THERMO 2000 MINI Ultra 6, MINI Ultra 7.5, MINI Ultra 9, MINI Ultra 12 Installation & Operating Manual
Electric Boilers
MINI ULTRA
M
odels from 6 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, insert this installation manual in its original
envelope, and keep in a safe place (close to the boiler) for future reference.
THERMO 2000 INC. revision: June.2014
Printed in Canada
BTH Electric Boilers USE & CARE MANUAL
(Revision June.2014)
, Page 2.
Ratings & Specifications at 120/240** Vac/1ph (3 wires L1-N-L2):
MINI ULTRA
Cable*!
90C
Breaker!
*
Model Capacity
KW/BTU at
240Vac**
Amps. !
Elements at
240Vac**
Electric
Element(s)
at 240Vac
Stages Cu Al Amp.
MINI Ultra 6 6 / 20,470 25 2 x 3 KW 2 8 6 40
MINI Ultra 7.5 7.5/25,590 31 1X4.5+1X3K 2 8 6 40
MINI Ultra 9 9 / 30,710 37.5 2 x 4.5 KW 2 8 6 50
MINI Ultra 12 12 / 40,940 50 2 x 6 KW 2 6 6 70
! Add the amperage (Max. 5amp-1/6hp) of the circulating pump if it is connected directly to the boiler
* A higher capacity cable an breaker could be required. In all cases the local Electrical Code has priority.
** Can be connected to a 208Vac/1ph electrical supply. The resulting capacity will be of 75% of the
nominal capacity at 240V and the amperage will be of 87%.
Dimensions
Connections Overall dimensions
Inlet/ heating return 3/4 “ NPT Fem Height 21-1/2 inches
Outlet/ heating supply
3/4 “ NPT Fem Width 9 inches
Pressure relief valve 3/4 “ NPT Fem Depth 9 inches
Drain valve 3/4 “ NPT Fem Weight 40 lbs.
Operating temp. range: 50°F (10C) to 190°F (88C). Maximum pressure : 30 psi (207kPa)
Figure 1.
BTH Electric Boilers USE & CARE MANUAL
(Revision June.2014)
, Page 3.
General Safety Precautions
Be sure to read and understand the entire Installation & operation manual before attempting to
install or to operate this water heater. Pay particular attention to the following General Safety
Precautions. Failure to follow these warnings could cause property damage, bodily injury or
death. Should you have any problems understanding the instructions in this manual, STOP,
and get help from a qualified installer or technician.
INTRODUCTION
These important safeguards and instruction
appearing in this manual are not meant to
cover all possible conditions and situations
that may occur. It should be understood that
common sense, caution and care are factors
which cannot be built into every product.
These factors must be supplied by the
person(s) caring for and operating the unit.
LOCAL INSTALLATION REGULATIONS
This electric boiler must be installed in
accordance with these instructions and in
conformity with local codes, or in the absence of
local codes, with the National Plumbing Code
and the National Electric Code, current edition.
In any case where instructions in this manual
differ from local or national codes, the local or
national codes take precedence.
SECURITY CONSIDERATIONS
All installations have a maximum design
operating pressure limited to 30 psi (207kPa) by
a safety relief valve.
Boiler operating temperature range is from
500F(10C) and 190°F(88C). This boiler is
designed to be used only in a hot water close
circuit heating system.
A mix of water and propylene-glycol antifreeze
specially formulated for heating system can be
used up to a maximum concentration of 50%.
CHECK LIST
Please check the identification tag on the unit to
make sure you have the right model.
List of components shipped with the unit :
• Pressure relief valve set at 30 PSI.
• Drain valve.
• Temperature & pressure indicator
(Factory installed).
• Outdoor temperature sensor
SHIPMENT INSPECTION
Inspect the electric boiler for possible shipping
damage. The manufacturer’s responsibility
ceases upon delivery of goods to the carrier in
good condition. Consignee must file any claims
for damage, shortage in shipments, or nondelivery immediately against carrier.
!
WARNING
!
BTH Electric Boilers USE & CARE MANUAL
(Revision June.2014)
, Page 4.
INSTALLATION
The manufacturer’s warranty does not cover any damage or defect caused by installation, or
attachment, or use of any special attachment other than those authorized by the manufacturer
into, onto, or in conjunction with the water heater. The use of such unauthorized devices may
shorten the life of the boiler and may endanger life and property. The manufacturer disclaims any
responsibility for such loss or injury resulting from the use of such unauthorized devices
LOCATION
The electric boiler should be installed in a clean,
dry location. Long hot water lines should be
insulated to conserve water and energy. The
electric boiler and water lines should be
protected from exposure to freezing
temperature.
The electric boiler must be located or protected
so as not to be subject to physical damage, for
example, by moving vehicles, area flooding, etc.
The electric boiler should not be located in
an area where leakage of the tank or water
connections will result in damage to the
adjacent area or to lower floors of the
structure. When such areas cannot be
avoided, a suitable drain pan or nonflammable catch pan, adequately drained,
and must be installed under the boiler.
The pan must be connected to a drain.
NOTE: Auxiliary catch pan MUST conform to
local codes.
The boiler can be mounted directly on a wall
with adequate screws. It needs to be properly
leveled.
All models in alcoves. The ambient temperature
must not exceed 90F (32C)
The electric boiler should not be located near an
air vent blowing a corrosive atmosphere or high
humidity. The limited warranty is void when the
failure of the electric boiler is due to a corrosive
atmosphere.
The choice of the mounting position of the boiler
shall be made in relation with the required
clearances shown below and the fact that the
electric element compartment of the boiler
needs clearance to allow their replacement.
°
CLEARANCE
For adequate inspection and servicing the
following minimum clearance is necessary:
Sides
4 in. /10cm
Electric elements side 14 in./35cm
Front side of the boiler
24 in./60cm
Back
0 in./0cm
Fig. 2 Mounting position
CAUTION
!
WARNING
!
BTH Electric Boilers USE & CARE MANUAL
(Revision June.2014)
, Page 5.
BOILER WATER CONNECTIONS
Make sure you connect the accessories and the piping to the proper connection fittings as indicated at figure
2 above and according to the selected mounting position.
Figure 3 below shows typical connections of a MINI boiler to a radiant floor heating system. The location of
the distribution system components may be different from what is represented.
Figure 3 : Typical piping lay-out
Flow check valve
On heating systems having more than one pump,
each pump will need to be equipped with a flow
check valve either incorporated into the pump or
separate.
Pressure relief valve
This component supplied with the unit must be
installed directly to the boiler housing to the
appropriate connection according to the mounting
position.
Connect the outlet of the relief valve downward to
a safe location in case of discharge.
The piping diameter used for the discharge piping
shall not be smaller than that of the valve outlet. .
No valve of any type, restriction or reducer
coupling should be installed on the discharge line.
Local codes shall govern the installation of relief
valves.
Expansion tank
The expansion tank must be able to store the
required volume of boiler water during maximum
design operating temperature. The maximum
allowable operating pressure is 30PSI (207kPa).
Contact your plumbing supply house for
assistance.
Water pressure feeder regulator
When a pressurized water supply is available in
the building, a make-up systems consisting in a
water pressure reducer generally set at 12psi
(83kPa) and equipped with check valve satisfying
local regulations must be installed between the
boiler and the water supply system.
If the boiler is installed in a building that does not
have a water supply and when the local plumbing
codes allows, it is possible to simply manually
pressurized the heating system equipped with an
expansion tank to 10 (7kPa)to 28psi (193kPa) and
BTH Electric Boilers USE & CARE MANUAL
(Revision June.2014)
, Page 6.
manually maintain a minimum pressure when
required. Another possibility is to install a
pressurized storage tank specially made for those
applications that will inject on request an
appropriate quantity of liquid to maintain an
appropriate pressure on the heating system.
Air bleeder
Installation of manual or automatic air vents are
required to eliminate all air from the boiler and the
heating distribution system.
When the boiler is installed above the heating
distribution system, an automatic air
separator/eliminator must absolutely be installed
at the outlet of the boiler in order to eliminate all
possibilities of air buildup inside the boiler that
would damage the heating elements.
Circulating pump
We recommend that the pump be installed at the
outlet of the boiler with isolating valves as shown
in figure 3.
The pump shall be selected such as to be able to
supply adequate flow in relation to the heating
distribution system on which it will be connected
and the heating capacity of the boiler installed.
The table below will give you details on required
water flow for distribution systems having to
operate with a differential temperature of 10F and
20F between their inlet and outlet
.
Model
Diff. 10F (usgpm)
Diff. 20F (usgpm)
Boilerpress.drop
MINI Ultra 6
4.0
2.0
Negligible
MINI Ultra 7.5
5.1
2.5
Negligible
MINI Ultra 9
6.0
3.0
Negligible
MINI Ultra 12
8.2
4.1
Negligible
The boiler has to be activated only upon a call for
heat and when a pump will be working (no jumper
allowed on TT terminals) a minimum water flow of
1usgpm is recommended.
Your heating wholesaler shall be in good position
to recommend the appropriate model for your
application.
The amperage drawn by the pump and other
120volts components shall not exceed 5 amps or
1/6HP.
Drain valve
Installed at the lowest point of the unit, it allows
the unit to be drained for the eventual
replacement of a defective component.
Strainer
This component is used to collect potential
sediments coming from the distribution system
and more particularly from systems made of steel
piping and radiators. 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.
ELECTRICAL CONNECTIONS:
Main boiler supply
Wiring must conform to the National Electrical
Code and to state or local code requirements.
The electric boiler must be electrically grounded in
accordance with local codes, or, in the absence of
local codes, with the National Electrical Code.
Wiring must come from a 120/240 Volt (single
phase, 60 Hz) “L1-L2-N” circuit protected by a
properly sized breaker.
Wire gage (3 wires+ground) must be properly
sized. Consult the boiler rating plate to select the
proper breaker and wire gage.
The main terminal block of the boiler is suitable for
#14 to #2 wires.
Supply cables can be made of Aluminum or
Copper and be rated for 90C (194F).
If aluminum cables are used, it shall be of an
adequate size (generally bigger) to meet the
National electrical code.
Electrical supply of External accessories
The total 120vac consumption of the boiler and
external accessories must not exceed 5A.
The maximum electrical consumption of 24vac
external accessories connected to R&C terminals
must not exceed 30Va. The available voltage at
the boiler transformer must not drop below 24Vac.
Outdoor temperature sensor
If you want the target boiler temperature to
modulate according to the outdoor temperature (
when the outdoor temp. will get colder, the target
temp. will get higher) , the supplied outdoor
sensor will have to be connected to S1 S1 before
turning the power on to the unit.
The installation of this sensor avoids the operation
of the boiler when the outdoor temperature
exceeds the selected value corresponding to the
maximum temperature required for heating.
The sensor shall be connected to terminals S1-S1
in the boiler using a two conductor cable 18ga.
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