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TURBOMAX Use and Care Manual with Installation Instructions July 2014 Page 

2

 

 

TURBOMAX

®

 Specifications

 

The Turbomax indirect water has an internal copper domestic 
heat exchanger  made of multiple helical copper tubes 
operating in parallel with a 150 psi.(200psi on ASME models 
109A) maximum operating pressure rating. 

All copper 

components and assembly meet the low lead 
requirements for potable plumbing products and adhere 
to the NSF 61 standard (International Standard Drinking 
Water Systems Components Health Effects

. The hot 

water heater has a patented steel injector through which the 
boiler water fluid enters the top side of the tank and a steel 
collector through which the boiler water fluid exits at the bottom 
of the tank.  The tank is be made of high grade carbon steel.  
All the steel joints are welded by the MIG/Argon gas process. It 
has a maximum operating pressure of 150psi (200psi on 
ASME model 109A).  The tank is wrapped with a fiberglass 
insulation jacket limiting the tank heat loss to less than ½°F per 
hour.  The outer steel jacket is painted with baked epoxy. The 
water heater has a temperature controller (aquastat)  that 
makes contact when the temperature falls below the tank water 
temperature set point minus an adjustable differential (10 to 
40F)and breaks contact when the temperature rises over the 
set point (95 to 195F).  The tank has a ¾” drain ball valve 
made of brass, which have a maximum working pressure of 
200 psi. 3 adjustable feet support the water heater for leveling. 
The hot water heater is shipped from the factory with an ASME 
rated pressure relief valve set at 30psi (50 psi. on model 109 , 
65A&109A), a temperature & pressure gage (except #23, 33) 
and an automatic air vent. The water heater is backed by a 15-
year warranty on residential applications and 10 years on 
commercial applications (consult the terms of the warranty 
included at the end of this manual).   
 
 

 

SPECIFICATION 

Model 

Tank 
Volume 

Heat transfer 
area (sq. ft.) 

Max. 
DHW   
flow * 

Utility 
connection 

Boiler 
connection 

Height 

Dia-
meter 

Shipping 
weight 

TURBOMAX

®

 109  119usgal

58.9 ft² 

27usgpm 

2’’ Sweat M 

2’’  NPT M 

74’’ 

29’’ 

555 lbs 

T

URBOMAX109A

 

110usgal 

58.9 pi² 

27usgpm 

2-1/2’ Sweat M 

2’’-NPT M 

74’’ 

29’’ 

755 lbs 

TURBOMAX

®

 65 

72 usgal. 

32.7 ft² 

15usgpm 

1-1/2’ Sweat M 

1-1/2’’ NPT M 

67’’ 

24’’ 

250 lbs 

TURBOMAX

 65A 

67usgal 

32.7 pi² 

15usgpm 

2’ Sweat M 

1-1/2’’ NPT M 

67’’ 

24’’ 

425 lbs 

TURBOMAX

®

 45 

48 usgal. 

32.7 ft² 

15usgpm 

1-1/2’’ Sweat M 

1-1/4’’ NPT M 

55’’ 

22’’ 

235 lbs 

TURBOMAX

®

 44 

48 usgal. 

26.2 ft² 

12usgpm 

1-1/2’’ Sweat M 

1-1/4’’ NPT M 

55’’ 

22’’ 

210 lbs 

TURBOMAX

®

 34 

36 usgal. 

26.2 ft² 

12usgpm 

1-1/2’’ Sweat M 

1-1/4’’ NPT M 

65“ 

18“ 

195 lbs 

TURBOMAX

®

 33 

36 usgal. 

19.6 ft² 

9usgpm 

1-1/4’’ Sweat M 

1-1/4’’ NPT M 

65“ 

18“ 

170 lbs 

TURBOMAX

®

 24 

26 usgal. 

26.2 ft² 

12usgpm 

1-1/2’’ Sweat M 

1-1/4’’ NPT M 

49’’ 

18’’ 

175 lbs 

TURBOMAX 23 

26usgal 

19.6 f

t2

 

9usgpm 

1-1/4” Sweat M 

1-1/4” NPT M 

49’’ 

18’’ 

150 lbs 

*Occasional  operation at higher gpm is acceptable but must be reduced on application where constant hi flow is required .

Summary of Contents for VOLTMAX 23

Page 1: ...this water heater read the instructions carefully so that they may understand how to do so Any questions regarding the operation maintenance service or warranty of this water heater should be directed to the entity from whom it was purchased When all installation steps have been completed replace this installation manual in its original envelope and keep in a safe place for future reference Note C...

Page 2: ...as a drain ball valve made of brass which have a maximum working pressure of 200 psi 3 adjustable feet support the water heater for leveling The hot water heater is shipped from the factory with an ASME rated pressure relief valve set at 30psi 50 psi on model 109 65A 109A a temperature pressure gage except 23 33 and an automatic air vent The water heater is backed by a 15 year warranty on resident...

Page 3: ...source has shut off To find hot water temperature being delivered turn on a hot water faucet and place a thermometer in the hot water stream and read the thermometer The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications TIME VS TEMPERATURE RELATIONSHIPS IN S...

Page 4: ...s a priority relay When the aquastat of the water heater calls for heat the relay shuts off the space heating zones giving priority to producing domestic hot water Any demand for space heating is postponed until the water heater has reached a preset level This delay in supplying the space heating zones is usually not noticed by those occupying the living space The water heater gets adequate hot wa...

Page 5: ...the water heater was purchased CORROSIVE ATMOSPHERES The heater should not be located near an air supply containing halogenated hydrocarbons or high humidity For example The air in beauty salons dry cleaning establishments photo processing labs and storage areas for liquid and powder bleaches or swimming pool chemicals often contains such hydrocarbons The limited warranty is voided when failure of...

Page 6: ...rotection of the water heater if dissimilar pipe material like galvanized pipe is used Install shutoff ball valves for servicing convenience Use only clean copper or approved plastic pipe for water connections Local codes or regulations shall govern the exact type of material to be used To minimize heat loss during non draw periods a heat trap formed from piping can be used Insulate all pipes cont...

Page 7: ... piping schematic It as to be adapted to your application 3 Install a safety valve temperature pressure on the domestic hot water line as near as possible to the hot water heater connection and before any shut off valve 4 Pipe all the safety valves and drain valves to the drain or accordingly to the code 5 When a back flow preventer or water meter or a pressure reducing valve is used on the domest...

Page 8: ...2 This is a basic piping schematic It as to be adapted to your application 3 Install a safety valve temperature pressure on the domestic hot water line as near as possible to the hot water heater connection and before any shut off valve 4 Pipe all the safety valves and drain valves to the drain or accordingly to the code 5 When a back flow preventer or water meter or a pressure reducing valve is u...

Page 9: ...TURBOMAX Use and Care Manual with Installation Instructions July 2014 Page 9 ...

Page 10: ...TURBOMAX Use and Care Manual with Installation Instructions July 2014 Page 10 ...

Page 11: ...mixed water supply VACUUM BREAKER IF REQUIRED Install a vacuum breaker or vacuum relief valve for water heater protection Prevents siphoning of the water from the system and collapse of the water heater BOILER WATER CONNECTIONS This water heater may be connected individually in multiples with others or with an external storage tank containing boiler water If two TURBOMAX or more are installed the ...

Page 12: ...loads such as domestic hot water generation the large temperature difference between the boiler and its return water can cause the boiler to become thermally shocked An experienced designer could work with other values than those proposed by looking into the TURBOMAX performance tables and use the guidelines stated above to design a state of the art system The following chart proposes a temperatur...

Page 13: ... if proper air control is provided to eliminate air and turbulence in the system the maximum flow rate can be established by the piping friction loss rate at 4 feet of water per 100 feet This allows the use of velocities higher than 4 feet per second in pipe sized 2 inches and larger Tables 1 and 2 provide friction loss values for new pipe It should be taken into consideration that as the pumping ...

Page 14: ...tem s side are expressed in p s i Example 4 What is the pressure loss of boiler water flowing through a TURBOMAX 109 at 60 GPM Answer the pressure loss is 2 feet of water Pressure loss from boiler or other equipment Information on pressure drops losses through a boiler or other equipment is obtained from the manufacturer Piping system pressure drop calculation The pressure loss from friction in a ...

Page 15: ...ves must be used with back flow preventors as required to maintain the minimum system pressure by supplying water to make up for leakage The safety relief valve installed on a hot water boiler in accordance with ASME Boiler and Pressure Vessel Code limits the maximum pressure on the boiler Since it is a safety device it should not be considered an operating control Oxygen should be excluded from t...

Page 16: ...e from an external source Any component which does not have insulated end switches must not be used unless a relay is added with the dry contacts wires to these terminals Circulator zoning wiring Components must be wired to ensure that only the circulator for each zone is powered when demand for supply water occurs in that zone An optional multi zone switching relay is available to simplify the wi...

Page 17: ...TURBOMAX Use and Care Manual with Installation Instructions July 2014 Page 17 ...

Page 18: ... 5 4 3 1 2 T T PUMP ZONE 2 R845A RELAY ZONE 2 TO ADDITIONAL R845 RELAYS FOR OTHER ZONES 1 POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREWS PROVIDED 2 PRIORITY RELAY 2 1 WIRING CIRCULATOR ZONING WITH DOMESTIC PRIORITY BOILER THERMOSTAT TERMINAL IF HIGH MASS BOILER THE BOILER TEMPERATURE MUST BE MAINTAINED C...

Page 19: ...THERMOSTAT ZONE 2 6 5 4 3 1 2 T T PUMP ZONE 2 R845A RELAY ZONE 2 TO ADDITIONAL R845 RELAYS FOR OTHER ZONES BOILER THERMOSTAT TERMINAL 1 POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREWS PROVIDED 2 2 1 WIRING CIRCULATOR ZONING IF HIGH MASS BOILER THE BOILER TEMPERATURE MUST BE MAINTAINED CONSTANT BY USING TH...

Page 20: ...TURBOMAX Use and Care Manual with Installation Instructions July 2014 Page 20 ...

Page 21: ...r Boiler water in the piping system and in the TURBOMAX tank will not flow back into the boiler if all the air is eliminated from the TURBOMAX tank and also from the supply and return lines from the boiler Ball valves must be installed on the supply line and on the return line near the boiler to isolate the TURBOMAX from the boiler Also a ball valve should be installed on the boiler supply pipe to...

Page 22: ...cold water supply line then a thermal expansion tank must be installed between the water heater and this device TURBOMAX DOMESTIC COLD WATER SUPPLY STEAM BOILER DOMESTCI HOT WATER MIXED ALL BRONZE OR STAINLESS STEEL IN LINE PUMP STEEL PIPE 40 OR COPPER TUBE TYPE L BOILER WATER PIPING GREY COLOR COPPER PIPE TYPE L DOMESTIC WATER PIPING WHITE COLOR DOMESTIC HOT WATER THERMOSTATIC MIXING VALVE BOILER...

Page 23: ...TURBOMAX Use and Care Manual with Installation Instructions July 2014 Page 23 ...

Page 24: ...ll or makeup water valve to boiler To let the air out of the TURBOMAXV tank during the fill process open the relief valve on top of the TURBOMAX Leave all shutoff valves open Return zone valve to automatic operation Check system for leaks and repair Purge air from the remaining zones if necessary Check boiler pressure gage reading afterwards 15 p s i is normal for most installations OPERATING THE ...

Page 25: ... THE WATER HEATER WITH A THERMOSTATIC MIXING VALVE A thermostatic mixing valve provides for automatic operation through the use of a thermostatic element inside the valve The element will control the mixing of the hot and cold water supply streams to provide a safe blend to connected fixtures This provides constant water temperature under different working conditions When using models which are ce...

Page 26: ... NOTE To prevent premature tank failure the air trapped inside the tank must be purged periodically use the safety relief valve installed on top of the tank to do so Before manually operating the relief valve make certain no one will be exposed to the danger of coming in contact with hot water released by safety relief valves The water may be hot enough to create a SCALD hazard The water released ...

Page 27: ... too high Lower the temperature setting of the mixing valve TURBOMAX aquastat temperature setting is too high Lower the temperature setting of the aquastat or lower the boiler temperature Improper system plumbing Compare plumbing to installation guide Water at faucet is too hot Improper system wiring Compare wiring to installation guide Boiler hi limit set too low Increase boiler hi limit Faulty b...

Page 28: ...w the aquastat from the metal jacket The water heater is equipped with an immersion well allowing the temperature sensor of the aquastat to be removed without having to drain the unit The temperature sensor of the aquastat is located behind its access panel door at the bottom section of the tank Remove the existing sensor and insert the new one in the well Screw the new aquastat to the steel jacke...

Page 29: ...10 68 3 33 3 91 2 35 1 71 1 36 0 46 14 9 17 42 58 5 47 12 19 3 59 4 46 2 54 1 95 1 46 0 52 15 9 83 48 17 5 86 13 79 3 84 5 04 2 72 2 20 1 57 0 59 16 10 48 54 08 6 25 15 47 4 10 5 66 2 90 2 47 1 67 0 66 17 6 64 17 23 4 35 6 30 3 08 2 75 1 78 0 74 18 7 04 19 08 4 61 6 97 3 26 3 04 1 88 0 82 19 7 43 21 02 4 87 7 68 3 44 3 35 1 99 0 90 20 7 82 23 04 5 12 8 41 3 62 3 67 2 09 0 98 1 35 0 35 25 9 77 34 3...

Page 30: ...1 24 0 39 14 8 43 43 39 5 20 12 82 3 00 3 27 2 21 1 53 1 34 0 45 15 9 03 49 49 5 57 14 59 3 22 3 71 2 36 1 73 1 43 0 51 16 9 63 55 99 5 94 16 48 3 43 4 18 2 52 1 95 1 53 0 57 17 10 24 62 88 6 31 18 48 3 65 4 68 2 68 2 18 1 62 0 64 18 6 68 20 58 3 86 5 20 2 84 2 42 1 72 0 71 19 7 06 22 80 4 07 5 75 2 68 2 99 1 81 0 78 20 7 43 25 13 4 29 6 33 3 15 2 94 1 91 0 86 1 34 0 36 25 9 28 38 44 5 36 9 61 3 9...

Page 31: ... 1 7 ft 2 4 ft Gate valve 1 4 closed 2 1ft 2 9 ft 3 4 ft 4 8 ft 5 6ft 7 0 ft 8 4 ft 10 0 ft 14 0 ft Gate valve 1 2 closed 12 0 ft 14 0 ft 18 0 ft 24 0 ft 28 0ft 36 0 ft 41 0 ft 52 0 ft 70 0 ft Gate valve 3 4 closed 44 0 ft 59 0 ft 70 0 ft 96 0 ft 116 0ft 146 0 ft 172 0 ft 213 0 ft 285 0 ft Globe valve open 18 0 ft 23 0 ft 29 0 ft 38 0 ft 46 0ft 58 0 ft 69 0 ft 86 0 ft 116 0 ft Angle valve open 9 0...

Page 32: ...5 70 75 80 85 90 95 100 105 110 BOILER WATER FLOW RATE IN U S GALLONS PER MINUTE PRESSURE DROP IN FEET OF HEAD OF WATER OLD TURBOMAX 23 24 TURBOMAX 23 24 33 34 44 45 TURBOMAX 65 TURBOMAX 109 Domestic Water Side Secondary Circuit Pressure Drop VS Domestic Water Flow rate TURBOMAX Indirect Hot Water Heater 0 2 4 6 8 10 12 14 16 18 0 5 10 15 20 25 30 DOMESTIC WATER FLOW RATE IN U S GALLONS PER MINUTE...

Page 33: ...00 feet Quantity Equivalent Feet of Itemdescription Diameter Valves at systemflow rate of Valves Straight Pipe Inches US GPM Feet 100 Feet X X Equivalent Feet 100 Feet of Head Inches US GPM Feet 100 Feet X X Equivalent Feet 100 Feet of Head Inches US GPM Feet 100 Feet X X Equivalent Feet 100 Feet of Head Step 5 System Quantity of Flow rate Friction Loss TURBOMAX Flow rate TURBOMAX through one thro...

Page 34: ... 2 482 2 879 3 305 3 760 4 245 4 759 5 302 5 875 132 65 145 259 404 582 792 1 034 1 309 1 616 1 955 2 327 2 730 3 167 3 635 4 136 4 669 5 235 5 833 6 463 144 71 159 282 441 635 864 1 128 1 428 1 763 2 133 2 538 2 979 3 455 3 966 4 512 5 094 5 711 6 363 7 050 156 76 172 306 477 687 936 1 222 1 547 1 909 2 310 2 750 3 227 3 742 4 296 4 888 5 518 6 187 6 893 7 638 168 82 185 329 514 740 1 008 1 316 1...

Page 35: ...200 13 2 13 8 20 0 20 8 31 1 32 3 220 14 5 15 2 22 0 22 9 34 2 35 5 240 15 9 16 6 24 0 25 0 37 3 38 7 260 17 2 18 0 26 0 27 1 40 4 41 9 280 18 5 19 4 28 0 29 2 43 5 45 2 300 19 8 20 8 30 0 31 3 46 6 48 4 320 21 1 22 1 32 0 33 3 49 7 51 6 340 22 5 23 5 34 0 35 4 52 8 54 8 360 23 8 24 9 36 0 37 5 55 9 58 1 380 25 1 26 3 38 0 39 6 59 0 61 3 400 26 4 27 7 40 0 41 7 62 1 64 5 420 27 7 29 1 42 0 43 8 65...

Page 36: ...200 13 4 13 9 20 1 21 0 31 3 32 4 220 14 7 15 3 22 2 23 0 34 4 35 6 240 16 0 16 7 24 2 25 1 37 5 38 9 260 17 4 18 1 26 2 27 2 40 6 42 1 280 18 7 19 5 28 2 29 3 43 8 45 4 300 20 0 20 9 30 2 31 4 46 9 48 6 320 21 4 22 3 32 2 33 5 50 0 51 9 340 22 7 23 7 34 2 35 6 53 2 55 1 360 24 0 25 1 36 3 37 7 56 3 58 3 380 25 4 26 5 38 3 39 8 59 4 61 6 400 26 7 27 9 40 3 41 9 62 5 64 8 420 28 0 29 3 42 3 44 0 65...

Page 37: ...r Water content Quantity TURBOMAX tank US Gallons X US Gallons Boiler s US Gallons X US Gallons Storage tank s US Gallons X US Gallons Other components US Gallons X US Gallons Volume of water in system Total US Gallons Expansion Tank Working Parameters Volume of Diaphragm Tank see Table 6 or Table 7 US Gallons Expansion Tank Brand Model Volume Selection Maximum operating pressure at tank safety re...

Page 38: ...and handling to and from Manufacturer The components repaired or replaced are warranted for the residual period of the initial warranty on the unit Exclusions This warranty is void and shall not apply if 1 Defects or malfunctions resulting from installation repair maintenance and or usage that are not done in conformity with the manufacturer s installation manual or 2 Defects or malfunctions resul...

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