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TURBOMAX Use and Care Manual with Installation Instructions July 2014 Page

28

Replacement Parts List

INSTRUCTIONS FOR PLACING A PART ORDER

Address parts orders to the distributor or store where the heater water purchased.
All parts orders should include:

1. Model number and Serial number of heater, from embossed plate.
2. Part Description & Part Number as noted below

and number of parts desired

For your safety, DO NOT attempt repair of aquastat, safety devices or others parts.
Refer repairs to qualified service personnel.

Replacement of the Aquastat

To avoid shock injury, power shall be
disconnected before doing any electrical work.

Note the temperature and the differential settings
of the aquastat.  Turn off the boiler electrical
service switch.  Turn off the pump or circulator
service switch.  Turn off the safety switch if
separate from service switch.
Disconnect the electrical wires from the aquastat.
Unscrew 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 jacket.
Connect the electrical wires and set the
adjustments of the aquastat as they were initially.
Turn on the safety switch. Turn on the pump or
circulator service switch. Turn on the boiler
service switch. Check the operation of the system.

Reference

from

drawing

Description

Part

Number

Heater

Models

A

Aquastat

ZMC200-

AQU_AJUS

All models

ZMC200-

SV30PSI1

ZMC200-

SV50PSI2

Models 23 to 65

Model-65A

B

Safety Valve

30 psi, ¾ “

50psi, 3/4'”

ZMC200-

SV50PSI3

Models

109-109A

C

Pressure &

Temperature

Gage

ZMC300-
60P120C

ZMC300-

120P120C

models 24,

34,44,45,65,109

Models

65A&109A

ZMC200-

BV3/4NPT

Turbomax 44-

45-65-65A-109-

109A

D

Drain valve,

1/2 ”

ZMC200-

ROB1/2

Models 23-24-

33-34

E

Air vent

½’’

ZMC600-

AW1/2

All

models

CAUTION

!

WARNING

!

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Содержание VOLTMAX 23

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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