Full Text Searchable PDF User Manual
Electric Boilers
MINI ULTRA
M
odels from 6 kW to 12 kW :
2 08 / 2 40 V s in g le p h a s e
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)
, Page
2.
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)
, Page
3.
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
50
0
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)
, Page
4.
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)
, Page
5.
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)
, Page
6.
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)
, Page
7.
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 “P and “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
W of 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
R W
BTH Electric Boilers USE & CARE MANUAL
(Revision June.2014)
, Page
8.
BTH Electric Boilers USE & CARE MANUAL
(Revision June.2014)
, Page
9.
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)
, Page
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
4C
30F
0C
20F
-7C
0F
-17C
-10F
-23C
-20F
-29C
70F/21C
80F/27C
100F/-38C
90F/32C
110F/43C
120F/49C
130F/54C
Température ext. / Outdoor temperature
T
e
m
p
. d
e
c
o
n
s
ig
n
e
/
T
a
rg
e
t t
e
m
p
.
STD
MAX
MIN
PLANCHER CHAUFFANT DANS BÉTON
RADIANT FLOOR IN CONCRETE
80F
27C
70F
21C
60F
15C
50F
10C
10F
-12C
40F
4C
30F
0C
20F
-7C
0F
-17C
-10F
-23C
-20F
-29C
100F/-38C
90F/32C
110F/43C
120F/49C
130F/54C
Température ext. / Outdoor temperature
T
e
m
p
. d
e
c
o
n
s
ig
n
e
/
T
a
rg
e
t t
e
m
p
.
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
4C
30F
0C
20F
-7C
0F
-17C
-10F
-23C
-20F
-29C
100F/-38C
90F/32C
110F/43C
120F/49C
130F/54C
Température ext. / Outdoor temperature
T
e
m
p
. d
e
c
o
n
s
ig
n
e
/
T
a
rg
e
t t
e
m
p
.
STD
MAX
MIN
RADIATEURS EN FONTE
CAST IRON RADIATORS
140F/60C
150F/65C
160F/71C
170F/77C
T
e
m
p
. d
e
c
o
n
s
ig
n
e
/
T
a
rg
e
t t
e
m
p
.
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
BTH Electric Boilers USE & CARE MANUAL
(Revision June.2014)
, Page
11.
motorised fast closing time zone valves with in
order to prevent noise from water hammering.
-“15 sec to 60min” delay where the pump will be
kept running to enable the pump to circulate
water into the system to equilibrate the heat in
all the building.
-“ON” The pump is in continuous operation.
Required on particular heating distribution
systems.
AUTOMATIC HEATING SHUT DOWN
When the outdoor sensor is installed and that
the unit then operates in the “outdoor reset”
mode, the controller offers the user the
possibility to automatically stop the boiler when
the outdoor temperature reaches an adjustable
value
(0F
(-17C)
à
105F
(40C).
This
characteristic is especially interesting on the
following applications:
-Heating
systems
equipped
with
many
thermostats where the user wants to prevent the
operation of the unit if one of the thermostats
has inadvertently been activated
-Heating systems where the owner supplies heat
to a lodger
-Systems connected to a geothermic heat pump
where we do not want the electric boiler to be
operating unless the outdoor temperature drops
to a selected degree.
CONFIGURATION OF THE CONTROLLER
Since each type of heating distribution system is
designed to operate at water temperatures that
are particular to its operation, the proper
configuration of the operating parameters of this
particular system is important to maximize its
performance.
In order to do this, the installer will access the
configuration menu by pressing the
button for 2 sec. until the first menu appears.
The selection of the item or value is made by
pressing the
button and by
pressing the
button to get to the next
menu. See table 1 below to visualize the menu
list that will gradually be displayed.
If the buttons remain untouched for a period of
10 sec., the controller will register the value of
the selection made and return to the regular
display position. It will also return to the regular
display after reviewing all the operating
parameters of the controller.
In case of a power failure, the parameters will be
restored as they were established before the
failure.
BTH Electric Boilers USE & CARE MANUAL
(Revision June.2014)
, Page
12.
Table 1:
ITEM
DESCRIPTION
RANGE
DEFAULT
Choose the units the user prefers to work with
F
0
or C
0
F
0
Select the type of heating system on which the
boiler will be installed.
-Radiant Floor in concrete
-Radiant Floor between
joists
-Cast iron radiator
Hot water baseboards
Adjust the maximum boiler target temperature
required to adequately heat the building when
the outdoor temperature is very cold.
-Radiant Floor in concrete
85à 105F
-Radiant Floor between
joists 110Fà140F
-Cast iron radiator 135F à
165F
-Baseboard
160F à 185F
100F
125F
150F
175F
Select the purge period that the pump will be
running once the heat demand is completed.
Select OFF if the heat system is equipped with
electric zone valves.
OFF
15 sec. to 60min.
ON
30sec
Select the outdoor temperature at which no
heating of the building is required (the outdoor
sensor has to be installed)
0F à 105F
75F
Note1: Once these parameters have been set, the controller will automatically return to its normal view
but the user has the possibility to change the target temperature without having to go through the
complete menus
.
Adjustments of the target temperature by
the user:
By pressing the
the end
user has the possibility to offset the programmed
target temperature without going through the
tool menus.
When the + or- button is pressed, the value “0”
will appear and blink to show a “0” offset value
from the original settings. When the + or-
BTH Electric Boilers USE & CARE MANUAL
(Revision June.2014)
, Page
13.
buttons are pressed again the offset value will
change up to a value of + -10F(5C) from the
original setting made in the configuration menu.
The new value will blink during 5 sec. and the
display will then go back to the standard view
and the new target temperature will be shown.
Afterward, when the
button will be pressed, it will show the value of
the offset made previously and can be re-
adjusted.
Boost system operation
The controller incorporates a unique feature that
enables the target boiler temperature to automatically
be increased when the building heat load increases
but cannot be fulfilled with the actual boiler target
temperature and consequently the room thermostat(s)
cannot be satisfied within a pre-determined period.
Example:
-Return to normal heat load after low demand periods
occurring during sunny days.
-Long periods without heating which needs higher
boiler temp. to recuperate.
-Return
to
normal
room
temperature
after
thermostat’s “nights set back” program
.
80F
27C
70F
21C
60F
15C
50F
10C
10F
-12C
40F
4C
30F
0C
20F
-7C
0F
-17C
-10F
-23C
-20F
-29C
70F/21C
80F/27C
100F/-38C
90F/32C
110F/43C
120F/49C
130F/54C
Température ext. / Outdoor temperature
T
e
m
p
.
d
e
co
n
si
g
n
e
/
T
a
rg
e
t
te
m
p
.
NOR
MAL
BOO
ST
HAUSSE AUTOMATIQUE DU POINT DE CONSIGNE
« BOOST »
AUTOMATIC INCREASE OF TARGET TEMPERATURE
The controller will engage the “Boost” program
when the heat demand on terminals W&R has
been maintained for a pre-determined period
according to the type of selected application.
Once this period has been reached, the “Boost”
icon will appear on the display and the boiler
target temperature will start increasing very
slowly over a pre-determined period and up to a
pre-calculated maximum value until the heat
demand applied on W&R terminals has been
completed.
On a new heat demand, the previous boost
period is forgotten and the boiler target gets
back to its original setting
If the system is in “boost” most of the time, this
means
that the
boiler
target parameter
established during “Setting procedure” would be
too low for the heating system on which the unit
is applied. This boiler target could simply be
gradually increased by pressing the + button or
by re-setting the operating parameters using the
tool menus.
N.B. The boost program is a marvellous feature
that works fine on applications where the
number of room thermostats is in limited quantity
otherwise it may happen that during very cold
periods the heat demand from all the
thermostats may not become satisfied.
If your application needs the boost program to
be cancelled, you can do it by pressing the
button
for 6 sec. and the display will show
icon and the two options ON or OFF will blink
and can be selected using the + - button. The
controller will register the selected option and
return to normal operation if the buttons remains
untouched for 5 sec. or if the
button is
pressed.
BTH Electric Boilers USE & CARE MANUAL
(Revision June.2014)
, Page
14.
START UP OPERATION
Before operating this boiler, be sure to read and follow these instructions, as well as the warnings
printed in this manual. Failure to do so can result in unsafe operation of the boiler resulting in
property damage, bodily injury, or death. Should you have any problems reading, following or
difficulty in understanding the instructions in this manual, STOP, and get help from a qualified
person.
Do not turn on the boiler unless it is filled with water. Do not turn on the boiler if the cold water
supply shut-off valve is closed.
Preparatory step
Make sure that all the piping and
electrical connections have been made.
Fill the boiler and the heating system
with water.
Check for leaks.
Check the pressure reading at the
temperature and pressure indicator. It
should be around 12psi.
Turn On the electrical supply to the
boiler with no heat demand from the
thermostat(s).
Completely eliminate all the air from the
boiler and the distribution piping system.
To do so, activate the circulating pump
without the heating elements. If the
pump is connected directly on PP
terminals of the boiler, it can be
activated by selecting “ON” in the
configuration
menu
after
having
pressed
for 2 seconds.
Adjust the UltraSmart boiler temperature
controller as explained earlier and set
the purge delay of the pump from On to
its normal operation setting.
Set the room thermostat ON to generate
a heat demand. The pump shall start.
The heating elements shall gradually
come on and the boiler temperature will
increase.
Start up & Inspection
Measure the amperage value drawn by
the unit. It shall be around the value
indicated on the boiler name plate.
Partially close the isolating valve at the
outlet of the boiler to reduce the water
flow and consequently slowly increase
the outlet temperature. The heating
elements shall gradually stop as the
temperature increases and gets near
the target temperature.
Lower the adjustment of the room
thermostat(s), the heating elements
shall stop and the pump shall stop after
the delay set on the controller.
Check the pressure reading on the
gauge of the unit. It should not be higher
than 28 psi when the distribution system
will get to its maximum operating
temperature.
N.B. On initial start up it may take a
considerable amount of time before the water
reaches the target temperature
Further adjustments may be necessary as you
use your boiler and the space heating system.
SAFETY PRECAUTIONS
!
BTH Electric Boilers USE & CARE MANUAL
(Revision June 2014)
, Page
15
MAINTENANCE
INTRODUCTION
Properly maintained, your boiler will provide years of dependable, trouble free service. It is recommended that a regular
routine maintenance program be established and followed by the user. Components are subject to eventual failure that
requires service. Failure to use the correct procedures or parts in these circumstances may make the unit unsafe or
reduce the life of the boiler.
The owner should have the following inspection and
maintenance procedures performed:
At all time
An immediate inspection shall be made if:
An odor of melted plastic or overheated
material is detected
A leak coming from the unit or the heating
system is observed
If a leak is detected at the outlet of the safety relief
valve, it could be related to a problem with components
installed on your heating distribution system. A quick
correction is then required.
Do not plug the outlet of this valve if a dripping condition
occurs.
Twice a year:
Check for the proper operation of the automatic
air purger(s) and eliminate air from the
radiators.
Annually:
It is recommended that a visual inspection be
made on the electrical compartments of the
boiler to check the water tightness of the gasket
on the element flange and also check for any
signs of overheating of the components and
wires. Required corrections should be made as
soon as possible.
Parts used for replacement should be the same
as the original equipment.
Make sure that the power on the unit has been
turned off before opening the electrical
compartments of the boiler.
Close isolating valves and clean the strainer
located on the heating return piping.
Open the boiler drain valve to eliminate
deposits that could have settled at the bottom of
the boiler. Stop when water gets clear. If there
is no flow or a very small flow, it could be due to
a large accumulation of deposits at the bottom
of the unit. If so, close the isolating valves at the
inlet and outlet of the boiler, remove heating
element(s) and clean the inside of the tank with
a strong jet of water
WARNING
!
BTH Electric Boilers USE & CARE MANUAL
(Revision June 2014)
, Page
16
REPAIR PARTS
MINI ULTRA
**When replacing a heating element, make sure to install it in the same orientation it was
installed at the factory.
TROUBLE SHOOTING
PROBLEM
CAUSES
SOLUTION
The display shows
---
in “TARGET
TEMP”
-There is no heating demand
-When the outdoor sensor
is used and the icon is
shown, the outside temperature
is above the boiler shut down
setting.
-The switch located on the back
of the controller is set to “Bi-
Energ” and the icon
is
shown.
-Generate a heat demand
-Temporarily increase the value of this
setting on the controller configuration.
-Set the switch to “Elect”
The display shows
“Er1”
and the
icon
is displayed.
The controller is not detecting the
presence of the outdoor sensor.
-Make sure that the sensor cable
connected to the unit is not in short or
open circuit. Do not install a jumper
between S1-S1 when the sensor is
not required.
-Check the resistance value (ohms) of
the sensor. It should correspond to the
value shown on the table below
otherwise it should be replaced.
Check for proper connection of the
wires inside the boiler connected to
S1S1 and at the controller terminals.
The display shows “Er2” and blinks
The controller is not detecting the
presence of the boiler
temperature sensor.
-Check the state of the sensor located
in the immersion well located at the
top of the elect. element compartment.
Heating elements
**
3kW : ZEL300-240V3KW
4.5kW : ZEL300-240V45KW
6kW : ZEL300-240V6KW
Temperature & Pressure
indicator
ZMC300-75P160C
Transformer
ZEL400-120V50VA
Fuse
ZEL250-TDCC15A
Power relays 24VAC
ZEL100-24ACNO30
High limit control
ZEL200-L6C732
Pressure relief valve
ZMC200-SV30PSI1
Control multi-pin connector
Controller
ZEL100-ULTRA
Contacteur 2 pôles
(6,7.5,9kW)
ZEL100-2PC50120
Contacteur 4 pôles (12kW)
ZEL100-4P50A120
BTH Electric Boilers USE & CARE MANUAL
(Revision June 2014)
, Page
17
--Check the resistance value (ohms)
of the sensor. It should correspond to
the value shown on the table below
otherwise it should be replaced.
Stage 2 is ON but not Stage 1
There is no problem. A rotation
of the stages is provided to allow
an equal time of operation of the
stages
The boiler target temperature does
not change when the outdoor
temperature varies
The outdoor sensor has not been
detected when the power has
been applied to the unit.
Check the connection of the outdoor
sensor to terminals S1S1. Turn OFF
the power to the unit for 5 sec. and set
it back ON.
The boiler water temperature at the
outlet of the unit “BOILER T
0
”does
not get to the “BOILER TARGET T
0”
-The room thermostat is not in
constant demand.
-Some heating elements are
defective
-The total capacity of the boiler is
expelled
to
the
heating
distribution
system
at
this
temperature.
-Adjust the thermostat anticipator (If
available) to obtain longer operating
cycles
-Replace defective elements
-If a boiler water temperature higher is
required to satisfy the heat demands
of the thermostats, a boiler having a
larger capacity is required.
Boiler stays in demand even when
the thermostat is not in demand.
(Systems with more than one
thermostat)
-On systems with electric zone
valves, one or many end
switches included in the valve is
defective.
-A jumper has been installed on
terminals W&R of the boiler
-Change defective end switch.
-Make appropriate connections as
shown in fig.5
An overheated plastic odour is
released from the boiler
Turn the power OFF to the boiler.
Open the front and left side panel
of the boiler. Check the
components and electric wires
for indications of overheating.
Replace overheated components and
check supply voltage to the boiler.
Boiler safety valve is leaking
-Pressure reading at the indicator
shows a pressure above 28psi
-Pressure is below 28psi
-The pressure regulator on the
distribution system is defective or the
expansion tank is too small or
defective.
-Replace the safety valve
Table 2: Sensors resistance value vs real temperature.
BTH Electric Boilers USE & CARE MANUAL
(Revision June 2014)
, Page
18
MINI ULTRA
LIMITED WARRANTY
Warranty Coverage for Residential Installation.
Thermo 2000 Inc. hereby warrants to the original residential purchaser that the MINI
ULTRA tank installed in a residential setting shall be free of leaks during normal use
and service for a period of fifteen (15) years from the date of purchase as long as
the original residential purchaser owns the home in which the unit was originally
installed. Residential setting shall mean usage in a single-family dwelling in which
the consumer resides on a permanent basis. Also, residential setting shall mean use
in multiple family dwellings in which one (1) MINI ULTRA tank is to be used in only
one (1) dwelling. In the event that a leak should develop and occur within this
limited warranty period due to defective material or workmanship, such leak having
been verified by an authorized company representative, Thermo 2000 inc. will repair
or replace at our sole discretion the failed unit with the nearest comparable model at
the time of replacement.
The
original residential purchaser is responsible for all costs associated with the
removal and reinstallation, shipping and handling to and from manufacturing plant.
The replacement unit will be warranted for the remaining portion of the original
Warranty.
Warranty Coverage for Commercial Installation.
Thermo 2000 Inc. warrants to the original purchaser that the MINI ULTRA tank
installed in a commercial setting shall be free of leaks during normal use and service
for a period of fifteen (15) years from the date of purchase.
Commercial setting shall mean use in other than residential setting stated above in
the residential setting definition. In the event that a leak should develop and occur
within this limited warranty period due to defective material or workmanship, such
leak having been verified by an authorized company representative, Thermo 2000
inc. will repair or replace at our sole discretion the failed unit with the nearest
comparable model at the time of replacement.
The
original purchaser is responsible for all costs associated with the removal and
reinstallation, shipping and handling to and from Manufacturer. The replacement
unit will be warranted for the remaining portion of the original Warranty.
Limited two years warranty on all MINI ULTRA
components & parts
All other MINI ULTRA components & parts are warranted for a period of two (2)
years against defects due to defective material or workmanship.
The
original
purchaser is responsible for all costs associated with the removal and reinstallation,
shipping and handling to and from Manufacturer. The components, repaired or
replaced are warranted for the residual period of the initial warranty on the unit.
Exclusions
This warranty is void and shall not apply if:
1.
Defects or malfunctions resulting from installation, repair, maintenance and/or usage
that are not done in conformity with the manufacturer’s installation manual; or
2.
Defects or malfunctions resulting from installation, maintenance, or repair that are
not done in accordance with regulations in force; or
3.
Defects or malfunctions resulting from improper installation, maintenance or repair
done carelessly or resulting from consumer damage (improper maintenance,
misuse, abuse, accident or alteration); or
4.
Installation in which a relief valve (pressure) is not installed or if it is not functioning
properly, or when it is not connected to a drain to avoid damage to the property; or
5.
Installation in which liquid circulating in the tank does not remain in closed circuit or
installation in which piping is leaking; or
6.
A polybutylene pipe or radiant panel installation without an oxygen absorption
barrier is used; or
7.
Installation where the acidity of water is not within the normal Environmental
Protection Agency (EPA) (between pH 6.5 – 8.5) guidelines or the domestic water
contains abnormal levels of particulate matter or water exceeding 10.5 gpg; or
8.
Your home contains any type of water softener system and the unit is not installed
and maintained in accordance with the manufacturer specifications; or
9.
The MINI ULTRA unit has been subjected to non authorized modifications; or
10.
Defects or malfunction resulting of storing or handling done elsewhere than Thermo
2000’s manufacturing plant; or
11.
Units on which the serial number is removed or obliterated.
Limitations
Thermo 2000 shall not be responsible for any damage, loss, and inconvenience of any
nature whatsoever, directly or indirectly, relating to the breakdown or malfunction of the
unit. This warranty limits its beneficiary’s rights. Nevertheless, the beneficiary may have
other rights, which vary from state to state.
This warranty replaces any other expressed or implicit warranty and constitutes the sole
obligation of Thermo 2000 towards the consumer. The warranty does not cover cost of
removal, reinstallation or shipping to repair or replace the unit, nor administration fees
incurred by the original consumer purchaser.
Thermo 2000 reserves its rights to make changes in the details of design, construction, or
material, as in its judgment constitute an improvement of former practices.
This warranty is valid only for installations made within the territorial limits of Canada and
the United States.
Warranty service procedure
Only authorized MINI ULTRA dealers are permitted to perform warranty obligations. The
owner or its contractor must provide Thermo 2000’s head office or authorized depot with
the defective unit together with the following information: MINI ULTRA model and serial
number, copy of the original sales receipt and owner’s identification certificate.
THERMO 2OOO INC.
500, 9e Avenue, Richmond (Qc) Canada J0B 2H0
phone: (819) 826-5613 Fax: (819) 826-6370
www.thermo2000.com