• Dual Function Design - HydroStat performs both high temperature limit and lowwater cut-off functions when installed with a Hydrolevel Electro-Well TM.

• Digital Display - Easy to read LED continually displays boiler temperature. Alsodisplays temperature limit and differential settings during adjustment.

• Easy to Set - Dials for setting temperature limits and differentials eliminatecomplicated programming.

• Advanced Micro-Controller Design - Utilizes dual thermistor technology forbetter accuracy, response and reliability.

Z_ WAR N[ NG Electrical shockhazard. To preventelectricalshock,deathor /_ CAUT[ C_ To Preventseriousequipmentdamage,disconnectpower supplybefore burns, boiler

installingor servicing control. Onlyqualified personnelmay install or servicethis control in should bethoroughly cooled before installingoraccordancewith local codesand ordinances.Readinstructionscompletelybefore proceeding, servicingcontrol.

Remove screw to access

HydroStat control.

HydrolevelElectro-WelP

PROVIDESTEMPERATURE AND

LOW WATER CUT=OFFFUNCTIONALITY

important: The PWXL Boiler is equipped with a HydroStat Etectro-We_i. Do not replace the Electro-Wall1 with a standardimmersion welt or the low water cut-off function will be disabled.

83 Water Street. New Haven, CT 06511. Phone (203) 776-0473. FAX (203) 773-1019. www. hydrolevel.com

IMPORTANT: This control requires the use of a Hydrolevel Company Electro-Well only. Use of

an immersion type well produced by another manufactuer will eliminate the low water cut offfunction.

The Electro-Well must remain in the tapping currently provided to insure safe operation.

_ep 1 The 6 screws must be used to install the control into the vestibule of the boiler.Make the transformer connection.

Attachment screws

4 required _!

/

Transformer

Connection

Step :2 Establish the electrical connections as follows on page 3.

WAR NING installingElectriCalorSh°ckhazard.servicingthisT° preventelectriCalcontrol, shock, death or equipment damage, disconnect power supply before ]

S T E P O Connect the 120VAC three position plug into the three position

mating connector.

S T E P O Connect the Circulator two position plug into its matingconnector.

A

S T E P Connect wire from the 24VAC Burner Circuit to B1 (quick connect).Connect wire from the 24VAC Burner Circuit common to B2 (fork).

O O OCOMM_T

Line I_ _

Voltage _ ('_ i_ Circulat°r

GND L2 L1 B2 BI C2 C1

S T E P Ob Connect wires from Low Voltage Thermostat to T and TV.

Terminals Tv (R), T(W) and Z(C) offer a 24V supply for operating theboiler and thermostat ONLY. DO NOT CONNECT ANY OTHER DEVICES

TO THESE TERMINALS!

S T E P O If the boiler is equipped with a plug-in style vent damper,un-plug the factory installed jumper from the receptacleon the circuit board and replace it with the vent damper

plug. NOTE: Once a vent damper plug is connected to the

Hydrostat, the control is permanently altered, and will nolonger function when the vent damper plug is disconnected.

S T E P _ Insert the temperature sensor into the Electro-Well.

WARNUNG: DO NOT USE ANY HEATTRANSFER GREASEOR PASTE

O_ LowVoltage

Thermostat

T (w)z (c)

RemoveJumperPlug

T-STATRELAY N.O.

A LW HI TEMP 51 _2 _ I---'---'1 f

24VAC

)

)

BOILER

GROUND

3

O O O

NOTE: Be careful not to select overlapping temperature settings.

For example: If the HIGH TEMPERATURE LIMIT is set at

180°F witha HIGH TEMPERATURE DIFFERENTIAL setat20°F,

then the LOW TEMPERATURE LIMIT needs to be setat 160°F

(180°F - 20°F = 160°F) or below.

IMPORTANT: To prevent flue gas condensation and reduce fatigue

caused by thermal cycling on conventional (non-condensing) boilers,

both HIGH and LOW LIMIT set points should be 150°F or above

(Limit S etting - Differential Setting > 150°F). Boiler manufacturer's

temperature requirements s upercede these recommendations.

To set COLD START

Operates on call for heat only.

e! High Temperature Limit

O

operation

(factory setting = 180°F)

Adjust setting until desired temperature is displayed.

High Temperature Differential

(factory setting = 10°F)

Using a small screwdriver, adjust setting until desired differ-

ential is displayed.

O Low Temperature DifferentialNo change is required.

Low Temperature Limit

Make sure Low Temperature Limit is turned fully counter-clockwise (OFF position).

To set WARM START o]2erationMaintains temperature in boiler.

el High Temperature Limit

(factory setting = 180°F)

Adjust setting until desired temperature is displayed.

O

O

High Temperature Differential

(factory setting = IO°F)

Using a small screwdriver, adjust setting until desired differ-

ential is displayed.

Low Temperature Differential (factory set=10°F)

Using a small screwdriver, adjust setting until desired differ-

ential is displayed.

Low Temperature Limit (factory set = off)

Adjust setting until desired temperature is displayed.

COLD START W ARM STARTLow Limit Switch = OFF (maintains temperature for domestic hot water)

Low Limit Switch = ON

High Temperature Limit(Adjustable 130°to 220°F)De-energizes burner at HIGHLIMIT setting

High TemperatureDifferential

(Adjustable 10° to 30°F)Re-energize sburner whentemperature falls to the HIGHLIMIT DIFFERENTIALset point

Example

High Limit= 180 °

Differential = 10 °

On a call for heat, the bLrner will

shut offat 180 ° and restart at

170 ° (1 80°-10°). The circulator

will run as long as there is a callfor heat.

)

HighTemperature Limit(Adjustable 130°-220 °F)De-energizes burner at HIGHLIMIT setting

HighTemperatureDifferential

(Adjustable 10° to 30°F)Re-energizes burner whentemperature falls to the HIGHLIMIT DIFFERENTIALset point

LowTemperature Limit(Adj ustable 110° to 200°F)De-energizes burner at LOWLIMIT setting

LowTemperatureDifferential

(Adjustable 10_to 30°F)Re-energizes burner whentemperature falls to the LOWLIMIT DIFFERENTIALset point

Example

High Limit= 180 °

Differential = 10°

On a call for heat the burner willshut off at 180 ° and restat at

170°(180°-10°). Tfie circulator

will run as long as there is a callfor heat.

Example

Low Limit = 150 °

Differentia = 10 °

When there is no call for heat,

the burner fires at 140 °

(150°-1 0 °) to maintain boiler

temperatu£. Burner shuts offat 150 °.

NOTE:To prioritize domastic hot

water tfie Hy:lroStat control willnot allow the circulator to

operate at any time the

temperatu£ is below the low

limit set'ring.

4

_[_ LOW WATER Indicatesthat the boiler is in a low water

condition. The HydroStat control willprevent burner operation during thiscondition.

IMPORTANT:

The system must be checked by aqualified heating professional prior toresuming operation.

WARNING: ALLOW THE BOILER TOFULLY COOL BEFORE ADDINGWATE R.

OTSTATIndicates that the circulator is running andwater is flowing through the boiler due toa call from the thermostat(s).

0LOW HIGHTSTAT

WATER LIMITPOWER

RED GREEN YELLOW GREEN

O 0 0 O

HIGH LIMIT Illuminateswhen the boiler water temperaturereaches the high limit setting. It willremain lit until the water temperaturefalls below the high limit setting less

the differential setting. The HydroStatcontrol will prevent burner operationwhile this LED is on.

NOTE: This LED illuminates regularlyduring normal boiler operation.

POWER Indicates thatthe HydroStat control is powered andthat the temperature function is active.

Burner Will Not Fire See Flow Chart 1, page 6

Burner Will Not Shut Down See FlowChart2, page 7

Under normal operation, boiler temperature will continue to rise after the control shuts offTemperature Display Exceeds

the burner. This condition, known as "thermal stacking", results from hot boiler surfacesHigh Limit Setting continuing to release heat into the boiler water.

Red Light on Circuit Board The red light to the left of the temperature display will flash if the transformer has beenis Flashing overloaded. (See top portion of troubleshooting flow chart on page 6.)

If the boiler is equipped with a tankless coil, make sure the low limit setting on theNo Domestic Hot Water HydroStat is set properly. NOTE: If the low limit setting is dialed fully counter clockwise, it

will shut off the low temperature maintenance feature.

Check for overlapping high temperature setting. If the high limit setting is set below theBoiler Will Not Maintainlow limit setting, the control will default to the high limit setting and the corresponding

Low Limit Temperature high limit differential setting.

Temperature Dis playDiffers from Boiler

T&P Gauge TemperatureReading

TSTAT Light(Green LED)Is NotOn

Low Water Light(Red LED)Is On

Temperature variances can result from differing water temperatures within the boiler ordifferent reaction times oft he two devices. If the HydroStat temperature is significantlybelow the T&P gauge temperature, make sure the thermistor is inserted all the way tothe end of the well. DO NOT USE ANY HEATTRANSFER PASTE OR GREASE

The TSTAT light indicates when there is a call for heat. If a call is known to be present,and this light is not on, check to see if the circulator is actively circulating water. If not,check circulator and thermostat wiring.

WARNING: A low water condition is a serious and potentially dangerous condition. Donot attempt to add water to a hot boiler. Allow the boiler to fully cool before adding water.

1. If the heating system is filled with water, pull the sensor out of the well and inspect it.Make sure that the metal clip on the sensor is intact This metal clip must be in contactwith the inside of the copper well in order for the control to sense the presence ofwater. Check that the well does not have excessive build-up of heat transfer grease

that may interfere with clip contacting the well.

2. Remove well and examine for excessive residue build-up. Clean and re-install.

5

Troubleshooting Flow Chart 1 - Burner Will Not Fire

.... [An overload or

_the Circuit Board_" Ish°rtcircuit

r

\ <po

The burner will not fire until overload condition is corrected.

I1_Recheck wiring - Terminal TV is electrically connected to boiler

ground. If wiring to TV & Z is reversed, there could be a short [

acrossthetransformer. II1_Make sure that there are no other loads connected I

except the thermostat and burner circuits.

CAUT,ON-ALWAYSALLOWABO,LERTOCOOLBEFOREAOD,NGWAmERiii!'Theburnerwl,,notflreuntl,the,owwaterconditionissatisfied.[iii_iI_ Check that the system is filled with water. 1[

I_ Check that the sens or is ins erted correctly into well. [

Note: The use of heat-conductive grease may interfere with the

contactbetween thespringclipand thecopper welltube. l

I_Check thatthe controlistightlyclamped tothewell.

When the low temperature

setting is set to OFF,the

HydroStat will act as a coldstart control. The burner will

not fire unless there is a call

from the thermostat (T-TV).

I_ Set thermostat to call for

heat. Burner should fire.

I_ If the boiler has a tank-

less coil, set the Low

Temperature Limit to

maintain temperature.

The Control24 VAC

is OperatingBetween B1

Properly.

1: [Ifboththe red and yellowLEDs areoffand

| | there s a ca to f re the burner, there w beReplace .....[ _ 24 VAC on terminals BI and B2.

I Control I v I l:[ [ [ t_ If 24 VAC is not present, the control should

be replaced.

6

Troubles hooting Flow Chart 2 - B urner Will Not S hut Down

Red LED

\

The Control is I

Sensing _

The Control is

Sensing High

Temperature,

TUR,OFFPOWERTOBUR,ER_MMEO,_EL_.li!i_iiiitAUT,ON- A,WA_SALLOWABO,,ERTOFU,,_COOLIBEFOREAOD,.GWATER. /I_ Recheck wiring. Make sure that burner is wired to J

B1. Burner should never fire when red or yellow J

LEo_s,t.

Thermostat

(T-TV) Calling

I_ Check temperature display, When the Low Limit is

set, the HydroStat will fire the burner until the

temperature reaches the Low Limit Setting,

If there is no callforheat (from T-TV or Low Limit),

there should be 0 VAC between B1-B2, l:

I_ If there is voltage between B1-B2 the control

should be replaced, j

7

HydroS tat's low water cut-off function is active when the control is installed on a Hydrolevel E lectro-Well. To test the low water cut-off function:

O Turn OF F power to the control. O Set the thermostat to call for heat. _ Gently slide the sensor out of the well to s imulate a low water condi-

tion. _ Turn ON power to the control. The red LOW WATER light should come on and the burner should not fire. _ Turn OF F power again and

reinstall the sensor in the well. The sensor should be tight against the bottom of the well._Turn ON power to the control. The burner should fire.

NOTE: Do not remove the sensor from the well while the control is powered.

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.

!Input voltage 120 VAC, 60 HZ I Operating range - low limit Off or 110°F - 200OF _MADE IN

Burner contacts 30VA@24VAC I Operating range- high limit 130°F - 220°FCirculator contacts 5.8 FLA, 34.8 LRA@ 120VAC Operating range- differential 10°F -30°F

83 Water Street, New Haven, CT 06511 , Phone (203) 776-0473, FAX (203) 773-1019, www. hydrolevel.com

8