THERMO 2000 VOLTMAX 108 Installation And Operation Manual Download | Manualshive

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VOLTMAX

Electric Boiler

INSTALLATION AND OPERATION MANUAL

mo

Your

VOLTMAX Electric Boiler

was carefully assembled and checked at the factory to ensure its proper

functioning for many years. 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 installer or to a skilled technician.

When all installation steps have been completed, keep this installation manual in a safe place (near the
boiler) for future reference.

THERMO 2000 INC.

Printed in Canada Revised: August 2017

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Summary of Contents for VOLTMAX 108

Page 1: ...tenance 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 installer or to a skilled technician When all installation steps have been completed keep this installation manual in a saf...

Page 2: ...ucet 13 3 4 9 Pressure loss 14 3 5 ELECTRICAL CONNECTIONS 20 3 5 1 Main electrical supply 20 3 5 2 Pump supply 20 3 5 3 Connection of external signals to the controller 20 SECTION 4 CONTROLLER OPERATION 23 4 1 USER INTERFACE 23 4 1 1 Symbol description 23 4 1 2 Control panel 24 4 1 3 Navigation and adjustements 24 4 1 4 Main menu navigation 25 4 1 5 Navigation in boiler setting 26 4 2 MAIN MENU 29...

Page 3: ...BOILER SETTINGS 49 4 10 1 BACKUP MODE 49 4 10 2 EXTERNAL CONTACT MODE 50 4 10 3 ManuAl MODE 50 4 10 4 Bi Energy MODE 50 4 11 LIMIT CONFIGURATION MENU SETTINGS 51 4 12 CONFIG ALARM MENU SETTINGS 52 4 13 OCCUPATION MENU SETTINGS 52 4 14 BOOST MENU SETTINGS 53 4 15 WARM WEATHER SHUTDOWN MENU SETTINGS 53 SECTION 5 BOILER START UP 54 5 1 FILLING THE BOILER 54 5 2 ADJUSTEMENT OF THE CONTROLLER OPERATING...

Page 4: ... 6 x 6 kW 3 x 12 kW 2 x 12 kW 1 x 12 kW VOLTMAX 40 40 136 480 166 7 8 x 5 kW 4 x 10 kW 3 x 10 kW 1 x 10 kW VOLTMAX 48 48 163 776 200 8 x 6 kW 4 x 12 kW 3 x 12 kW 1 x 12 kW VOLTMAX 55 55 187 660 229 2 5 x 5 kW 5 x 6 kW 5 x 11 kW 4 x 11 kW 1 x 11 kW VOLTMAX 60 60 204 720 250 10 x 6 kW 5 x 12 kW 4 x 12 kW 1 x 12 kW VOLTMAX 66 66 225 192 275 6 x 5 kW 6 x 6 kW 6 x 11 kW 5 x 11 kW 1 x 11 kW VOLTMAX 72 7...

Page 5: ...kW 1 x 15 kW 1 x 15 kW VOLTMAX 36 36 122 832 43 3 6 x 6 kW 2 x 18 kW 1 x 18 kW 1 x 18 kW VOLTMAX 45 45 153 540 54 1 9 x 5 kW 3 x 15 kW 2 x 15 kW 1 x 15 kW VOLTMAX 54 54 184 248 65 9 x 6 kW 3 x 18 kW 2 x 18 kW 1 x 18 kW VOLTMAX 60 60 204 720 72 2 12 x 5 kW 4 x 15 kW 3 x 15 kW 1 x 18 kW VOLTMAX 72 72 245 664 86 6 12 x 6 kW 4 x 18 kW 3 x 18 kW 1 x 18 kW VOLTMAX 75 75 255 900 90 2 15 x 5 kW 5 x 15 kW ...

Page 6: ... 99 337 788 95 3 9 x 5 kW 9 x 6 kW 3 x 33 kW 2 x 33 kW 1 x 33 kW VOLTMAX 108 108 368 496 103 9 18 x 6 kW 3 x 36 kW 2 x 36 kW 1 x 36 kW VOLTMAX 120 120 409 440 115 5 24 x 5 kW 4 x 30 kW 3 x 30 kW 1 x 30 kW VOLTMAX 132 132 450 384 127 12 x 5 kW 12 x 6 kW 4 x 33 kW 3 x 33 kW 1 x 33 kW VOLTMAX 144 144 491 328 138 6 24 x 6 kW 4 x 36 kW 3 x 36 kW 1 x 36 kW VOLTMAX 150 150 511 800 144 3 30 x 5 kW 5 x 30 ...

Page 7: ...NPT F MIN CLEARANCES FOR INSTALLATION MAINTENANCE Left and Right sides 3 76mm Rear 3 76mm Front 24 610mm Bottom 0 0mm Top 32 813mm GENERAL INFORMATIONS Weight 310lbs 141kg Water Volume 11 Us gal 41 6 liters Max operating pressure STANDARD 30psi OPTION 70 PSI Available at 125PSI See Shop Drawing 99 180KW COMPONENTS IDENTIFICATION A Electrical main supply B Boiler controller C On Off switch D Discon...

Page 8: ...e return sensor 1 2 NPT F MIN CLEARANCES FOR INSTALLATION MAINTENANCE Left and Right sides 3 76mm Rear 3 76mm Front 24 610mm Bottom 0 0mm Top 32 813mm GENERAL INFORMATIONS Weight 550lbs 250kg Water Volume 30 gal Us 113 5 liters Max operating pressure STANDARD 60psi OPTION 125 PSI COMPONENTS IDENTIFICATION A Electrical main supply B Boiler controller C On Off switch D Disconnect switch rotary handl...

Page 9: ... 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 RECEPTIO...

Page 10: ...TION 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 The electric boiler must be located or protected to avoid risk of physical damage such...

Page 11: ...ECTION When an auxiliary boiler used as back up is twinned to the VOLTMAX boiler to act as a back up controlled by the VOTLMAX the auxiliary boiler shall be installed downstream of the electric boiler as shown on Figure 5 and 7 3 4 3 SAFETY VALVE The installation of a safety valve is an integral part of the boiler s installation The trigger point of the valve must not exceed the design pressure of...

Page 12: ...nimum system pressure by supplying water to make up for leakage A minimum pressure of 5psi 34kPa must be maintained at all times A backflow prevention device that complies with local standards must be installed upstream of the pressure regulator 3 4 6 AIR BLEEDER The air contained in the heated water must be removed from the system to allow the proper functioning of the heating system and the boil...

Page 13: ...TMAX 23 15 7 7 8 5 2 3 9 VOLTMAX 27 18 4 9 2 6 1 4 6 VOLTMAX 30 20 5 10 2 6 8 5 1 VOLTMAX 36 24 6 12 3 8 2 6 1 VOLTMAX 40 27 3 13 6 9 1 6 8 VOLTMAX 41 28 0 14 0 9 3 7 0 VOLTMAX 45 30 7 15 4 10 2 7 7 VOLTMAX 48 32 8 16 4 10 9 8 2 VOLTMAX 50 34 1 17 1 11 4 8 5 VOLTMAX 54 36 8 18 4 12 3 9 2 VOLTMAX 55 37 5 18 8 12 5 9 4 VOLTMAX 60 40 9 20 5 13 6 10 2 VOLTMAX 66 46 4 23 2 15 5 11 6 VOLTMAX 68 45 0 22 ...

Page 14: ...ration Manual Revised August 2017 Page 14 3 4 9 PRESSURE LOSS The graph of pressure loss due to flow of water inside the VOLTMAX boiler is shown in the following figure Figure 2 Pressure loss FTH as a function of the flow rate of heated water GPM ...

Page 15: ...VOLTMAX ELECTRIC BOILER Installation and Operation Manual Revised August 2017 Page 15 Figure 3 Basic installation ...

Page 16: ...VOLTMAX ELECTRIC BOILER Installation and Operation Manual Revised August 2017 Page 16 Figure 4 Basic installation with indirect water heater and radiator ...

Page 17: ...VOLTMAX ELECTRIC BOILER Installation and Operation Manual Revised August 2017 Page 17 Figure 5 Dual Energy installation with a condensing boiler ...

Page 18: ...VOLTMAX ELECTRIC BOILER Installation and Operation Manual Revised August 2017 Page 18 Figure 6 Multiple boiler parallel installation ...

Page 19: ...VOLTMAX ELECTRIC BOILER Installation and Operation Manual Revised August 2017 Page 19 Figure 7 Basic installation with auxiliary boiler for production of domestic hot water and heating ...

Page 20: ...ture up to 90 C 3 5 3 1 Connecting the building heat demand signal Upon reception of a closed contact connected to terminals 24V and W1 or W2 the corresponding circulating pump P1 or P2 will start and the boiler will be allowed to operate If external controllers control the heating system pumps they must provide the operating authorization signal The boiler must not receive a heat demand without t...

Page 21: ...a corresponding signal coming from the network system shall be connected with a cable of minimum gauge 20 max 100pi to terminals S Ext of the controller This probe does not need to be connected during an operation with a fixed setpoint temperature unless you want to use the Warm weather Shutdown function N B Do not install a jumper if the outside sensor is not used Outdoor sensor location o Outsid...

Page 22: ...on and Operation Manual Revised August 2017 Page 22 Figure 8 ELECTRICAL CONNECTIONS OF THE INPUT AND OUTPUT SIGNALS TO THE CONTROLLER SCR MODEL Figure 9 ELECTRICAL CONNECTIONS OF THE INPUT AND OUTPUT SIGNALS TO THE CONTROLLER STG MODEL ...

Page 23: ...t indicates that the unit is currently in a critical state high temperature alarm or in lock out mode More detail is provided in Section 6 Troubleshooting The controller can also be configured to activate an internal buzzer and activate an external alarm signal SCR only when an alarm condition occurs causing the boiler to fail Figure 10 Illustration of the display 4 1 1 SYMBOL DESCRIPTION The main...

Page 24: ... navigation within the display is done with the five pushbuttons on the right of the screen Navigation between the elements is done with the up and down arrows Use the right key to change the page in the menus The return key will bring you to the previous menu The return key returns you to the main display when it is pressed for 2 seconds or more The OK button confirms the selection and allows you...

Page 25: ...X ELECTRIC BOILER Installation and Operation Manual Revised August 2017 Page 25 4 1 4 MAIN MENU NAVIGATION Press one of the 5 buttons on the main display to access the main menu Figure 12 Main menu navigation ...

Page 26: ...VOLTMAX ELECTRIC BOILER Installation and Operation Manual Revised August 2017 Page 26 4 1 5 NAVIGATION IN BOILER SETTING Figure 13 Navigation in boiler setting menu 1 3 ...

Page 27: ...IC BOILER Installation and Operation Manual Revised August 2017 Page 27 You can switch from page by using the left or right arrow Ex 1 3 to 2 3 by using the right arrow Figure 14 Navigation in boiler setting menu 2 3 ...

Page 28: ...VOLTMAX ELECTRIC BOILER Installation and Operation Manual Revised August 2017 Page 28 Figure 15 Navigation in boiler setting menu 3 3 ...

Page 29: ...mperature pressure flow alarm summary version of the programme and the status of the heating element The set of variables presented in this menu are presented in Section 4 5 4 2 2 BOILER CONFIGURATION Configuration of the boiler operating mode This menu is accessible only to the installer or to an authorized person The options in the Boiler setting menu are detailed in Section 4 3 The Manufacturer...

Page 30: ...key And all saved report is available on the History tab The beginning of the consumption cycles can be reset using the Reset button The controller records up to 30 consumption report N B For the STG model the calculation of power consumption is based on a theoretical approach there may be differences between the actual consumption of the boiler and the consumption displayed on the screen N B The ...

Page 31: ...supply temperature 4 3 1 2 DDC 0 10 VDC Available only on SCR model This operating mode allows modulating the boiler set point temperature according to a 0 10VDC signal applied the terminal 0 10VDC and bornier 0 10Vdc G et 0 10Vdc T produced by an external controller Ex Building Energy Management Controller The details of the parameters in this mode are presented in Section 4 6 3 4 3 1 3 Outdoor r...

Page 32: ...e boiler to operate only when there is a flow of water present 4 3 4 CAPACITY LIMITING Adjusting the maximum authorized power This menu allows you to configure the boiler output limit The selection of the limit mode can be selected in the Capacity limiting menu o None o Manual o DDC 0 10 VDC o T Ext o Schedule Details of each of these options are presented in Section 4 9 N B It is not recommended ...

Page 33: ...than the setpoint temperature In External mode the Aux contact closes when there is a request on W1 or W2 DHW regardless of the boiler output temperature VOLTMAX The VOLTMAX boiler thus has no set temperature and is only used to activate the auxiliary boiler relay The various configurations of the Aux boiler mode are the following None No auxiliary boiler is present Backup Aux This mode allows the...

Page 34: ... of the variables in this mode are presented in Section 0 4 3 5 6 Manual Manual mode is used to manually select the operating mode of the system Electrical or Auxiliary Details of the variables in this mode are presented in Section 4 10 3 4 3 6 LIMIT SETTING Configuring the boiler operating limits Use this menu to adjust the permissible operating boiler limits for various parameters This menu s co...

Page 35: ...d Default Address IP 10 0 0 100 User administrator Password password Remote connection using a boiler specific wireless network If the boiler cannot be connected to the local network a wireless router for remote connection can be installed The configuration may differ depending on the model of the router being used The methodology is presented with a TP LINK model TL WR810N 1 Plug the router into ...

Page 36: ...ours specified in the Schedule Setting menu The temperature drop the value should be negative in the set point can be changed in the Occupation Setting menu The SCR model allows the connection of a contact OCC Contact on the controller allowing the use of an external timer to control the OCCUPATION function The Contact OCC option activates the operating mode using an external contact switch Ex Whe...

Page 37: ...er than a pre determined temperature ex 68 F Note If the boiler is configured with DHW mode it will continue to operate normally in order to meet the DHW heating demand 4 3 12 CHANGE PASSWORD Changing the password This menu allows you to change the installer account password 4 4 INTERNET The settings available on the controller are also available remotely on a web portal This portal works only whe...

Page 38: ...mail Server Type Gmail The M171 controller does not support SSL encryption Thus your SMTP Email server must accept an unencrypted connection Internet service providers usually have a specific server that accepts connections without encryptions On line messaging services such as Hotmail G mail do not accept unencrypted communications In order to work around the problem there are relay services such...

Page 39: ...age of the nominal power AV_CapLimitPrc Consumption The power consumption of the last cycle You must first begin a history cycle MAIN MENU CONSUMPTION Actual Current A This variable allows the reading of the current sensor inside the boiler This sensor is only available on SCR models AV_SigCaptCourant Demand W1 When requesting heating on W1 allowing the operation of the heating elements BV_Heating...

Page 40: ...ler s internal temperature is higher than the threshold BV_AlarmIntHL 0 Normal operation 1 Alarm activated LL Alarm Alarm triggered by the boiler s lack of capacity BV_AlarmLL 0 Normal operation 1 Alarm activated Low Pressure Alarm Alarm triggered by a low pressure BV_AlarmLowPressure 0 Normal operation 1 Alarm activated High Pressure Alarm Alarm triggered by a high pressure BV_AlarmHighPressure 0...

Page 41: ...tingMod eW1 Selects the power limitation mode between Stop Modulation T Ext DCC 0 10VDC and Fixed 0 Stop 1 Outdoor Reset 2 DCC 0 10VDC 3 Fixed Fixed 4 6 1 FIXED MODE Configure the fixed set point temperature Display BACnet Variable Description Selection Default W1 Set point WP_FixedSTPT W1 Selects the fixed set point temperature when there is demand on W1 10 to 93 0 C 50 to 200 0 F 140 0 F ...

Page 42: ...s Default Calculated SPTP AV_TBoilerSTP TCalculatedOU TRST Current set point temperature calculated based on the adjustment curve and the outside temperature 10 to 93 0 C 50 to 200 0 F STPT at Min Outd T WP_STPTatMin OutdT Boiler set point temperature when the outside temperature reaches the Min Outd T 10 to 93 0 C 50 to 200 0 F 140 0 F STPT at Max Outd T WP_STPTatMa xOutdT Boiler set point temper...

Page 43: ...DDC 0 10 VDC Display BACnet variable Description Parameters Default T STPT 0 10VDC AV_TBoilerSTPTCalculatedV This variable represents the set point temperature based on the voltage of the building control system 0 C or 0 F STPT at Min Volt WP_STPTatMinRemote010V Set point of the boiler temperature corresponding to the voltage level of Min Voltage 0 C or 0 F 80 0 F STPT at Max Volt WP_STPTatMaxRemo...

Page 44: ...emperature during demand on W2 terminale 10 to 93 0 C 50 to 200 0 F 175 0 F T Min Boiler WP_FixedSTPT W0 Selects the boiler s minimum temperature The boiler s heating elements will activate automatically to keep the hydronic system at the selected temperature 10 to 93 0 C 50 to 200 0 F 150 0 F 4 8 PUMP CONFIGURATION MENU SETTINGS 4 8 1 PUMP 1 Display BACnet Variable Description Selection Default P...

Page 45: ...VDC Display BACnet variable Description Parameters Default Max capacity kW The calculated power value as a function of the current and the nominal operating voltage of the boiler 0 to maximum rated power kW at Min Volt The maximum permissible power of the boiler when the voltage of the external controller is at Min Voltage 0 to maximum rated power 0 kW at Max Volt The maximum permissible power of ...

Page 46: ... VDC controller is used to adjust the maximum power Display BACnet Variable Description Selection Default Current authorized max kW AV_ActualCapLi mitkW The value of power calculated based on the current and the boiler s nominal operating voltage 0 to maximum rated power kW Minimum Power Volt kW WP_MinRemote VCapLimit The boiler s maximum power when the external controller voltage is at Min Voltag...

Page 47: ...voltage 0 to maximum rated power Cap At T Ext Min WP_CapLimitatM inOutdT Maximum authorized capacity according to T Ext Min Ex Maximum power is 170 kW for T Ext min 0 to maximum rated power Cap At T Ext Max WP_CapLimitatM axOutdT Maximum authorized capacity according to T Ext Max Ex Maximum power is 120 kW for T Ext min 0 to maximum rated power Actual T Exterior AV_OutdoorT This variable allows yo...

Page 48: ...city allowed at present time 0 to maximum rated power Cap In Schedule WP_CapLimitDay Mode Power limitation when the boiler internal clock is within the power limitation schedule 0 to maximum rated power Cap Out Schedule WP_CapLimitNig htMode Power limitation when the boiler internal clock is outside the power limitation schedule 0 to maximum rated power Schedule Configuring the boiler power limita...

Page 49: ...ond boiler as a backup Display BACnet variable Description Parameters Default STPT Source WP_STPTSource Aux Selects the source used to control the set point temperature Auxiliary means that the set point will be determined by the auxiliary boiler The VOLTMAX boiler therefore has no set point temperature and is only used to activate the auxiliary boiler relay Voltmax means that the set point temper...

Page 50: ...4 10 4 BI ENERGY MODE This mode selects the hydronic system heating source VOLTMAX boiler or auxiliary boiler using the BI E terminal s electrical switch The benefit of this mode is that the system can operate the back up boiler when needed Display BACnet variable Description Parameters Default STPT Source WP_STPTSource Aux Selects the source used to control the set point temperature Auxiliary mea...

Page 51: ... temperature differential to activate the LL alarm 0 to 55 C 0 to 99 F 20 F Delay LL min WP_DelayLL Adjusts the LL alarm trigger delay 0 to 180 min 60 min Pressure sensor WP_ActivatePressureSensor Activates the boiler s internal pressure sensor module OFF ON 0 Off 1 On ON Actual pressure AV_SensorPressureSignal Reads the boiler s internal pressure sensor Current sensor WP_ActivateCurrentSensor Act...

Page 52: ...rnalBuzzer Activates the controller s internal buzzer 0 Off 1 On On Deactivate LL alarm WP_DeactivateAlarmLL Deactivates the LL alarm 0 Off 1 On Off 4 13 OCCUPATION MENU SETTINGS Display BACnet Variable Description Possible Settings Default Occupation Mode WP_ActivateOccupationMode Activates the Occupation function 0 Off 1 On Source OCC WP_SourceOccupation Selects the source used to determine the ...

Page 53: ...iable Description Possible Settings Default Warm Weather Shutdown WP_ActivateWarmWeatherSD Shuts down the boiler when the outside temperature reaches a specific temperature This temperature can be set in the Warm Weather Shutdown Temperature box OFF ON 0 Off 1 On OFF T Ext Shutdown WWSD WP_WarmWeatherSDTemp Sets the outside temperature that activates the Warm Weather Shutdown if it shuts down the ...

Page 54: ... boiler s water temperature It is more energy efficient to maintain a set point as low as possible while still meeting heating needs Safety and energy conservation are factors to be considered when setting the boiler water operating temperature The most energy efficient operation will result when the temperature setting of the controller is the lowest that satisfies the heating needs Make sure tha...

Page 55: ...stem The boiler temperature shall gradually increase and the boiler capacity shall drop gradually and stabilize when the boiler temperature will reach a temperature near the target temperature 9 When the heating request is completed the circulating pump can continue to operate depending on the operating mode or the purge time or switch off The heating elements stop working 10 Check the operation o...

Page 56: ... the boiler according to the low water level sensor Standard on 120 kW models and higher or when the high temperature limit control detects a temperature higher than 210 F The external alarm contact will be activated immediately if it has been activated Ext Alarm Contact in the Alarm menu The heating elements stop working and will start again when the water level returns to normal If this alarm ha...

Page 57: ...d within one hour When the lock mode is activated the boiler is deactivated and can only be restarted by restarting the boiler to the left of the control panel or by using the reset Lock Out function in the alarm setting menu Tableau 12 Resistance Ohm according to the outdoor sensor measuring temperature Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance F ...

Page 58: ...a dripping condition occurs 7 3 AIR PURGE TWICE A YEAR Check for proper operation of the automatic air purgers and activate manual air vents to eliminate air present 7 4 ELECTRICAL INSPECTION ANNUALLY It is recommended to perform a visual inspection of the boiler electric compartment annually during the heating season to ensure it is watertight and that there are no signs of component or wiring ov...

Page 59: ...es its rights to make changes in the details of design construction or material as shall in its judgment constitute an improvement of former practices This warranty is valid only for installations made within the territorial limits of Canada and the United States Warranty service procedure Only authorized VOLTMAX retailers may handle warranty claims The owner or contractor must provide the defecti...

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