BTH Electric Boilers
Models ranging from 8 kW to 36 kW :
240 Volts ( 1 phase ) & 600 Volts ( 3 phases ).
USE & CARE MANUAL
WITH INSTALLATION INSTRUCTIONS FOR THE CONTRACTOR
Your BTH 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 INCORPORATED revision:August/06
Printed in Canada
Ratings & Specifications
Electric Ratings for 240 VAC (1 phase) Electric Boilers:
Model
No.
BTH 8 5 000 3 000 ------ ------ 8 000 33.3 27 296 8 6 50 50 41.3
BTH 10 5 000 5 000 ------ ------ 10 000 41.6 34 120 6 6 60 60 52
BTH 12 3 000 3 000 3 000 3 000 12 000 50 40 944 6 4 70 70 62.5
BTH 15 3 000 4 500 3000 4 500 15 000 62.5 51 180 4 3 100 80 78.2
BTH 18 4 500 4 500 4500 4 500 18 000 75 61 416 3 2 100 100 93.8
BTH 20 5 000 5 000 5000 5 000 20 000 83.4 68 240 3 1 125 110 104
BTH 24 6 000 6 000 6000 6 000 24 000 100 81 888 1 0 125 125 125
BTH 27 3 x 4 500 3 x 4 500 27 000 112.5 92 124 1 0 150 150 140
BTH 30 3 x 5 000 3 x 5 000 30 000 125 102 360 2/0 3/0 200 175 156
BTH 33 3 x 5 000 3 x 6 000 33 000 138 112 596 2/0 3/0 200 200 172
Electric Elements
(in Watts)
A B C D Watts Amp. BTU CU AL Amp. Amp. Amp.
Total Wires Breakers Fuse
Electric Ratings for 600 VAC (3 phases) Electric Boilers:
Model
No. Quantity Watts Quantity Watts kW Amp. BTU RW-90 HRC “D”
BTH 9 3 3 000 ------- ------ 9 8.7 30 708 14 15 A
BTH 13 3 4 500 ------- ------ 13.5 13 46 062 12 20 A
BTH 18 6 3 000 ------- ------- 18 17 61 416 10 30 A
BTH 22 3 3 000 3 4 500 22.5 22 76 770 10 30 A
BTH 27 6 4 500 ------- ------- 27 26 92 124 8 40 A
BTH 30 6 5 000 ------- ------- 30 29 102 360 8 40 A
BTH 36 6 6 000 ------- ------- 36 35 122 832 8 50 A
Electric Elements Electric Elements Total Wires Fuse
Note: 1 kW =3,412Btu
Connections sizes & overall dimensions
125%
Connections sizes Boiler overall dimensions
Boiler return 1 “ NPT M Height 12 inches
Boiler feed 1 “ NPT M Width 12 inches
Waterworks 1/2 “ NPT F Depth 34 inches
Safety valve 3/4 “ NPT F Shipping weight 99 lbs.
Drain valve 1/2 “ NPT F
Drain valve
(BTH 33,36)
3/4 “ NPT M
Operating temperature : from 50°F to 190°F. Maximum operating pressure: 30 p.s.i.
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 2.
Unit description:
Legend :
A. Boiler Water Supply Connection ( 1 inch diameter, NPT male)
B. Boiler Water Return Connection ( 1 inch diameter, NPT male)
C. Safety Relief Valve ( ¾ inch NPT female )
D. Temperature & Pressure Gage (1/2 inch NPT female )
E. Drain Valve (1/2 inch NPT female )
F. Fill Water Connection (1/2 inch NPT female )
G. Electric Line Knock-Out ( 1 inch )
H. Pilot Light
I. Boiler Wall Hanging Brackets
J. Electrical Compartment
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 3.
General Safety Precautions
!
Be sure to read and understand the entire Use & Care 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
WARNING
!
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
Domestic and commercial installations have a
maximum design operating pressure limited to
30 psi by a safety relief valve.
Boiler maximum operating temperature is 190°F
by design. This boiler is designed to be used
only in a hot water heating system.
CAUTION
!
The heat transfer medium must be water or
other non-toxic fluid having a toxicity rating
or class of 1, as listed in clinical Toxicology
of Commercial products, 5
th
edition
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 installed horizontally
directly on the wall. Use the hanging brackets
for leveling the unit 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. All models can be
installed on combustible floors and in alcoves.
Ambient temperature must not exceed 80°F.
CLEARANCE
For adequate inspection and servicing the
following minimum clearance is necessary:
Right side 2 inches
Left side 14 inches
Top & Bottom of the boiler 6 inches
Front side of the boiler 24 inches
Back side of the boiler 1 inch
CAUTION
!
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 nonflammable 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.
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 4.
CORROSIVE ATMOSPHERE
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.
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.
• Tridicator (temperature & pressure
gage).
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 nondelivery immediately against carrier.
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 5.
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 may endanger life and property. The
manufacturer disclaims any responsibility for
such loss or injury resulting from the use of
such unauthorized devices
WIRING
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.
240Vac models
Wiring must be from a 240 Volt (single phase, 60
Hz) 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.
600Vac models
Line wiring must be from a 600 Volt ( 3 phase, 60
Hz) 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.
Circulator zoning wiring
Components must be wired to ensure that only the
circulator corresponding to the zone calling for
heat is actuated.
Zone valve zoning wiring
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 and that the circulator
is powered on a demand from any zone. The
transformer used to power the zone valves must
be sized for the load represented by all zone
valves in the heating system.
WARNING
!
BOILER WATER CONNECTIONS
This electric boiler may be connected individually
or in parallel with other boilers. If two or more
boilers are connected, the “reverse-return piping”
method (whereby the boiler with the first return
inlet also has the last supply outlet and so forth
until the last return inlet corresponds to the first
supply outlet) should be used to connect the
boilers in parallel, to ensure an equal water flow
rate through each boiler.
The boiler water supply, located on the top side,
and the boiler water return, located on the bottom
side of the boiler are steel pipes (male NPT
threaded connection) where supply and return line
connections are to be made.
Installing a union is recommended on the boiler
water supply and return lines to facilitate boiler
disconnection for servicing.
Dielectric unions are required for protection of the
boiler and piping if dissimilar pipe material such as
galvanized steel and copper are present.
Use only clean, new piping for boiler water lines.
Local codes or regulations shall govern the exact
type of material to be used.
Insulate all pipes containing hot water, especially
in unheated areas.
Install shutoff (ball) valves for servicing
convenience. Thermometer(s) should be installed
on the boiler water supply and return lines.
Cap or plug unused connections on the boiler. Do
not cap the pressure relief valve on the boiler
since it will damage and shorten the life of the
boiler and may endanger life and property.
Flow check valve
If the heating system includes a single pump, then
to minimize flow by gravity and heat loss during
non-draw periods, a flow check valve must
installed.
be
Pressure relief valve
An automatic pressure relief valve must be
installed during boiler setup. The pressure rating
of the relief valve must not exceed 30 psi. The
safety relief valve must meet the requirements of
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 6.
the ASME Boiler and Pressure Vessel Code and
limit the maximum operating boiler pressure. It is
a safety device, not an operating control.
The BTU per hour rating of the relief valve must
equal or exceed the BTU per hour input of the
boiler(s) or heat source(s) as marked on the
boiler(s) rating plate.
Connect the outlet of the relief valve to a
discharge line with its lower tip at most 6” above a
floor drain, well clear of any live electrical parts.
The discharge line must pitch downward from the
valve to allow complete draining by gravity of the
relief valve and discharge line, and be of a
diameter no smaller than that of the valve outlet.
The tip of the discharge line should not be
threaded or concealed and should be protected
from freezing. 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.
SYSTEM PRESSURE CONTROL
Expansion tank
Pressure control devices within the system ensure
that each component operates within minimum
and maximum allowable pressures and maintain
minimum pressure for all normal operating
temperatures. They also allow air bleeding,
prevent cavitation at the pump inlet and prevent
water from boiling within the system; all this is
accomplished with minimal addition of new water.
The increase in boiler water volume resulting from
higher temperature is stored in the expansion tank
during periods of high operating temperature and
is returned to the system when the temperature
decreases.
The expansion tank must be able to store the
required volume of boiler water during maximum
design operating temperature without exceeding
the maximum allowable operating pressure, and
to maintain the required minimum pressure when
the system is cold. Contact your installing
contractor, plumbing supply house, or local
plumbing inspector for assistance.
The point where the expansion tank is connected
should be carefully selected to avoid the
possibility that normal operation of automatic
check or manual valves will isolate the tank from a
hot boiler or any part of the system. Pre-charged
diaphragm expansion tanks are preferable to air
control.
These tanks incorporate a balloon-like bladder or
diaphragm. It is inflated, prior to filling the system,
to a pressure equal to the setting of the water
pressure makeup regulator.
The expansion tank should be located on the
suction or intake side of the pump. The pump can
be located either just upstream or just
downstream from the boiler.
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 7.
Water pressure makeup regulator
Make-up systems must be employed as required
by codes. An automatic fill valve must be used
with a backflow preventer as required, to maintain
minimum system pressure by supplying water to
make up for leakage.
Air bleeder
Oxygen should be excluded from the system to
prevent corrosion. As mentioned in the expansion
tank paragraph above, this precludes the use of
air in direct contact with the boiler water as a
pressurization means.
Installation of manual or automatic air vent
devices prevents air from accumulating in the
system. Air vents should be installed at all high
points to remove trapped air during initial setup
and to ensure that the system is tight. Regularly
purge the air out of the system while taking care to
avoid personal injuries or property damage
caused by hot boiler water spray.
Circulator zoning recommendations
The preferred location of the circulator pump for
each zone is on the boiler supply side, with the
expansion tank between the boiler and the pump.
A flow check valve must be installed in each zone,
preferably on the outlet side of each circulator
pump, to prevent water flow to other zones where
no heat is required.
Zone valve zoning recommendations
The preferred location of the circulator pump is on
the boiler supply side, with the expansion tank
between the boiler and the circulator. Use zone
valves with low pressure drop.
Dual energy installation
In order to obtain a special rate from your electric
utility for residential use, your BTH boiler can be
hooked-up to an existing oil heater. Contact your
electric utility to find out if your property is eligible
for such rates and how to register for them.
The CBE-EM dual-energy control (an available
option, three-way, motorized valve (1’’ NPT F
standard) included) is specially designed to
electric utility standards. The CBE-EM control
selects the least expensive energy source based
on outside temperature, user choice or a signal
from your utility.
The CBE-EM dual-energy control will start up the
oil burner upon receiving the appropriate signal,
even if the thermostat in the house is not calling
for heat. It will shut off when the temperature in
the boiler reaches its target on the Limit Control. It
is for this reason that the piping requires an antigravity valve (flow check valve) or motorized zone
valves.
A three-way, motorized valve (1’’ NPT F standard)
will direct the water flow either to the oil-fired
heater or to your DTH electric boiler, depending
on the signal received. This way, your oil heater
will cool down and eliminate any energy loss,
either through the chimney or by way of
conduction in the boiler room.
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 8.
1
2
3
4
5
6
7
8
9
10
11
12
15
L1 L2 N
16
T=150 F
o o o o o o o o o
H H V1 V2 V3 T1 T2 E1 E 2
E2V2
Legeng/Légende:
1) Main water supply / Alimentation d'ea u
2) Maintenance valve/ Valve d'entretien
3) Check valve/ Clapet anti-retour
4) Pressure reducer/ Réducteur de pression
5) Expension tank/ Réservoir d'expansion
6) Circulating pump/ Pompe circulatrice
7) Purge valve/ Robinet élimination d'a ir
8) Drain valve/ Valve drainage
9) Safety valve/ Valve d e sécur ité
10) T & P Gage/ Tridicateur
11) Automatic air vent/ Purgeur d'air
12) Flow check valve/ C lapet antigravité
(required on systems without motorised zone valves)
(requise sur les systèmes n'ayant pas de valv es motorisées)
14) Dual energy outside senso r / S o n d e ex t. Bi-energie
15) Thermostat/ Thermostat
16) Dual energy control C BE- EM/ C o n trô le Bi-énergie CBE-EM
17) Motorised 3 way valve/ Valve motorisée 3 voies
14
T
T
L1
N
17
jumper/ cavalier
Noir
Bleu
Brun
B
A
AB
Relais
Pompe
Pump
Relay
L N
Schéma d'installation général/
General installation
THERMO 2000 inc.
BTH 240V
Bi-Énergie avec valve 3 voies/
Dual-energy with 3-way valve
ELECTRIC BOILER WIRING DIAGRAM
L1 G
TH1
C1
TH2
Note 1: Bloc terminal (24 VAC) pour une installation avec le
controleur bi-énergie Thermo 2000 m odè le: "CBE-EM"/
Terminal block (24 VAC) f or an installation with Thermo 2000 dual
energy controller model: "CBE-EM"
Note 2: Couper le cavalier lorsque vous utilisez le controleur
bi-énergie Thermo 2000 modèle: "CBE-EM"/
Cut open this jumper when using Thermo 2000 dual energy
controller model: "CBE-EM"
Légende/ Legend
TH
Aquastat
Élément chauffant/
Heating element
Contacteur de puissance
C
Power relay
HL
Haute limite
Hi-Limit
Disjoncteur
Braker
R
EL1
EL2
Relais
Relay
Lampe témoin
Pilot light
Commutateur ON/OFF
ON/OFF switch
Fusible
Fuse
Cablage en usine/
Factory wiring
Cablage par l'installateur/
Wiring by others
Diagramme électrique/ Wiring diagram
BTH 240V
Modèle/Model 6 - 10 KW
L2
F1
F2
C1
OPTION: BTH-BE
V2
E2
Voir/see note 2
R1
R1
HL
C1
Voir/see note 1
OPTION: BTH-BE
N
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 10.
L1 G
Voir/see note 3
OPTION
C1
C1
TH
Aquastat
Élément chauffant/
Heating element
Contacteur de puissance
C
Power relay
HL
Haute limite
Hi-Limit
Disjoncteur
Braker
TH1
TH2
TH3
TH4
Légende/ Legend
Relais
R
Relay
Lampe témoin
Pilot light
Commutateur ON/OFF
ON/OFF switch
Fusible
Fuse
Cablage en usine/
Factory wiring
Cablage par l'installateur/
Wiring by others
Diagramme électrique/ Wiring di ag ram BTH 240V
modèle/ model 12 - 24 KW
L2
F1
B3
EL1
F2
C1
EL2
EL3
C1
EL4
Note 1: Bloc terminal (24 VAC) pour une installation avec le
controleur bi-énergie Thermo 2000 modèle: "CBE-EM"/
Terminal block (24 VAC) for an installation with Thermo 2000 dual
energy controller model: "CBE-EM"
Note 2: Couper le cavalier lorsque vous utilisez le controleur
bi-énergie Thermo 2000 modèle: "CBE-EM"/
Cut open this jumper when using Thermo 2000 dual energy
controller model: "CBE-EM"
V2
E2
Voir/see note 2
OPTION: BTH-BE
R1
R1
HL
C1
Voir/see note 1
OPTION: BTH-BE
N
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 11.
L1 G
Voir/see note 3
OPTION
C1
C1
C1
TH
Aquastat
Élément chauf fant/
Heating element
Contacteur de puis sanc e
C
Power relay
TH1
TH2
TH3
TH4
TH5
TH6
Légende/ Legend
Relais
R
Relay
Lampe témoin
Pilot light
Commutateur ON/OFF
ON/OFF switch
Diagramme électriq ue/ Wiring di ag ram BTH 240 V
modèle/ model 27 KW
L2
F1
EL1
F2
C2
EL2
EL3
C2
Note 1: Bloc terminal (24 VAC) pour une installation avec le
controleur bi-énergie Thermo 2000 modèle: "CBE-EM"/
Terminal block (24 VAC) for an installation with Thermo 2000 dual
energy controller model: "CBE-EM"
Note 2: Couper le cavalier lorsque vous utilisez le controleur
bi-énergie Thermo 2000 modèle: "CBE-EM"/
Cut open this jumper when using Thermo 2000 dual energy
controller model: "CBE-EM"
EL4
EL5
C2
V2
E2
EL6
Cablage en usine/
Factory wiring
Cablage par l'installateur/
Wiring by others
Disjoncteur
Braker
HL
Haute limite
Hi-Limit
Fusible
Fuse
Voir/see note 2
OPTION: BTH-BE
R1
R1
HL
Voir/see note 1
OPTION: BTH-BE
N
C1
C2
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 12.
L1 G
B1 B2 B3
TH
C
TH1
C1
TH2
TH3
C1
TH4
TH5
C1
TH6
Légende/ Legend
Aquastat
Élément chauffant/
Heating element
Contacteur de puissance
Power relay
Relais
R
Relay
Lampe témoin
Pilot light
Commutateur ON/OFF
ON/OFF switch
Diagramme électrique/ Wiring di agr am BTH 240V
modèle/ model 30-33 KW
L2
B1 B2 B3 B4
F
EL1
C2
EL2
EL3
C2
Note 1: Bloc terminal (24 VAC) pour une installation avec le
controleur bi-énergie Thermo 200 0 m odèle: "CBE-EM"/
Terminal block (24 VAC) for an installation with Th erm o 2000 dual
energy controller model: "CBE-EM"
Note 2: Couper le cavalier lorsque vous utilisez le controleur
bi-énergie Thermo 2000 m odèle: "CBE-EM"/
Cut open this jumper when using T her m o 2000 du al energy
controller model: "CBE-EM"
EL4
EL5
C2
V2
Voir/see note 1
E2
EL6
Cablage en usine/
Factory wiring
Cablage par l'installateur/
Wiring by others
Disjoncteur
Braker
HL
Haute limite
Hi-Limit
Fusible
Fuse
Voir/see note 2
R1
R1
HL
N
C1
C2
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 13.
Diagramme électrique/ Wiring diagram BTH 600V
modèle/ model 9 - 13 KW
G
EL1
L1 L2
C1 C1 C1
R1
L3
EL2
HL
TH1
EL3
Voir note 2
OPTION: BTH-BE
R3
Voir/see note 1
OPTION: BTH-BE
V2
E2
R1
R3
F1 F2
600 V
Transfo
120 V
C1
R1
Note 1: Bloc terminal (24 VAC) pour une installation avec le
controleur bi-énergie Thermo 2000 modèle: "CBE-EM"/
Terminal block (24 VAC) for an installation with Thermo 2000 dual
energy controller model: "CBE-EM"
Note 2: Couper le cavalier lorsque vous utilisez le controleur
bi-énergie Thermo 2000 modèle: "CBE-EM"/
Cut open this jumper when using Thermo 2000 dual energy
controller model: "CBE-EM"
TH
C
Aquastat
Élément chauffant/
Heating element
Contacteur de puissance
Power relay
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 14.
Légende/ Legend
R
Relais
Relay
Lampe témoin
Pilot light
Commutateur ON/OFF
ON/OFF switch
HL
Disjoncteur
Braker
Haute limite
Hi-Limit
Fusible
Fuse
Diagramme électrique/ Wiring diagram BTH 600V
modèle/ model 18 - 36 KW
G
EL1
L1 L2
C1 C1 C1
R1
L3
R2R2EL4
HL
TH1
TH2
EL2
EL3
Voir note 2
OPTION: BTH-BE
R3
Voir/see note 1
OPTION: BTH-BE
V2
E2
R1
R3
EL5
EL6
F1 F2
600 V
Transfo
120 V
C1
R1
R2
Note 1: Bloc terminal (24 VAC) pour une installation avec le
controleur bi-énergie Thermo 2000 modèle: "CBE-EM"/
Terminal block (24 VAC) for an installation with Thermo 2000 dual
energy controller model: "CBE-EM"
Note 2: Couper le cavalier lorsque vous utilisez le controleur
bi-énergie Thermo 2000 modèle: "CBE-EM"/
Cut open this jumper when using Thermo 2000 dual energy
controller model: "CBE-EM"
TH
C
Aquastat
Élément chauffant/
Heating element
Contacteur de puissance
Power relay
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 15.
Légende/ Legend
R
Relais
Relay
Lampe témoin
Pilot light
Commutateur ON/OFF
ON/OFF switch
HL
Disjoncteur
Braker
Haute limite
Hi-Limit
Fusible
Fuse
L1 Diagramme électrique/ Wiring diagram
Contrôle Bi-énergy/ Dual control energy CBE-EM
120 Vac
Transfo
24 Vac
Lumière haut tar if/
High tarif light
H
Sonde extérieur/
Outdoor sensor
V1
H
Bi-energie/ Dual energy
Electrique/ Electric
Mazout/ Oil
Interrupteur DPDT
Switch ON-OFF-ON
Cablage en usine/
Factory wiring
Cablage par l'instal lateur (chaudière BTH)/
Wiring by others (BTH Boiler)
V3
SPDT
Relais/ Relay
Noir/ Black
Brun/ Brown
Bleu/ Blue
N
V2
Relais BTH/
E2
E1
T1
E2
T2
T
T
Valve 3 voies optionn el le/
Optional 3-way valve
BTH Relay
Relais chaudière
mazout/
Oil boiler Relay
Electrique/ Electric
V2
B
AB
A
Mazout/ Oil
120 Vac
Transfo
24 Vac
Sonde extérieur/
Outdoor sensor
SPDT
Relais/ Relay
H H V1 V2 V3 T1 T2 E1 E2
Bleu/ Blue
Noir/ Black
Brun/ Brown
Valve 3 voies optionnelle/
Optional 3-way valve
Interrupteur DPDT
Switch ON-OFF-ON
Chaudière électrique BTH
Electric boiler BTH
("E2 V2" bornier 24 Vac/
terminal E2-V2)
Chaudière mazout
Oil boiler
("T T" relais de combustion/
oil boiler burner)
Bi-energie/ Dual energy
Electrique/ Electric
Mazout/ Oil
Lumière haut tarif/
High tarif light
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 16.
E
S
Basic Piping Schematics
:
/
U
T
O
Y
A
L
G
I
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14
1
2
3
4
11 12
13
5
9
10
B T H
8
6
7
LEGEND/ LÉGENDE :
1- MAIN WATER SUPPLY/ ALIMENTATION D'EAU
2-MAINTENANCE VALVE/ VALVE D'ENTRETIEN
3-CHECK VALVE/ CLAPET ANTI-RETOUR
4-PRESSURE REDUCER/ RÉDUCTEUR DE PRESSION
5-EXPANSION TANK/ RÉSERVOIR DE DILATATION
6-CIRCULATING PUMP/ POMPE CIRCULATRICE
7-PURGE VALVE/ ROBINET D'ÉLIMINATION D'AIR
Requirements:
1. The installation must conform to local, state, provincial, national codes. In any case where instructions conflict with the above,
let those codes take precedence.
2. This is a basic piping schematic. Please consult the installation manual.
3. Install a pressure relief valve (safety relief valve) on the boiler.
4. Pipe all the safety relief valves and drain valves to the drain or according to the code
8-DRAIN VALVE/ VALVE DRAINAGE
9-SAFETY VALVE/ SOUPAPE DE SÛRETÉ
10-TEMPERATURE AND PRESSURE GAUGE/
THERMOMANOMÈTRE
11-AUTOMATIC AIR VENT/ PURGEUR D'AIR
12-FLOW CHECK VALVE (REQUIRED ON SYSTEMS
WITHOUT MOTORIZED ZONE VALVES)/
CLAPET ANTI-GRAVITÉ (REQUIS SUR SYSTÈME
N'AYANT PAS DE ROBINETS MOTORISÉS)
13-MOTORIZED ZONE VALVE/ ROBINETS MOTORISÉ
14-HOT WATER BASEBOARD/ PLINTHES CHAUFFAG
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 17.
ÈT
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N
A
F
F
U
A
H
R
C
E
H
C
N
A
L
P
1
2
3
6
TYP.: 105°F
12
11
4
5
9
10
14
B T H
3
1
8
TYP.: 90°F
7
LEGEND/ LÉGENDE :
1- MAIN WATER SUPPLY/ ALIMENTATION D'EAU
2-MAINTENANCE VALVE/ VALVE D'ENTRTIEN
3-CHECK VALVE/ CLAPET ANTI-RETOUR
4-PRESSURE REDUCER/ RÉDUCTEUR DE PRESSION
5-EXPANSION TANK/ RÉSERVOIR DE DILATATION
6-CIRCULATING PUMP/ POMPE RECIRCULATION
7-PURGE VALVE/ ROBINET D'ÉLIMINATION D'AIR
Requirements:
1. The installation must conform to local, state, provincial, national codes. In any case where
instructions conflict with the above, let those codes take precedence.
2. This is a basic piping schematic. Please consult the installation manual.
3. Install a pressure relief valve (safety relief valve) on the boiler.
4. Pipe all the safety relief valves and drain valves to the drain or according to the code.
8-DRAIN VALVE/ VALVE DE DRAINAGE
9-SAFETY VALVE/ SOUPAPE DE SÛRETÉ
10-TEMPERATURE AND PRESSURE GAUGE/ THERMOMANOM
11-AUTOMATIC AIR VENT/ PURGEUR D'AIR
12-SUPPLY HEADER/ COLLECTEUR D'ALIMENTATION
13-RETURN HEADER/ COLLECTEUR DE RETOUR
14-RADIANT IN-FLOOR PIPING/ PLANCHER CHAUFFANT
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 18.
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19
20
17
1
2
6
12
11
3
4
5
9
15
TYP.:150°F
18
14
10
3
B T H
1
16
8
7
TYP: 85°F
LEGEND :
1- MAIN WATER SUPPLY/ ALIMENTATION D'EAU
2-MAINTENANCE VALVE/ VALVE D'ENTRETIEN
3-CHECK VALVE/ CLAPET ANTI-GRAVITÉ
4-PRESSURE REDUCER/ RÉDUCTEUR DE PRESSION
5-EXPANSION TANK/ RÉSERVOIR DE DILATATION
6-CIRCULATING PUMP/ POMPE RECIRCULATION
7-PURGE VALVE/ ROBINET D'ÉLIMINATION D'AIR
8-DRAIN VALVE/ VALVE DE DRAINAGE
9-SAFETY VALVE/ SOUPAPE DE SÛRETÉ
10-TEMPERATURE AND PRESSURE GAUGE/
THERMOMANOMÈTRE
11-AUTOMATIC AIR VENT/ PURGEUR D'AIR
12-SUPPLY HEADER/ COLLECTEUR D'ALIMENTATION
13-RETURN HEADER/ COLLECTEUR DE RETOUR
14-RADIANT IN-FLOOR PIPING/ PLANCHER CHAUFFANT
15-INJECTION VALVE (SLOW OPENNING)/
VALVE D'INJECTION
16-CIRCUIT BALANCING VALVE/ VALVE DE BALANCEMENT
17-INDOOR / OUTDOUR CONTROLLER/
CONTRÔLEUR MODULANT INT.-EXT.
18-BOILER WATER SUPPLY TEMP. SENSOR/
SONDE DE TEMPÉRATURE D'EAU
19-EXTERIOR TEMPERATURE SENSOR/ SONDE TEMP. EXT.
20-AMBIANT TEMPERATURE SENSOR/ SONDE TEMP. AMBIANTE
Requirements:
1. The installation must conform to local, state, provincial, national codes. In any case where instructions conflict with the
above, let those codes take precedence.
2. This is a basic piping schematic. Please consult the installation manual.
3. Install a pressure relief valve (safety relief valve) on the boiler.
4. Pipe all the safety relief valves and drain valves to the drain or according to the code.
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 19.
PUMP AND PUMP SIZING
Boiler water temperature drop (BWTD)
through the heating loop
A simplified design method based on a 20°F
temperature drop (BWTD) between boiler outlet
and inlet is commonly used. Although such a
method is widely used and generates
satisfactory system performance when applied
properly, it does not determine the system
operating point. The pipe size is often
uneconomically large, and the actual system
flow rate is likely to be much higher than
intended. Such design methods seldom
consider temperature drops higher than 20°F,
which results in overdesign.
Another method by which the boiler water
temperature drop (BWTD) could be calculated
is to assume a constant supply boiler water
temperature minus the return boiler water
temperature. For example a boiler might have a
return temperature of 140 °F. Assuming a
constant supply boiler temperature of 180 °F,
the BWTD would be 40 °F ( = 180 °F – 140 °F).
Second example: If the boiler water has a return
temperature of 120 °F and the boiler supply is at
140 °F, then the temperature drop is 20 °F (=140
°F – 120 °F).
By design the boiler water supply temperature
cannot be higher than 190°F. Also, when the
boiler surfaces are hot due to previous loads
such as domestic hot water generation, the large
temperature difference between the boiler and
its return water can cause the boiler to become
thermally shocked.
An experienced designer could work with other
values than those proposed by looking into the
performance tables and using the guidelines
stated above to design a state of the art system.
The following chart suggests the temperature
drop (BWTD) to be used to calculate the pump
flow rate.
PROPOSED BOILER WATER
TEMPERATURE DROP THROUGH THE
HEATING CIRCUIT (BWTD)
System
type
Baseboards
Cast Iron
Radiators
Radiant
In-Floor
Boiler
water
Supply
tempera-
ture
190°F to
140°F
160°F to
130°F
130°F to
90°F
Boiler
water
Return
tempera-
ture
170°F to
120°F
140°F to
110°F
110°F to
70°F
BWTD
20°F to
40°F
20°F to
40°F
20°F to
40°F
Pump flow rate calculation
The boiler’s output rating must correspond to the
heating load calculations or be within the sizing
guide recommendations. Use the equation
below to calculate the pump flow rate.
Pump flow rate = Boiler output ÷
BWTD ÷ 500
• Pump flow rate is express in U.S. gallons
per minute or GPM.
• The Boiler output ( in net BTU per hour) is
the maximum heat to be transferred through
the heating loop to meet the heating
demand.
• BWTD is the boiler water temperature drop
through the heating loop.
For example, a BTH 24 as an output rated at
81,888 BTU per hour. The system is designed
for a temperature drop (TD) of 20°F.
Pump flow rate = 81,888 ÷ 20 ÷ 500 = 8.2 GPM.
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 20.
Pipe sizing criteria
Proper selection of pipe size is important to
efficient system operation. A large pipe size
results in lower friction losses and may allow the
selection of smaller, more economical pump.
The increased pipe size, however, costs more
initially and must be balanced against the cost
savings realized be smaller pump. Likewise,
small pipe costs less initially but must be
balanced against the increased operating cost of
pumping water through a system with high
friction losses. An economical balance should
be reached between pump size, operating costs,
and pipe diameter.
The ASHRAE fundamentals handbook states
the general range of pipe friction loss used for
the design of hydraulic systems and upper limits
of water velocity in piping.
A variety of upper limits of water velocity and/or
pressure drop in piping and piping systems are
used. One recommendation places a velocity
limit of 4 feet per second for 2 inch and smaller
diameter pipe, and a pressure drop limit of 4 feet
of water per hundred feet for piping over 2
inches. These limitations are imposed either to
control the levels of pipe and valve noise,
erosion and water hammer pressure or for
economic reasons.
Please note that in the smaller pipe sizes, this
velocity limit permits the use of friction loss rates
higher than 4 feet per 100 feet.
Fluid velocity should be above 1-1/2 to 2 feet per
second in order to carry entrained air along to a
high point in the system where it can be purged.
It is generally accepted that if proper air control
is provided to eliminate air and turbulence in the
system, the maximum flow rate can be
established by a piping friction loss rate of 4 feet
of water per 100 feet. This allows velocities
greater than 4 feet per second in pipe sizes 2
inches and larger.
As piping ages, friction losses increase. It is
recommended that for most commercial design
purposes a safety factor of 10 to 15 % be added
to the values in the tables.
What is a “foot of water”? A column of water at
60°F, 5 feet tall, creates a constant pressure of 5
feet of water at the bottom of the column. If the
water column is 2.31 feet tall, the mass of water
creates a constant pressure (head) of one (1) psi
(pound per square inch). Pressure losses are
expressed either in “feet of water” or in psi.
Pump manufacturers usually prefer feet of water
units.
Pump or circulator selection
Performance characteristics of centrifugal
pumps are described by pump curves, which
plot flow versus head or pressure together with
other information such as efficiency and power.
Consult the manufacturer’s pump curves to
select the proper model or ask your pump dealer
or your HVAC wholesaler for a recommendation.
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 21.
Operation
SAFETY PRECAUTIONS
!
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.
After the boiler has been plumbed and wired, it
is now ready to be set for automatic operation.
FILLING THE BOILER
Open the shutoff valve (and on a zone valve
system, manually open zone valve) on the
supply piping from the boiler. Open cold water
supply valve (fill or makeup water valve) to
boiler.
To let the air out of the boiler tank during the fill
process open the relief valve on top of the
boiler. Leave all shutoff valves open. Return
zone valves to automatic operation. Check
system for leaks and repair. Purge air from the
remaining zones, if necessary. Check boiler
pressure gage reading. 15 to 20 psi is normal for
most installations.
ADJUSTING THE AQUASTATS
After the system has been manually purged of
air, and all components (valves, vents,
controllers) have been set properly, the boiler
can be started. Never operate this boiler until
this has been done.
Safety and energy conservation are factors to be
considered when setting the boiler water
temperature by using the aquastats. The most
energy efficient operation will result when the
temperature setting of each aquastat is the
lowest that satisfies the needs consistent with
the application.
table for more details.
Please refer to the BWTD
Each electric element has it own aquastat.
Set the temperature on the aquastat using the
knob graduated in degrees Celsius and
Fahrenheit.
Set the temperature on the first aquastat to the
highest supply temperature required by the
heating system.
Set the temperature on the second aquastat
from 1°F to 20°F below the setpoint of the first
aquastat. Usually 5°F below the setpoint of the
first aquastat is adequate if the boiler water
temperature drop is 20°F.
Proceed in a similar manner for the 3
any supplementary aquastats, lowering the set
point by 5°F each time. The elements will thus
be activated (and de-activated) in the number
required by the set points and the drop (or rise)
in boiler water temperature.
On initial start up (on the first day of the heating
season) with a cold tank, a considerable amount
of time may be required for the tank to reach
desired temperature. Check the temperature on
the boiler temperature gage.
Adjust the boiler aquastats as needed. Note that
setting the aquastat to a lower setting will not
have an immediate effect. The stored boiler
water heat will first have to be consumed.
Additional checks of the water temperature
should follow completion of a cycle. Further
adjustments may be necessary as you use your
boiler and space heating system.
Note: The maximum setting for the boiler water
supply to the heating system is 190°F.
rd
, 4th and
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 22.
PUMP POWER SUPPLY
Use a relay (Honeywell #RA-889, RA-89A) or
the secondary contact of a zone valve (if the
heating system is zoned using 4-wire zone
valves). When a thermostat calls for heat, the
relay will power either the boiler pump or the
zone valve (the zone valve will power the boiler
pump upon opening fully).
Diagramme électrique/ Wiring diagram
Raccordement de pompe BTH/ Wiring pump for BTH
Relais d e p o mpe/pump relay
Thermostat
T T
2
L2 L1
120Vac
Diagramme électrique/ Wiring diagram
Raccordement de zone valves/ Wiring for zoned valves system
Thermostat
Zone 1
1
Thermostat
Zone 2
If the heating system is designed to use only a
single pump, then to minimize flow by gravity
and heat loss during non-draw periods, a flow
check must
be installed.
Relais/Relay
RA89A
jumper
4
3
Pompe/Pump
Thermostat
Zone 3
24 Vac
120 Vac
Electrical servic e
22
Zone
valve
1
Transfo
40Va T r ans f o (3 z ones )
20Va T r ans f o (2 z ones )
4
Zone
valve
3
22
4
1
22
Zone
valve
3
4
1
Diagramme électrique/ Wiring diagram
Racco rde m en t d e m ult iples cir cu late urs / Wiring fo r m u ltiple c irc ulat ors
Thermostat
Zone 1
T
T
Relais/Relay
RA845A
12
L2L1
120Vac
electrical service
4
3
6
5
Circulateur/
circulator
Zone 1
Thermostat
Zone 2
T
Relais/Relay
RA845A
T
4
23
1
3
6
5
Circulateur/
circulator
Zone 2
To/ Vers
RA-89A
BTH Electric Boilers USE & CARE MANUAL (Revision August /06), Page 23.
R
Maintenance
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:
BOILER WATER PIPING:
Yearly visual inspection.
Check all piping for signs of leakage near joints, unions
and shut-off valves. Repair as needed.
PRESSURE RELIEF VALVE
Monthly inspection.
Must be manually operated to ensure safe and proper
operation. By opening the pressure relief valve, the air
trapped inside the heater tank is purged.
Make sure that the discharged water is directed to a
suitable drain or other collection device, and will not
spray onto anyone. Use the lever on the pressure relief
valve to open. A steady discharge of hot water should
occur. After releasing this lever the safety relief valve
should close and fully shut off this flow. If the pressure
relief valve does not function properly, it must be
replaced with the same model or its equivalent. Do not
plug the outlet of this valve if a dripping condition
occurs.
The manufacturer’s warranties DO NOT cover tank
failure due to improper installation or maintenance.
If the pressure relief valve on the heater discharges
periodically, this may be due to thermal expansion.
Immediately call a qualified service technician to
inspect and to remedy as needed.
NOTE: To prevent premature tank failure, the air
trapped inside the tank must be purged periodically.
Use the safety relief valve on top of the tank to
perform this task.
Before manually operating the relief valve, make
certain no one will be sprayed with the hot water
released by its opening. The water may be hot
enough to create a SCALD hazard. The water
released should be directed to a suitable drain to
prevent injury or damage.
WARNING
!
DANGE
!
24
BTH LIMITED WARRANTY
Warranty Coverage for Residential Installation.
Thermo 2000 Inc. hereby warrants to the original residential purchaser that the BTH
tank installed in a residential setting shall be free of leaks during normal use and
service for a period of ten (10) years from the date of purchase as long as the
original residential purchaser owns the home in which the unit was originally
installed, the first (5) years in full and years six (6) through ten (10) prorated 20%
each year at suggested retail price. Residential setting shall mean usage in a singlefamily dwelling in which the consumer resides on a permanent basis. Also,
residential setting shall mean use in multiple family dwellings in which one (1) BTH
tank is to be use 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 option 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 BTH tank installed in a
commercial setting for ten years, the first (5) years in full and years six (6) through
ten (10) prorated 20% each year at suggested retail price
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 option 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 one year warranty on all BTH components &
parts
All other BTH components & parts are warranted for a period of one (1) year 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 inst alled
and maintained in accordance with the manufacturer specifications; or
9. The BTH unit is being subject 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 shall 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.
In order to receive the benefit of this warranty, the original consumer purchaser
must fill in and return the attached registration card within thirty (30) days of date of
purchase.
Warranty service procedure
Only authorized BTH dealers are permitted to perform warranty obligations. The owner or
its contractor must provide Thermo 2000’s head office or authorized depot with defect unit
together with the following information: BTH 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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