THERMO 2000 MINI ULTRA Installation & Operating Manual Download

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MINI ULTRA ELECTRIC BOILERS Installation and operating manual (Revision: May 2015)

6.2 REPLACEMENT PARTS

Figure 11 : Replacement Parts (Front view)

Figure 12 : Replacement Parts (Top view)

** When replacing a heating element, make sure to install it in the same orientation it was installed at the factory.

Heating Elements

3 kW : ZEL300-240V3KW
4.5 kW : ZEL300-240V45KW
6 kW : ZEL300-240V6KW

Fuse
ZEL250-TDMIDJ5

High-Limit automatic
reset Switch
ZEL200-L6C732

Power Relays 24Vac
ZEL100-24ACNO30

Pressure Relief
Valve
ZMC200-SV30PSI1

2 Poles Contactor 24Vac
(3, 4.5, 6, 7.5, 9 kW)
ZEL100-2PC5024
4 poles Contactor 24Vac
(12 kW)
ZEL100-4P50A24

Transformer 208/240Vx24V
(40va)
ZEL400-

20842440

Temperature and
Pressure Indicator
ZMC300-75P160CN

Control Module
ZEL100-ULTRA

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

Summary of Contents for MINI ULTRA

Page 1: ... 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...

Page 2: ...CAL 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 ...

Page 3: ...gure 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 ...

Page 4: ...ith 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 respon...

Page 5: ... 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 sup...

Page 6: ... 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 boile...

Page 7: ...wer 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 fro...

Page 8: ...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 83kPa 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 4 Ai...

Page 9: ...able 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 The main terminal block of the boiler is suitable for 14 to 2 wires Supply cables can be made o...

Page 10: ...ctly on terminals P and P N B The amperage of the pump and 120Vac accessories must not exceed 5A or 1 6HP Multiple pumps zoning applications 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 illust...

Page 11: ...MINI ULTRA ELECTRIC BOILERS Installation and operating manual Revision May 2015 11 Figure 7 Wiring diagram 3 9 KW Figure 8 Wiring diagram 12 KW ...

Page 12: ...re 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 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 F...

Page 13: ...ation 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 temperatur...

Page 14: ...on Required on particular heating distribution systems 4 7 AUTOMATIC HEATING SHUT DOWN When the outdoor sensor is installed and that 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 0F 17C à 105F 40C This characteristic is especially interesting on the following ...

Page 15: ...r temperature at which no heating of the building is required the outdoor sensor has to be installed 0 F to 105 F 75 F Note1 Once these parameters have been set the controller will automatically return to its normal view but the user has the possibility to change the target temperature without having to go through the complete menus 4 8 1 Adjustments of the target temperature by the user By pressi...

Page 16: ...e determined period and up to a pre calculated maximum value until the heat demand applied on W R 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 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 ...

Page 17: ...directly on PP terminals of the boiler it can be activated by selecting ON in the configuration menu after having pressed for 2 seconds Adjust the UltraSmart boiler temperature controller as explained earlier and set the purge delay of the pump from On to its normal operation setting Set the room thermostat ON to generate a heat demand The pump shall start The heating elements shall gradually come...

Page 18: ...t plug the outlet of this safety relief valve if a dripping condition occurs 6 1 2 Twice a year Check for the proper operation of the automatic air purger s and eliminate air from the radiators 6 1 3 Annually 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 o...

Page 19: ...ements 3 kW ZEL300 240V3KW 4 5 kW ZEL300 240V45KW 6 kW ZEL300 240V6KW Fuse ZEL250 TDMIDJ5 High Limit automatic reset Switch ZEL200 L6C732 Power Relays 24Vac ZEL100 24ACNO30 Pressure Relief Valve ZMC200 SV30PSI1 2 Poles Contactor 24Vac 3 4 5 6 7 5 9 kW ZEL100 2PC5024 4 poles Contactor 24Vac 12 kW ZEL100 4P50A24 Transformer 208 240Vx24V 40va ZEL400 20842440 Temperature and Pressure Indicator ZMC300 ...

Page 20: ...ould 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 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...

Page 21: ...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 1...

Page 22: ...ressure 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 wit...

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