Dettson HYDRA COMPACT HYDRAC03-M2401M Assembly instructions

ELECTRIC BOILER
MECHANICAL CONTROL
2013-08-29 X40202 Rev. D
www.dettson.ca
HYDRAC03-M2401M
HYDRAC04-M2401M
HYDRAC05-M2401M
HYDRAC06-M2401M
HYDRAC07-M2401M
HYDRAC08-M2401M
HYDRAC09-M2401M
HYDRAC10-M2401M
HYDRAC11-M2401M
HYDRAC12-M2401M
Models:
Installation Instructions
and Homeowner’s Manual
Dettson Industries Inc
Manufactured by:
3400, Industrial Boulevard
Sherbrooke, Qc, Canada, J1L 1V8
Attention
Do not tamper with the unit
or its controls. Call a
qualified service technician.
Printed in Canada on 100% recycled paper
INSTALLER / SERVICE TECHNICIAN :
Use the information in this manual for the installation / servicing of the
boiler and keep the document near the unit for future reference.
HOMEOWNER :
Please keep this manual near the boiler for future reference.
c

2
SECTION 1
INSTALLATION
1.1) DANGER, WARNING AND CAUTION
The words DANGER, WARNING and CAUTION are used to identify
the levels of seriousness of certain hazards. It is important that you
understand their meaning. You will notice these words in the manual
as follows:
DANGER
Immediate hazards which WILL result in death or
serious injury.
WARNING
Hazards or unsafe practices which CAN result
in death or injury.
CAUTION
Hazards or unsafe practices which CAN result in
personal injury, product or property damage.
1.2) HEATING WITH HOT WATER
Your HYDRA COMPACT electric boiler was carefully assembled
and checked in our plant, so that it will deliver warmth and comfort to
your home for many years to come.
This manual is intended to provide the necessary information for the
installation of the unit, how it functions and explains security
measures which are particular to this type of equipment.
It is essential that the persons installing, operating or adjusting the
boiler carefully read this manual, in order to completely understand
and be familiar with the procedures to be followed.
Any questions relative to the operation, maintenance or guarantee
should be directed to the company where the equipment was
purchased.
Upon completion of the installation, this manual should be placed
back into its original envelope and kept near the boiler for future
reference.
1.3) DELIVERY
Upon delivery of the boiler, check the nameplate to be sure that
you have received the model with the correct rating and proper
voltage.
The following items are supplied with the unit:
- A pressure relief valve, adjusted to 30 psi;
- A drain valve;
- A ¼‘’ plug to cork the ¼’’ tapped hole between the
elements in the case the boiler is installed in any
other position than upside.
- A 4’’ long nipple ¼’’ NPT and a ¼’’NPT coupling if
unit is installed upright position, water connections at
the bottom.
1.4) INSTALLATION
WARNING
The installation of this unit must be performed
by a qualified technician and it must conform
to the standards and regulations in force as
well as the Canadian Installation Code for
Hydronic Heating Systems CSA B214-01.
1.4.1) Positioning
The unit must be installed in an area that is dry, non-corrosive,
without excessive dust, well ventilated and where the ambient
temperature does not exceed 27oC (80oF).
The boiler can be installed directly on a wall with 4 screws. 2 screws
in the elements compartment and 2 screws on each side of the unit.
Ensure that the unit is well fixed on the wall utilizing the 4
points of fixation.
The boiler can be installed in 6 possible configurations as shown in
figure 1.
Ensure that it is installed level and that the clearances indicated in
Table 1 are respected.

3
Figure 1 : Mounting configurations
1.5) CLEARANCES
The following clearances should be provided for the servicing of the
unit:
Table 1
Minimum clearances to combustible materials
LOCATION CLEARANCE
Access side to elements 13 ¼‘’ (34 cm)
Sides 4’’ (10 cm)
Bottom (water connections) 6 5/8’’ (17 cm)
Front* 0
Back 0
* If the boiler is in an enclosure, provide a door or a removable panel
in front to access the control panel.
1.6) DISTRIBUTION SYSTEM
The proper functioning of your heating system is directly related to
the quality of the plumbing installation. Therefore, the entire
installation must be performed by qualified technicians.
See Figure 2 for the functions of the various boiler components.
The heating system must be set-up to operate at a maximum
pressure of 28 psi and the operating temperature may range from
21oC to 88oC (70oF to 190oF).

4
Figure 2 : Boiler components
Freeze protection (when required)
WARNING
Only propylene glycol may be used in this
hydronic heating system, to prevent freezing.
It is recommended to add a maximum of 50%
of propylene glycol mixture to ensure proper
operation.
Do not use automotive anti-freeze, ethylene
glycol or any undiluted anti-freeze.
If the above recommendations are not
followed, severe personal injury, death or
substantial property damage can result.
All installations must include the following items:
a. 1 pressure regulator, adjusted to 12 psi, must be installed
between the boiler and the main water supply in the building;
b. 1 expansion tank, pre-pressurized to 12 psi and of appropriate
size;
c. 1 or more automatic air purge valves;
d. 1 or more circulating pumps of appropriate capacity.
CAUTION
To avoid water damage and/or scalding due to relief
valve operation, a discharge line must be connected to
the valve outlet and run to a drainage area. The
discharge line shall be installed in such a way that it
will allow for the complete drainage of the valve and
the discharge line.
1.7) INSTALLATION OF THE BOILER
At the time of installation, the following steps should be followed.
Refer to Figure 3, 4, 5, 6 and 7.
1. Choose an appropriate location. Mount the boiler securely on
the wall, with the help of the mounting plate. Ensure that it is
level and that the minimum clearances are observed;
2. Install the drain valve and the safety valve according to the
mounting configuration as shown in Figure 1;

5
3. An air vent should be installed on the unit if installed upright
position, water connections at the bottom. In all other mounting
position, cork the hole with the ¼’’ plug provided.
4. Install the water supply and return piping with the 1” NPT fitting;
5. The heating supply line must include:
a. 1 circulator along with 2 maintenance valves;
b. 1 automatic pressure reducing valve adjusted to 12 psi,
with a shut-off valve on the return water line;
c. 1 expansion tank;
d. 1 automatic vent.
6. The flow of water through the system must be sufficient to
continuously discharge the energy generated by the boiler. If
not, the High Limit protector will disconnect all the electric
elements and a more or less frequent cycling mode will be
established by the Safety Control (see the Technical
Specifications Table);
7. In order to ensure satisfactory water flow, the friction in the
piping system must not exceed the capacity of the circulator;
8. After having completed all piping connections, run water
through the system and purge the air. The automatic vent
should be in operation.
Note: Remove the plastic cover and check to see if the elements
are watertight.
1.8) ELECTRIC POWER SUPPLY
All electrical wiring must conform to the standards and regulations in
force and the Canadian Electrical Code CSA C22.1.
Electrical power to the boiler must come from a 120/240V-60 Hz or
208V-60 Hz, single phase, 3-wire, grounded circuit, protected by an
appropriately sized breaker, based on the total rating of the boiler.
When using 208V, change the connector’s position at the primary of
the transformer. Refer to the boiler nameplate and the technical
specifications in this manual to select the proper breaker and wire
size.
WARNING
Risk of fire.
The conductor sizing must conform to the last
edition of the local or national codes.
Failure to follow this rule can result in death,
bodily injury and/or property damage.
Power supply to the unit can be made using copper or aluminum
wires. The wire size must be decided in accordance to unit power
consumption, the over current protection type and capacity, the wire
type and length, and the environment where the unit is installed. If
an aluminum wire is used, other precautions (such as the use of a
DE-OX inhibitor) must be taken to insure the conformity of the
installation. In all cases, all the factors affecting the wire gauge must
be considered and the installation codes followed.
The exterior of the unit must have an uninterrupted ground to
minimize the risk of bodily harm. A ground terminal is supplied with
the control box for that purpose.
In the event that wires inside the unit require replacement, these
must be as same type as originals. (Copper wiring only)
1.8.1) CONNECTING THE CIRCULATING PUMP
Connect the circulating pump on 120V connections points identified
P-P in the control panel as shown in Figure 2. The control is
designed to operate the circulator on thermostat demand or
continuous flow when the continuous flow switch, on the side of the
unit, is ON.
1.8.2) CONNECTING THE THERMOSTAT
Single heating zone
Connect the low voltage thermostat to R-W terminals located inside
the control panel. See Figure 4.
Multiple heating zones
Connect the contacts of the motorized valves or pump controls to R-
W terminals inside the control panel. See Figure 5 and 6.

6
SECTION 2
OPERATION
2.1) ADJUSTMENTS AND START-UP
CAUTION
The boiler must be filled with water and all air
purged from the system, before turning on the
power.
CAUTION
If the power is turned on before the boiler is filled
with water, the elements will become seriously
damaged.
1. Adjust the setpoint of the boiler on the aquastat.
2. Turn on the power, set the thermostat at 30C (85F). The
circulator; The circulator should start as well as the electrical
elements in sequence with a 8 seconds delay;
3. The circulator stays on for as long as there is a call for heat
except if continuous flow switch, ob the side of the unit, is ON.
2.2) MECHANICAL HIGH LIMIT
Mechanical High Limit Control
The mechanical limit control must be set 20oF above the setpoint
temperature on control aquastat.
SECTION 3
MAINTENANCE
The property owner has the following responsibilities:
a. Maintain the area around the boiler clean at all times and free
from combustible and highly flammable material;
b. Ensure that the ambient air at the boiler is not excessively
dusty or humid;
c. Have all water leaks repaired in the system as they arise.
d. Ensure that the ambient temperature in the area where the unit
is installed does not exceed 27oC (80oF).
CAUTION
The boiler guaranty may be invalidated if: water
leaks in the system are not repaired; the boiler is
used as a source of domestic hot water or a
significant amount of new water or air is
introduced into the system.
It is recommended that the boiler be purged annually, in order to
eliminate sediment and sludge that may have accumulated at the
bottom of the boiler and covering the heating elements.
Procedure:
1. Let the boiler cool down;
2. Close the maintenance valves, which are installed at the water
inlet and outlet of the boiler. N.B.: It is not recommended to
drain the water from the heating pipe system;
3. Hook-up a garden hose to the drain valve and place it close to
a floor drain;
4. Open the purge valve until the water comes out clean and
clear;
5. Close the valve.
It is recommended to perform a visual inspection of the boiler
electrical compartment annually, during the heating season. The
items to check are the water tightness of the elements, signs of
overheating of the electrical components and the wiring. Corrective
measures must be undertaken as required, as soon as possible.
Defective components should always be replaced with the Original
Equipment Manufacturer’s parts.
SECTION 4
INFORMATION
Model: Serial number:
Installation date of the electric boiler:
Service telephone # – Day: Night:
Dealer name and address:

7
SECTION 5
TECHNICAL DATA
Table 2
Hydra Compact – Technical specifications
POWER (kW@208V) POWER (kW@240V) Volts - Hertz - Phase Electric element #1 (Kw) Electric element #2 (Kw) Consumption (Amp) Circuit Amperage (wire sizing) GENERAL INFORMATIONS Supply - Return Minimum water flow USG/min Overall Dimensions
(widht x deep x hight
)
Shipping weight
2.25 3 3 - 9.4 / 12.5 12 / 15.6 0.81 / 1.08
3 4 4 - 12.5 / 16.7 15.6 / 20.9 1.08 / 1.44
3.75 5 5 - 15.6 / 20.8 19.5 / 26 1.35 / 1.81
4.5 6 3 3 18.8 / 25.0 23.5 / 31.3 1.63 / 2.17
5.25 7 4 3 21.9 / 29.2 27.4 / 36.5 1.90 / 2.53
6 8 4 4 25 / 33.3 31.3 / 41.6 2.17 / 2.89
6.75 9 5 4 28.2 / 37.5 35.3 / 46.9 2.44 / 3.25
7.5 10 5 5 31.3 / 41.7 39.1 / 52.1 2.71 / 3.61
8.25 11 6 5 34.4 / 45.8 43 / 57.3 2.98 / 3.97
9 12 6 6 37.6 / 50.0 47 / 62.5 3.25 / 4.33
44 lb (20 kg)
In all cases, refer to applicable local and national codes.
208 / 240 - 60 - 1
1'' NPT female
8 3/16'' X 8 7/16'' X 21 3/4''
Figure 3 : Boiler Dimensions

8
Figure 4 : Typical Diagram of a Single Zone Installation
Figure 5 : Multizone Diagram with more than one Circulator

9
Figure 6 : Multizone diagram with Motorized Valves
Figure 7 : Electrical Diagram

10
SECTION 6
REMPLACEMENT PARTS
Figure 8 : Exploded Vue
B50121 Rev. D

11
Table 3
Parts list
ITEM
PART #
DESCRIPTION
COMMENTS
1 B03996 ELECTRICAL PANEL Panel only
2 B04004 EXIT/ENTRIES PLATE INSULATION
3 L07F016 SWITCH
4 L01J001 BREAKER
5 B03998 END PLATE
6 B03995 JACKET
7 B03994 CABINET
8 B04003 INSULATION CONTOUR
9A L99H013 ELEMENT 3KW
9B L99H014 ELEMENT 4KW
9C L99H015 ELEMENT 5KW
9D L99H016 ELEMENT 6KW
10 B03970 SEALING GASKET ELEMENT
11 R02J012 WELL 3/8"NPT
12 R02J001 WELL 1/2"NPT
13 G06F006 PLUG 1/4"NPT
14 B03977-01 BOILER ASSEMBLY (1 ELEMENT) Boiler only
14 B03977-02 BOILER ASSEMBLY (2 ELEMENTS) Boiler only
15 R02L006 TRIDICATOR 1/4"NPT
16 B03984-01 COVER ASSEMBLY Cover, cosmetic and wiring diagram included
17 B04000-02 TERMINAL (2X6 POSITIONS)
18 B04184 AQUASTAT ASSEMBLY Adjustment hi-limit temperature
19 R99G006 RECTIFIER CONTROL
20 L01H030 RELAY SPDT 22VDC
21 B04002 ELECTRICAL KIT
22 A20009-04 BLACK WIRE ELEMENT
23 A20009-05 RED WIRE ELEMENT
24 L01H009 RELAY SPDT 24VAC
25 R99G007 RECTIFIER /TEMPORISATOR CONTROL
26 B04184-01 AQUASTAT ASSEMBLY Adjustment temperature control
27 L01F010 TRANSFORMER 208/240/24
28 L99F005 TERMINAL BLOCK
29 G11F012 RELIEF VALVE 3/4"
30 G11Z002 DRAIN FAUCET 3/4"
31 G03F001 COPPLING 1/4" NPT
32 G01G001 NIPPLE STANDRAD 1/4" NPT X 4" B50121 Rev. D