THERMO 2000 MINI Ultra 6 Installation & Operating Manual

Full Text Searchable PDF User Manual

Electric Boilers

MINI ULTRA

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

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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

Amp.

MINI Ultra 6

6 / 20,470

2 x 3 KW

MINI Ultra 7.5

7.5/25,590

1X4.5+1X3K

MINI Ultra 9

9 / 30,710

37.5

2 x 4.5 KW

MINI Ultra 12

12 / 40,940

2 x 6 KW

! 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.

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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
50

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

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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

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

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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

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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,

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.

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.

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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 “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

the

manufacturer’s

instructions.

Fig. 5 Zone valves electrical diagram.

R W

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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.

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10.

OPERATION

“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

the

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

. d

t t

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

. d

t t

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

. d

t t

STD

MAX

MIN

RADIATEURS EN FONTE

CAST IRON RADIATORS

140F/60C

150F/65C

160F/71C

170F/77C

. d

t t

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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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)

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.

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12.

Table 1:

ITEM

DESCRIPTION

RANGE

DEFAULT

Choose the units the user prefers to work with

or C

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.

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-

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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

normal

room

temperature

after

thermostat’s “nights set back” program
.

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

NOR

MAL

BOO

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)

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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

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

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

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

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)

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--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

”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

the

heating

distribution

system

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

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:

Defects or malfunctions resulting from installation, repair, maintenance and/or usage
that are not done in conformity with the manufacturer’s installation manual; or

Defects or malfunctions resulting from installation, maintenance, or repair that are
not done in accordance with regulations in force; or

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

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

Installation in which liquid circulating in the tank does not remain in closed circuit or
installation in which piping is leaking; or

A polybutylene pipe or radiant panel installation without an oxygen absorption
barrier is used; or

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

Your home contains any type of water softener system and the unit is not installed
and maintained in accordance with the manufacturer specifications; or

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

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