New Hydrosmart installation issues

[MNMike]

Hi Guys,
Installed a Hydrosmart panel last weekend and I am having some issues. Below is what I sent to Hydrosmart this morning, I have yet to receive a reply so I thought I would run it by the experts on this forum. The garage is detached 28x32x10 2" foam under slab, R19 walls, R30 ceiling. 4 250' 1/2" loops of Pex 1 zone.

"I was able to get my system put together this weekend but ran into some issues. It is a 1 zone panel with a 115 NG boiler.

The system has been filled and purged, pumps work when plugged in. The thermostat calls for heat and the boiler runs for about 2 minutes and turns off. The thermostat is still calling for heat as indicated by the light ( HS135 ) I can close the Purge T and the boiler will turn on and continue to run. As soon as it hits 100-110 degrees ( set at 120 ) the boiler will shut off and the flow on the controller will go from .8 to .5 then to 0.0. The system will not turn back on although the thermostat calls for heat. I can open and close the purge T and the boiler will turn on and run with the purge T in the closed position. I have adjusted the flow meters on the manifold to .6 GPM and have adjusted the pumps form HI to LOW and all positions in between with no difference in operation.

What am I missing??"

Any help would be appreciated.

Thx,
Mike

 

[MNMike]

Was able to talk to the Hydosmart people yesterday after work and it is determined that there is a clog in the boiler reducing the flow. It was suggested that I tear it apart and clear it out. Now I'm not the most inept person around but, If I pay this much for a NEW system I would expect it to work and not have to fix it myself. We agreed that I would return it to them and they will clear it out along with fixing some other issues. The two pressure gauges leak and one of the isolator valves can not be fully closed as it hits one of the pipes coming out of the boiler.

We will see what happens tomorrow when we bring it in.

Mike

 

[Burl]

I've been looking at the Hydrosmart systems for a while. This should be intresting. In the meantime, your garage just gets colder.

 

[howpeculiar]

Hmmm, I figured the temp gauges would leak, mine did. Surprised that the boiler is clogged. The strainer should have gotten any debris out of the coolant flow.

 

[MNMike]

That is what they are saying is that the strainer is clogged enough to restrict flow so the boiler shuts off.

Hopefully they can get it cleaned out and operational.
I have a wall heater in the garage to take the edge off but boy am I going thru the propane.

 

[MNMike]

I had someone bring the unit to Hydrosmart today and I am being told that Hydrosmart fixed the clog and other associated problems while they waited. I am going to re-install it tonight when I get home and we will see if it works.

The quality of their systems might be suspect but customer service is top notch.

Good Luck,
Mike

 

[MNMike]

Installed the unit and it works great. They replaced the screen and now I get the 3.2 GPM I am supposed to. Went out this morning to check on it and it was 50* inside, outside temp was 18*

Looks like I am in business.

Howpecullar, I'll be talking to you soon.

Good Luck,
Mike

 

[Burl]

What clogged the system? Supposedly nothing but fluid in there.

 

[MNMike]

I am hearing this second hand but they were told it could be from sitting on a shelf somewhere. I personally find that hard to believe because it took 3 weeks to get it from the time I ordered it. If it was sitting on a shelf @ Menards I could have just picked it up.

Either way the guys took care of the situation.


Good Luck,

Mike

 

[Firebrick43]

More than likely **** in the pex and panel plugged it.

 

[MNMike]

Pex was blown out prior to getting hooked up to the manifolds, the hydro Smart system I bought was a panel system All pieces were put together at the factory.
The guys didn't say anything about what exactly blocked it and it was not a surprise to them. Google it, it happens.

Good Luck,
Mike

 

[howpeculiar]

Happy to hear you got it running! I know problems are a pain, but I think it may be the price of being a DIY!

 

[howpeculiar]

Funny Mike, I was also at Menards when you called! I was in the shop when you dropped off the pump, thanks! Hope you get many years of staying warm!

 

[MNMike]

Thanks again, That was very nice of you.

Mike

 

[howpeculiar]

No problem at all! Hope you are warm and toasty, going to get a bit snowy here in another day!

 

[Burl]

I've been looking at the HydroSmart small boilers for a while, and my garage is similar to yours Mike. I'll be anxious to see how your boiler performs in your colder-than-my temps (and getting much colder next week). Could you post as to how your system is working?

 

[MNMike]

Burl,

Not sure where you are but I took the day off of work yesterday and was in the shop for most of it. Temp outside was 19*-23* I had the temp inside set at 55*. The system would cycle every 20-30 minutes for a very short time period, so short I thought something might be wrong with it. I could hear the thermostat call for heat, pumps start, furnace kick on then stop.. weird. But it maintained 55* all day long.
I am luck that HydroSmart is not too far from me so it was easy to have them help me out with the filter. You might want to source a manufacturer close to your location in case something needs repair or service.

I am having an issue with air in my lines and it is coming from the manifold, one of the flow meters is leaking. I called the manufacturer to ask how to fix it and they said that they would send me a couple of replacements.

Howpeculiar, when I was in your shop looking at your system you mentioned that the system just cycled because the pump had turned off. I don't remember hearing your furnace kick on...... is it that quiet???

Mine thumps pretty good on the initial burn, that is why I think I have air in the lines.

Over all I'm pretty happy with the set-up. still working on fine tuning it but it will come in time.

Good Luck,
Mike

 

[Burl]

Thanks for the reply Mike. I'm about 60 miles west of Pittsburgh, not quite the cold temps as you, but still consistent cold temps in the winter. I use a HWH to heat my fluid, and it runs a lot in very cold weather, and I'm looking for something more suited to the task. A small boiler seems good, but people sometimes have problems with them. You talk about your flow meters leaking, I had the same problem a few years ago and just removed all 4 of them. What are your outgoing/incoming temps of your boiler?

 

[MNMike]

I have mine set 122* out and I am getting 90*ish coming in when it runs.

 

[Burl]

If these temps stay consistent throughout the cycle, this is why the cycle is so short. This is what I am looking for. My temps with the HWH begin about the same and drop fast, as the HWH cannot maintain because of low-ish BTU output, making my cycles quite long in some instances. Are these temps what the guys at Hydrosmart suggested?, because the 122 is in the upper range for pex tubing.

 

[MNMike]

The 122 is preset from the factory, I am thinking about turning down to the next level, I think it is 112 or 114, they have set increments of numbers on the controller. The controller for the boiler goes up to 160 I believe.

 

[MNMike]

Little bit of an update...

I've been adjusting the GPM and the temp on my system and I think I finally have it tuned in. Now my next issue is I am throwing error codes 10 & 99, they state it is a combustion issue. Hydro Smart seems to think it is the back flow flap in the exhaust pipe. When I take the front panel off and clear the codes it will run fine, when I put the panel back on it will throw codes. The system is set up to pull fresh air from inside garage, per Hydro Smart that shouldn't be the issue. Sure seems like it is not getting enough fresh air.

When it is running it sure is nice but the intermittent problems are getting old.

Anybody else run into this issue?
Thx,
Mike

 

[dglennon]

Just read this thread - I have the same setup with 3 loops of approx 75' each pex. This is the second winter on my system in North Dakota. It works well to keep garage about 60 even when it is -20 outside. However, about January, I started getting the "10" code on my boiler. Took the cover off and it looked like too much effort to tear into that time of year as it still cycled fine and put out 122 degree water. I did try a voicemail and email to Hydrosmart with no reply, but figure I will try them again this summer when I tear into it.

 

[Burl]

Not a good thing when there is no response from Hydrosmart. I am seriously considering one of their heaters and this is discouraging. I hope this is not a typical problem.

 

[Redraptor]

When I take the front panel off and clear the codes it will run fine,

You must be running really rich thru the gas valve for that to happen, or an obstruction on the intake port.

 

[MNMike]

I put the panel back on Saturday morning and worked in the garage all weekend and it didn't throw any codes, granted the boiler didn't run very much as it was in the high 30's low 40's outside.
Redraptor, I took the exhaust pipe apart to check the flap and all seems fine. We'll have to wait to see what happens next.

Mike

 

[MNMike]

Ok, so it is throwing codes again. Hydro Smart says I need to install a Direct vent conversion kit available at Menards for the price of $79.99, special order 2 weeks. Prior to buying this unit I talked to them about fresh air for the boiler and they said that the garage 28x32 should have enough air inside to work. Apparently the garage is too tight.

Seems like there should be an alternative to the conversion kit made by HydroSmart, doesn't seem to be much to it.
I've searched the web and could not find an alternative.

Mike

 

[papp101]

HI Mike,

Looking at one of these units for my new garage build in South Minneapolis.

What is the model number of your unit? Is it one of these below?

Hydro Smart™ 120K BTU Condensing Natural Gas Microboiler

Hydro Smart™ 115K BTU Natural Gas Microboiler

 

[moserjj]

HI Mike,

Looking at one of these units for my new garage build in South Minneapolis.

What is the model number of your unit? Is it one of these below?

Hydro Smart[emoji769] 120K BTU Condensing Natural Gas Microboiler

Hydro Smart[emoji769] 115K BTU Natural Gas Microboiler

I have the 120k unit, West Central WI. No issues work it but watch the little filter on the inlet when filling the system. Mine got clogged a few times before it ran clean. I went with that heater and the pre plumbed panel. Very easy diy

Sent from my ONEPLUS A3000 using Tapatalk

 

[papp101]

Thanks for the info! Did you ever price out the panel vs diy? I haven't yet, but seems like it is a bit spendy. Bluridge systems had a quote for me around 600 for the parts, and I would supply the boiler.

Seem right to anyone?

Thank you!

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[moserjj]

I didn't price the components, I knew I couldn't build it anywhere as neat as the panel. I'm not great at plumbing or sweating pipes so that wasn't a consideration in my case. If you have the skills, it would be a way to save some cash. Sure was easy to install!

Sent from my ONEPLUS A3000 using Tapatalk

 

[mlyonsdc]

I am in NE Ohio and just poured my floor. I am considering getting everything I need from hydro-smart. How are they to deal with and have you been happy with the quality? I am considering the same micro-boiler vs the Takagi tankless NG hot water heater which is close to half the price.

On the boiler I wont have a drain close enough so I have to run a non-condensing unit with SS vent system?