THERMO 2000 BTH ULTRA 12, BTH ULTRA 15, BTH ULTRA 20, BTH ULTRA 18, BTH ULTRA 24 Installation & Operation Manual

Electric Boilers

Models ranging from 12 kW to 36 kW 208/240 Volts (1 phase)

Your BTH 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, keep this installation manual in a safe place
(close to the boiler) for future reference.

BTH ULTRA

INSTALLATION & OPERATION MANUAL

THERMO 2000 INC. Revision : June 2015

Printed In Canada

Table des matières

Section 1: Technical specifications ............................................................................................................... 4

Table 1: Technical data on boilers operating at 240 Vac /1ph1 : .................................................................. 4

Table 2 : Boiler connections and dimensions (12-24 KW) ............................................................................ 5

Table 3 : Boiler connections and dimensions (27-36 KW) ............................................................................ 5

Section 2: INTRODUCTION .......................................................................................................................... 6

2.1 LOCAL INSTALLATION REGULATIONS .......................................................................................... 6

2.2 CORROSIVE ENVIRONMENT........................................................................................................... 6

2.3 INSPECTION UPON RECEPTION .................................................................................................... 6

2.4 TO BE CHECKED .............................................................................................................................. 6

Section 3: INSTALLATION............................................................................................................................ 7

3.1 SAFETY MEASURES ......................................................................................................................... 7

3.2 LOCATION.......................................................................................................................................... 7

3.3 CLEARANCES ................................................................................................................................... 7

Table 4: Boiler Clearances ............................................................................................................................ 7

3.4 PIPING INSTALLATION ..................................................................................................................... 8

3.4.1 Type of installation ...................................................................................................................... 8

3.4.2 Boiler piping connection ............................................................................................................ 11

Local codes may dictate the type of pipe to be used for the connections.......................................... 11

Install isolating valves to facilitate maintenance ................................................................................. 11

3.4.3 Pressure relief valve .................................................................................................................. 11

3.4.4 Expansion tank .......................................................................................................................... 11

3.4.5 Water pressure regulator ........................................................................................................... 11

3.4.6 Air eliminator.............................................................................................................................. 11

3.4.7 Circulating pump ....................................................................................................................... 11

Table 5: Temperature rise vs flow rate (GPM) ............................................................................................ 11

3.4.8 Drain valve ................................................................................................................................. 11

3.4.9 Strainer ...................................................................................................................................... 11

3.4.10 Dual Energy piping .................................................................................................................. 12

3.5 ELECTRIC CONNECTIONS ............................................................................................................ 12

3.5.1 Main Electric supply .................................................................................................................. 12

3.5.2 Electrical supply of External accessories .................................................................................. 13

3.5.3 Outdoor temperature sensor ..................................................................................................... 13

3.5.4 Connecting the thermostat and pump. ...................................................................................... 13

3.5.4 Dual-energy connection with an auxiliary boiler. ....................................................................... 14

Section 4: ADJUSTMENT OF THE CONTROLLER ................................................................................... 16

4.1 INTRODUCTION .............................................................................................................................. 16

4.2 DISPLAYED INFORMATION ........................................................................................................... 16

4.3 OPERATION OF THE INTERFACE ................................................................................................. 17

4.4 OPERATION IN “FIXED BOILER TEMPERATURE SET POINT” ................................................... 17

4.5 OPERATION WITH “OUTDOOR RESET”: ...................................................................................... 17

4.6 PURGE DELAY OF THE PUMP ...................................................................................................... 18

4.7 AUTOMATIC HEATING SHUT DOWN ............................................................................................ 18

4.8 CONFIGURATION OF THE CONTROLLER .................................................................................... 18

4.9 ADJUSTMENTS OF THE TARGET TEMPERATURE BY THE USER: ........................................... 20

4.10 BOOST SYSTEM OPERATION ..................................................................................................... 20

4.11 OPERATION IN DUAL-ENERGY: .................................................................................................. 21

Section 5: START UP OPERATION ........................................................................................................... 22

5.1 PREPARATORY STEP .................................................................................................................... 22

5.2 STARTUP & INSPECTION ............................................................................................................... 22

5.3 COMPLEMENTARY CHECKS ON DUAL-ENERGY INSTALLATIONS .......................................... 22

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 2

Section 6 MAINTENANCE .......................................................................................................................... 23

6.1 INTRODUCTION .............................................................................................................................. 23

6.2 AT ALL TIMES .................................................................................................................................. 23

6.3 TWICE A YEAR ................................................................................................................................ 23

6.4 ANNUALY ......................................................................................................................................... 23

Section 7- TROUBLE SHOOTING .............................................................................................................. 24

7.1 TROUBLE SHOOTING TABLE ........................................................................................................ 24

7.2 SPARE PARTS ................................................................................................................................. 26

BTH ULTRA LIMITED WARRANTY ............................................................................................................ 29

Figure 1 : Boiler dimensions (12-24 KW) ...................................................................................................... 5

Figure 2 : Boiler dimensions (27-36 KW) ...................................................................................................... 5

Figure 3 : Mounting positions ........................................................................................................................ 8

Figure 4 : Typical Installation on heating floor .............................................................................................. 8

Figure 5 : Typical installation on fin-tube baseboards with zoning valves .................................................... 9

Figure 6 : Multi-pump zoning......................................................................................................................... 9

Figure 7 : Typical Installation in Dual-Energy Series .................................................................................. 10

Figure 8 : Typical installation with three way valve ..................................................................................... 10

Figure 9 : Zoning with Multiple pumps ........................................................................................................ 13

Figure 10 : Zoning with motorized valves ................................................................................................... 14

Figure 11 Connexions without three way valve ......................................................................................... 14

Figure 12 : Connexions with three way valve ............................................................................................. 14

Figure 13 : Wiring diagram (12-24 KW) ...................................................................................................... 15

Figure 14 : Wiring diagram (27-36 KW) ...................................................................................................... 15

Figure 15 : UltraSmart Controller Display ................................................................................................... 16

Figure 16 : UltraSmart Control Module ....................................................................................................... 17

Figure 17 : Back of the controller ................................................................................................................ 19

Figure 18 : Spare parts (front, 12-24 KW) ................................................................................................... 26

Figure 19 : Spare parts (top, 12-24 KW) ..................................................................................................... 26

Figure 20 : Spare parts (front, 27-29 KW) ................................................................................................... 27

Figure 21 : Spare parts (top, 27-36 KW) ..................................................................................................... 27

Figure 22 : Spare parts (front, 33-36 KW) ................................................................................................... 28

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 3

Section 1: Technical specifications

BTH

ULTRA

Capacity

(KW)

Amps2

Heating

Elements (240 V)

Stages

Suggested size at 240V/1ph.

3

Cable

Breaker

(Amp.)

Cu

Al

208V

240V

208V

240V

12

9,0

12

43.5

50

4 x 3 KW

4 6 4

70

15

11.2

15

54.3

62.5

2 x 3 KW +
2 x 4.5 KW

4 6 4

80

18

13.5

18

65.2

75

4 x 4.5 KW

4 4 2

100

20

15

20

72.5

83.3

4 x 5 KW

4 3 2

110

24

18

24

87

100

4 x 6 KW

4 2 0

125

27

20.2

27

97.9

112.5

6 x 4.5 KW

6

1 x 1

or

2 x 6

4

1 x 00

or

2 x 44

2 x 80

or

150

29

21.7

29

104

120

4 x 5 KW +
2 x 4.5 KW

6

1 x 1

or

2 x 64

1 x 00

or

2 x 44

2 x 80

or

175

33

25

33

119.6

137.5

3 x 5 KW +

3 x 6 KW

6

2 x 4

5

2 x 25 2 x 100

36

27

36

130.5

150

6 x 6 KW

6

2 x 45

2 x 25

2 x 100

Table 1: Technical data on boilers operating at 240 Vac /1ph1 :

1

Electrical supply 120/240V or 120/208V – 1ph (L1-N-L2) with three conductors and a ground or a supply
with two conductors 240V or 208V – 1ph (L1-L2) with a ground if the application does not require a 120V
electrical supply for external accessories such as a pump, etc

2

Add the amperage of the circulating pump and other external accessories if they are connected to the

boiler (max. 5A).

3

A higher cable size could be required. In all cases the local electrical code has priority. The electrician has
the responsibility to select the appropriate size.

4

Two main terminal blocks that could be converted to one on the job site.

5

Two double pole breakers
1 kW = 3412 Btu

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 4

Table 2 : Boiler connections and dimensions (12-24 KW)

Connections

Inlet (return)

1 “ NPT Fem

Outlet (supply)

1 “ NPT Fem

Safety valve

1“reduced to 3/4 “ NPT Fem

Draining valve

1“reduced to 3/4 “ NPT Fem

Shipping weight

63 lbs

Item

Dimension (inches)

A

21-1/2 B 9 C 11-3/4

D

3-5/8

E

2-3/8

F

14-3/4 G 5 H 9-3/4

I

20 J 1-1/2

Connections

Inlet (return)

1 ¼ “ NPT Fem

Outlet (supply)

1 ¼ “ NPT Fem

Pressure relief valve

1 ¼“reduced to 3/4 NPTFem

Drain valve

1 ¼“reduced to 3/4NPT Fem

Shipping weight

75 lbs

Item

Dimension (inches)

A

21-1/2

B

11

C

11-3/4

D

3-1/2

E

2-3/4

F

14-1/4 G 7 H 11-5/8

I

20 J 1-3/4

Figure 1 : Boiler dimensions (12-24 KW)

Figure 2 : Boiler dimensions (27-36 KW)

Table 3 : Boiler connections and dimensions (27-36 KW)

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 5

General Safety Precautions

List of components shipped with the unit :

 Pressure relief valve set at 30 PSI.
 Drain valve.
 Two reducer fittings
 Temperature & pressure indicator
 Outdoor temperature sensor
 Installation and operating manual

!

WARNING

!

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

Section 2: 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.

2.1 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

2.2 CORROSIVE ENVIRONMENT

The electric boiler must not be installed near an
air duct supplying corrosive atmosphere or with
high humidity content.
When a boiler defect is caused by such
conditions, the warranty will not apply

2.3 INSPECTION UPON RECEPTION

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.

2.4 TO BE CHECKED

Please check the identification tag on the unit to
make sure you have the right model (Capacity in
kilowatt, voltage, number of phase and ASME
construction or not ASME).

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 6

Section 3: INSTALLATION

Sides

3 inches

Electric elements side

14 inches

Front side of the boiler

3 inches*

Back

0 inches

CAUTION

!

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

3.1 SAFETY MEASURES

All installation will include the supplied pressure
relief valve which limits the maximum operating
pressure to 30 psi (207 kPa).
This electric boiler is designed to be installed on
a circuit operated between 50°F to 190°F (10°C
to 90°C) and at a maximum operating pressure
of 30 psi (207 kPa).
The unit in designed solely to be used on a
close loop hydronic heating system. The heat
transfer solution must be a solution of water or if
a freeze protection is required, a mix solution
Water/propylene glycol specially made for
hydronic heating systems and having a
maximum concentration of 50% (do not use
plumbing or automobile glycol).
The boiler is equipped with an automatic high
limit temperature control set at 210°F 99°C) and
some models have a second limit device
manually re-settable set at 227F (108C). If the
heating distribution system on which the boiler is
installed requires a high limit controller having a
lower setting, this controller will be added to the
system and connected in series with the factory
installed limit control.

3.2 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 boiler can be mounted vertically or
horizontally directly on a solid surface with 4
adequate screws inserted in the provided boiler
openings. Make sure it is properly leveled
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 directly on a
combustible wall and into an alcove. The
location must have sufficient ventilation to
maintain an ambient temperature not exceeding
90°F (32°C).

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
must be installed under the boiler.
The pan must be connected to a drain.
NOTE: Auxiliary catch pan MUST conform to
local codes.

3.3 CLEARANCES

For adequate inspection and servicing the
following minimum clearance is necessary:

Table 4: Boiler Clearances

*If the boiler is installed in a closed
compartment, allow an access service opening
and adequate ventilation to maintain an ambient
temperature lower than 90°F/32°C.

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 7

3.4 PIPING INSTALLATION

The inlet and outlet piping of the boiler must be in conformity with the different configurations shown
below. Make sure that the fluid flows is in the proper direction.

Figure 3 : Mounting positions

3.4.1 Type of installation

You will find below on figures 4 to 8 the typical piping arrangement for the two main types of installation.
The first being as a self-operating unit and the others being connected to an auxiliary boiler in dual­energy.

Figure 4 : Typical Installation on heating floor

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 8

Figure 5 : Typical installation on fin-tube baseboards with zoning valves

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 9

Figure 6 : Multi-pump zoning

Figure 7 : Typical Installation in Dual-Energy Series

Figure 8 : Typical installation with three way valve

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 10

3.4.2 Boiler piping connection

Model

KW
Diff. Temp.

Diff. Temp.

10oF

20oF

BTH ULTRA 12

12

8,2

4,1

BTH ULTRA 15

15

10,2

5,1

BTH ULTRA 18

18

12,3

6,1

BTH ULTRA 20

20

13,7

6,8

BTH ULTRA 24

24

16,4

8,2

BTH ULTRA 27

27

18,4

9,2

BTH ULTRA 29

29

20,5

10,2

BTH ULTRA 33

33

22,5

11,3

BTH ULTRA 36

36

24,7

12,3

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. The outlet and inlet
boiler connections are located on each sides.
They consist of 4 steel couplings (1”NPTF on 12 to
24kW models and 1-1/4”NPTF on 27 to 36kW)
where the piping connection will be made.
Local codes may dictate the type of pipe to be
used for the connections.
Install isolating valves to facilitate maintenance

3.4.3 Pressure relief valve

This component is supplied with the unit and must
be installed on the boiler. It is designed to
automatically open at approximately 30 psi.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.

3.4.4 Expansion tank

The expansion tank must be able to store the
increase volume of boiler water occurring when
the boiler water increase in temperature.. The
maximum allowable operating pressure is 30 psi
(207 kPa). Contact your plumbing supply house
for assistance.

3.4.5 Water pressure regulator

The boiler should be installed in such a way that it
can automatically be fed with water in the event of
a pressure drop.
The minimum pressure obtained when the system
is cold is generally 12 psi (83 kPa).
This accessory shall be equipped with one or
more check valves to avoid all possibilities of the
boiler water returning to the potable water supply
network (local regulation should be applied)

3.4.6 Air eliminator

Installation of manual or automatic air vents are
required to eliminate all air from the boiler and the
heating distribution system.
The main air eliminator must be installed near the
outlet of the boiler on the highest point of the main
supply piping. It is imperative to insure that all air

possibly located in the boiler be eliminated at all
time.

3.4.7 Circulating pump

Water flow is required at all time when the boiler is
operating.
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.

Table below shows required flow in relation to the
power capacity of the boiler and the required
temperature drop in the heating distribution
system. On System with baseboard heaters, 20°F
temperature drop is normally recommended and
on radiant floor application a value of 10°F is
generally used.

Table 5: Temperature rise vs flow rate
(GPM)

Your heating wholesaler shall be in good position
to recommend the appropriate model for your
application.
If the pump is supplied by the PP terminals of the
boiler, its amperage plus the amperage drawn by
other 120V external components must not exceed
5A.

3.4.8 Drain valve

Installed at the lowest part of the unit, it allows the
boiler to be drained if defective components need
to be replaced.

3.4.9 Strainer

This component could be required on old heating
distribution systems made of steel or cast iron that
could carry sediments and sludge. 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.

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 11

3.4.10 Dual Energy piping

Models

AMPERE @ 208/240 VAC/1ph

Terminal Block #1

Terminal Block #2

27

49/56 Amps

49/56Amps

One terminal block 98/112A

29

52/60 Amps

52/60 Amps

One terminal block 104/120A

Piping connections between the two boilers can be
made in parallel or in series as illustrated in fig.
7&8.
When installed in parallel, a three way motorized

valve (1”NPTF) is used to guide the heating

system return water toward the auxiliary boiler or
the BTH ULTRA electric boiler according to the
operating mode in demand. This way, the oil or
gas boiler is not maintained hot by the return water
when the operation is in Electricity.
N.B.: Make sure to select the appropriate port A, B
and AB when making the connection of the piping
(see fig.8)

3.5 ELECTRIC CONNECTIONS

3.5.1 Main Electric supply

Boiler wiring and grounding must conform to the
National Electrical Code and to state or local code
requirements. The latter having precedence.
Wire gauge must be properly sized by a qualified
electrician in such a way as to meet the national
electrical code.
To do so, consult the boiler rating plate which will
indicate the amperage drawn by the boiler at full
capacity. Extra amperage will have to be added if
external electrical equipment are connected to the
boiler.
This value and the electrical code will be used to
determine the electric cable required together with
the appropriate breaker.
Many other factors must be taken into
consideration in the selection of the appropriate
electrical material such as the length and the type
of cable used, the environment where the cable
will be installed and the type of the over-current
protection used.
Supply cables can be made of Aluminum or
Copper and be rated for a minimum of 75oC
(165oF).
If aluminum cables are used, it shall be of an
adequate size (generally bigger) and particular
consideration will have to be respected such as
the use of DE-OX inhibitors in order to meet the
National electrical code.
If the boiler electrical supply is on 208V, the
position of wire terminal on the transformer
connected to 240V will have to be changed to
208V.
The electrical supply can be done in two different
ways depending on the necessity of supplying or
not external accessories (such as a pump) at
120Vac.

Alternative #1: A 120VAC electrical supply
is required to serve external accessories.

Models 12 to 24 kW

Electrical wiring must come from a 120/240 Vac/or
120/208Vac -1ph “L1-N-L2-” circuit protected by a
properly sized breaker.
The main terminal block of the boiler is suitable for
#14 to #00 copper or aluminum wires rated for
75°C (165°F) min.

Models 27 & 29

1. The main electrical supply comes from two
electrical supply circuits

The electrical supply may come from two circuits
at 240V or 208V/1ph/60Hz with one of the circuit
having a neutral conductor.
The two circuits must be protected by a properly
sized breaker (see table below giving the
amperage drawn by the boiler on each terminal
block) in conformity with local electrical codes.
Connections are made on the two main terminal
block inside the boiler.

The boiler can then be operated at 50% of its
nominal capacity when the breaker supplying the
electric circuit connected to terminal block #2 is
turned OFF during periods of low demand.

These terminal blocks are suitable for #14 to #00
copper or aluminum wires rated for 75°C (165°F)
min.

2. The main electrical supply comes from one

electrical supply circuit)

The boiler electrical boiler supply could come from
only one circuit at 120/240 Vac or 120/208Vac
1ph/60Hz L1/N/L2 where the cable size will not
exceed AWG#00.
All the factory connected wires to terminal block
#2 will have to be transferred to terminal block #1.

Models 33 & 36

The electrical supply must come from two different
electrical circuits. One circuit having three

conductors 120/240V or 120/208V “L1/N/L2” and
the other two conductors 240 or 208V “L1/L2”.

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 12

Both circuits will need to be protected with

Model

Modèle

AMPERE @ 208/240 VAC/1ph

Breaker #1

Breaker #2

33

2 x 5 KW, 1 x 6 KW

2 x 6 KW, 1 x 5 KW

57/66 Amps

61/70 Amps

36

3 x 6 KW

3 x 6 KW

65/75 Amps

65/75 Amps

appropriate breakers or fuse (see table below
giving the amperage drawn by the boiler on each
breaker) in conformity with local electrical codes.
Connections are made directly on the two
breakers inside the boiler.
These breakers can receive copper or aluminum
cable up to #1AWG..
The boiler can then be operated at approximately
50% of its nominal capacity when the breaker
supplying the electric circuit connected to breaker
#2 is turned OFF during periods of low demand.

Alternative #2: No 120Vac electrical supply
is required to serve external accessories
(pump is supplied by a separate circuit
outside the boiler)

The electrical supply is made the same way as
described in alternative #1 excepting that it does
not need the Neutral (N) conductor.

3.5.2 Electrical supply of External
accessories

When the boiler is supplied with a 120V circuit, 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 15VA.

3.5.3 Outdoor temperature sensor

If you want the boiler target 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 cancels the
operation of the boiler when the outdoor
temperature exceeds the selected value
corresponding to the maximum temperature
required for heating.
If you wish to operate the boiler at a fixed target
temperature, simply do not connect the sensor
before applying the power to the unit

The sensor shall be connected to terminals S1-S1
in the boiler using two 20 ga conductors.
Maximum length 100 ft. (33 m).
Do not put a jumper between S1&S1 if the outdoor
sensor is not used.

3.5.4 Connecting the thermostat and
pump.

Thermostat: Use a low voltage 24Vac thermostat

designed for central heating system (do not use a
240Vac thermostat designed for electric
baseboards).
Some thermostats are equipped with a
temperature sensor for radiant floor application.
The purpose of the thermostat is to give a signal to
the boiler that there is a demand for heat. When
the boiler will receive this signal, it will control the
activation of the heating elements.
A two stage thermostat could also be installed.
Then the second heating stage would be used to

activate the “Boost” program allowing the boiler

target to be gradually increased (see section

4.10).

Heating systems equipped with one thermostat
and one pump:

With an 18gauge cable, connect the room
thermostat directly to the following boiler terminals.

Two wire thermostat: Terminals “R” and “W”
Three wire thermostat: Terminals “C”, “R” and “W”

Using 14 gauge wires, connect the circulating
pump directly on terminals “P” and “P
N.B. The amperage of the pump and 120Vac
accessories must not exceed 5A or 1/6HP

Zoning applications with multiple pumps

Components shall be connected in such a way
that when a thermostat is generating a heat
demand, only the corresponding pump be
operated and that this heat demand is brought to
the boiler in order to activate the elements.
To do so, you will need relays as illustrated below.
Boiler terminals P-P will not be used.

Figure 9 : Zoning with Multiple pumps

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 13

Zoning applications with motorized valves

Connect the end switch contact of all motorized
valve to terminals R & W on the boiler.

Connect the circulator to terminals “P” and “P”- in
the boiler.
The connection of the thermostats to their
corresponding zone valve shall be done according

to the zone valve manufacturer’s instructions. See

on fig.5 below a typical example.
The R & C terminals on the boiler can be used to
supply 24Vac to the zone valves if the
corresponding load does not exceed 15VA.
Otherwise an external transformer will be required.
Voltage at the outlet of the transformer shall never
be under 24Vac.

operation in electricity, Red R wire and green
V wire of Hydro-Quebec) of the external
device making the selection of the operating
mode and terminals E1E2

o If the piping installation is made as shown

on fig.7 without a three way valve:

Install an 18ga two wire cable between boiler
terminals “AUX” and the TT terminals of the
auxiliary boiler. The capacity of the AUX
contact is 2A/24Vac max.

o Do not connect the main electrical supply

of the auxiliary boiler to AUX terminals

o The auxiliary boiler target temperature will not

be controlled by the electric boiler. It has to be
controlled by its own operating and limit
controller.

o See the operating sequence in Dual-energy at

section 4.11.

Figure 10 : Zoning with motorized valves

3.5.4 Dual-energy connection with an
auxiliary boiler.

The BTH ULTRA boiler is designed to enable the
installation on Dual-energy applications without
the need to install an interface controller between
the boilers and the electricity supplier authorization
signal. Upon the reception of that signal (dry
contact), the BTH ULTRA will select the
appropriate heating mode and will activate the
required boiler.
If the heating distribution system is equipped with
only one pump connected to the P P terminals of
the boiler, it will be activated on heat calls from the
thermostat no matter the heating mode selected.
To allow the operation in dal-energy:
o Open the front access panel to the boiler

electric compartment. Remove the screw at
the bottom of the controller, raise the upper
section of the controller. You will see a switch
at the back of the controller having two

positions “ELECT” and “Bi-Energ”. Position the
switch at “Bi-Energ”

o Install a 2 wire 18ga cable between the

contact (N/F close contact to allow the

Figure 11 Connexions without three way valve
If the installation is made as shown on fig.8

then with a three way valve (in Option): Install a

three wire 18ga cable between the valve and the
electric boiler terminals. Following this, connect
the end switch of the valve (grey and orange wire)
to the T T terminals of the auxiliary boiler.The
auxiliary boiler target temperature will not be
controlled by the electric boiler. It has to be
controlled by its own operating and limit controller.

Figure 12 : Connexions with three way valve

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 14

L2

G

Diagramme électrique/ Wiring diagram

BTH ULTRA (240V/1ph-12 @ 24kW)

BTH ULTRA (208V/1ph-9 @ 18kW)

N

F-5A

L1

12 C
11
10
9 Com
8 Boil in
7 Boil O
6 Sup/D
5 Os
4 Com
3 Set D
2 Ht D
1 CD

24 R
23 Alarm
22 Stg 4
21 Stg 4
20 Stg 3
19 Stg 3
18 Stg 2
17 Stg 2
16 Stg 1
15 Stg 1
14 Pmp
13 Pmp

W

R

P1

P2

R2

R1

S1

S1

40VA

G

C1

208 or

240V

24Vac

Pompe/
Pump
120V x 1/6HP max

Demande Chauffage thermostat/
Heat Demand thermostat

Sonde extérieure (facultatif)
Outdoor Sensor (optional)

Sonde sortie chaudière
Boiler Outlet Sensor

Légende/ Legend

C

R

Relais
Relay

Fusible
Fuse

Cablage en usine/
Factory wiring

Cablage par l'installateur/
Wiring by others

Élément chauffant/
Heating element

Contacteur
Power relay

Contrôleur/Control

ULTRA SMART

Aux.

Bi-E
R

Outdr sens

Boiler out

Noir/blk

Noir/blk

Rouge/Red

Blanc/white

Bleu
Bleu

Brun/Brown

Gris/grey

Bleu

Bleu

Rouge/Red

Rouge/Red
Rouge/Red

Noir/blk

Orange

Noir/blk

Brun/Brown

Bleu

Rouge/Red

Boiler in

C

R

W
C

Rouge/Red

E2

E1

AUX

AUX

HQ

Contact NF (Hydro)
NF contact (Hydro)

Chaudière auxiliaire
Auxiliary boiler

EL1

R1

EL3

C1-4

C1-2

R3

C1-3

EL2

R2

EL4

R4

R4

R3

T
T

2A /24v

Jaune/Yel

Gris/Grey

Orange

Rouge/Red

Rouge/Red

Jaune/Yel
Brun/Brown
Orange

Noir/blk

120Vac

Noir/blk

Pour bi-énergie seul.
For dual-énergie only

24Vac

208-240V/1ph

G

HL#2 MR
USA only

HL#1

AR

C1-1

HL-AR

Haute limite à ré-enclen­chement automatique
High limit « automatic reset »

HL-MR

Haute limite à ré-enclen­chement manuel
High limit « manual reset »

T
T

ZDV200-DIABTHU4

L1-2

Diagramme électrique/ Wiring diagram

BTH ULTRA (240V/1ph 27@36 kW)

(208V/1ph 20@27 kW)

N

L1-1

R5

R3

50VA

208/240Vac

24Vac

*Disjoncteur (33&36kW)
*Breaker (33&36kW only)

Contrôleur/Control
« ULTRA SMART »

R6

R4

C2

EL1

R1

C1

white

blue

red

black

black

red

red

208-240V/1ph

12
11
10
9 Com
8 Boil in
7 Boil O
6 Sup/D
5 Os
4 Com
3 Set D
2 Ht D
1 CD

24 R
23 Alarm
22 Stg 4
21 Stg 4
20 Stg 3
19 Stg 3
18 Stg 2
17 Stg 2
16 Stg 1
15 Stg 1
14 Pmp
13 Pmp

W

R

E2

E1

P1

P2

R2

R1

S1

S1

AUX

AUX

G

Pompe/
Pump
120V x 1/6HP max

Demande Chauffage thermostat/
Heat Demand thermostat
(Contact sec/ Dry Contact)

Contact Bi-Énergie NC
Dual Energy contact NC

Sonde extérieure de modulation /
Outdoor Reset Sensor

Sonde sortie chaudière/
Boiler Outlet Sensor

Aux.

24

Bi-E

R

Outdr sens

Boiler out

C

Chaudière auxiliaire/

Auxiliary boiler

white

black

blue

blue

brown

grey

red

yellow

Blue

orange

orange

red

red

red

red

red

red

red

red

black

black

blue
orange
orange

black

black

grey
brown
yellow

blue

W

R

C

blue

T
T

Pour bi-énergie seul.
(Voir fig.11&12 du manuel)
For dual-energy only
(Se fig.11&12 of manual)

T
T

G

5A

black

EL3

R3

C1C1

EL4

R4

C1C1

EL2

R2

EL5

R5

C2

EL6

R6

C2C2

C2

L2-1

L2-2

black

red

HL#2

MR

HL#1

AR

Légende/ Legend

C

Relais
Relay

Fusible
Fuse

Cablage en usine/
Factory wiring

Cablage par l'installateur/
Wiring by others

Élément chauffant/
Heating element

Contacteur
Power relay

HL-AR

Haute limite à ré-enclen­chement automatique
High limit automatic reset

Haute limite à ré-enclen­chement manuel
High limit manual reset

R

HL-MR

*100A

*100A

T
T

sur 33-36kW

&USA mod.

ZDV200-DIABTHU6

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 15

Figure 13 : Wiring diagram (12-24 KW)

Figure 14 : Wiring diagram (27-36 KW)

Section 4: ADJUSTMENT OF THE CONTROLLER

4.1 INTRODUCTION

The BTH 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)

Or

 Outdoor reset

4.2 DISPLAYED INFORMATION

The electronic control uses an LCD display to
make all adjustments and to visualize the
operation of the system.

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 16

Figure 15 : UltraSmart Controller Display

4.3 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 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.

4.4 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

4.5 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.

Figure 16 : UltraSmart Control Module

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 -10°F (-23°C).
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.

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 17

80F
27C

70F
21C

60F
15C

50F
10C

10F

-12C

40F4C30F0C20F

-7C

0F

-17C

-10F

-23C

-20F

-29C

110F/43C

120F/49C

130F/54C

Température ext. / Outdoor temperature

Temp. de consigne / Target temp.

STD

MAX

MIN

PLINTHES CHAUFFANTES À AILLETTES

FINNED-TUBE HOT WATER BASEBOARDS

140F/60C

150F/65C

160F/71C

170F/77C

180F/82C

190F/88C

80F
27C

70F
21C

60F
15C

50F
10C

10F

-12C

40F4C30F0C20F

-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

Temp. de consigne / Target temp.

STD

MAX

MIN

PLANCHER CHAUFFANT DANS BÉTON

RADIANT FLOOR IN CONCRETE

80F
27C

70F
21C

60F
15C

50F
10C

10F

-12C

40F4C30F0C20F

-7C

0F

-17C

-10F

-23C

-20F

-29C

100F/-38C

90F/32C

110F/43C

120F/49C

130F/54C

Température ext. / Outdoor temperature

Temp. de consigne / Target temp.

STD

MAX

MIN

PLANCHER CHAUFFANT ENTRE SOLIVES

RADIANT FLOOR BETWEEN JOISTS

140F/60C

80F/27C

80F
27C

70F
21C

60F
15C

50F
10C

10F

-12C

40F4C30F0C20F

-7C

0F

-17C

-10F

-23C

-20F

-29C

100F/-38C

90F/32C

110F/43C

120F/49C

130F/54C

Température ext. / Outdoor temperature

Temp. de consigne / Target temp.

STD

MAX

MIN

RADIATEURS EN FONTE
CAST IRON RADIATORS

140F/60C

150F/65C

160F/71C

170F/77C

The following tables show the values of the target
temperature that will be obtained in relation to the
outdoor temperature.

4.6 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:

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 18.

 “OFF” The pump will stop immediately when the

heat demand has been satisfied. This selection
shall be selected on systems equipped with
motorised fast closing zone valves in order to
prevent noise from water hammering.

 “15 sec to 60 min” 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.

4.7 AUTOMATIC HEATING
SHUT DOWN

When the outdoor sensor is installed and 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 (0°F (-17°C) à 105°F (40°C). 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.

4.8 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 first have to tell the
controller if the application is in Dual-energy with an
auxiliary boiler. The selection is made by selecting the
position “Elect.” Or “Bi-Energ” on the switch located at
the back of the controller. This selection will have to be
made before applying voltage to the unit. The default
setting is “Elect.”

This being done, the installer will have to access the

ITEM

DESCRIPTION

RANGE

DEFAULT

Choose the units the user prefers to work with

°F or °C

°F

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

85°F to 105°F

-Radiant Floor between
joists 110°F to 140°F

-Cast iron radiator 135°F
to 165°F

-Baseboard

160°F to 185°F

100°F

125°F

150°F

175°F

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

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

Figure 17 : Back of the controller

restored as they were established before the failure.
Table 5 below shows the presentation sequence of the

menus.

Table 6: CONFIGURATION SEQUENCE OF THE MENU (Appuyez 2 secondes sur le bouton )

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 19.

Select the outdoor temperature at which no
heating of the building is required (the outdoor
sensor has to be installed)

0°F à 105°F

75°F

Note 1: Once the operating parameters have been set, the controller will automatically come back to

80F
27C

70F
21C

60F
15C

50F
10C

10F

-12C

40F4C30F0C20F

-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

Temp. de consigne / Target temp.

NORMAL

BOOST
maximum

HAUSSE AUTOMATIQUE DU POINT DE CONSIGNE

« BOOST »

AUTOMATIC INCREASE OF TARGET TEMPERATURE

80F
27C

70F
21C

60F

15C

50F
10C

10F

-12C

40F4C30F0C20F

-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

Temp. de consigne / Target temp.

NORMAL

Offset max

.

FONCTIONNEMENT DES TOUCHES

Offset min

.

80F

27C

70F

21C

60F
15C

50F
10C

10F

-12C

40F4C30F0C20F

-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

Temp. de consigne / Target temp.

NORMAL

BOOST

HAUSSE AUTOMATIQUE DU POINT DE CONSIGNE

« BOOST »

AUTOMATIC INCREASE OF TARGET TEMPERATURE

normal display screen. If the user needs to increase or decrease the target temperature, he can do it
without having to enter in the configuration menu (see the following section).

4.9 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- buttons are pressed
again the offset value will change up to a value of + ­10°F (5°C) 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.

4.10 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
temperature to recuperate.

-Return to normal room temperature after thermostat’s
“night set back” program.

Three “Boost” operating options are available when the

the three options ON1, ON2 and OFF will be proposed.
Press the + - button to select. The controller will register

OPERATION OF THE + - BUTTONS

is pressed for 6 sec. The icon will appear and

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 20.

the selected item and will return to normal operation
after 5 sec.

Operation in “Boost” Option ON1 (default setting)

The controller will engage the “Boost” program when
the heat demand on terminals RW 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 RW 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

Operation in “Boost” Option ON2 (only offered on
installation not operating in Dual-energy)

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.
This option requires the installation of one or two stages
heating thermostats. The second stage of the
thermostat(s) will have to be connected to E1-E2 of the
boiler and the option ON2 selected.
Then the Boost mode will be instantaneously started
increasing the target temperature when the signal from
the second heating stage will be received. The target
temperature will immediately start increasing.

N.B. 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 .

The Boost menu can be cancelled by selecting “OFF” in

the Boost menu.

4.11 OPERATION IN DUAL-ENERGY:

In Dual-energy mode, the display will indicate that this
mode is active in showing the icon

If it is not shown, check the position of the switch
located at the back of the controller. It must be set to
“Bi-Energ” position.
N.B. The controller will have to be reset to register the
new mode of operation. Just turn the power OFF and
back ON to the unit.

Operation in Dual-energy with Electric

When the authorisation signal to operate in electricity is
received, (close contact between E1&E2), the following
icons will be shown.

The circulating pump and the heating elements will be
activated according to the operating parameters
established earlier.

Operation in Dual-energy with the auxiliary boiler

When the authorisation signal will be absent (open
contact between E1&E2), the following icons will be
shown.

Manual selection for the electricity or auxiliary
boiler mode.

If the user wishes to manually select the electricity or
auxiliary boiler operation, it can be done in following the
sequence below:

o Push on the button for 6 sec. and the

following icons will appear

The selection of the dual-energy or electric only or
auxiliary boiler only is made with the + - button. Once
the selection has been made it will be registered by

pressing the or by waiting for 5sec.
If the electricity only or auxiliary boiler only has been

selected, the corresponding icon and the icons will
blink to advise the user that an unusual heating mode
has been selected.

Upon reception of a heat demand on terminals R W of
BTH ULTRA boiler, terminals P1&P2 will be energized at
120volts and the pump will be activated. At the same
time, the contact will close on the “AUX” terminals to
activate the auxiliary boiler. This boiler will be activated
only when there will be a heat demand to the R W
terminals and when the auxiliary boiler temperature will
be lower than the settings of its own temperature
controls.
If a three way valve is used on the piping as shown in
fig.6, it will change position when the contact will close
on AUX terminals and it will be the end switch of the
valve that will give the signal to the auxiliary boiler to
come on. The water flow will then circulate only in the
auxiliary boiler.

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 21.

SAFETY PRECAUTIONS

!

Section 5: 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.

5.1 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 12
psi.

 Turn On the electrical supply to the boiler with

no heat demand from the thermostat(s).

 If the boiler is installed in dual energy, adjust

the external device making the selection of the
heating mode for an operation on Electricity
(close contact between E1&E2).

 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.

 Do not set the room thermostat at ON to avoid

the operation of the heating elements.

 Adjust the UltraSmart boiler temperature

controller as explained earlier and set the purge
delay of the pump from On to its normal
operation setting. The pump should stop.

5.2 STARTUP & INSPECTION

 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.
N.B: A rapid activation of all the elements and
external components can be done by pressing
simultaneously the + and – buttons and
maintaining the pressure on the buttons until all
the components are operating

 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

5.3 COMPLEMENTARY CHECKS ON DUAL­ENERGY INSTALLATIONS

N.B. On initial startup 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.

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.

 Check the proper operation of the external

authorization signal to operate on electricity or
auxiliary in simulating the operation of the
signal (open or close contact) on E1 and E2.
Verify the change of the operating mode.

 Check the operating sequence in the “AUX”

mode as decrribed in section 4.11 of the
manual.

 Adjust and check the operation of the auxiliary

boiler.

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 22.

WARNING

!

Section 6 MAINTENANCE

6.1 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:

6.2 AT ALL TIMES

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.

6.3 TWICE A YEAR

 Check for the proper operation of the automatic

air purger(s) and eliminate air from the
radiators.

6.4 ANNUALY

Make sure that the power on the unit has been
turned off before opening the electrical
compartments of the boiler.

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. At the beginning of the heating
season, check the proper operation of the
operating/safety controls, circulating pump and heating
distribution system components. Required corrections
should be made as soon as possible. Parts used for
replacement shall be the same as the original
equipment.

 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

 If the system piping includes a strainer to collect

sediments from the heating distribution system,
it must be clean.

 If the installation includes an auxiliary boiler,

have it checked by a qualified technician.

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 23.

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 “Bi­Energ” 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.

--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

When stage 3 or 4 comes ON,
stage 1 or 2 comes OFF

This sequence is normal on
boilers from 27 to 33kW since
stage 2 and 3 activate two
elements. Stage 1 or 2 is
disactivated to obtain an equal
increase of capacity of the boiler.

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 controller shows that the
heating stages are ON but the
heating elements do not heat.

The main contactor inside the
unit is not activated. There is no
24Vac at his coil.

The contact of the hi limit temp.
control (automatic reset or manual
reset in some models) is open. Reset
the control and check for proper

operation.

The boiler water temperature at the

outlet of the unit “BOILER T0”does
not get to the “BOILER TARGET T

0”

-The room thermostat is not in
constant demand.

-Some heating elements are

-Adjust the thermostat anticipator (If
available) to obtain longer operating
cycles

Section 7- TROUBLE SHOOTING

7.1 TROUBLE SHOOTING TABLE

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 24.

defective

-The total capacity of the boiler is
expelled to the heating
distribution system at this
temperature.

-Replace defective elements

-If a higher boiler water temperature 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 TT of the boiler

-Change defective “end switch”.

-Make appropriate connections as
shown in fig.7

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

Temperature

Resistance

Temperature

Resistance

Temperature

Resistance

Temperature

Resistance

°F

°C Ω °F

°C Ω °F

°C Ω °F

°C

Ω

-50

-46

490,813

20

-7

46,218

90

32

7,334

160

71

1,689

-45

-43

405,71

25

-4

39,913

95

35

6,532

165

74

1,538

-40

-40

336,606

30

-1

34,558

100

38

5,826

170

77

1,403

-35

-37

280,279

35 2 29,996

105

41

5,21

175

79

1,281

-30

-34

234,196

40 4 26,099

110

43

4,665

180

82

1,172

-25

-32

196,358

45 7 22,763

115

46

4,184

185

85

1,073

-20

-29

165,18

50

10

19,9

120

49

3,76

190

88

983

-15

-26

139,402

55

13

17,436

125

52

3,383

195

91

903

-10

-23

118,018

60

16

15,311

130

54

3,05

200

93

829

-5

-21

100,221

65

18

13,474

135

57

2,754

205

96

763

0

-18

85,362

70

21

11,883

140

60

2,49

210

99

703

5

-15

72,918

75

24

10,501

145

63

2,255

215

102

648

10

-12

62,465

80

27

9,299

150

66

2,045

220

104

598

15

-9

53,658

85

29

8,25

155

68

1,857

225

107

553

Table 7: Resistance value of the outdoor sensor vs outdoor temperature

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 25.

Pressure relief valve

ZMC200-SV30PSI1

Power relay 24Vac
ZEL100-24ACNO30

4 poles Contactor
24Vac

ZEL100-4P50A24

Transformer 208/240V x 24Vac

ZEL400- 20842440 (40VA)

Fuse
ZEL250-TDMIDJ5

UltraSmart Controller

ZEL100-ULTRA

Temp.&Pressure indicator

ZMC300-75P160CN

Figure 18 : Spare parts (front, 12-24 KW)

Surface High-Limit

manual reset switch
(on some Models)
ZEL200-DISC227

High-Limit automatic
reset Switch

ZEL200-L6C732

Heating elements**
3kW : ZEL300-240V3KW

4.5kW : ZEL300-240V45KW
5kW : ZEL300-240V5KW
6kW : ZEL300-240V6KW

Figure 19 : Spare parts (top, 12-24 KW)

7.2 SPARE PARTS

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 26.

Temperature and
Pressure Indicator

ZMC300-75P160CN

Transformer 208/240V x
24Vac

ZEL400-20842450 (50VA)

Fuse
ZEL250-TDMIDJ5

UltraSmart Controller

ZEL100-ULTRA

Power relay 24Vac
ZEL100-24ACNO30

Pressure relief valve

ZMC200-SV30PSI1

4 poles Contactor 24Vac

ZEL100-4P50A24

Surface High-Limit
manual reset switch
(USA Models only)
ZEL200-DISC227

High-Limit automatic
reset Switch

ZEL200-L6C732

Heating elements**
3kW : ZEL300-240V3KW

4.5kW : ZEL300-240V45KW
5kW : ZEL300-240V5KW
6kW : ZEL300-240V6KW

Figure 20 : Spare parts (front, 27-29 KW)

Figure 21 : Spare parts (top, 27-36 KW)

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 27.

Pressure relief valve

ZMC200-SV30PSI1

Power relay 24Vac
ZEL100-24ACNO30

4 poles Contactor 24Vac

ZEL100-4P50A24

Temperature and
Pressure Indicator

ZMC300-75P160CN

Transformer 208/240V x
24Vac

ZEL400-20842450 (50VA)

Fuse
ZEL250-TDMIDJ5

UltraSmart Controller

ZEL100-ULTRA

Breaker

ZEL900-2P100A

Figure 22 : Spare parts (front, 33-36 KW)

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 28.

THERMO 2OOO INC.

500, 9

ième

Avenue, Richmond (Qc) Canada J0B 2H0

Tel: [phone] Fax: [phone]

www.thermo2000.com

BTH ULTRA LIMITED WARRANTY

Warranty Coverage on the tank.

Thermo 2000 Inc. hereby warrants that the BTH ULTRA tank on
normal use and service will not leak for a period of fifteen (15) years
from the date of purchase. The warranty is valid as long as the original
residential purchaser owns the building in which the unit was originally
installed. In the event that a leak should 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
the manufacturing plant. The replacement unit will be warranted for the
remaining portion of the original Warranty.

Warranty coverage on parts

All BTH 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 the
Manufacturer. The components, repaired or replaced are warranted for
the residual period of the initial warranty on the parts.

Exclusions

This warranty is void and shall not apply if:

A) Defects or malfunctions resulting from installation, repair,

maintenance and/or usage that are not done in conformity
with the manufacturer’s installation manual.

B) Defects or malfunctions resulting from installation,

maintenance, or repair that are not done in accordance with
regulations in force.

C) Defects or malfunctions resulting from improper installation,

maintenance or repair done carelessly or resulting from
consumer damage (improper maintenance, misuse, abuse,
accident or alteration).

D) 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.

E) Installation in which liquid circulating in the tank does not

remain in closed circuit or installation in which piping is
leaking or on systems with polybutylene pipes or other
having no oxygen absorption barrier.

F) 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 particles matter or water exceeding 10.5
gpg.

G) The BTH ULTRA unit has been subjected to non-authorized

modifications.

H) Defects or malfunction resulting from storing or handling

done elsewhere than Thermo 2000’s manufacturing plant.

I) Units on which the serial number is removed or obliterated.

Limitations

Thermo 2000 Inc. 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 jurisdiction to jurisdiction..

This warranty replaces any other expressed or implicit warranty and
constitutes the sole obligation of Thermo 2000 Inc. 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 Inc. reserves its rights to make changes in the 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 BTH ULTRA dealers are permitted to perform warranty

obligations. The owner or his contractor must provide Thermo 2000’s

head office or authorized depot with the defective unit together with the
following information: BTH ULTRA model and serial number, copy of

the original sales receipt and owner’s identification certificate.

BTH ULTRA Electric Boilers Installation & Operation manual (Revision: June 2015) 29.