Dettson HYDRAI016-208-3 Quick start guide

INSTALLATION INSTRUCTIONS AND
HOMEOWNER’S MANUAL
INDUSTRIAL
ELECTRIC BOILER
ELECTRONIC CONTROL
Models:
HYDRAI016-208-3
HYDRAI016-240-3
HYDRAI016-480-3
HYDRAI016-600-3
HYDRAI024-208-3
HYDRAI024-240-3
HYDRAI024-480-3
HYDRAI024-600-3
HYDRAI032-208-3
HYDRAI032-240-3
HYDRAI032-480-3
HYDRAI032-600-3
HYDRAI040-208-3
HYDRAI040-240-3
HYDRAI040-480-3
HYDRAI040-600-3
HYDRAI048-240-3
HYDRAI048-480-3
HYDRAI048-600-3
HYDRAI064-480-3
HYDRAI016-600-3
HYDRAI080-480-3
HYDRAI080-600-3
HYDRAI096-480-3
HYDRAI096-600-3
INSTALLER / SERVICE TECHNICIAN:
Caution:
Do not tamper with the unit or its controls.
Call a qualified service technician.
USE THE INFORMATION IN THIS MANUAL FOR THE
INSTALLATION AND SERVICING AND KEEP THE
DOCUMENT NEAR THE UNIT FOR FUTURE REFERENCE.
HOMEOWNER: Manufactured by:
PLEASE KEEP THIS MANUAL NEAR THE FURNACE FOR
FUTURE REFERENCE. Dettson Industries Inc.
Sherbrooke, Qc, Canada
www.dettson.com
Printed in Canada on
100% recycled paper
2018-05-18 X40227 Rev.E

Table of Content
1 SAFETY 3
1.1 DANGER, WARNING AND CAUTION . . . 3
1.2 IMPORTANT INFORMATION . . . . . . . . . 3
1.3 DANGER OF FREEZING . . . . . . . . . . . . 3
2 INSTALLATION 4
2.1 HEATING WITH HOT WATER . . . . . . . . . 4
2.2 DELIVERY....................... 4
2.3 POSITIONING AND CLEARANCES . . . . . 4
2.4 DISTRIBUTION SYSTEM . . . . . . . . . . . . 6
2.4.1 Circulating Pump . . . . . . . . . . . 6
2.4.2 Freeze protection (when required) . 6
2.5 BOILER INSTALLATION . . . . . . . . . . . . . 7
2.6 ELECTRIC POWER SUPPLY . . . . . . . . . 7
2.6.1 Connecting the Circulation Pump . 7
2.6.2 Power Stealing Thermostat . . . . . 7
2.6.3 Thermostat Connection . . . . . . . 8
2.6.4 Outdoor Sensor Connection . . . . 8
3 OPERATION 8
3.1 ADJUSTMENTS AND START-UP . . . . . . . 8
3.2 MECHANICAL HIGH LIMIT . . . . . . . . . . . 8
3.3 QuietMode ...................... 8
3.4 Load-Shedding.................... 8
3.5 LowFlow ........................ 9
3.6 Communication.................... 9
3.7 ELECTRONIC CONTROL . . . . . . . . . . . . 9
3.7.1 Display . . . . . . . . . . . . . . . . 9
3.7.2 Installer . . . . . . . . . . . . . . . . 9
3.7.3 Configuration . . . . . . . . . . . . . 10
3.7.4 Alarm ................. 10
3.7.5 Boost Mode . . . . . . . . . . . . . 10
3.7.6 Consumption . . . . . . . . . . . . . 10
4 MAINTENANCE 14
5 INFORMATION 14
6 TECHNICAL DATA 15
List of Figures
Figure 1: Mounting Configurations . . . . . . 5
Figure 2: Power Stealing Thermostat
Resistance .............. 8
Figure 3: Connection of Multiple Boilers . . . 9
Figure 4: Menu Navigation . . . . . . . . . . 11
Figure 5: Modulation as Function of the
Outdoor Temperature . . . . . . . . 12
Figure 6: Boiler Dimensions . . . . . . . . . . 16
Figure 7: One Boiler Installation Schematic . 16
Figure 8: Multiple Boilers Installation
Schematic .............. 17
Figure 9: Parts List . . . . . . . . . . . . . . . 18
Figure 10: Electrical Diagram . . . . . . . . . . 20
List of Tables
Table 1: Minimum Clearances to Combustible
Material................ 5
Table 2: Circulating Pump Flow Rates . . . . 6
Table 3: Alarm Description . . . . . . . . . . 13
Table 4: Technical Specifications . . . . . . . 15
Table 5: Parts List . . . . . . . . . . . . . . . 19
2

1 SAFETY
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 bodily and/or material damage.
WARNING
Hazards or unsafe practices which CAN result in
death or serious bodily and /or material damage.
CAUTION
Hazards or unsafe practices which CAN result in minor
bodily and /or material damage.
1.2 IMPORTANT INFORMATION
WARNING
Non-observance of the safety regulations
outlined in this manual will potentially lead to
consequences resulting in death, serious bodily
injury and/or property damage.
WARNING
Installation and repairs performed by unqualified
persons can result in hazards to them and to
others. Installations must conform to local codes
or, in the absence of such codes, to codes of the
country having jurisdiction.
The information contained in this manual is
intended for use by a qualified technician, familiar
with safety procedures and who is equipped with
the proper tools and test instruments.
Failure to carefully read and follow all instructions
in this manual can result in death, bodily injury
and/or property damage.
(a) It is the homeowner’s responsibility to engage
a qualified technician for the installation and
subsequent servicing of this boiler;
(b) Do not store any flammable substances, such as
paper or carton, near the boiler;
(c) Ask the technician installing your boiler to show and
explain to you the main disconnect switch or circuit
breaker;
(d) Before calling for service, be sure to have the
information of section 5 of your manual close by in
order to be able to provide the contractor with the
required information, such as the model and serial
numbers of the boiler.
IMPORTANT : All local and national code
requirements governing the installation of central
electric heating equipment and wiring MUST be
followed. Some of the codes that may apply are:
•CSA B214-01 Installation Code Hydronic
Heating Systems
•CSA C22.1 ou CSA C22.10 Canadian
Electrical Code
Only the latest issues of these codes shall be used,
and are available from:
The Canadian Standards Association
178 Rexdale Blvd.
Rexdale, Ontario M9W 1R3
www.shop.csa.ca
1.3 DANGER OF FREEZING
CAUTION
If your boiler is shut down during the cold weather
season, water pipes may freeze, burst and cause
serious water damage. Turn off the water supply and
bleed the pipes.
3

If the heater is left unattended during the cold weather
season, take the following precautions:
a) Close the main water valve in the house and purge
the pipes if possible. Open all the faucets in the
house;
b) Ask someone to frequently check the house during
the cold weather season to make sure that there is
sufficient heat to prevent the pipes from freezing.
Tell this person to call an emergency number if
required.
2 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.
2.1 HEATING WITH HOT WATER
Your HYDRA INDUSTRIAL 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.
2.2 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;
• An exterior probe for modulation;
• Two 2" X ¾" reducers for drain valve and pressure
relief valve.
2.3 POSITIONING AND
CLEARANCES
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 27°C
(80°F).
The boiler can be installed using the included mounting
brackets. First, unfold the four tabs on the back panel of
the boiler. Position the top bracket and secure it to a wall.
Place the boiler on the top bracket and then secure the
bottom. Finally, use self-tapping screw to secure the tabs
to the bracket. Ensure that the unit is well fixed on the
wall utilizing the 2 mounting brackets.
The boiler can be installed in 6 possible configurations as
shown in Figure 1. The arrows represent the direction of
the water flow.
Ensure that it is installed level and that the clearances
indicated in Table 1 are respected.
If the boiler is in an enclosure, provide a door or a
removable panel in front to access the control panel.
Ideally have a 24" clearance on the front for servicing.
4

Figure 1 – Mounting Configurations
Table 1 – Minimum Clearances to Combustible Material
Location Clearance
Top (access to elements) 13 ¼" (34 cm)
Sides 4" (10 cm)
Bottom 0
Front 0
Back 0
5

Table 2 – Circulating Pump Flow Rates
Model kW Minimal flow : ∆T=20°F ∆T=10°F
USGPM (L/min) USGPM (L/min)
HYDRAI016-XXX-3 16 5.8 (22.0) 10.9 (41.2)
HYDRAI024-XXX-3 24 8.6 (32.6) 16.3 (61.8)
HYDRAI032-XXX-3 32 11.5 (43.5) 21.8 (82.5)
HYDRAI040-XXX-3 40 14.4 (54.5) 27.2 (103.1)
HYDRAI048-XXX-3 48 17.3 (65.5) 32.7 (123.7)
HYDRAI064-XXX-3 64 23.0 (87.1) 43.6 (165.0)
HYDRAI080-XXX-3 80 28.8 (109.0) 54.5 (206.2)
HYDRAI096-XXX-3 27 34.6 (131.0) 65.4 (247.4)
2.4 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.
The heating system should be set-up to operate at a
maximum pressure of 30 psi. The operating temperature
may range from 15°C to 88°C (60°F to 190°F).
All installations must include the following items:
• 1 pressure regulator must be installed between the
boiler and the main water supply in the building;
• 1 expansion tank, pre-pressurized and of
appropriate size;
• 1 or more circulating pumps of appropriate
capacity;
• 1 or more air purge valves.
WARNING
BURN HAZARD
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.
2.4.1 Circulating Pump
The circulating pump must be selected according to
the heating distribution system and the heating capacity
of the boiler. Table 2 shows necessary water flows
according to various temperature rises. For example, a
system using baseboard heaters will usually require a
temperature rise of 20°F, wheras a radiant floor system
will use a rise around 10°F.
2.4.2 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.
6

2.5 BOILER INSTALLATION
At the time of installation, the following steps should be
followed.
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;
3. An automatic air vent should be installed on the
unit;
4. Install the water supply and return piping with the
2” NPT fittings;
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. In order to ensure satisfactory water flow, the
friction in the piping system must not exceed the
capacity of the circulator;
7. After having completed all piping connections, run
water through the system and purge the air. An
automatic vent should be in operation.
Note: Remove the top cover and check to see if the
elements are watertight.
2.6 ELECTRIC POWER SUPPLY
All electrical wiring must conform to the standards and
regulations in force and to the Canadian Electrical Code
CSA C22.1.
Electric power to the boiler must come from a 120/240V
60 Hz or 208V 60 Hz, single phase, grounded circuit,
protected by an appropriately sized breaker, based
on the total rating of the boiler. Refer to the boiler
nameplate and the technical specifications in this manual
to select the proper breaker and wire size. Normally, 3
conductors are required. If the circulating pump has an
external power source, and if no other accessory requires
the 120V output from the boiler, only 2 conductors can
be used. Use cable rated at 60°C or higher.
When using 208V, change the connector’s position at the
primary of the transformer.
Make sure to turn off all electrical circuits when
working in the appliance.
WARNING
FIRE HAZARD
The conductor sizing must conform to the last
edition of the local or national codes.
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.
It is highly recommended to have a surge protector
installed on the boiler.
In the event that wires inside the unit require
replacement, these must be as same type as originals
(copper wiring only).
2.6.1 Connecting the Circulation Pump
Connect the circulating pump on connection points
identified P-P in series with the power source. The relay
is limited to 400 VAC 5 amps. The electronic control
is designed to operate the circulator on thermostat
demand, with a heat purge delay at the end of heating
cycle or continuous flow. Refer to the electronic control
section to learn how to configure this function.
2.6.2 Power Stealing Thermostat
A 150 OHMS - 10W must be installed if a power stealing
thermostat is used. This resistance must be connected
to C-W, as shown in figure 2.
7

Figure 2 – Power Stealing Thermostat Resistance
2.6.3 Thermostat Connection
Single Heating Zone
Connect the low voltage thermostat to R-W terminals
located inside the control panel.
Multiple Heating Zone
Connect the contacts of the motorized valves or pump
controls to R-W terminals inside the control panel.
2.6.4 Outdoor Sensor Connection
Mount the sensor on an outside wall, protected from
direct sunlight, so that it will accurately measure the
outside temperature. Install 2 #20 wires between the
outdoor sensor and the terminals identified as EXT1 and
EXT2 inside the control panel of the boiler. This sensor
will allow the boiler to modulate its set point according to
the outdoor temperature, as per figure 5.
3 OPERATION
3.1 ADJUSTMENTS AND
START-UP
CAUTION
The boiler must be filled with water and all air purged
from the system, before turning on the power. If
the power is turned on before the boiler is filled with
water, the elements will become seriously damaged.
Warranty will be void.
1. Turn the power on.
2. Adjust the set point of the boiler on the electronic
control. See the electronic control section for
adjustments.
3. Set the thermostat at 30°C (85°F). The circulator
should start as well as the electrical elements in
sequence with a 15 seconds delay, if CMD displays
100% (see section 3.7.1).
4. The circulator stays on for as long as there is a
call for heat except if differently configured on the
electronic control, as explained in section 3.7.2.
3.2 MECHANICAL HIGH LIMIT
The two mechanical limit aquastats (big black knobs)
must be set 30°F above the set point. The aquastat
labeled "high limit" will deactivate the upper contactors.
The aquastat labeled "control" will deactivate the lower
contactors.
3.3 Quiet Mode
To make the boiler quieter, in the installer menu, choose
noise mode to low. The low noise option reduces
the switching frequency of the contactors. This option
shall be used only in installation areas where noise is
problematic.
The normal mode allows the boiler to reach the
temperature setpoint more precisely, optimizing the
energy consumption. Preferably, use normal mode.
3.4 Load-Shedding
When a jumper is connected between D1 and D2
terminals, the boiler will reduce the maximum power
8

to the number of elements programmed in the installer
menu. This function allows the building owner to reduce
his peak consumption. Refer to section 3.7.2 for more
details.
3.5 Low Flow
The boiler will automatically detect a low flow condition
using temperature sensors. It is also possible to connect
a low flow switch to the LF1 and LF2 terminals. In
this case, a low flow condition would turn off the high
limit contactors, which would de-energize the heating
elements.
3.6 Communication
For installations needing more power, many appliances
can be connected in parallel. A serial communication
allows the different units to exchange operational
information. There can be up to 255 appliances
connected on the same BUS.
The COM+ and COM- must be connected between
each appliance. The master appliance will need to
be configured in the installer menu, while the others
must be configured as slaves. When change in the
configuration is required, only the master appliance need
to be configured, while the others will be automatically
modified.
If an exterior sensor is used, it shall be connected to the
master appliance only.
Figure 3 – Connection of Multiple Boilers
3.7 ELECTRONIC CONTROL
Figure 4 shows how to navigate the various menus.
3.7.1 Display
PUMP: State of the pump.
SET P: Temperature
setpoint.
TARGET: Target temperature. This will vary according to
the outdoor temperature (Figure 5).
T° IN: Temperature inside the device.
T° OUT: Outdoor temperature.
CMD: Percentage of power sent to the elements.
From this screen and by pressing the directional buttons,
the user can switch from the various menus available.
3.7.2 Installer
The installer menu’s goal
is to make the technician’s
work easier. This menu
is protected by a password
that can be found on the
electrical schematic affixed
to the plastic case of the
Hydra. The password
consists of a combination
of characters entered with
the three buttons of the
Hydra (left, center, right
then center).
Once the password is confirmed, press the center button
to enter the menu. The homeowner shouldn’t try to
gain access to this menu as it is used to program the
behaviour of the appliance.
9

TYPE: Gives a pre-set value
to the temperature set point.
Mass, Baseboard, Light and
Cast Iron are pre-set values
for determining temperature
set point. Manual allows the
installer to manually choose
the set point.
PUMP: Choose the way to
drive the pump. OFF means
the pump will activate only
when there is a demand
from the thermostat. ON
means that the pump will
always be active.
Time values indicate that the pump will stay on for this
time before deactivating following the end of a heating
demand from the thermostat.
SET P: Indicates the temperature the device will try to
reach upon the reception of a signal from the thermostat,
unless the outdoor sensor modifies it.
T° OUT: Allows the device to know if an outdoor sensor
is being used.
DEV ID: Allows to configure the boiler when used in
parallel with others.
LOW FL: When active, the boiler will make sure the water
flow is adequate before activating more elements.
RELIEF: Sets the number of active elements when a
jumper is connected between D1 and D2.
NOISE: The low noise function will prevent contactors to
cycle rapidly which will make the output temperature less
precise.
BACK: Allows going back to the previous menu. This has
the same functionality across all menus.
3.7.3 Configuration
The configuration menu allows the user to adjust some
settings.
UNITS T: Units for
temperature (Fahrenheit or
Celcius degrees).
LANGUAGE: Language of
displayed text (English or
French).
TESTS: Access to the Tests tab is password protected.
Under no circumstances should a user try to access it.
This function is used at the Dettson factory to test the
Hydra before it is shipped.
3.7.4 Alarm
Some events may alter the functionality of the device in
an undesired manner. These events trigger alarms in
the system that remains stored in the device’s memory.
Reasons for alarms are: troubles with the internal or
the external heat sensor, problems with elements and
overheating (Table 3).
CURRENT: Shows alarms
currently afflicting the
device.
PAST: Shows a history
of alarms triggered by
the device. This allows
to revisit the previous 25
alarm messages with an
approximated time span
since they happened.
CLR ALARM: Clears the alarm history.
3.7.5 Boost Mode
The boost mode menu
allows the user to raise
the boiler’s temperature
set point by 10 degrees
Fahrenheit during 24 hours.
Press the central button
while in this menu to
activate or deactivate this
measure.
3.7.6 Consumption
The consumption menu shows an approximated value of
the power consumed by the boiler since it’s last reset.
Consumption is written in
kilowatt hour and time since
last reset is given in hours or
in days.
As shown on the screen, pressing the central button will
reset the time and power consumed.
10

Figure 4 – Menu Navigation
11

Figure 5 – Modulation as Function of the Outdoor Temperature
12

Table 3 – Alarm Description
Alarm Description Possible causes
The boiler temperature Misconnected sensor
T in sensor returns a temperature T in and T ext inverted
that is not within standard Damaged wire
values Defective sensor
The outdoor temperature Misconnected sensor
T out sensor returns a temperature T in and T ext inverted
that is not within standard Damaged wire
values Defective sensor
The control is experiencing The high limit aquastat is not set properly (see section 3.2)
Overheat an increase in temperature External heat source active in dual energy systems
when it does not send Defective relay or element
command to elements
The temperature in the An element is broken
Element boiler does not increase The load is more important than usual (large house,
at a standard rate concrete floor, beginning of season)
Not all elements are heating (Check the current
drawn by the unit against the one on the rating plate)
13

4 MAINTENANCE
The property owner has the following responsibilities:
1. To maintain the area around the boiler clean at
all times and free from combustible and highly
flammable material;
2. To ensure that the ambient air at the boiler is not
excessively dusty or humid;
3. To have all water leaks repaired in the system as
they arise.
4. To ensure that the ambient temperature in the area
where the unit is installed does not exceed 27°C
(80°F).
CAUTION
The boiler guarantee 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 covered 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.
5 INFORMATION
Model: .................................................. Serialnumber: ..........................................
Installation date of the electric boiler: .................................................................................
Servicetelephone #- Day: .............................. Night: ...................................................
Dealername and address: ...........................................................................................
......................................................................................................................
......................................................................................................................
14

6 TECHNICAL DATA
Table 4 – Technical Specifications
Model number
Power (kW)
Electric element #1 (kW) Electric element #2 (kW) Electric element #3 (kW) Electric element #4 (kW) Electric element #5 (kW) Electric element #6 (kW)
Consumption (A)
Voltage - Frequeny - Phase
Supply - Return
Dimensions (L x P x H) in
Shipping weight (lbs)
HYDRAI016-208-3 16 8 8 - - - - 44.4 208V - 60Hz - 3
2" NPT Male
33.3 x 21.7 x 11.3
155
HYDRAI016-240-3 16 8 8 - - - - 38.5 240V - 60Hz - 3
HYDRAI016-480-3 16 8 8 - - - - 19.2 480V - 60Hz - 3
HYDRAI016-600-3 16 8 8 - - - - 15.4 600V - 60Hz - 3
HYDRAI024-208-3 24 8 8 8 - - - 66.6 208V - 60Hz - 3
HYDRAI024-240-3 24 8 8 8 - - - 57.7 240V - 60Hz - 3
HYDRAI024-480-3 24 8 8 8 - - - 28.9 480V - 60Hz - 3
HYDRAI024-600-3 24 8 8 8 - - - 23.1 600V - 60Hz - 3
HYDRAI032-208-3 32 8 8 8 8 - - 88.8 208V - 60Hz - 3
HYDRAI032-240-3 32 8 8 8 8 - - 77.0 240V - 60Hz - 3
HYDRAI032-480-3 32 16 16 - - - - 38.5 480V - 60Hz - 3
HYDRAI032-600-3 32 16 16 - - - - 30.8 600V - 60Hz - 3
HYDRAI040-208-3 40 8 8 8 8 8 - 111.0 208V - 60Hz - 3
HYDRAI040-240-3 40 8 8 8 8 8 - 96.2 240V - 60Hz - 3
HYDRAI040-480-3 40 8 8 8 8 8 - 48.1 480V - 60Hz - 3
HYDRAI040-600-3 40 8 8 8 8 8 - 38.5 600V - 60Hz - 3
HYDRAI048-240-3 48 8 8 8 8 8 8 115.5 240V - 60Hz - 3
HYDRAI048-480-3 48 16 16 16 - - - 57.7 480V - 60Hz - 3
HYDRAI048-600-3 48 16 16 16 - - - 46.2 600V - 60Hz - 3
HYDRAI064-480-3 64 16 16 16 16 - - 77.0 480V - 60Hz - 3
HYDRAI064-600-3 64 16 16 16 16 - - 61.6 600V - 60Hz - 3
HYDRAI080-480-3 80 16 16 16 16 16 - 96.2 480V - 60Hz - 3
HYDRAI080-600-3 80 16 16 16 16 16 - 77.0 600V - 60Hz - 3
HYDRAI096-480-3 96 16 16 16 16 16 16 115.5 480V - 60Hz - 3
HYDRAI096-600-3 96 16 16 16 16 16 16 92.4 600V - 60Hz - 3
In all cases, refer to applicable local and national codes
15

Figure 6 – Boiler Dimensions
Figure 7 – One Boiler Installation Schematic
16

Figure 8 – Multiple Boilers Installation Schematic
17

Figure 9 – Parts List
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18

Table 5 – Parts List
Item Description Note
A20015 Outdoor temperature sensor
B03970 Gasket element
B04218 End insulation
B04237-05 Kit element 208V - 8KW Element L99H023
B04237-06 Kit element 240V - 8KW Element L99H021
B04237-07 Kit element 480V - 8KW Element L99H019
B04237-08 Kit element 480V - 16KW Element L99H020
B04237-09 Kit element 600V - 8KW Element L99H017
B04237-10 Kit element 600V - 16KW Element L99H018
B04238 Plastic door
B04240 Contour insulation
B04241 High temperature wire harness For elements
B04247 End plate
B04248 Top front plate
B04249 Top rear plate
B04251 Controller bracket
B04252 Wall bracket
B04256 Contactor wire harness
B04257 Control wire harness
B04262 Machine bracket
B04263 Contactor bracket
B04268 Tank assembly
F07F015 Hexagonal nut 5/16-18 brass
G03J012 2" - 3/4" NPT reducer
G11F025 Relief valve
G11Z002 Purge valve
L01F014 Transfo 120/208/240/277/480V - 24V
L01F015 Transfo 600V - 480V
L01H009 24V DPST relay
L01H030 24V SPDT relay
L01H032 Contactor
L05F013 Control terminal block
L99F007 Terminal block
L99G005 Ground terminal
R02F018 Aquastat - HL Replacement kit: B04184
R02J015 Sensor well
R02Z010 Temperature sensor
R99F052 Pressure transducer
R99F054 Current transducer
R99G006 Rectifier relay card
R99G007 Replay delay control card
R99G021 Dettson controler (Industrial)
R99H006 Low water cutoff
X50039 Controller label
X50043 Elec label 2.5"
X50044 Dettson label 3.5"
19

Figure 10 – Electrical Diagram
20