THERMO 2000 VoltMax105 Installation And Operation Manual Download | Manualshive

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VoltMax 400

Electric Boiler

INSTALLATION AND OPERATION MANUAL

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: march 2019

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Summary of Contents for VoltMax105

Page 1: ...intenance 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 s...

Page 2: ...trical supply 19 Pump supply 19 Connection of external signals to the controller 19 CONTROLLER OPERATION 23 USER INTERFACE 23 Symbol description 23 Control panel 24 Navigation and adjustements 24 Main menu navigation 25 Navigation in boiler setting 26 MAIN MENU 29 Boiler status 29 Boiler configuration 29 User setting 29 Clock setting 30 Consumption 30 BOILER SETTINGS 30 Heating mode W1 31 Heating ...

Page 3: ...TTINGS 52 WARM WEATHER SHUTDOWN MENU SETTINGS 52 BOILER START UP 53 STARTUP PREPARATION 53 ADJUSTEMENT OF THE CONTROLLER OPERATING PARAMETERS 53 STARTUP PROCEDURE 54 TROUBLESHOOTING 55 WARNING LIGHTS 55 OPERATING PROBLEM IDENTIFICATION 55 External HL LWCO 55 Sensor SE 55 Low limit LL 55 Flow F 56 Current A 56 HL temperature HL 56 Low pressure P 56 High pressure P 56 Battery low level 56 Lock out 5...

Page 4: ...0 VoltMax 306 1 044 072 306 295 12 x 18 kW 6 x 15 kW 6 x 51 kW 3 x 500 VoltMax 315 1 074 780 315 303 21 x 15 kW 7 x 45 kW 3 x 500 VoltMax 324 1 105 488 324 312 18 x 18 kW 6 x 54 kW 3 x 500 VoltMax 336 1 146 432 336 324 14 x 15 kW 7 x 18 kW 7 x 48 kW 3 x 600 VoltMax 357 1 218 084 357 344 14 x 18 kW 7 x 15 kW 7 x 51 kW 3 x 600 VoltMax 378 1 289 736 378 364 21 x 18 kW 7 x 54 kW 6 x 300 VoltMax 384 1 ...

Page 5: ...h a ground 2 The 45 kW stage is composed of three 15 kW elements The 48 kW stage is composed of two 15 kW elements and one 18 kW element The 51 kW stage is composed of one 15 kW element and two 18 kW elements 3 Maximum capacity of the boilers connection terminals Table 3 VoltMax 240 VAC 60 Hz 3 Phases1 Model BTU h kW Amps Elements 240V Stage max power supply MCM 2 VoltMax 105 358 260 105 253 7 x 1...

Page 6: ...ty of the boilers connection terminals Table 6 VoltMax 208 VAC 60 Hz 1 Phase1 Model BTU h kW Amps Elments 240V 2 Stage 3 max power supply MCM 4 VoltMax 58 197 043 57 75 278 7 x 5 kW 7 x 6 kW 7 x 8 25 kW 2 x 500 VoltMax 60 204 720 60 288 16 x 5 kW 8 x 7 5 kW 2 x 500 VoltMax 63 214 956 63 303 14 x 6 kW 7 X 9 kW 2 x 500 VoltMax 66 225 192 66 317 8 x 5 kW 8 x 6 kW 8 x 8 25 kW 2 x 500 VoltMax 72 245 66...

Page 7: ...ht sides 6 152mm Rear 6 152mm Front 24 610mm Bottom 0 0mm Top 32 813mm GENERAL INFORMATIONS Weight 1200 lbs 545 kg Water Volume 62 Us gal 235 liters Max operating pressure STANDARD 160psi COMPONENTS IDENTIFICATION A Electrical main supply B Boiler controller C On Off switch D Disconnect switch rotary handle E Fuses for controls F Solid state SCR relay G Low water cut off test button and indicator ...

Page 8: ...ode current edition In any case where instructions in this manual differ from local or national codes the local or national codes take precedence 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 INSPECTION UPON RECEPTION Inspect ...

Page 9: ...he 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 as fr...

Page 10: ... PIPING CONNECTION 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 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 press...

Page 11: ... to maintain minimum 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 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...

Page 12: ...88 60 1 30 0 20 0 15 0 VoltMax 96 65 5 32 8 21 8 16 4 VoltMax 105 71 7 35 8 23 9 17 9 VoltMax 120 81 9 40 9 27 3 20 5 VoltMax 126 86 0 43 0 28 7 21 5 VoltMax 144 98 3 49 1 32 8 24 6 VoltMax 192 131 0 65 5 43 7 32 8 VoltMax 204 139 2 69 6 46 4 34 8 VoltMax 216 147 4 73 7 49 1 36 8 VoltMax 225 153 5 76 8 51 2 38 4 VoltMax 240 163 8 81 9 54 6 40 9 VoltMax 255 174 0 87 0 58 0 43 5 VoltMax 270 184 2 92...

Page 13: ...Operation Manual Revised March 2019 Page 13 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 14: ...VOLTMAX ELECTRIC BOILER Installation and Operation Manual Revised March 2019 Page 14 Figure 3 Basic installation ...

Page 15: ...VOLTMAX ELECTRIC BOILER Installation and Operation Manual Revised March 2019 Page 15 Figure 4 Basic installation with indirect water heater and radiator ...

Page 16: ...VOLTMAX ELECTRIC BOILER Installation and Operation Manual Revised March 2019 Page 16 Figure 5 Dual Energy installation with a condensing boiler ...

Page 17: ...VOLTMAX ELECTRIC BOILER Installation and Operation Manual Revised March 2019 Page 17 Figure 6 Multiple boiler parallel installation ...

Page 18: ...VOLTMAX ELECTRIC BOILER Installation and Operation Manual Revised March 2019 Page 18 Figure 7 Basic installation with auxiliary boiler for production of domestic hot water and heating ...

Page 19: ...ons shall resist temperature up to 90 C Connecting the building heat demand signal or running authorization 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...

Page 20: ...tdoor sensor supplied with the unit or 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 no...

Page 21: ...nternal audible alarm inside the controller is available on all models Just activate it in the settings Connecting an external high limit EXT HL An additional high limit control pressure temperature flow water low level could be required in a particular application It shall be installed outside of the unit and its contact shall be connected the EXT HL contactor of the terminal bloc after removing ...

Page 22: ...VOLTMAX ELECTRIC BOILER Installation and Operation Manual Revised March 2019 Page 22 Figure 8 ELECTRICAL CONNECTIONS OF THE INPUT AND OUTPUT SIGNALS TO THE CONTROLLER ...

Page 23: ...ht 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 when an alarm condition occurs causing the boiler to fail Figure 9 Illustration of the display SYMBOL DESCRIPTION The main display shows ...

Page 24: ...play 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 to edit a parameter Only ...

Page 25: ...TMAX ELECTRIC BOILER Installation and Operation Manual Revised March 2019 Page 25 MAIN MENU NAVIGATION Press one of the 5 buttons on the main display to access the main menu Figure 11 Main menu navigation ...

Page 26: ...VOLTMAX ELECTRIC BOILER Installation and Operation Manual Revised March 2019 Page 26 NAVIGATION IN BOILER SETTING Figure 12 Navigation in boiler setting menu 1 3 ...

Page 27: ...IC BOILER Installation and Operation Manual Revised March 2019 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 13 Navigation in boiler setting menu 2 3 ...

Page 28: ...VOLTMAX ELECTRIC BOILER Installation and Operation Manual Revised March 2019 Page 28 Figure 14 Navigation in boiler setting menu 3 3 ...

Page 29: ...ature 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 BOILER CONFIGURATION Configuration of the boiler operating mode This menu is accessible only to the installer or to an authorized person The default installator password is 1111 To enter the password Press up or down arrows until ...

Page 30: ...is unpowered at 25 C When the battery is low an indicator will appear on the screen The battery shall be replaced to keep to clock active Following a battery replacement the internal clock must be reprogrammed to remove the indicator on the bottom of the screen CONSUMPTION Boiler consumption cycle report This menu allows visualization of the boiler power consumption report First you must activate ...

Page 31: ...and or a demand must be present on W1 and or W2 DHW so that the boiler can heat up Otherwise the boiler will indicate During a heat demand the boiler activates depending on a PID curve the number of stages required in sequence so that the boiler output temperature is maintained at the approximate set point temperature Here is the list of W1 heating modes FIXED Fixed boiler set point DDC 0 10 VDC M...

Page 32: ...he 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 8 N B It is not recommended to disconnect one of the power relays inside the VoltMax boiler to accomplish this function None The boiler is not limited in power the maximum power it can deliver is equivalent to its maximum rated po...

Page 33: ...e Electrical or Auxiliary N B The auxiliary boiler can only be switched on when a heat demand is present on W1 or and W2 DHW None This mode must be active when there is no auxiliary boiler on the hydronic heating system Backup Aux The boiler will be activated according to the configuration of the lack of capacity of the VoltMax boiler In the event of a lack of capacity the boiler is started to com...

Page 34: ...in detail in Section 4 11 ALARM Alarm Mode Configuration When an alarm is active it will be displayed on the main display as a symbol An alarm is active The boiler is in lock mode HL The high limit temperature has been reached LL Low limit Lack of capacity P Pressure problem alarm A Electrical problem alarm F Flow problem alarm Se Sensor problem alarm The internal clock battery level is low A summ...

Page 35: ... the default the username and password are as givien in the next table By default Username administrator Password password Distant wireless connexion with a WI FI rooter If the boiler cannot be directly connected to the network a WI FI rooter may be added to it to act as connexion between the boiler and the network Connexion procedure may varie from one rooter to another This exemple is for a test...

Page 36: ...and deactivated within the menu Occupation under Occupation mode This function allows the set point temperature to be lowered when the boiler is within the hours 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 allowing the use of an ex...

Page 37: ...hed threshold This mode stops the boiler s heating production when the outside temperature is higher 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 CHANGE PASSWORD Changing the password This menu allows you to change the installer account password ETHERNET The settings available o...

Page 38: ... list of e mails The parameters to enter on the web page are indicated on the screen shot below Personal Email 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 ...

Page 39: ...power The actual power used in kilowatt AV_ActualPowerkw 8 8388616 max authorized power The maximum permissible power as a percentage of the nominal power AV_CapLimitPrc 54 8388662 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 onl...

Page 40: ... BV_StatusAlarmHL LW 14 20971534 0 Normal operation 1 Alarm activated HL Alarm Alarm triggered when the boiler s internal temperature is higher than the threshold BV_AlarmIntHL 15 20971535 0 Normal operation 1 Alarm activated LL Alarm Alarm triggered by the boiler s lack of capacity BV_AlarmLL 21 20971541 0 Normal operation 1 Alarm activated Low Pressure Alarm Alarm triggered by a low pressure BV_...

Page 41: ... W1 WP_HeatingW1 43 20971563 Allows to select W1 heating demand source BACnet or Local Local Bacnet Local Operating Mode WP_HeatingMod eW1 11 8388619 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 FIXED MODE Configure the fixed set point temperature Display BACnet Variable Instance Tag Description Selection D...

Page 42: ... AV_TBoilerSTPT CalculatedOUTR ST 12 8388625 Current set point temperature calculated based on the adjustment curve and the outside temperature 10 to 93 0C 50 to 200 0F STPT at Min Outd T WP_STPTatMinO utdT 13 8388621 Boiler set point temperature when the outside temperature reaches the Min Outd T 10 to 93 0C 50 to 200 0F 140 0F STPT at Max Outd T WP_STPTatMax OutdT 14 8388622 Boiler set point tem...

Page 43: ...nce Tag Description Parameters Default T STPT 0 10VDC AV_TBoilerSTPT CalculatedV 17 8388625 This variable represents the set point temperature based on the voltage of the building control system 0C or 0F STPT at Min Volt WP_STPTatMinR emote010V 20 8388626 Set point of the boiler temperature corresponding to the voltage level of Min Voltage 0C or 0F 80 0F STPT at Max Volt WP_STPTatMax Remote010V 21...

Page 44: ... 0C 50 to 200 0F 175 deg F0 DHW MODE Configures the fixed set point temperature during demand on DHW mode Display BACnet Variable Instance Tag Description Selection Default T Set point DHW WP_FixedSTPT W2 24 8388632 Selects the fixed set point temperature during demand on W2 terminale 10 to 93 0C 50 to 200 0F 175 0F T Min Boiler WP_FixedSTPT W0 26 8388634 Selects the boiler s minimum temperature T...

Page 45: ... the current and the boiler s nominal operating voltage 0 to maximum rated power Minimum Power Volt kW WP_MinRemote VCapLimit 33 8388641 The boiler s maximum power when the external controller voltage is at Min Voltage 0 to maximum rated power 0 Maximum Power Volt kW WP_MaxRemote VCapLimit 34 8388642 The boiler s maximum power when the external controller voltage is at V for max cap 0 to maximum r...

Page 46: ...ximum rated power Cap At T Ext Min WP_CapLimitatM inOutdT 37 8388645 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 38 8388646 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 2 8388610 This v...

Page 47: ...le Configuring the boiler power limitation schedule In order to operate correctly you must first adjust the internal boiler clock in the Clock Setting menu AUXILIARY BOILER SETTINGS Variables beginning with AV and BV are read variables while variables beginning with W are editable Only available on SCR model The system allows control of an auxiliary boiler to the system The different configuration...

Page 48: ...he VoltMax boiler used to deactivate the auxiliary boiler 0 to 55 0C 0 to 100 0F 5 0F Delay Start Aux WP_DelayStartA ux 46 8388654 This option adjusts the delay before activating the auxiliary boiler Min 10 EXTERNAL CONTACT MODE This mode selects the hydronic system heating source VoltMax boiler or auxiliary boiler using the BI E terminal s electrical switch Display BACnet Variable Instance Tag De...

Page 49: ... will be determined by the auxiliary boiler The VoltMax boiler has no set point temperature and is only used to activate the auxiliary boiler relay Voltmax means that the set point temperature will be determined by the VoltMax boiler Auxiliary or VoltMax 0 Auxiliary 1 VoltMax VoltMax Delta T Start Aux WP_DeltaTStartA ux 44 8388652 This option adjusts the temperature differential Set point temperat...

Page 50: ...arm 0 to 55 C 0 to 99 F 20 F Delay LL min WP_DelayLL 49 8388657 Adjusts the LL alarm trigger delay 0 to 180 min 60 min Pressure sensor WP_ActivatePres sureSensor 24 20971544 Activates the boiler s internal pressure sensor module OFF ON 0 Off 1 On ON Actual pressure AV_SensorPress ureSignal 6 8388614 Reads the boiler s internal pressure sensor Current sensor WP_ActivateCurr entSensor 25 20971545 Ac...

Page 51: ... temperature or low water level alarms over a short period 0 Off 1 On Off Internal buzzer WP_ActivateInter nalBuzzer 30 20971550 Activates the controller s internal buzzer 0 Off 1 On On OCCUPATION MENU SETTINGS Variables beginning with AV and BV are read variables while variables beginning with W are editable Display BACnet Variable Instance Tag Description Settings Default Occupation Mode WP_Acti...

Page 52: ... are read variables while variables beginning with W are editable Display BACnet Variable Instance Tag Description Settings Default Warm Weather Shutdown WP_ActivateWar mWeatherSD 26 20971546 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_WarmWeat...

Page 53: ...r out of the boiler tank during the fill process Leave all shutoff valves open Check system for leaks and repair Purge air from all the heating distribution zones Bleed air from different areas of the heat distribution system Check boiler pressure gage reading The indicated pressure should be lower than the pressure relief valve design rating ADJUSTEMENT OF THE CONTROLLER OPERATING PARAMETERS Afte...

Page 54: ...ue indicated is it is because the authorization or start up signal is not established 2 When the boiler capacity has reached 100 as displayed on the controller measure the amperage and voltage values drawn by the unit These values shall be close to those shown on the boiler name plate 3 Slow down the heat demand from the heating system The boiler temperature shall gradually increase and the boiler...

Page 55: ...ns when one of the following contacts is open the adjustable mechanical high limit the manual reset high limit located in the heating elements compartiment a low level of water or an external contact connected to EXT HL terminals The external alarm contact SCR models only will be activated immediately if it has been activated Ext Alarm Contact in the Alarm menu The heating elements will stop worki...

Page 56: ...f the heating elements of the boiler The boiler is restarted when the temperature drops below the high limit and the set point If the boiler is in this alarm state for more than 60 minutes or the condition occurs 3 times in an hour the boiler switches to Lock Out mode LOW PRESSURE P The Low Pressure alarm P is activated when the pressure inside the boiler is below the allowed limit default 5 psi T...

Page 57: ...6 30 1 34 558 100 38 5 828 170 77 1 403 35 37 280 279 35 2 29 996 105 41 5 210 175 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 29 165 180 50 10 19 900 120 49 3 760 190 88 983 15 26 139 402 55 13 17 436 125 52 3 383 195 91 903 10 23 118 018 60 16 15 311 130 54 3 050 200 93 829 5 21 100 221 65 18 13 474 135 57 2 754 205 96 763 0...

Page 58: ...make sure there is no sediment deposits in the tank befor installing new elements If deposites are present A Sieve or other accessorie preventing sediment deposits shall be installed TEMPERATURE SENSOR Water outlet sensor The sensor is located in an immersion well located in the heating elements compartiment on the top of the boiler illustration 5 1 and the resistance vs temperature value is indic...

Page 59: ...R Check for proper operation of the automatic air purgers and activate manual air vents to eliminate air present 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 overheating Repair as soon as possible if necessary Defecti...

Page 60: ...be responsible for any damage loss and inconvenience of any nature whatsoever directly or indirectly relating to the breakdown or malfunction of the unit This warranty limits its beneficiary s rights Nevertheless the beneficiary may have other rights which vary from state to state This warranty replaces any other expressed or implicit warranty and constitutes the sole obligation of Thermo 2000 tow...

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