. 1). Select which of the two
positions (2 knockouts) is best for the location of the control. Remove the
knockout.
STEP 2 Place control on the well.
While holding box against well nut, tighten well clamp screw. (Fig. 2)
STEP 3 Insert sensor ALL THE
WAY into well through the knockout (A or B) you have chosen. (Fig. 3)
BACK OF FUEL SMART HYDROSTAT BOX
FIG. 1
FIG. 2
FIG. 3
IMPORTANT Sensor must be inserted all the way into the well for proper operation.
CORRECT
INCORRECT
NOTE: In the case of space restrictions, the Fuel Smart HydroStat control may be mounted in a horizontal orientation without any loss of function. Hydrolevel recommends vertical mounting, when possible, for proper orientation of LED display.
REMOTE MOUNTING KITS
Remote Mounting Kits are available separately for mounting the Fuel Smart
HydroStat control box in a remote location. Each kit includes mounting
hardware and a remote sensor.
Part No.
48-101 48-102 48-103 48-104 48-121
Description
HydroStat Remote Mount Kit with 24″ sensor HydroStat Remote Mount Kit with 48″
sensor HydroStat Remote Mount Kit with 10′ sensor HydroStat Remote Mount Kit
with 20′ sensor HydroStat Pipe Mounting Kit with 48″ sensor
GROUNDING: When using Remote Mounting Kits, ensure your incoming voltage ground wire is connected to the HydroStat’s ground screw (see “GROUNDING” section on next page)
3
WIRING
WARNING Electrical shock hazard. To prevent electrical shock, death or
equipment damage, disconnect power supply before installing or servicing this
control.
STEP 1
Connect 120 VAC Hot to terminal L1. Connect 120 VAC Common to terminal L2.
Disconnect means and overload protection as required (provided by others).
STEP 2
Connect the burner circuit to B1-B2. (B2 is common.)
STEP 3
Connect the circulator to C1-C2. (C2 is common.)
STEP 4
Connect the thermostat to T/TV.
STEP 5
If the boiler is equipped with a plug-in style vent damper, unplug the factory
installed jumper from the receptacle on the circuit board and replace it with
the vent damper plug.
WARNING: Failure to remove jumper can result in personal injury or death.
GROUNDING
In order to ensure proper operation, It is important to confirm that the
ground wire attached to the HydroStat’s ground screw, which generally comes
from the boiler’s J-box, is actually tied to the house’s ground.
If the ground attached to the HydroStat’s ground screw is insufficient for
proper control operation, use one of the options below to prevent noise
interference.
Option1: Install a ground wire from the ground screw in the HydroStat 3200 to
a non-painted area on the appliance (ex. the screws that hold the burner cover
panel in place).
Option 2: Remove the white wire from the B2 terminal on the HydroStat 3200 and
reinstall it on a screw that holds the burner cover panel.
Option 3: Install a wire from the Hydrostat ground plate screw to the
ElectroWell (immersion well) and secure it with a clamp.
4
WIRING continued
WARNING Electrical shock hazard. To prevent electrical shock, death or
equipment damage, disconnect power supply before installing or servicing this
control.
STEP 6 For Systems with Indirect Water Heaters
When installing with an indirect water heater, the signal from the indirect
must be separated from the heating zone signals and wired to I1 and I2 as
shown above. Calls to I1 and I2 will bypass the Thermal Targeting or Outdoor
Reset feature and allow the boiler to fire to the high limit setting to heat
the indirect tank. NOTE: If you choose not to separate the indirect signal
from the heating zones, the Economy Feature should be turned OFF to insure
that the boiler supplies adequate temperature to heat the indirect tank (see
page 6).
ZONE VALVE WIRING
IMPORTANT: Use a separate transformer to power zone valves. Connecting zone
valves to Z-TV may overload the HydroStat and cause a lock-out condition (see
Troubleshooting on page 12 for more information). The total load, including
the burner circuit, vent damper, and Z-TV connections must not exceed 1.2 amps
(30 VA). Connect zone valve end-switch to T/TV as shown below.
5
SETTING THE CONTROL
Dynamic Display
Water Temperature and Real Time
Verification of Setting Adjustments.
High Temperature
Limit Setting
(100°-220°F)
Factory 180°F
“Circ Delay” LED (see page 11)
Low Temperature
Limit Setting
(OFF or 110°-220°F)
Factory OFF
Damper Power LED
Vent Damper Receptacle
Diagnostic LEDs Test/Settings Button
Jumper
Economy Dial
(OFF or LO, 1, 2, 3, 4, 5, HI) Factory 1
Indicator Light (announces heat call)
Spade Connectors for OS-100 Outdoor Sensor Kit
Differentials are automatic and will vary based on control settings and boiler
temperature.
NOTE: Settings can be checked using the TEST/SETTINGS Button. See page 11 for
details.
Setting the High Limit
The high limit is factory set at 190°F. To adjust, turn the HI
TEMP Dial until the desired setting is displayed. (Setting
range: 100°-220°F)
Setting the Low Limit
The low limit will maintain temperature in the boiler and should only be used
for boilers with tankless coils. The low limit is factory set to OFF. Prior to
adjusting, remove the
jumper (not equipped on all units) . Then turn the LOW TEMP Dial clockwise
until the desired temperature is
displayed.
For proper operation, the low temperature limit setting should be at least 10°
below the high limit setting.
IMPORTANT: · If the display reads OFF when the Low Limit dial is adjusted,
the dial functionality has been turned off in the Program Options. See page 9
for instructions on reactivating the dial.
· If Low Limit temperature cannot be set above 140°F, remove
jumper .
Setting the Economy Feature
The Economy Feature is factory set for a 1 zone heating sys-
tem. To adjust, turn the ECONOMY Dial until the number
displayed equals the number of heating zones. Do not include indirect water
heaters in the number of heating zones. The Economy Feature conserves fuel by
reducing boiler temperature (see “How Thermal Targeting Works” on page 7). If
the heating system is unable to supply needed heat to the house, the ECONOMY
Dial should be turned to a lower setting (example: In a three zone house, turn
the dial to 2 or 1). Conversely, if the boiler provides adequate heat, added
fuel savings can be achieved by selecting a higher setting (example: 4 or 5).
If the heating and indirect water heater signals were not separated when
wiring the control, the Economy Feature should be turned OFF to ensure the
boiler supplies adequate temperature to heat the indirect tank.
SETTING
Disables economy function. Will allow boiler to fire until hilimit temp is
reached and re-fire with a 10° subtractive differential.
Provides lowest level of fuel savings. Use this setting only if the house does
not stay warm at higher settings.
Recommended setting for single zone systems
Recommended setting for Two zone systems
Recommended setting for Three zone systems
Recommended setting for Four zone systems
Recommended setting for Five zone systems
Provides highest level of fuel savings
6
SYSTEM START-UP
At initial start up, with the Economy Feature active, the control establishes
a 145°F target temperature. To test the high limit shut-off function, the
Economy Dial must be turned to OFF. Once tested, restore the Economy setting.
If the heating demand is high, the target will increase over time to satisfy
the heat load. NOTE: · Smart DHW Priority: During a call from an indirect
water heater, the control will de-energize the circulator contacts (C1/C2) to
heat only the indirect tank ensuring an adequate supply of domestic hot water.
The control will re-energize the circulator when the indirect tank is
satisfied or if the boiler temperature reaches 170°F. If the indirect call
continues for 45 minutes, the control will override the priority function
energizing the circulator to provide space heating.
HOW THERMAL TARGETING WORKS
Thermal Targeting technology analyzes thermostat activity and continually
evaluates how much heat the house requires. When it is very cold outside, the
heat demand is high and the Fuel Smart HydroStat will raise the boiler’s
Target temperature to provide needed heat to the home. When the outside
temperature is milder, the heat demand is lower. During these periods, the
Fuel Smart HydroStat will lower the boiler’s Target temperature saving fuel
while continuing to provide comfort to the house.
RECORD YOUR SETTINGS
DATE INSTALLED
____ LOW LIMIT SETTING ____
HIGH LIMIT SETTING ____ ECONOMY SETTING ____
OPTIONAL FEATURES
NOTE: The Program Mode Pro is accessed by turning the
LOTEMP dial to a position just above OFF.
Thermal Pre-Purge
Thermal Pre-Purge is designed to maximize boiler efficiency. When activated,
the control will supply latent heat that may remain in the boiler from a
previous run cycle to the next heating zone that calls. The control monitors
how quickly the boiler temperature is declining and activates the burner only
when it determines that the latent heat is insufficient to satisfy the call.
Pur During the purge cycle, the display will indicate . This feature works
with single-zone and multi-zone heating systems uti-
lizing circulators or zone valves. No change in wiring is needed.
To activate Thermal Pre-Purge
1. Turn the LO TEMP dial to access the Program Mode indicated in the
display as Pro 2. Turn the HITEMP dial to select feature 1 3. Push the
Test/Settings Button to turn Thermal Pre-Purge on or OFF
4. Reset LO TEMP and HITEMP settings to desired temperatures (see page 6)
MORE OPTIONAL FEATURES ON NEXT PAGE
7
OPTIONAL FEATURES continued
Degrees Fahrenheit or Celsius c The control has the ability to operate in
degrees Fahrenheit or Celsius. When operating in Celsius, a will appear in the
dis-
play next to the temperature whenever the temperature is below 100 degrees.
To change between degrees Fahrenheit and degrees Celsius
1. Turn the LO TEMP dial to access the Program Mode indicated in the
display as Pro 2. Turn the HITEMP dial to select feature 2 3. Push the
Test/Settings Button to c for Celsius or F for Fahrenheit
4. Reset LO TEMP and HITEMP settings to desired temperatures (see page 6)
Manual Reset Low Water Cut-Off
The low water cut-off operation on the HydroStat can be set to operate in
automatic (default) or manual reset mode. When in manual reset mode, the
control will shut-down the burner immediately when a low water condition is
detected. If the low water condition is sustained for 30 seconds, the low
water light will blink, indicating that the control has locked out the burner.
The control can only be reset by pushing the Test Settings button on the top
of the control. The manual reset feature meets CSD-1 code requirements.
IMPORTANT: The system must be checked by a qualified heating professional
prior to resuming operation. WARNING: DO NOT ADD WATER UNTIL THE BOILER HAS
FULLY COOLED.
To activate Manual Reset LWCO mode
1. Turn the LO TEMP dial to access the Program Mode indicated in the
display as Pro 2. Turn the HITEMP dial to select feature 3 3. Push the
Test/Settings Button to A for Automatic Reset Mode or b for Manual Reset Mode
4. Reset LO TEMP and HITEMP settings to desired temperatures (see page 6) To
Test the Manual Reset Feature: Press and hold the Test/Settings button located
on the top of the control for 30 seconds to simulate a low water condition.
After 30 seconds, the Low Water light will blink indicating that the control
is locked out. To reset the lock-out condition, press the Test/Settings button
momentarily.
Circulator Activation Options
When in the default mode, the HydroStat activates the circulator (C1/C2
contacts) on calls to T/TV. The control can be programmed to activate the
circulator on calls to I1/I2 in place of, or in addition to, calls to T/TV.
To change how the Circulator is activated
1. Turn the LO TEMP dial to access the Program Mode indicated in the
display as Pro 2. Turn the HITEMP dial to select feature 4
3. Push the Test/Settings Button to select between the following options:
A – Circulator on T/TV call only b – Circulator on I1/I2 call only C –
Circulator on both T/TV & I1/I2 calls
4. Reset LO TEMP and HITEMP settings to desired temperatures (see page 6)
MORE OPTIONAL FEATURES ON NEXT PAGE
8
OPTIONAL FEATURES continued
Circulator Hold Off (Enhanced Condensing Protection)
To reduce the potential for condensing, on a call for heat the control will
allow the boiler to heat to 125°F prior to energizing the circulator. Once
energized, the circulator will remain on for the duration of the heating call
unless the boiler temperature drops below 115°F. If this occurs, the
circulator will re-energize when the boiler returns to 125°F. The blue LED
above the vent damper plug will light to indicate the control is in
“circulator hold off” mode. Circulator Hold Off will expire after 15 minutes.
To activate Circulator Hold Off
1. Turn the LO TEMP dial to access the Program Mode indicated in the
display as Pro 2. Turn the HITEMP dial to select feature 5 3. Push the
Test/Settings Button to turn Circulator Hold Off on or OFF
4. Reset LO TEMP and HITEMP settings to desired temperatures (see page 6)
Low Limit Setting
The low limit temperature setting is designed for boilers equipped with
tankless coils. When set, the control will operate the
burner to maintain the set point temperature in the boiler at all times. This
setting should be turned to OFF (fully counterclock-
wise) when the boiler does not have a tankless coil. This optional program
feature provides for disabling the low limit dial so that it cannot be turned
on inadvertently. Use the instructions below to deactivate or reactivate the
low limit dial functionality.
To disable the Low Limit Setting
1. Turn the LO TEMP dial to access the Program Mode indicated in the
display as Pro 2. Turn the HITEMP dial to select feature 7 3. Push the
Test/Settings Button to turn Low Limit Function to on or OFF
4. Reset LO TEMP and HITEMP settings to desired temperatures (see page 6)
Setting the Well Type (Electro-Well vs. Standard Immersion Well)
When used to replace older temperature-only controls, the HydroStat can be
installed on the existing well. (The Hydrolevel Electro-Well is required to
activate low water cut-off operation see page 2 for details). Older wells
may contain hardened heat transfer grease or other contaminants that could
interfere with metal-to-metal continuity between the sensor head and the
inside of the well. Insufficient contact could lead to false low water
conditions and burner shut downs. Setting the well type to Standard Well
prevents the possibility of this occurring.
To change the well type
1. Turn the LO TEMP dial to access the Program Mode indicated in the
display as Pro 2. Turn the HI TEMP dial to select feature 8 3. Push the
Test/Settings Button to select A for Electro-Well or b for Standard Well.
NOTE: To ensure that the low water cut-off is always active when the control
is installed on an Electro-Well, setting b will ONLY be available
when installed on a standard well. The Hydrostat sensor checks to determine if
a standard well is used by looking for low resistance to ground,
a condition that can only exist with a standard well. If you are installing on
a standard well and either Low Water LED’s are on, setting b will not
be available. Check to see if the inside of the well tube is badly oxidized or
contaminated with heat transfer grease. It may be necessary to
clean the well to allow for setting b to be selected (See Troubleshooting
Guide on page 12 for more information).
RESTORING FACTORY DEFAULT SETTINGS ON NEXT PAGE
9
OPTIONAL FEATURES continued
High Limit Differential
When the Economy feature is on, the control’s Thermal Targeting feature
actively sets varying differentials based on system conditions. This option
allows for selecting a 10, 20 or 30 degree fixed differential when the Economy
feature is turned OFF. These optional differential settings are subtractive
from the HIGH LIMIT setting. Note: If the Economy feature is on, this setting
will be overridden by the control’s Thermal Targeting function.
To change the high limit differential
1. Turn the LO TEMP dial to access the Program Mode indicated in the display
as Pro 2. Turn the HI TEMP dial to select feature 9 3. Push the Test/Settings
Button to select a high limit differential of 10, 20, or 30
4. Reset LO TEMP and HI TEMP settings to desired temperatures (see page 7)
Restore Factory Default Settings
To restore all features to the factory default settings (see following chart
for default settings)
1. Turn the LO TEMP dial to access the Program Mode indicated in the
display as Pro 2. Turn the HITEMP dial to select feature dEf 3. Push the
Test/Settings Button to Y to reset all features to the default settings.
4. Reset LO TEMP and HITEMP settings to desired temperatures (see page 6)
Dial Setting
Feature
Options
Description
Default Setting
1 Thermal Pre-Purge OFF Purge Inactive on Purge Active
OFF
2 Fahrenheit or Celsius F c
Degrees Fahrenheit Degrees Celsius
F
3
LWCO Manual or
Automatic Reset
A
Automatic Reset
b
Manual Reset
A
4
Circulator Options
A
Circulator operation on TT call only
b
Circulator operation on I1/I2 call only
c
Circulator operation on call from either
A
5 Circulator Hold Off on Circulator Hold Off Active OFF Circulator Hold Off Inactive
on
6
Not available on this control
7
Low Limit Dial
on Low Limit Dial Functional
OFF Low Limit Dial Disabled
on
8
Well Type
A
Hydrolevel Electro-Well
b
Standard Immersion Well
A
9
High Limit Differential
10
10° Differential
20 20° Differential
10
30 30° Differential
dEF Restore Factory
Defaults
Y
Restore Defaults
n
Do Not Restore Defaults
n
NOTE: If the HydroStat is factory-equipped on a boiler, some options may be set differently from the default settings. Not all features are available on older HydroStat models.
SEE PAGE 6 FOR ADDITIONAL SETTINGS
10
LED LEGEND and TEST/SETTINGS BUTTON
TEMP ACTIVE Indicates that the Fuel Smart
HydroStat control is powered and that the temperature function is active.
TEMP HI TEMP Illuminates when the boiler water
temperature reaches the high limit setting. It will remain lit until the water
temperature falls 10°. The Fuel Smart HydroStat prevents burner operation
while this LED is on. See Differential explanation on page 6.
LWCO ACTIVE Indicates that the low water cut-off
(LWCO) function of the Fuel Smart HydroStat is active. When the control is
installed with a Hydrolevel Electro-Well, this LED will be on at all times
when the control is powered. IMPORTANT: If the control is installed with a
well other than the Electro-Well, this LED will not illuminate indicating that
the control is not providing low water cut-off functionality.
LWCO LOW WATER Indicates that the boiler is in a
low water condition. The HydroStat control will prevent burner operation
during this condition. If the LOWWATER light is blinking, the control has been
programmed to provide lock-out protection in the event a low water condition
is detected (see Manual Reset Low Water Cut-Off on page 8). Pressing the
TEST/SETTINGS button will reset the control.
IMPORTANT: The system must be checked by a qualified heating professional
prior to resuming operation.
WARNING: ALLOW THE BOILER TO FULLY COOL BEFORE ADDING WATER.
ECONOMY ACTIVE Indicates that the Thermal
Targeting function is active and the Fuel Smart HydroStat will reduce boiler
temperature to conserve fuel. The Economy feature is activated using the
ECONOMY dial. (See “How Thermal Targeting Works” on page 7 for more
information).
ECONOMY TARGET When the Economy feature is
active, the Fuel Smart HydroStat continually sets target temperatures below
the high limit setting to maximize fuel efficiency. When the boiler water
reaches the target temperature, the LED illuminates and the burner will shut
down. The boiler water will continue to circulate and heat the house as long
as the thermostat call continues. The LED will stay lit until the boiler
temperature drops below the differential set point at which point the boiler
will be allowed to fire again. See Differential explanation on page 6. NOTE:
This LED illuminates regularly during normal boiler operation.
TEST/SETTINGS Button
To Test Low Water Cut-Off: Press and hold the Test/ Settings button for 5
seconds. The display will read LCO.
LWCO TEST 00
The red Low Water light should illuminate and the burner circuit (B1 and B2)
should de-energize. NOTE: The control must be installed with a Hydrolevel
Electro-Well for low water cut-off functionality (see page 2 for more
details). To View Current Settings: Press and release the Test/Settings Button
in short intervals to sequentially display the following settings:
HIGH LIMIT SETTING 00
LOW LIMIT SETTING 00
ECONOMY SETTING 000
CURRENT TARGET TEMPERATURE The display will return to boiler temperature
(default) if
Test/Settings Button in not pressed for 5 seconds.
DAMPER POWER LED
Indicates the control is energizing the vent damper. For applications where
the vent damper is not plugged into the HydroStat, the LED indicates that the
burner circuit (B1 – B2) is powered. If this LED is on and the burner is not
firing: 1. Make sure the plug connection (or jumper, on boilers
where vent damper plug is not used) is secure. 2. Make sure that the plug
connection at the vent damper
end is secure and oriented correctly. 3. Make sure damper motor turns 4.
Verify the damper end switch has closed
Carbon Monoxide Hazard: If the burner DANGER fires when the vent damper is not
fully opened or there is any other blockage in the flue, dangerous flue
products, such as carbon monoxide, will escape into the living space causing
severe personal injury or death. The flue as well as the vent damper must be
checked for proper operation before allowing the system to operate.
Circ Delay LED
The blue “circ delay” LED lights to indicate the heating circulator (terminal
C1) is being held off. See Circulator Hold Off (option 5) top of page 9 for
more information.
11
TROUBLESHOOTING
Burner Will Not Fire
See Flow Chart 1, page 13
Burner Will Not Shut Down Temperature Display Exceeds
High Limit Setting
No or Insufficient Domestic Hot Water
Low Water Light (Red LED) is On
or Blinking
Boiler Will Not Maintain Low Limit Temperature
House Will Not Get or Stay Warm
See Flow Chart 2, page 14
Under normal operation, boiler temperature will continue to rise after the
control shuts off the burner. This condition, known as “thermal stacking”,
results from hot boiler surfaces continuing to release heat into the boiler
water.
For boilers equipped with a tankless coil, make sure the low limit setting on
the HydroStat is set properly. NOTE: If the low limit setting is dialed fully
counter clockwise, it will shut off the low temperature maintenance feature
and will function as a cold start control. If installed with an indirect water
heater, verify that the end switch in the relay box controlling the indirect
water heater is connected to the I1-I2 terminals. This will ensure that the
domestic water calls are prioritized. (see “Heating and Indirect Water Heater”
on page 6).
WARNING: A low water condition is a serious and potentially dangerous
condition. Do not attempt to add water to a hot boiler. Allow the boiler to
fully cool before adding water.
When Installed on an Electro-WellTM
When the LOW WATER light is on, this indicates that the control is not
detecting water in the boiler. When the LOW WATER light is blinking, this
indicates that the control has been programmed to provide low water lock-out
protection and is currently locked out (see Manual Reset Low Water Cut-Off on
page 8). Pressing the TEST/SETTINGS button after the low water condition is
resolved will reset the lock-out condition.
1. If the light is on and the heating system is filled with water, pull the
sensor out of the well and inspect it. Make sure that the metal clip is
protruding enough to come in contact with the inside of the well tube. Check
that the well does not have excessive build-up of heat transfer grease that
may interfere with the clip contacting the well.
2. Remove well and examine for excessive residue build-up. Clean and re-
install.
When Installed on a Standard Immersion Well
If either LWCO LED lights are illuminated and the control is installed on a
standard immersion well, this is a false reading caused by a loss of
continuity between the sensor and the inside of the well tube. Follow steps 1
and 2 (above) to ensure that the metal sensor head is making good contact with
the inside surface of the copper well.
Check for overlapping high temperature setting. If the high limit setting is
set below the low limit setting, the control will default to the high limit
setting and the corresponding high limit differential setting.
1. Check for air-bound radiators. 2. Check thermostat settings including heat
anticipator settings (common on non-digital
thermostats). 3. Check the Economy setting. The Economy feature, much like
outdoor reset controls,
lowers average boiler temperature and can slow or, in some cases, prevent the
house from coming up to temperature. Move to a lower setting (see “Setting the
Economy Feature” on page 6).
Circulator Contacts C1 and C2 Not Energized
on Call for Heat
If the Circulator Hold Off is active (see page 9), check to see that boiler water is at or above 125°F. On a call for heat, the control will not permit the circulator to operate if the boiler water temperature is below 125°F.
All LED Lights and Temp Display are Blinking
If the LED lights and the temp display are blinking alternately, this indicates the control has sensed a boiler temperature of 250°F. When this occurs, the control pulses the burner relay and then shuts down and locks out the burner until the temperature falls below 210°F. The system should be analyzed to determine the cause of the overheating condition. Check that the sensor is inserted all the way into the well so it can accurately sense the temperature of the boiler water. Check system wiring and operation as well as the control’s high limit setting. If the cause of the overheating condition cannot be determined, the control should be replaced.
Snr in display
Check sensor connection or replace sensor.
Temperature Display Flickering Confirm proper grounding of control (see page 4) Control Continually Resets Confirm proper grounding of control (see page 4)
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Troubleshooting Flow Chart 1 Burner Will Not Fire
Does the Display Read YES
?
The Control is Purging Latent Heat from the
Boiler.
The Thermal Pre-Purge feature holds off the burner until the control determines if the latent heat in the boiler can satisfy the heat call.
NO
Is the
Green LED (TEMP ACTIVE) NO
On?
The Control is Not Powered.
The Temp Active LED will be on at all times when the control is powered.
Check for 120 VAC on terminals L1 and L2.
YES
Is the Red LED (LOW WATER) YES
On?
NO
The Control is Sensing
Low Water.
CAUTION ALWAYS ALLOW A BOILER TO COOL BEFORE ADDING WATER The burner will
not fire until the low water condition is satisfied. Check that the system is
filled with water. Check that the sensor is inserted fully into the well and
contact
between its spring clip and the copper well tube is made. Check that the
control is tightly clamped to the well.
Also see page 12 for additional troubleshooting information.
Is the
Yellow LED
(HI TEMP)
YES
On?
NO
Is the
Yellow LED
(TARGET)
YES
On?
NO
Is the
Thermostat
(T/TV) Calling
NO
for Heat?
YES
Is There
24 VAC
Between B1
YES
and B2?
NO
Replace Control
The Control is Sensing High Temperature.
The burner will not fire until the boiler water has dropped to the high limit
differential set-point (10° below high limit setting).
Check that the high temperature setting is correct.
The Boiler has Reached the
Target Temperature.
When the ECONOMY function is active, the control monitors heating demand and establishes Target boiler temperatures below the high limit setting to conserve fuel (see “How Thermal Targeting Works” on page 7). The burner will not fire until the boiler temperature drops to the automatically calculated Target Temp Differential.
Is the Indirect (I1-I2) Calling NO for Heat?
YES
Is the Low Limit Dial YES
Set to OFF?
NO
When the low temperature setting is set to OFF, the HydroStat will act as a
cold start control. The burner will not fire unless there is a call from the
thermostat (T/TV) or an external zone (I1/I2).
Set thermostat to call for heat. Burner should fire.
If the boiler has a tankless coil, set the Low Temperature Limit to maintain
temperature.
The Control is Operating
Properly.
HydroStat is supplying 24 VAC to the burner circuit. Recheck wiring and operation of burner and other limit controls.
If both the red and yellow LEDs are off and there is a call to fire the
burner, there will be 24 VAC on terminals B1 and B2.
If 24 VAC is not present, the control should be replaced.
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Troubleshooting Flow Chart 2 Burner Will Not Shut Down
Is the Red LED (LOW WATER) YES
On?
The Control is Sensing
Low Water.
NO
Is either Yellow LED
On?
YES
The Control has Reached Target or High Limit Temperature.
NO
Is the Thermostat (T/TV) Calling YES for Heat?
NO
The Control is Operating Normally.
Is the Indirect (I1/I2) Calling YES for Heat?
NO
The Control is Operating Normally.
WARNING!
TURN OFF POWER TO BURNER IMMEDIATELY! CAUTION ALWAYS ALLOW A BOILER TO FULLY
COOL BEFORE ADDING WATER. Recheck wiring. Make sure that burner is wired to
B1. Burner should never fire when red or yellow LED is lit.
The burner will continue to fire when there is a call from the thermostat or
external zone.
Is the Low Limit Dial NO
Set to OFF?
Check temperature display. When the Low Limit is set, the HydroStat will fire the burner until the temperature reaches the Low Limit Setting.
YES
Is there 24 VAC between NO
B1 and B2?
Recheck Wiring.
When there is no call to fire the burner, the voltage should be 0 volts
between B1 and B2.
Make sure the burner is wired to B1.
YES
Replace Control.
If there is no call for heat (from T/TV, I1/I2 or Low Limit), there should be
0 VAC between B1-B2.
If there is voltage between B1-B2, the control should be replaced.
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MAINTENANCE
Remove the Electro-Well from the heating system every five years and clean any
scale or sediment deposits from all parts that are exposed to the boiler
water. After cleaning, reinstall the well using pipe sealing compound. Teflon
tape is not recommended.
ELECTRO-WELLS
Fuel Smart HydroStat installed with Electro-WellTM
When installed with the Hydrolevel Electro-Well, Fuel Smart HydroStat will
provide both temperature and low water cut-off functionality. If the control
was supplied by the boiler manufacturer, it was installed with an Electro-
Well. The Electro-Well is available separately for field installations.
1/2″ CLEARANCE 1/2″ CLEARANCE
1/2″ CLEARANCE
IMPORTANT: For proper operation of the low water cut-off function, there must be a minimum of ½” clearance between the copper well tube and any surface within the boiler.
Electro-WellTM Models
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OUTDOOR SENSOR KITS
Hydrolevel’s optional Outdoor Sensor Kits automatically activate outdoor reset
functionality and warm weather shutdown capability when plugged into the Fuel
Smart HydroStat control. These kits are available separately at Hydrolevel
distributors.
Part No. Description
48-140 Model OS-100 Outdoor Sensor Kit 48-145 Model OS-200 Wireless Outdoor
Sensor Kit
Model OS-100
DIMENSIONS
Model OS-200
SPECIFICATIONS FUEL SMART HYDROSTAT MODEL 3200-Plus
Input voltage Burner contacts Circulator contacts Operating range low limit Operating range high limit Operating range differentials Thermostat heat anticipator setting
120 VAC, 60 HZ 30 VA @ 24 VAC 5.8 FLA, 34.8 LRA@120 VAC Off or 110°F (43°C) – 200°F (93°C) 100°F (38°C) – 220°F (104°C) Automatic 0.2A
LIMITED MANUFACTURER’S WARRANTY
We warrant products manufactured by Hydrolevel Company to be free from defects in material and workmanship for a period of two years from the date of manufacture or one year from the date of installation, whichever occurs first. In the event of any claim under this warranty or otherwise with respect to our products which is made within such period, we will, at our option, repair or replace such products or refund the purchase price paid to us by you for such products. In no event shall Hydrolevel Company
be liable for any other loss or damage, whether direct, indirect, incidental or consequential. This warranty is your EXCLUSIVE remedy and shall be IN PLACE OF any other warranty or guarantee, express or implied, including, without limitation, any warranty of MERCHANTABILITY or fitness for a particular purpose. This warranty may not be assigned or transferred and any unauthorized transfer or assignment thereof shall be void and of no force or effect.
126 Bailey Road, North Haven, CT 06473 · Phone 203-776-0473 · FAX 203-764-1711 · www.hydrolevel.com
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3200P-021622