THERMO 2000 MINI ULTRA Installation & Operating Manual
Electric Boilers
MINI ULTRA
Models from 3 kW to 12 kW : 208/240V single phase
INSTALLATION & OPERATING MANUAL
Your MINI ULTRA Electric Boiler has been carefully assembled and factory tested to provide
years of trouble-free service. The following information and safety measures are provided to
enable proper installation, operation, and maintenance of this product.
It is imperative that all persons who are expected to install, operate or adjust this boiler
should read these instructions carefully.
Any questions regarding the operation, maintenance, service or warranty of this electric
boiler should be directed to the supplier.
When all installation steps have been completed, keep this installation manual in a safe
place (close to the boiler) for future reference.
THERMO 2000 Inc. Revision: May 2015
Printed In Canada
MINI ULTRA ELECTRIC BOILERS Installation and operating manual (Revision: May 2015)
2
Table of contents
Section 1: TECHNICAL SPECIFICATIONS..............................................................................................4
Table 1: Ratings & Specifications at 208 & 240**Vac / 1ph1.................................................................4
Table 2 : Boiler connections and dimensions.......................................................................................4
Section 2: INTRODUCTION.....................................................................................................................5
2.1 LOCAL INSTALLATION REGULATIONS.......................................................................................5
2.2 CORROSIVE ENVIRONMENT ......................................................................................................5
2.3 INSPECTION UPON RECEPTION................................................................................................5
2.4 TO BE CHECKED .........................................................................................................................5
Section 3 : INSTALLATION .....................................................................................................................6
3.1 SAFETY MEASURES....................................................................................................................6
3.2 LOCATION....................................................................................................................................6
3.3 CLEARANCES..............................................................................................................................6
Table 3: Boiler Clearances ..................................................................................................................6
3.4 BOILER WATER CONNECTIONS.................................................................................................7
3.4.1 Pressure relief valve...............................................................................................................8
3.4.2 Expansion tank.......................................................................................................................8
3.4.3 Water pressure regulator ........................................................................................................8
3.4.4 Air eliminator ..........................................................................................................................8
3.4.5 Circulating pump ....................................................................................................................8
3.4.6 Drain valve .............................................................................................................................9
3.4.7 Strainer ..................................................................................................................................9
3.5 ELECTRICAL CONNECTIONS......................................................................................................9
3.5.1 Main boiler supply...................................................................................................................9
3.5.2 Electrical supply of External accessories.................................................................................9
3.5.3 Outdoor temperature sensor...................................................................................................9
3.5.4 Thermostat(s) and pump(s) connections............................................................................... 10
Section 4: ADJUSTMENTS OF THE CONTROL MODULE....................................................................12
4.1 INTRODUCTION.........................................................................................................................12
4.2 DISPLAYED INFORMATION.......................................................................................................12
4.3 OPERATION OF THE INTERFACE.............................................................................................13
4.4 OPERATION IN “FIXED BOILER TEMPERATURE SET POINT”.................................................13
4.5 OPERATION WITH “OUTDOOR RESET”....................................................................................13
4.6 PURGE DELAY OF THE PUMP..................................................................................................14
4.7 AUTOMATIC HEATING SHUT ....................................................................................................14
DOWN ..............................................................................................................................................14
4.8 CONFIGURATION OF THE CONTROLLER................................................................................14
4.8.1 Adjustments of the target temperature by the user................................................................15
4.8.2 ’’Boost system operation’’ .....................................................................................................16
Section 5: START UP OPERATION.......................................................................................................17
5.1 PREPARATORY STEP ...............................................................................................................17
Section 6: MAINTENANCE.................................................................................................................... 18
6.1 INTRODUCTION.........................................................................................................................18
6.1.1 At all times............................................................................................................................18
6.1.2 Twice a year.........................................................................................................................18
6.1.3 Annually ............................................................................................................................... 18
6.2 REPLACEMENT PARTS.............................................................................................................19
Section 7 : TROUBLESHOOTING.........................................................................................................20
Table 4: Sensors resistance value vs real temperature. .....................................................................21
MINI ULTRA LIMITED WARRANTY ....................................................................................................22
MINI ULTRA ELECTRIC BOILERS Installation and operating manual (Revision: May 2015)
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Figure 1 : Dimensions..............................................................................................................................1
Figure 2 : Mounting positions...................................................................................................................7
Figure 3 : Typical piping lay-out ...............................................................................................................7
Figure 4 : Typical installation on high temperature application..................................................................8
Figure 5 : Zoning with Multiple pumps....................................................................................................10
Figure 6 : Zoning with Motorized valves.................................................................................................10
Figure 7 : Wiring diagram (3-9 KW)........................................................................................................11
Figure 8 : Wiring diagram (12 KW).........................................................................................................11
Figure 9 : UltraSmart Controller Display.................................................................................................12
Figure 10 : UltraSmart Control Module...................................................................................................13
Figure 11 : Replacement Parts (Front view)...........................................................................................19
Figure 12 : Replacement Parts (Top view).............................................................................................19
MINI ULTRA ELECTRIC BOILERS Installation and operating manual (Revision: May 2015)
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Section 1: TECHNICAL SPECIFICATIONS
Table 1: Ratings & Specifications at 208 & 240**Vac / 1ph
1
Suggested size at
240V/1ph.
3
Capacity
(KW)
Amps
2
Cable
MINI ULTRA
208 V 240 V 208 V 240 V
Electric element(s)
(240 V)
Stages
Cu Al
Breaker
(Amp.)
3 2.2 3 10.9 12.5 1 x 3 KW 1 12 10 20
4.5 3.4 4.5 16.3 18.9 1 x 4.5 KW 1 10 10 30
6 4.5 6 21.8 25.0 2x 3 KW 1 8 6 40
7.5 5.6 7.5 27.2 31.2 1 x 3 KW + 1 x 4.5 KW 2 8 6 40
9 6.7 9 32.6 37.5 2 x 4.5 KW 2 8 6 50
12 9 12 43.5 50.0 2 x 6 KW 2 6 4 70
• 1Electrical 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
• 2Add 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.
Table 2 : Boiler connections and dimensions
Connections
Inlet/Outlet 3/4 “ NPT Fem
Pressure relief valve
3/4 “ NPT Fem
Drain valve 3/4 “ NPT Fem
Shipping weight 47 lbs
Item
Dimension (inches)
A 21-1/2
B 8-7/8
C 8-3/4
D 3-1/4
E 2-1/2
F 15
G 5
H 9-3/4
I 20
Some provinces or states, may require boilers built in conformity to ASME standards. If
such models are required, model with an “H” suffix shall be used.
Figure 1 : Dimensions
MINI ULTRA ELECTRIC BOILERS Installation and operating manual (Revision: May 2015)
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General Safety Precautions
Be sure to read and understand the entire Installation & operation manual before attempting to
install or to operate this water heater. Pay particular attention to the following General Safety
Precautions. Failure to follow these warnings could cause property damage, bodily injury or
death. Should you have any problems understanding the instructions in this manual, STOP,
and get help from a qualified installer or technician.
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).
List of components shipped with the unit :
• Pressure relief valve set at 30 PSI.
• Drain valve.
• Temperature & pressure indicator
• Outdoor temperature sensor
• Installation and operating manual
!
WARNING
!
MINI ULTRA ELECTRIC BOILERS Installation and operating manual (Revision: May 2015)
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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 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 30psi (207kPa)
This electric boiler is designed to be installed on
a circuit operated between 50F to 190F (10C to
90C) and at a maximum operating pressure of
30psi (207kPa). 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 a mix solution Water/Glycol
having a maximum glycol concentration of 50%.
The boiler high limit temperature control is set at
a fixed temperature of 210F 99C). 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
90F (32C).
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 3: Boiler Clearances
Sides 3 inches
Electric elements side 14 inches
Front side of the boiler 3 inches*
Back 0 inches
*If the boiler is installed in a closed
compartment, allow an access service opening
and adequate ventilation to maintain an ambient
temperature lower than 90F/32C.
WARNING
!
CAUTION
!
MINI ULTRA ELECTRIC BOILERS Installation and operating manual (Revision: May 2015)
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Figure 2 : Mounting positions
*In position #5 and #6: on boilers MINI ULTRA
3 & 4.5kW
, the heating element located in the upper section of the
boiler must be relocated into the lower opening.
3.4 BOILER WATER CONNECTIONS
Make sure you connect the accessories and the piping to the proper connection fittings as indicated at
figure 2 above and according to the selected mounting position.
Figure 3 &4 below shows typical connections of a MINI BTH boiler to a radiant floor and cast iron radiator
heating systems. The location of the distribution system components may be different from what is
represented.
Figure 3 : Typical piping lay-out
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