THERMO 2000 ECO ULTRA 4.5, ECO ULTRA 7.5, ECO ULTRA 9, ECO ULTRA 12, ECO ULTRA 18 Installation Use And Care Manual
...
ECO ULTRA
Power capacity : 4.5 kW to 29 kW :
120V- 208/240V (single phase)
Your ECO ULTRA electric boiler has been carefully assembled and factory tested to provide
years of trouble-free service. This manual contains instructions for the safe and proper
installation, operation and maintenance of the boiler, in order to ensure your full satisfaction.
It is imperative that all persons who are expected to install, operate or adjust this boiler read
the instructions carefully.
Any questions regarding the operation, maintenance, service or warranty of this water heater
should be directed to the dealer or distributor you purchased it from. When all installation
steps have been completed, replace this installation manual in its original envelope, and keep
in a safe place near the heater for future reference.
Electric thermal mass boiler
INSTALLATION, USE AND CARE MANUAL
THERMO 2000 INC. Revision : June 2017
Printed in Canada
Table of contents
Section 1 : TECHNICAL SPECIFICATIONS ......................................................................................................................................... 3
1.1POWER AND DIMENSIONS ...................................................................................................................................................... 3
1.2 BUFFER TANK ......................................................................................................................................................................... 4
1.3 STORAGE TANK ...................................................................................................................................................................... 4
1.4 HYDRAULIC SEPARATOR ....................................................................................................................................................... 4
1.5 BACK UP BOILER ..................................................................................................................................................................... 4
1.5.1 Autonomous electrical mode ............................................................................................................................................. 4
1.5.2 Automatic transfer mode ................................................................................................................................................... 4
Section 2 : INTRODUCTION ................................................................................................................................................................ 5
2.1 LOCAL INSTALLATION REGULATIONS .................................................................................................................................. 5
2.2 CORROSIVE ATMOSPHERE ................................................................................................................................................... 5
2.3 SHIPMENT INSPECTION ......................................................................................................................................................... 5
2.4 TO VERIFY ............................................................................................................................................................................... 5
Section 3 : INSTALLATION .................................................................................................................................................................. 6
3.1 SAFETY MEASURES................................................................................................................................................................ 6
3.2 LOCATION ................................................................................................................................................................................ 6
3.3 CLEARANCES ................................................................................................................................................................ .......... 6
3.4 PIPING INSTALLATION ............................................................................................................................................................ 7
3.5 BOILER COMPONENTS ........................................................................................................................................................... 7
3.6 SYSTEM SETUP ..................................................................................................................................................................... 12
3.6.1 Connecting the boiler ...................................................................................................................................................... 12
3.6.2 Flow-check valve ............................................................................................................................................................. 12
3.6.3 Pressure relief valve ........................................................................................................................................................ 12
3.6.4 Expansion tank ................................................................................................................................................................ 12
3.6.5 Water pressure regulator ................................................................................................................................................. 12
3.6.6 Automatic Air Vent ........................................................................................................................................................... 12
3.6.7 Heating pump .................................................................................................................................................................. 13
3.7 BOILER WIRING: .................................................................................................................................................................... 13
3.7.1 Main power supply .......................................................................................................................................................... 13
3.7.2 Heating pump wiring ........................................................................................................................................................ 13
3.7.3 Outdoor temperature sensor ............................................................................................................................................ 13
3.7.4 Room thermostat wiring ................................................................................................................................................... 13
3.7.5 Automatic transfer mode wiring ...................................................................................................................................... 14
3.8 WIRING DIAGRAMS ............................................................................................................................................................... 16
Section 4 : ADJUSTMENT OF THE CONTROLLER ........................................................................................................................... 18
4.1 INTRODUCTION ..................................................................................................................................................................... 18
4.2 DISPLAYED INFORMATION ................................................................................................................................................... 18
4.3 OPERATION OF THE INTERFACE ........................................................................................................................................ 19
4.4 OPERATION IN “FIXED BOILER TEMPERATURE SET POINT” ............................................................................................ 19
4.5 OPERATION WITH “OUTDOOR RESET”: .............................................................................................................................. 19
4.6 PURGE DELAY OF THE PUMP .............................................................................................................................................. 20
4.7 AUTOMATIC HEATING SHUT DOWN .................................................................................................................................... 20
4.8 CONFIGURATION OF THE CONTROLLER ............................................................................................................................ 20
4.9 ADJUSTMENTS OF THE TARGET TEMPERATURE BY THE USER: .................................................................................... 22
4.10 BOOST SYSTEM OPERATION............................................................................................................................................. 22
4.11 OPERATION IN AUTOMATIC TRANSFER MODE: ............................................................................................................... 23
Section 5 : START UP OPERATION .................................................................................................................................................. 24
5.1 PREPARATORY STEP ........................................................................................................................................................... 24
5.2 STARTUP & INSPECTION ...................................................................................................................................................... 24
5.3 COMPLEMENTARY CHECKS ON AUTOMATIC TRANSFER MODE ..................................................................................... 24
Section 6 : MAINTENANCE ................................................................................................................................................................ 25
6.1 INTRODUCTION ..................................................................................................................................................................... 25
6.1 AT ALL TIMES ........................................................................................................................................................................ 25
6.2 EVERY 6 MONTHS ................................................................................................................................................................. 25
6.3 YEARLY INSPECTION ............................................................................................................................................................ 25
Section 7 : TROUBLE SHOOTING ..................................................................................................................................................... 26
7.1 TROUBLE SHOOTING TABLE................................................................................................................................................ 26
7.2 SPARE PARTS ....................................................................................................................................................................... 28
Section 8 : OPTION DHW HEAT EXCHANGER ................................................................................................................................. 31
ECO ULTRA LIMITED WARRANTY ................................................................................................................................................... 40
ECO ULTRA Electric Boiler Installation, Use and Care Manual (Revision June 2017), Page 2.
Model
ECO ULTRA
Power
(kW)
Heating
Elements
Amperage
2
Suggested
electrical
cable
at 240V
3
Suggested
Breaker/Fuse
at 240V
3
208 V
240V
208 V
240V
cu
al
4.5
3.4
4.5
1 x 4,5 kW
16.3
18.9
10
10
30
7.5
5.6
7.5
1 x 4.5 kW +
1 x 3 kW
27.2
31.2 8 6
40
9
6.8 9 2 x 4,5 kW
32.6
37.5 8 6
50
12
9
12
2 x 6 kW
43.5
50 6 4
70
15
11.2
15
2 x 3 kW +
2 x 4,5 kW
54.3
62.5 6 4
80
18
13.5
18
4 x 4,5 kW
65.2
75 4 2
100
20
15
20
4 x 5 kW
72.5
83.3 3 2
110
24
18
24
4 x 6 kW
87
100 2 0
125
27
4
20.3
27
6 x 4,5 kW
97.9
112.5
1
00
150
29
4
21.8
29
2 x 4,5 kW +
4 x 5 kW
104
120 1 00
175
ECO ULTRA 50
ECO ULTRA 70
Height
56-7/16’’
66-7/16’’
Diameter
22’’
24’’
Depth (with door)
25-1/2’’
28’’
Weight
280 lb
380 lb
Heating supply
1’’ NPTM
1-1/4’’ NPTM
Heating return
1’’ NPTM
1-1/4’’ NPTM
Section 1 : TECHNICAL SPECIFICATIONS
1.1 POWER AND DIMENSIONS
Table 1: Boiler specifications 208V/240V/1ph.1:
1
Electrical supply: 120/240V or 120/208V single-phase (L1 – N – L2) with three 90°C conductors, or two conductors
L1 – L2 if the boiler does not require power to a 120 VAC pump or accessories.
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
These models are only available on the ECO ULTRA 70.
Maximum operating pressure on the tank: 207 kPa / 30 psi
Tank temperature range : 10°C to 88°C (50°F to 190°F)
1 kW = 3412 BTU/h
Table 2: Dimensions:
ECO ULTRA Electric Boiler Installation, Use and Care Manual (Revision June 2017), Page 3.
1.2 BUFFER TANK
The ECO ULTRA boiler optimizes runtimes and
limits on/off cycling of the energy source(s).
When the minimum system load is lower than the
energy source’s minimum capacity, the system
will generate short cycles. This causes premature
wear of the equipment and substantially
decreases the system’s energy efficiency.
1.3 STORAGE TANK
Any hydronic heating system with the ECO
ULTRA stores energy like a battery. When a
demand is made for limited heating (for example,
when there is little difference between indoor and
outdoor temperatures) or when it is used with a
low-capacity energy source, the energy required
will first come from the tank’s thermal storage.
1.4 HYDRAULIC SEPARATOR
Adding an ECO ULTRA boiler to a hydronic
heating system helps to evacuate air, eliminates
impurities, and ensures the optimal functioning of
the pumps—not only for the energy source but
also for the distribution system.
1.5 BACK UP BOILER
The addition of an ECO ULTRA electric boiler to
a hydronic heating system acts as a back-up
source to the main renewable energy system.
The boiler can operate in two modes:
autonomous electrical mode or automatic
transfer mode.
For both modes, it is recommended to use the
outdoor sensor supplied with the equipment. The
outdoor sensor allows the boiler water
temperature to be modulated according to the
outside temperature. It also makes it possible to
stop the heating of the electric elements when the
outside temperature exceeds a certain
temperature. The use of these functions makes it
possible to optimize the start-up of the main
renewable energy system.
1.5.1 Autonomous electrical mode
By default, the boiler operates in autonomous
electrical mode where, on request of heat, the
ECO ULTRA boiler turns on the distribution
pump, reads the water temperature and activates
the electrical elements according to the
Parameters of the UltraSmart controller
independently if the main renewable energy
source is on or off.
In addition, for this mode, it is recommended to
adjust the setpoint of the renewable energy
source to a value greater than 10°F to 20°F than
the ECO ULTRA to reduce the start-up of the
electrical elements.
1.5.2 Automatic transfer mode
The boiler can also be operated in the automatic
transfer mode, where the ECO ULTRA electric
boiler turns on the distribution pump, reads the
water temperature and activates the electrical
elements if authorized by an external signal. The
elements are then switched on according to the
adjustment parameters of the UltraSmart
controller.
ECO ULTRA Electric Boiler Installation, Use and Care Manual (Revision June 2017), Page 4.
!
WARNING
!
WARNING
!
General Safety Precautions
Be sure to read and understand the entire Manual before attempting to install or operate
this unit. 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
The important safeguards and instructions
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 ECO ULTRA electric boiler must be installed
in accordance with these instructions and must
conform to local regulation, or in the absence of
local codes, with the current edition of the
National Plumbing Code and the National Electric
Code. In any case where instructions in this
manual differ from local or national codes, the
local or national codes take precedence.
2.2 CORROSIVE ATMOSPHERE
The electric boiler should not be located near an
air supply containing halogenated hydrocarbons
or high humidity. The limited warranty is voided
when failure of the water heater is due to a
corrosive atmosphere.
2.3 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.
2.4 TO VERIFY
Please check the boiler identification plate to
ensure you have the right model.
The following items are factory installed and
shipped with the unit:
207 kPa (30 psi) tank pressure relief
valve.
Tank drain valve
Thermo manometer (heat and
pressure indicator).
Automatic air vent.
Electric heating elements
ULTRA SMART™ controller.
The ECO ULTRA electric boiler should not be
located in an area where leakage from 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.
ECO ULTRA Electric Boiler Installation, Use and Care Manual (Revision June 2017), Page 5.
Left side
0 mm/ 0 ‘’
Right side
0 mm/ 0 ‘’
Top
127 mm / 5 ’’
Front*
75 mm / 3 ’’
Back
0 mm/ 0 ‘’
WARNING
!
Section 3 : 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 water heater 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 installations will include a pressure relief valve
limiting the operating pressure to 207 kPa (30
psi).
This ECO ULTRA electric boiler is designed for a
maximum operating temperature of 88°C
(190°F). It is designed for hot water heating
systems only. When allowed by local regulation a
maximum 50% blend of water and antifreeze (
designed specifically for water heating systems)
may be used.
The boiler is equipped with an automatic high limit
temperature control set at 210°F (99°C) and
models sale in USA have a second limit device
manually re-settable set at 227°F (108°C). 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 ECO ULTRA boiler should be installed in a
clean, dry location. Long hot water lines should
be insulated to conserve energy. The boiler and
piping should be protected from exposure to
freezing.
The ECO ULTRA boiler must be installed levelled
and vertically. Adjustable legs allow for levelling
and stability.
The ECO ULTRA 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.
3.3 CLEARANCES
The minimal clearances required for proper
inspection and servicing are as follows.
Supplementary clearances could be required for
piping installation.
Table 3: Minimum clearances required
*If the installation is inside a closet with an access
door, ventilation openings could be required to
maintain the ambient temperature below 32°C
(90°F).
ECO ULTRA Electric Boiler Installation, Use and Care Manual (Revision June 2017), Page 6.
Pressure relief valve (30 psi)
Automatic air vent
Temperature and pressure
indicator
Main Electrical Supply
Low voltage
connections
Heating supply
Model 50: 1” NPTM
Model 70: 1 ¼“ NPTM
3.4 PIPING INSTALLATION
Make sure that the installation complies with one
of the configuration shown below and that the
water circulation is done in the right way.
Figure 1: Possible installation configurations
3.5 BOILER COMPONENTS
Figures 2 and 3 show various components of the
ECO ULTRA electric boiler. Figures 4 and 6 show
some installation drawings of the boiler in the
autonomous electrical mode. Figures 5, 7 and 8
show some installation drawings of the boiler in
the automatic transfer mode.
Figure 2 : Components identification and location (top right side view)
ECO ULTRA Electric Boiler Installation, Use and Care Manual (Revision June 2017), Page 7.
Adjustable feet
UltraSmart controller
Heating elements
Heating return
Model 50: 1” NPTM
Model 70: 1 ¼“ NPTM
Electrical components
mounting panel
Drain valve
Heating supply
Model 50: 1” NPTM
Model 70: 1 ¼“ NPTM
Figure 3: Components identification and location (left side view)
ECO ULTRA Electric Boiler Installation, Use and Care Manual (Revision June 2017), Page 8.
RA89
34
21
ECO ULTRA INSTALLED WITH WOOD BOILER
AUTOMATIC TRANSFER MODE
Legend
Outdoor sensor
Circulating pump
Room thermostat
Pressure and temperature
indicator
Drain valve
Automatic air vent
Air seperaor
Service valve
Pressure relief valve
Union
Expansion tank
Pressure regulator
Thermostatic mixing
Chaudière au bois
ECO ULTRA
Back flow preventor
TT
120 V
EE
ECO ULTRA INSTALLED WITH WOOD BOILER
Legend
Outdoor sensor
Circulating pump
Room thermostat
Pressure and temperature
indicator
Drain valve
Automatic air vent
Air seperaor
Service valve
Pressure relief valve
Union
Expansion tank
Pressure regulator
Thermostatic mixing valve
Wood boiler
ECO ULTRA
Back flow preventor
AUTONOMOUS ELECTRICAL MODE
Figure 4: Basic dual energy Installation drawing for radiant floor.
valve
Figure 5: Dual energy Installation drawing for radiant floor and wood boiler.
ECO ULTRA Electric Boiler Installation, Use and Care Manual (Revision June 2017), Page 9.
ECO ULTRA INSTALLED WITH AIR-TO-WATER HEAT PUMP
AUTONOMOUS ELECTRICALMODE
Legend
Outdoor sensor
Circulating pump
Room thermostat
Pressure and temperature
indicator
Drain valve
Automatic air vent
Air seperaor
Service valve
Pressure relief valve
Union
Expansion tank
Pressure regulator
Thermostatic mixing
Air-to-water heat pump
ECO ULTRA
Back flow preventor
EE
ECO ULTRA INSTALLED WITH AIR-TO-WATER HEAT PUMP
AUTOMATIC TRANSFER MODE
Legend
Outdoor sensor
Circulating pump
Room thermostat
Pressure and temperature
indicator
Drain valve
Automatic air vent
Air seperaor
Service valve
Pressure relief valve
Union
Expansion tank
Pressure regulator
Thermostatic mixing
Air-to-water heat pump
ECO ULTRA
Back flow preventor
valve
Figure 6: Basic dual energy Installation drawing for radiant floor and Air-to-water heat pump
valve
Figure 7: Dual energy Installation drawing for radiant floor and Air-to-water heat pump
ECO ULTRA Electric Boiler Installation, Use and Care Manual (Revision June 2017), Page 10.
Diverter valve
ECO ULTRA INSTALLED WITH AIR-TO-WATER HEAT PUMP
Legend
Outdoor sensor
Circulating pump
Room thermostat
Pressure and temperature
indicator
Drain valve
Éliminateur d’air automatique
Air seperaor
Service valve
Pressure relief valve
Union
Expansion tank
Pressure regulator
Thermostatic mixing
Air-to-water heat pump
ECO ULTRA
Back flow preventor
Cooling system
EE
AUTOMATIC TRANSFER MODE
valve
Figure 8: Dual energy Installation drawing for radiant floor and Air-to-water heat pump
ECO ULTRA Electric Boiler Installation, Use and Care Manual (Revision June 2017), Page 11.
ECO ULTRA
Baseboards
Radiant
floor
Cast-iron
radiators
ECO ULTRA 50
#30
#30
#60
ECO ULTRA 70
#60
#60
#90
3.6 SYSTEM SETUP
Figures 2 to 8 indentify and show location of the
different components. They also provide typical
heating system installation. External components
location may vary in order to accommodate
specific installation and local codes and
regulation.
3.6.1 Connecting the boiler
The boiler heating supply and return connections
are located on the left or right side and are 1”
NPTM for Model 50 and 1-¼’’ NPTM for model
70. The connections at the left or right can be
used. The important thing is that the fluid
circulation must be made from the bottom to the
top (see figure 1)
Unions are recommended on the inlet and outlet
pipes to disconnect the water heater easily for
servicing if necessary.
Dielectric (insulating) unions should be used if
copper-steel connections are made.
Insulate all pipes containing hot water, especially
in unheated areas.
3.6.2 Flow-check valve
If the heating system uses a single or multiple
circulators without motorized zone valves, a flow-
check valve must be installed to avoid all
possibility of gravity flow and heat loss during
non-draw periods. Modern circulators are
typically provided with spring loaded check valves
that will provide adequate protection.
If the heating system uses motorized zone
valves, these will provide adequate protection.
3.6.3 Pressure relief valve
The boiler is delivered with a factory installed tank
pressure relief valve set at 207 kPa (30 psi).
NEVER replace the pressure relief valve by a
higher set pressure one.
Connect the outlet of the relief valve downward
toward a safe location.
Relief valve outlet pipe diameter must not be of
smaller diameter than the relief valve outlet. The
oulet pipe end must be visible in order to observe
any relief incident and be protected from freezing.
NEVER cap or plug a pressure relief valve
outlet. The pressure relief valve is a safety
apparatus and preventing its proper operation
may cause death, injury or property damage.
3.6.4 Expansion tank
When operating the ECO ULTRA and the heating
system, pressure will vary between 83 kPa and
193 kPa (12 psi to 28 psi). The operating
pressure is affected by the type of heating system
and the size of the expansion tank installed.
The expansion tank is used to absorb the
increase of water volume from the boiler and the
system when it is working.
The model selection should be based on the
maximum working temperature and the water
volume of the total system. For example, a
system with radiators contains much more water
volume than a baseboards system. Likewise, the
ECO ULTRA also contains an important volume
of water that has to be added :
ECO ULTRA 50 : 48 usgal
ECO ULTRA 70 : 71 usgal
With this information, the installator or distributor
should be able to make an appropriate selection
for an expansion tank.
Here are some minimal recommendations for
different types of heating systems.
The expansion tank is generally installed on the
wall or ceiling. It also has to be well supported.
3.6.5 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)
3.6.6 Automatic Air Vent
The ECO ULTRA has a factory installed tank
automatic air vent. This air vent function is to vent
any air present in the tank.
For proper operation, do not cap or block the air
bleeder outlet.
For proper operation of the heating system, it may
be necessary to add air bleeders to the heating
system circuits.
ECO ULTRA Electric Boiler Installation, Use and Care Manual (Revision June 2017), Page 12.
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