THERMO 2000 MINI Ultra 6 Montageanleitung

ElectricBoilers

MINI ULTRA

odels from 6 kW to 12 kW :

208/240V single phase

INSTALLATION & OPERATING MANUAL

Your MINI ULTRA Electric Boiler has been carefully assembled and factory tested to provide

years of trouble-free service. The following information and safety measures are provided to

enable proper installation, operation, and maintenance of this product.

It is imperative that all persons who are expected to install, operate or adjust this boiler

should read these instructions carefully.

Any questions regarding the operation, maintenance, service or warranty of this electric

boiler should be directed to the supplier.

When all installation steps have been completed, insert this installation manual in its original

envelope, and keep in a safe place (close to the boiler) for future reference.

THERMO 2000 INC. revision: June.2014

Printed in Canada

BTH Electric Boilers USE & CARE MANUAL

(Revision June.2014)

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Ratings & Specifications at 120/240** Vac/1ph (3 wires L1-N-L2):

MINI ULTRA

Cable*!

90C Breaker!

Model Capacity

KW/BTU at

240Vac**

Amps. !

Elements at

240Vac**

Electric

Element(s)

at 240Vac

Stages

Cu Al Amp.

MINI Ultra 6 6 / 20,470 25 2 x 3 KW 2 8 6 40

MINI Ultra 7.5 7.5/25,590 31 1X4.5+1X3K 2 8 6 40

MINI Ultra 9 9 / 30,710 37.5 2 x 4.5 KW 2 8 6 50

MINI Ultra 12 12 / 40,940 50 2 x 6 KW 2 6 6 70

! Add the amperage (Max. 5amp-1/6hp) of the circulating pump if it is connected directly to the boiler

* A higher capacity cable an breaker could be required. In all cases the local Electrical Code has priority.

** Can be connected to a 208Vac/1ph electrical supply. The resulting capacity will be of 75% of the

nominal capacity at 240V and the amperage will be of 87%.

Dimensions

Connections Overall dimensions

Inlet/ heating return 3/4 “ NPT Fem Height 21-1/2 inches

Outlet/ heating supply

3/4 “ NPT Fem Width 9 inches

Pressure relief valve 3/4 “ NPT Fem Depth 9 inches

Drain valve 3/4 “ NPT Fem Weight 40 lbs.

Operating temp. range: 50°F (10C) to 190°F (88C). Maximum pressure : 30 psi (207kPa)

Figure 1.

BTH Electric Boilers USE & CARE MANUAL

(Revision June.2014)

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General Safety Precautions

Be sure to read and understand the entire Installation & operation manual before attempting to

install or to operate this water heater. Pay particular attention to the following General Safety

Precautions. Failure to follow these warnings could cause property damage, bodily injury or

death. Should you have any problems understanding the instructions in this manual, STOP,

and get help from a qualified installer or technician.

INTRODUCTION

These important safeguards and instruction

appearing in this manual are not meant to

cover all possible conditions and situations

that may occur. It should be understood that

common sense, caution and care are factors

which cannot be built into every product.

These factors must be supplied by the

person(s) caring for and operating the unit.

LOCAL INSTALLATION REGULATIONS

This electric boiler must be installed in

accordance with these instructions and in

conformity with local codes, or in the absence of

local codes, with the National Plumbing Code

and the National Electric Code, current edition.

In any case where instructions in this manual

differ from local or national codes, the local or

national codes take precedence.

SECURITY CONSIDERATIONS

All installations have a maximum design

operating pressure limited to 30 psi (207kPa) by

a safety relief valve.

Boiler operating temperature range is from

F(10C) and 190°F(88C). This boiler is

designed to be used only in a hot water close

circuit heating system.

A mix of water and propylene-glycol antifreeze

specially formulated for heating system can be

used up to a maximum concentration of 50%.

CHECK LIST

Please check the identification tag on the unit to

make sure you have the right model.

List of components shipped with the unit :

•Pressure relief valve set at 30 PSI.

•Drain valve.

•Temperature & pressure indicator

(Factory installed).

•Outdoor temperature sensor

SHIPMENT INSPECTION

Inspect the electric boiler for possible shipping

damage. The manufacturer’s responsibility

ceases upon delivery of goods to the carrier in

good condition. Consignee must file any claims

for damage, shortage in shipments, or non-

delivery immediately against carrier.

WARNING

BTH Electric Boilers USE & CARE MANUAL

(Revision June.2014)

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INSTALLATION

The manufacturer’s warranty does not cover any damage or defect caused by installation, or

attachment, or use of any special attachment other than those authorized by the manufacturer

into, onto, or in conjunction with the water heater. The use of such unauthorized devices may

shorten the life of the boiler and may endanger life and property. The manufacturer disclaims any

responsibility for such loss or injury resulting from the use of such unauthorized devices

LOCATION

The electric boiler should be installed in a clean,

dry location. Long hot water lines should be

insulated to conserve water and energy. The

electric boiler and water lines should be

protected from exposure to freezing

temperature.

The electric boiler must be located or protected

so as not to be subject to physical damage, for

example, by moving vehicles, area flooding, etc.

The electric boiler should not be located in

an area where leakage of the tank or water

connections will result in damage to the

adjacent area or to lower floors of the

structure. When such areas cannot be

avoided, a suitable drain pan or non-

flammable catch pan, adequately drained,

and must be installed under the boiler.

The pan must be connected to a drain.

NOTE: Auxiliary catch pan MUST conform to

local codes.

The boiler can be mounted directly on a wall

with adequate screws. It needs to be properly

leveled.

All models in alcoves. The ambient temperature

must not exceed 90F (32C)

The electric boiler should not be located near an

air vent blowing a corrosive atmosphere or high

humidity. The limited warranty is void when the

failure of the electric boiler is due to a corrosive

atmosphere.

The choice of the mounting position of the boiler

shall be made in relation with the required

clearances shown below and the fact that the

electric element compartment of the boiler

needs clearance to allow their replacement.

CLEARANCE

For adequate inspection and servicing the

following minimum clearance is necessary:

Sides

4 in. /10cm

Electric elements side

14 in./35cm

Front side of the boiler

24 in./60cm

Back

0 in./0cm

Fig. 2 Mounting position

CAUTION

WARNING

BTH Electric Boilers USE & CARE MANUAL

(Revision June.2014)

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BOILER WATER CONNECTIONS

Make sure you connect the accessories and the piping to the proper connection fittings as indicated at figure

2 above and according to the selected mounting position.

Figure 3 below shows typical connections of a MINI boiler to a radiant floor heating system. The location of

the distribution system components may be different from what is represented.

Figure 3 : Typical piping lay-out

Flow check valve

On heating systems having more than one pump,

each pump will need to be equipped with a flow

check valve either incorporated into the pump or

separate.

Pressure relief valve

This component supplied with the unit must be

installed directly to the boiler housing to the

appropriate connection according to the mounting

position.

Connect the outlet of the relief valve downward to

a safe location in case of discharge.

The piping diameter used for the discharge piping

shall not be smaller than that of the valve outlet. .

No valve of any type, restriction or reducer

coupling should be installed on the discharge line.

Local codes shall govern the installation of relief

valves.

Expansion tank

The expansion tank must be able to store the

required volume of boiler water during maximum

design operating temperature. The maximum

allowable operating pressure is 30PSI (207kPa).

Contact your plumbing supply house for

assistance.

Water pressure feeder regulator

When a pressurized water supply is available in

the building, a make-up systems consisting in a

water pressure reducer generally set at 12psi

(83kPa) and equipped with check valve satisfying

local regulations must be installed between the

boiler and the water supply system.

If the boiler is installed in a building that does not

have a water supply and when the local plumbing

codes allows, it is possible to simply manually

pressurized the heating system equipped with an

expansion tank to 10 (7kPa)to 28psi (193kPa) and

BTH Electric Boilers USE & CARE MANUAL

(Revision June.2014)

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manually maintain a minimum pressure when

required. Another possibility is to install a

pressurized storage tank specially made for those

applications that will inject on request an

appropriate quantity of liquid to maintain an

appropriate pressure on the heating system.

Air bleeder

Installation of manual or automatic air vents are

required to eliminate all air from the boiler and the

heating distribution system.

When the boiler is installed above the heating

distribution system, an automatic air

separator/eliminator must absolutely be installed

at the outlet of the boiler in order to eliminate all

possibilities of air buildup inside the boiler that

would damage the heating elements.

Circulating pump

We recommend that the pump be installed at the

outlet of the boiler with isolating valves as shown

in figure 3.

The pump shall be selected such as to be able to

supply adequate flow in relation to the heating

distribution system on which it will be connected

and the heating capacity of the boiler installed.

The table below will give you details on required

water flow for distribution systems having to

operate with a differential temperature of 10F and

20F between their inlet and outlet

Model

Diff. 10F (usgpm)

Diff. 20F (usgpm)

Boilerpress.drop

MINI Ultra 6

4.0

2.0

Negligible

MINI Ultra 7.5

5.1

2.5

Negligible

MINI Ultra 9

6.0

3.0

Negligible

MINI Ultra 12

8.2

4.1

Negligible

The boiler has to be activated only upon a call for

heat and when a pump will be working (no jumper

allowed on TT terminals) a minimum water flow of

1usgpm is recommended.

Your heating wholesaler shall be in good position

to recommend the appropriate model for your

application.

The amperage drawn by the pump and other

120volts components shall not exceed 5 amps or

1/6HP.

Drain valve

Installed at the lowest point of the unit, it allows

the unit to be drained for the eventual

replacement of a defective component.

Strainer

This component is used to collect potential

sediments coming from the distribution system

and more particularly from systems made of steel

piping and radiators. If such sediments

accumulate at the bottom of the boiler it could be

harmful to the heat transfer of the elements and

generate premature failures.

ELECTRICAL CONNECTIONS:

Main boiler supply

Wiring must conform to the National Electrical

Code and to state or local code requirements.

The electric boiler must be electrically grounded in

accordance with local codes, or, in the absence of

local codes, with the National Electrical Code.

Wiring must come from a 120/240 Volt (single

phase, 60 Hz) “L1-L2-N” circuit protected by a

properly sized breaker.

Wire gage (3 wires+ground) must be properly

sized. Consult the boiler rating plate to select the

proper breaker and wire gage.

The main terminal block of the boiler is suitable for

#14 to #2 wires.

Supply cables can be made of Aluminum or

Copper and be rated for 90C (194F).

If aluminum cables are used, it shall be of an

adequate size (generally bigger) to meet the

National electrical code.

Electrical supply of External accessories

The total 120vac consumption of the boiler and

external accessories must not exceed 5A.

The maximum electrical consumption of 24vac

external accessories connected to R&C terminals

must not exceed 30Va. The available voltage at

the boiler transformer must not drop below 24Vac.

Outdoor temperature sensor

If you want the target boiler temperature to

modulate according to the outdoor temperature (

when the outdoor temp. will get colder, the target

temp. will get higher) , the supplied outdoor

sensor will have to be connected to S1 S1 before

turning the power on to the unit.

The installation of this sensor avoids the operation

of the boiler when the outdoor temperature

exceeds the selected value corresponding to the

maximum temperature required for heating.

The sensor shall be connected to terminals S1-S1

in the boiler using a two conductor cable 18ga.

BTH Electric Boilers USE & CARE MANUAL

(Revision June.2014)

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Thermostat(s) and pump(s) connections:

Thermostats:

Use a low voltage 24Vac thermostat designed for

central heating (not electric baseboards). Some

thermostats are equipped with floor temperature

sensor.

The purpose of the thermostat is to transmit an

heat demand to the boiler. When this demand is

received, the boiler will control the activation of

the heating elements.



Heating systems equipped with one

thermostat and one pump:

With an 18 gauge cable, connect the room

thermostat as follow:

Thermostat with 2 wires: Connect the two wires to

the R & W boiler terminals.

Thermostat with 3 wires: Connect the C/R/W

wires from the thermostat to corresponding

terminals on the boiler

Using 14 gauge wires, connect the circulating

pump directly to terminals “Pand “P” (120vac).

N.B. The amperage drawn by the pump must not

exceed 5A-1/6HP.



Multiple pumps zoning applications:

Components shall be connected in such a way

that when a thermostat is calling for heat, only the

corresponding pump be operated and an auxiliary

contact X-X closes to give the signal of the heat

demand to the boiler otherwise the elements will

not be working.

To do so, you will need relays as illustrated below.

Boiler terminals PP- will not be used.

N.B. Do not install a jumper between terminals R

Wof the boiler.

Fig.4: Multiple pumps electrical diagram.

Zoning with motorized valves

Connect the low voltage thermostat to the zone

valve. Components must be wired to ensure that

only the zone valve corresponding to the zone

calling for heat is actuated. When a zone valve

opens, it generally closes a switch that is

incorporated in it. Connect each switch to the “R”

& “W” terminals in the boiler.

Connect the circulator to terminals “P” and “P” in

the boiler.(max. 5A-1/6hp) . The electrical

connections of the motorized zone valves shall be

made according to the manufacturer’s

instructions.

Fig. 5 Zone valves electrical diagram.

R W

BTH Electric Boilers USE & CARE MANUAL

(Revision June.2014)

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BTH Electric Boilers USE & CARE MANUAL

(Revision June.2014)

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ADJUSTMENTS OF THE CONTROL MODULE

INTRODUCTION

The MINI Ultra boiler is mainly designed to be

installed on closed circuit applications where the

water of the heating system flows directly from the

boiler to the heating distribution system (Standard

parallel Piping system)

Two operation modes are then offered:



Fixed boiler temperature set point (the

outdoor sensor shall not be installed)



Outdoor reset

DISPLAYED INFORMATION

The electronic control uses an LCD display to

make all adjustments and to visualize the

operation of the system.

OPERATION OF THE INTERFACE

The controller uses four push buttons at the

bottom of the display to select and adjust the

parameters.

The button is used to access to the

configuration menu and confirm a selection.

The buttons are used to

select an item or adjust a value.

The button enables the illumination of the

display under two different modes.

The default mode will enable the illumination of

the display for a period of 10 sec. each time a

button is pressed. If the is pushed, the light

will be continuously illuminated. Just press the

button to change the mode of activation.

BTH Electric Boilers USE & CARE MANUAL

(Revision June.2014)

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10.

OPERATION IN “FIXED BOILER

TEMPERATURE SET POINT”

For installation where the boiler target

temperature shall be maintained at a fixed

temperature that will not vary in relation to the

outdoor temperature, the sequence of operation

will be as follow:

On a call for heat from the room thermostat, the

circulating pump will start and the boiler will

activate the number of stages required to get to

and maintain the outlet temperature of the boiler

near the selected target temperature. A rotation

of the stages based on an equal time period of

operation is provided.

N.B. The supplied outdoor temperature sensor

shall not be connected before applying the

electrical power to the unit

OPERATION WITH “OUTDOOR RESET”:

For installation where the boiler target

temperature shall modulate in relation to the

outdoor temperature; when the outdoor

temperature gets colder, the boiler target

temperature will increase.

On a call from the room thermostat, the

circulating pump will start and the boiler will

activate the number of stages required to get to

and maintain the outlet boiler temperature near

the target temperature established by the

controller according to the outdoor temperature.

A rotation of the stages based on an equal time

period of operation is provided.

N.B. The supplied outdoor temperature sensor

must be connected before applying the electrical

power to the unit.

The boiler target temperature will be calculated

by the controller in relation to the parameters

selected in the menu

and the

maximum target temperature required when the

outdoor temperature will get to -10F (-23C). The

“STD” curve corresponds to the default

maximum temperature for a typical system and

this value can be modified from the “MIN” to

“MAX” value shown on the following tables.

The following tables show the values of the

target temperature that will be obtained in

relation to the outdoor temperature.

80F

27C

70F

21C

60F

15C

50F

10C

10F

-12C

40F

30F

20F

-7C

-17C

-10F

-23C

-20F

-29C

70F/21C

80F/27C

100F/-38C

90F/32C

110F/43C

120F/49C

130F/54C

Température ext. / Outdoor temperature

Temp. de con igne / Target temp.

STD

MAX

MIN

PLANCHER CHAUFFANT DANS BÉTON

RADIANT FLOOR IN CONCRETE

80F

27C

70F

21C

60F

15C

50F

10C

10F

-12C

40F

30F

20F

-7C

-17C

-10F

-23C

-20F

-29C

100F/-38C

90F/32C

110F/43C

120F/49C

130F/54C

Température ext. / Outdoor temperature

Temp. de con igne / Target temp.

STD

MAX

MIN

PLANCHER CHAUFFANT ENTRE SOLIVES

RADIANT FLOOR BETWEEN JOISTS

140F/60C

80F/27C

80F

27C

70F

21C

60F

15C

50F

10C

10F

-12C

40F

30F

20F

-7C

-17C

-10F

-23C

-20F

-29C

100F/-38C

90F/32C

110F/43C

120F/49C

130F/54C

Température ext. / Outdoor temperature

Temp. de con igne / Target temp.

STD

MAX

MIN

RADIATEURS EN FONTE

CAST IRON RADIATORS

140F/60C

150F/65C

160F/71C

170F/77C

Temp. de con igne / Target temp.

PURGE DELAY OF THE PUMP

The controller offers the possibility to

stop the operation of the pump after an

adjustable delay once the heat demand has

been completed.

The following choices are offered:

-“OFF” The pump will stop immediately when the

heat demand has been satisfied. This selection

shall be selected on systems equipped with

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