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HYDRAC04-E2401M

Dettson HYDRAC07-E2401M, HYDRAC03-E2401M, HYDRAC04-E2401M, HYDRAC05-E2401M, HYDRAC06-E2401M Installation Instructions And Owner's Manual

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ELECTRIC BOILER
ELECTRONIC CONTROL
2015-06-09
X40203 Rev.E
www.dettson.ca
Models:
Installation Instructions
and Homeowner’s Manual
Dettson Industries Inc
Manufactured by:
Sherbrooke, Qc, Canada
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
TABLE OF CONTENT
SECTION 1 : INSTALLATION ......................................................................................................................................................................................... 3
1) DANGER, WARNING AND CAUTION ............................................................................................................................................................. 3
2) HEATING WITH HOT WATER ......................................................................................................................................................................... 3
3) DELIVERY ........................................................................................................................................................................................................ 3
4) INSTALLATION ................................................................................................................................................................................................ 3
Positioning .............................................................................................................................................................................................................. 3
5) CLEARANCES ................................................................................................................................................................................................. 4
6) DISTRIBUTION SYSTEM ................................................................................................................................................................................ 4
7) INSTALLATION OF THE BOILER ................................................................................................................................................................... 5
8) ELECTRIC POWER SUPPLY .......................................................................................................................................................................... 6
1. CONNECTING THE CIRCULATING PUMP ............................................................................................................................................... 6
2. CONNECTING THE THERMOSTAT .......................................................................................................................................................... 6
3. CONNECTING THE OUTDOOR SENSOR ................................................................................................................................................ 6
SECTION 2 : OPERATION ............................................................................................................................................................................................. 6
1) ADJUSTMENTS AND START-UP ................................................................................................................................................................... 6
2) MECHANICAL HIGH LIMIT .............................................................................................................................................................................. 6
3) ELECTRONIC CONTROL ................................................................................................................................................................................ 7
SECTION 3: MAINTENANCE ....................................................................................................................................................................................... 10
SECTION 4 : INFORMATION ....................................................................................................................................................................................... 10
SECTION 5 : TECHNICAL DATA ................................................................................................................................................................................. 11
LIST OF FIGURES
Figure 1: Mounting configurations ................................................................................................................................................................................... 4
Figure 2: Boiler components ........................................................................................................................................................................................... 5
Figure 3: Navigation in menus ........................................................................................................................................................................................ 8
Figure 4: Modulation in function of the exterior temperature ........................................................................................................................................... 9
Figure 5: Boiler Dimensions .......................................................................................................................................................................................... 11
Figure 6: Typical Diagram of a Single Zone Installation ................................................................................................................................................ 12
Figure 7: Multizone Diagram with more than one Circulator ......................................................................................................................................... 12
Figure 8: Multizone diagram with Motorized Valves ...................................................................................................................................................... 13
Figure 9: Electrical Diagram .......................................................................................................................................................................................... 13
Figure 10: Exploded Vue ............................................................................................................................................................................................... 14
LIST OF TABLES
Table 1: Minimum clearances to combustible materials ................................................................................................................................................. 4
Table 2: Hydra Compact – Technical specifications ..................................................................................................................................................... 11
Table 3: parts List .......................................................................................................................................................................................................... 15
2
SECTION 1 : INSTALLATION
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.
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.
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;
- An exterior probe for modulation;
- A ¼” NPT cap to cork the ¼” NPT nipple between the elements in the case the boiler is installed horizontally;
- A ¼‘’ NPT coupling for the installation of the air vent if unit is installed upright position;
- Two 1” x ¾” reducers for the pressure relief valve and the drain valve.
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.
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 must be installed using the mounting brackets that are included. Before all, unfold the four lugs at the back of the unit. First, position the upper support, hang the boiler, then fix the down support. Finally, use the included self-tapping screws to fix the unit to the wall brackets with the lugs.
The boiler can be installed in 5 possible configurations as shown in figure 2.
Ensure that it is installed level and that the clearances indicated in Table 1 are respected.
3
LOCATION
CLEARANCE
Access side to elements
13 ¼‘’ (34 cm)
Sides
4’’ (10 cm)
Bottom
0
Front*
0
Back 0
Figure 1: Mounting configurations
5) CLEARANCES
The following clearances should be provided for the servicing of the unit:
Table 1: Minimum clearances to combustible
materials
* If the boiler is in an enclosure, provide a door or a removable panel in front to access the control panel.
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 5oC to 88oC (41oF to 190oF).
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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.
7) INSTALLATION OF THE BOILER
At the time of installation, the following steps should be followed. Refer to Figure 5,6,7,8 and 9.
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;
3. An air vent should be installed on the unit if installed upside position, water connections at the bottom. In such case, use the 3/8’’ NPT to ¼’’ NPT reducer, which is provided; 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:
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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. The automatic vent should be in operation.
Warning: Remove the plastic cover and check to see if the elements
are watertight.
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 aluminium 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 aluminium 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. 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 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. 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 R­W terminals inside the control panel. See Figure 5 and 6.
3. CONNECTING THE OUTDOOR SENSOR
Mount the sensor on an outside wall, protected from direct sunlight, so that it will accurately measure the outside temperature. Install 2 only #20 wires between the outdoor sensor and the terminals identified as S
-EXT
and S
inside the control panel of the boiler.
-EXT
SECTION 2 : OPERATION
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. Turn on the power,
2. Adjust the set point of the boiler on the electronic control. See 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 12 seconds delay;
4. The circulator stays on for as long as there is a call for heat except if differently configured on the electronic control.
2) MECHANICAL HIGH LIMIT
Mechanical High Limit Control
The mechanical limit aquastat must be set 30oF above the set point temperature on the electronic control.
Manual reset high limit control
Disconnect the unit before resetting the high limit. The manual reset high limit is set at 100°C (212°F). To reset this protection, the boiler needs to cool down. Then the red button shall be pressed using a pen or screwdriver.
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3) ELECTRONIC CONTROL
Display and electrical controller:
Pump: Shows the state of the pump. Set P: Indicates the temperature set point. Target: Indicates the target temperature. T° in: Temperature inside of the device.
T° out: Temperature outside of the
device Cmd: Indicates the 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 and press the central button to access the desired menu.
These menus are the consumption menu, the alarm menu, the configuration menu and the installer menu.
Consumption:
The consumption menu shows an approximated value of the power consumed by the boiler since it was 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.
Configuration:
The configuration menu’s purpose is to allow the user to adjust settings linked to the interface, such as the temperature’s units and
the language.
Units: allows switching between Fahrenheit and Celsius degrees.
Language: allows switching the displayed text between French and English.
Important: Access to the
Tests tab appearing on the controller’s screen is protected by a
password. Under no circumstances should a user try to access it. This function is used at the Dettson factory to test the Hydra Revolution before it is shipped to a distributor. If the user manages to enter the correct password the machine will be stuck in the test function. To exit the test function, the machine must be shut down, it will then return to the main screen after being subsequently turned on.
Installer:
The installer menu’s goal is to make the installer’s work easier. This menu
is protected by a password that can be found on the electrical schematic glued to the plastic case of the Hydra Compact.
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.
In case of alarm, the controller’s screen will be illuminated by a
flashing red light. It is strongly advised that you tell an installer about this issue.
Using the left and right buttons, the arrow on the screen can be moved and the central button will allow the user to activate the element pointed by it.
Current: Indicate the alarms
currently afflicting the device.
Past: Shows a history of the alarms
triggered on the device.
Clear alarm: Ends alarms that still
appear active on the device.
The past alarm function allows you to revisit the previous 25 alarm messages and an approximated time span since they happened. The arrow buttons allow the user to scroll through the alarm reports and the central button allows them to return to the alarm menu.
The password consists of a combination of characters entered with the three buttons of the Hydra (left, center, right then center).
The user shouldn’t try to gain access
to this menu as it is used to program the behaviour of the device.
Type: Gives a preset value to the temperature set point. Mass, Plinth, Light and Cast Iron are preset values for determining temperature ceil. 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. 20 Seconds indicate that the pump will deactivate 20 seconds following the end of a heating demand from the thermostat.
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Set P: Set the target temperature the device will try to reach upon the reception of a signal from the thermostat.
T° out: Allows the device to know if an external sensor is being used.
Boost Mode:
The boost mode menu allows the user to raise the boiler’s temperature set point by 10 degrees Fahrenheit during 24 hour. Press the central button while in this menu to activate or deactivate this measure.
Figure 3: Navigation in menus
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Figure 4: Modulation in function of the exterior temperature
85,0
95,0
105,0
115,0
125,0
135,0
145,0
155,0
165,0
175,0
5,0 25,0 45,0
Boiler temperature (ºF)
Outdoor air temp (ºF)
Boiler temperature in function of outside temperature
Plinth (T_Setpoint = 175ºF)
Cast Iron (T_Setpoint = 150ºF)
Light (T_Setpoint = 125ºF)
Mass (T_Setpoint = 100ºF)
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SECTION 3: MAINTENANCE
Model:
Serial number:
Installation date of the electric boiler:
Service telephone # – Day:
Night:
Dealer name and address:
The property owner has the following responsibilities: a. To maintain the area around the boiler clean at all times and
free from combustible and highly flammable material;
b. To ensure that the ambient air at the boiler is not excessively
dusty or humid; c. To have all water leaks repaired in the system as they arise. d. To 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.
SECTION 4 : INFORMATION
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.
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SECTION 5 : TECHNICAL DATA
POWER (kW@208V)
POWER (kW@240V)
Volts - Hertz - Phase
Electric element #1 (Kw)
Electric element #2 (Kw)
Consumption (Amp 208/
240
)
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''
Table 2: Hydra Compact – Technical specifications
Figure 5: Boiler Dimensions
11
Figure 6: Typical Diagram of a Single Zone Installation
Figure 7: Multizone Diagram with more than one Circulator
12
Figure 8: Multizone diagram with Motorized Valves
Figure 9: Electrical Diagram
13
SECTION 6
REMPLACEMENT PARTS
Figure 10: Exploded View
14
Table 3: parts List
#
Item
Description
Comments
1
B04383-02
Tank
3kw @ 5kw (Tank only)
2
B04383-01
Tank
6kw @ 12kw (Tank only)
3
B04422
Cover assembly
Cover, cosmetic and wiring
diagram
4
R02L006
Tridicator
5
B04180-01
Thermodisc support assembly
Thermodisc, support and heat
paste
6
G11F025
Relief valve 30# 3/4m x 3/4f
7
G08F005
Adaptor 1 x 3/4
8
R02J013
Well probe 1/4 NPT
9
R02Z010
Temperature probe
10
G01G001
Standard nipple 1/4" NPT x 4"
11
G03F001
Coupling 1/4" NPT
12
G16G004
Cap 1/4" NPT
13
B04237-01
Element replacement kit
Element 3 kw and gasket
14
B04237-02
Element replacement kit
Element 4 kw and gasket
15
B04237-03
Element replacement kit
Element 5 kw and gasket
16
B04237-04
Element replacement kit
Element 6 kw and gasket
17
B03970
Sealing gasket element
18
B04401
Insulation
19
B04395
Cabinet
20
B04398
Jacket
21
B04391
End plate assembly
22
B03952
Wall support
23
B04201
Machine support
24
L01J001
Breaker 15amp
25
B04400
End plate insulation
26
G11Z002
Drain faucet 3/4m
27
B04396
Electrical panel
Panel only
28
A20015
Exterior probe -12 deg.C
29
L99F006
Terminal block
30
F14G007
Nylon standoff
31
R99G020
Dettson control
32
B04184
Aquastat assembly (Hi-limit)
33
R99G006
Rectifier control
34
L01H030
Relay DPST 22VDC
35
A20009-05
Red wire element
36
A20009-04
Black wire element
37
L01H009
Relay 24vac
38
B04291
Electrical kit (1 element)
3 kw to 5 kw
39
B04292
Electrical kit (2 elements)
6 kw to 12 kw
40
A00421
Exterior probe wiring
41
B04397
Control support
42
L01F010
Transformer 208/240/24
43
B04000-03
9 positions terminal
15
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