THERMO 2000 COMBOMAX 23-8, Combomax 23, COMBOMAX 23-24, COMBOMAX 34-8, COMBOMAX 34-10 Use And Care Manual
...
MC
COMBOMAX
RÉSIDENTIAL
23
TO
64
Electric boiler with integrated instantaneous water heater
Capacity from 8 kW to 24 kW :
240 Volts ( single phase )
Use and Care Manual
With installation instructions for the contractor
Your COMBOMAX® electric boiler has been carefully assembled and factory tested to
provide years of trouble-free service. This manual contains instructions for the safe and
proper installation, operation and maintenance of the boiler, in order to ensure your full
satisfaction
It is imperative that all persons who are expected to install, operate or adjust this boiler read
the instructions carefully.
Any questions regarding the operation, maintenance, service or warranty of this water
heater should be directed to the dealer or distributor you purchased it from. When all
installation steps have been completed, replace this installation manual in its original
envelope, and keep in a safe place near the heater for future reference.
THERMO 2000 INC. revised : Oct. 2015
Printed in Canada
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page 2.
Section 1 : Technical specifications
Table 1: Boiler specifications 240* Vac/1ph (3 wires L1/L2/N):
Modèle
Kw
À
240
V*
BTU/h
Amp.
Heating
elements
Heating
elements
Stage
Cable
(cu)**
Fuse **
COMBOMAX XX-8 8 27 296 33.3
1 X 3KW
1 X 5KW
2 8 50
COMBOMAX XX-10 10 34 120 41.6 2 X 5KW 2 6 60
COMBOMAX XX-15 15 51 180 62.5
2 X 3KW
2 X 4.5KW
4 6 80
COMBOMAX XX-18 18 61 416 75.0 4 X 4.5KW 4 4 100
COMBOMAX XX-20 20 68 240 83.4 4 X 5KW 4 3 110
COMBOMAX XX-24 24 81 888 100.0 4 X 6KW 4 3 125
*Can be also connected on an electrical supply at 208V/1ph giving 75% of the nominal capacity at 240V.
**Add amperage of the pump when required (8amp./1/3hp max). Local Electrical codes may require
different cable gauge according to the type of installation.
Table 2 : Boiler and connection dimensions
Model Capacity Utility
connection
Boiler
connection
Height Diam. Ship.
weight
Combomax 23 30 Gal US 3/4 ’’ Sweat F 1’’ NPT F 49’’ 18’’ 265 lbs
Combomax 34 40 Gal US 3/4 ’’ Sweat F 1’’ NPT F 65’’ 18’’ 315 lbs
Combomax 44 52 Gal US 3/4 ’’ Sweat F 1’’ NPT F 55’’ 22’’ 345 lbs
Combomax 64 76 Gal US 3/4 ’’ Sweat F 1’’ NPT F 67’’ 24’’ 425 lbs
Table 3 : Domestic hot water production capacity in US gallons
1st hour Continuous Model
110F 140F 180F 110F 140F 180F
COMBOMAX 23-8 75 44 28 47 33 24
COMBOMAX 23-10 87 52 33 59 41 29
COMBOMAX 23-15 116 73 48 88 62 44
COMBOMAX 23-18 134 85 57 106 74 53
COMBOMAX 23-20 145 93 63 117 82 59
COMBOMAX 23-24 169 110 75 141 99 71
1st hour Continuous Model
110F 140F 180F 110F 140F 180F
COMBOMAX 34-8 85 48 29 47 33 24
COMBOMAX 34-10 97 56 34 59 41 29
COMBOMAX 34-15 126 77 49 88 62 44
COMBOMAX 34-18 144 89 58 106 74 53
COMBOMAX 34-20 155 97 64 117 82 59
COMBOMAX 34-24 179 114 76 141 99 71
1st hour Continuous Model
110F 140F 180F 110F 140F 180F
COMBOMAX 44-8 97 53 31 47 33 24
COMBOMAX 44-10 109 61 36 59 41 29
COMBOMAX 44-15 138 82 51 88 62 44
COMBOMAX 44-18 156 94 60 106 74 53
COMBOMAX 44-20 167 102 66 117 82 59
COMBOMAX 44-24 191 119 78 141 99 71
1st hour Continuous Model
110F 140F 180F 110F 140F 180F
COMBOMAX 64-8 121 63 34 47 33 24
COMBOMAX 64-10 133 71 39 59 41 29
COMBOMAX 64-15 162 92 54 88 62 44
COMBOMAX 64-18 180 104 63 106 74 53
COMBOMAX 64-20 191 112 69 117 82 59
COMBOMAX 64-24 215 129 81 141 99 71
With domestic cold water at 40
°F and heating water at 180°F
Operating temperature : from 50°F to 190°F; Maximum operating pressure: 30 psi
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page 3.
Figure 1 : Component diagram
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page 4.
General Safety Precautions
Be sure to read and understand the entire Use & Care Manual before attempting to
install or operate this water heater. Pay particular attention to the following General
Safety Precautions. Failure to follow these warnings could cause property damage,
bodily injury or death. Should you have any problems understanding the instructions in
this manual, STOP, and get help from a qualified installer or technician.
Section 2 : Introduction
The important safeguards and instructions
appearing in this manual are not meant to
cover all possible conditions and situations
that may occur. It should be understood that
common sense, caution and care are factors
which cannot be built into every product.
These factors must be supplied by the
person(s) caring for and operating the unit.
2.1 LOCAL INSTALLATION
REGULATIONS
This water heater must be installed in
accordance with these instructions and must
conform to local, or in the absence of local
codes, with the current edition of the National
Plumbing Code and the National Electric Code.
In any case where instructions in this manual
differ from local or national codes, the local or
national codes take precedence.
2.2 CORROSIVE ATMOSPHERE
The heater should not be located near an air
supply containing halogenated hydrocarbons or
high humidity. The limited warranty is voided
when failure of the water heater is due to a
corrosive atmosphere.
2.3 SHIPMENT INSPECTION
Inspect the water heater for possible shipping
damage. The manufacturer’s responsibility
ceases upon delivery of goods to the carrier in
good condition. Consignee must file any claims
for damage, shortage in shipments, or nondelivery immediately against carrier.
2.4 CHECKLIST
Please check the technical information plate to
ensure you have the right model.
The following items are shipped with the
unit :
• 30 PSI pressure relief valve.
• Drain cock.
• Thermo manometer (heat and
pressure indicator).
• Thermostatic mixing valve
The boiler should not be located in an area
where leakage from the tank or water
connections will result in damage to the
adjacent area or to lower floors of the
structure. When such areas cannot be
avoided, a suitable drain pan or nonflammable catch pan, adequately drained,
must be installed under the boiler. The pan
must be connected to a drain.
NOTE: Auxiliary catch pan MUST conform to
local codes.
!
WARNING
!
WARNING
!
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page 5.
Section 3 : INSTALLATION
The manufacturer’s warranty does not cover
any damage or defect caused by installation
or attachment or use of any special
attachment other than those authorized by
the manufacturer into, onto, or in
conjunction with the water heater. The use of
such unauthorized devices may shorten the
life of the water heater and may endanger life
and property. The manufacturer disclaims
any responsibility for such loss or injury
resulting from the use of such unauthorized
devices.
3.1 SAFETY MEASURES
All domestic and commercial installations will
include a pressure relief valve limiting the
operating pressure to 30 psi.
This COMBOMAXMC electric boiler is designed
for a maximum operating temperature of 190°F.
It is designed as a hot water heating system
only. When allowed by local regulation an
antifreeze water and propylene-glycol blend
(50% maximum concentration) may be used on
installations having a potable water supply
pressure above 240 kPa (35 psi).
3.2 LOCATION
The COMBOMAXMC water heater should be
installed in a clean, dry location. Long hot water
lines should be insulated to conserve water and
energy. The water heater and water lines should
be protected from exposure to freezing.
COMBOMAX
MC
water heaters must be installed
vertically. Use the adjustable feet to level the
unit.
The COMBOMAXMC water heater must be
located or protected so as not to be subject to
physical damage, for example, by moving
vehicles, area flooding, etc..
All models can be installed on combustible floors
and in alcoves. If the water heater is to be
installed in a restaurant or other location where
the floor is frequently cleaned, it must be
elevated to provide at least 6 inches of
clearance from the floor to comply with NSF
International recommendations.
The room temperature must not exceed 80°F or
27°C.
3.3 CLEARANCE
The minimum clearances required for proper
inspection and servicing are as follows:
Table 4: Clearances
Left side 3 inches
Right side 3 inches
Top 6 inches
Front 24 inches
Back 3 inches
3.4 SYSTEM SETUP
Figures 2, 3 and 4 are general connection
diagrams including the circulator, the expansion
tank, the drain cock, the safety valve, the air
bleeder, the flow check valve and the thermo
manometer. Set-up details follow.
3.5 HEATING WATER CIRCUIT
3.5.1 Connecting the heating water
piping
The boiler may be set up alone or in parallel with
others. Parallel connections should be made
using the reverse-piping method to ensure equal
flow through each boiler.
The boiler water supply connector is located on
top of the boiler and the boiler water return
connector is located to the left of the three-way
valve. They are both threaded NPT female
connectors.
Unions are recommended on the hot and cold
water lines to disconnect the water heater easily
for servicing if necessary.
Dielectric (insulating) unions are required for
protection of the water heater if copper-steel
connections are made.
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.
WARNING
!
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page 6.
Insulate all pipes containing hot water,
especially in unheated areas.
Install shutoff (ball) valves for servicing
convenience. Install thermometers on the inlet
and outlet lines.
Never plug the pressure relief valve to avoid
creating a hazardous situation.
3.5.2 Flow-check valve
If the heating system uses a single circulator, a
flow-check valve must be installed to
minimize gravity flow and heat loss during nondraw periods.
3.5.3 Pressure relief valve
No boiler set-up is complete without a pressure
relief valve. Its pressure rating must not exceed
30 psi (207 kPa). It must conform to the « ASME
Boiler and Pressure Vessel Code» and limit the
boiler operating pressure. It is a safety device,
not a control device.
The BTU per hour rating of the relief valve must
equal or exceed the BTU per hour input of the
boiler(s) or heat source(s) as marked on the
boiler(s) rating plate.
Connect the outlet of the relief valve to a
suitable open drain, with the discharge at most
6” above the floor, far from any live electrical
parts. The discharge line must pitch downward
from the valve to allow complete draining and be
no smaller than the outlet of the valve. The end
of the discharge line should not be threaded or
concealed and should be protected from
freezing. No valve of any type, restriction or
reducer coupling should be installed in the
discharge line. Local codes shall govern the
installation of relief valves.
3.5.4 Operating pressure control :
Operating pressure control components ensure
minimum and maximum operating limits within
the design operating temperature range of the
heating system.
Expansion tank
The purpose of the expansion tank is to absorb
the water volume increase of the boiler and the
heating system related to the variation of its
water temperature during the heating season.
Consequently, the selection of the appropriate
expansion tank model must be made taking into
account both the maximum operating
temperature of the system and its water content.
Note that the water content of an heating system
with cast iron radiators is a lot more than a
system with hot water baseboard.
The important increase of heating water volume
brought with the addition of the Combomax will
also have to take into account.
Combomax 23 : 30usgal.
Combomax 34 : 40usgal
Combomax 44 : 52usgal
Combomax 64 : 76usgal
With these informations, these informations, the
installer with his distributor shall be in position to
make an appropriate selection.
You will find below our recommendation on the
minimum size of tank in relation to the type of
heating system of the application.
Combomax #
Hot water
Baseboards
Radiant
floor
Cast iron
radiator
Combomax 23
#30 #30 #60
Combomax 34
#30 #30 #60
Combomax 44
#30 #30 #60
Combomax 64
#60 #60 #90
The expansion tank connection point must be
carefully chosen to prevent a situation where
closing a valve would isolate the tank from the
boiler or any part of the circuit.
3.5.5 Makeup valve
Connecting a makeup valve must be done
according to code. This valve must include a
flow-check valve to maintain the minimum
operating pressure by admitting fresh water from
the cold water supply line in case a leak occurs.
3.5.6 Air bleeder
There should be as little oxygen as possible in
the heating circuit to prevent corrosion. As
foreseen in section 3.5.4, this excludes the use
of air as a pressure regulator within the circuit.
Installing manual or automatic air bleeders
prevents air accumulation within the system.
The bleeders must be set at the highest points
of the system to purge any air accumulated
during system set-up and to check its air
tightness. Bleed the air regularly from the piping,
making sure the heating water causes no bodily
harm or material damage.
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page 7.
3.5.7 Circulator zoning
A flow-check valve must be installed in each
zone, preferably at the outlet of each circulator,
to prevent water flowing to zones where no heat
is currently required. (see figure 4).
3.5.8 Zone valve zoning
Zone valves with low pressure drop are
recommended. (see figure 3)
3.5.9 Circulator selection criteria
The COMBOMAXMC boiler includes a premounted circulator. The information below will
help you select additional units for multiple
circulator set-ups.
3.5.9.1 Pump flow rate calculation
The boiler output rating must correspond to the
calculated heating load. Use the equation below
to calculate the pump flow rate:
Pump flow rate = Boiler output ÷÷÷÷ BWTD ÷÷÷÷ 500
• Pump flow rate is expressed in U.S. gallons
per minute or GPM.
• The Boiler output ( in net BTU per hour) is
the maximum amount of heat to be
transferred through the heating circuit to
meet the hot water demand.
• BWTD is the boiler water temperature drop
through the heating circuit.
For example, a 24 Kw COMBOMAXMC boiler has
a rated output of 81,964 BTU/hour. The system
is designed for a boiler water temperature drop
(BWTD) of 20°F.
Pump flow rate = 81,964 ÷ 20 ÷ 500 = 8,2 GPM.
The following table shows the required flow rate
as a function of boiler water temperature drop
(BWTD) and rated power output.
Table 5 : BWTD vs. flow (GPM)
BWTD
Model Kw
10
o
F
20
o
F
30
o
F
40
o
F
COMBOMAX XX-8 8 5,5 2,7 1,8 1,4
COMBOMAX XX-10 10 6,8 3,4 2,3 1,7
COMBOMAX XX-15 15 10,2 5,1 3,4 2,6
COMBOMAX XX-18 18 12,3 6,1 4,1 3,1
COMBOMAX XX-20 20 13,7 6,8 4,6 3,4
COMBOMAX XX-24 24 16,4 8,2 5,5 4,1
3.5.9.2 Selecting a circulator
Consult the manufacturer’s operating
characteristic curves to select the proper model.
These curves plot flow versus pressure, together
with other information such as efficiency and
power. Ask your pump dealer or HVAC
wholesaler to recommend the circulator which
best fits your needs.
3.6 DOMESTIC HOT WATER CIRCUIT
3.6.1 Connecting the domestic hot water
piping
The COMBOMAX
MC
domestic hot water coil may
be set up alone or in parallel combination with
other COMBOMAXMC units or storage tanks.
Parallel connections should be made using the
reverse-piping method to ensure equal flow
through each boiler.
The HOT WATER OUTLET and the COLD
WATER INLET connections are clearly marked.
Inlet water connections (COLD WATER INLET)
are to be made to the copper pipe (sweat
connection) at the bottom of the heater. Outlet
water connections (HOT WATER OUTLET) are
to be made to the three-way thermostatically
controlled valve (sweat connection) at the top of
the heater.
The installation of copper unions or copper alloy
unions is recommended on the HOT and COLD
water lines, so that the water heater may be
easily disconnected for servicing if necessary.
These unions must be dielectric (insulating) if
you are making steel-copper connections.
A shutoff (ball) valve is present on the
COMBOMAXMC domestic hot water outlet 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.
Insulate all pipes containing hot water,
especially in unheated areas.
Thermometer(s) should be installed to indicate
the temperature of the water at or near the outlet
of the water heater and storage tank(s), if
provided.
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page 8.
3.6.2 Expansion tank on the cold water
supply line
Determine if a flow check valve, a back flow
preventer, a pressure-reducing valve, a water
meter or a water softener is present on the cold
water supply line.
A flow check valve creates a closed system and
prevents the water, as it is being heated, from
expanding back into the cold water supply line.
Pressure can build up within the water heater,
causing the pressure relief valve to operate
during a heating cycle. This excessive operation
can cause premature failure of the relief valve
and possibly of the water heater itself.
Replacing the relief valve will not correct the
problem. One method of preventing pressure
build-up is to install an expansion tank on the
cold water supply line between the
COMBOMAXMC unit and flow check valve.
Contact your installing contractor, water
supplier, local plumbing inspector or plumbing
supply house for assistance.
3.6.3 Recirculation line (if applicable)
If a recirculation line is installed, the return
connection should be made to a tee close to the
inlet connection on the water heater. A check
valve should always be installed in the
recirculation line to prevent cold water from
entering.
3.6.4 Domestic hot water pressure relief
valve
An automatic pressure relief valve must be
installed on a tee installed on the domestic hot
water pipe coming out of the water heater. No
valve of any type should be placed between the
safety relief valve and the water heater. The
pressure rating of the relief valve must not
exceed 150 psi.
The BTU per hour rating of the relief valve must
equal or exceed the BTU per hour input of the
boiler(s) or heat source(s) as recorded on the
boiler(s) rating plate.
Connect the outlet of the relief valve to a
suitable open drain, with the discharge at most
6” above the floor, far from any live electrical
parts. The discharge line must pitch downward
from the valve to allow complete draining and be
no smaller than the outlet of the valve. The end
of the discharge line should not be threaded or
concealed and should be protected from
freezing. No valve of any type, restriction or
reducer coupling should be installed in the
discharge line. Local codes shall govern the
installation of relief valves.
3.6.5 Thermostatically controlled mixing
valve (included)
For general-purpose hot water requirements in a
domestic environment, a thermostatically
controlled mixing valve is recommended to
reduce the risk of scald injury. Contact a
licensed plumber or the local plumbing authority
for further information. Adjust the mixing valve to
the lowest required temperature setting.
3.7 BOILER WIRING
The boiler cabling and grounding must conform
to local codes or, in their absence, to the
National Electrical Code.
Power must be provided by a 120/240 volt
(single phase, 60 Hz) circuit, appropriately fused
and with 3-wire plus ground cabling of sufficient
gage. The fuse and cabling gauge may be
determined from the boiler rating plate.
3.8 CIRCULATOR WIRING
The COMBOMAXMC heating pump (120 Vac,
1/25 Hp) is connected to the C&C terminals on
the boiler electrical panel. The control circuit is
designed to start the pump upon receiving a
heating signal from the thermostat or priority
aquastat.
3.9 CONNECTING THE THERMOSTAT
3.9.1 Single heating zone
Connect the low-voltage thermostat to the T&T
terminals on the COMBOMAXMC electrical panel
(DO NOT apply current to these terminals).
(see figure 2&3).
3.9.2 Zone valve zoning
Connect the low-voltage thermostat to the zone
valve. The components must wired such that,
upon a heating signal from a thermostat, only
the corresponding zone valve will be actuated
and will in turn activate the COMBOMAXMC
circulator relay. Connect the zone valve switch
to the T&T terminals on the COMBOMAXMC
electrical panel (DO NOT apply current to
these terminals). See figures 8.
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page 9.
The transformer used to power the zone valves
must be of sufficient capacity to handle the load
represented by all zone valves.
3.9.3 Multiple circulator zoning
Connect the low-voltage thermostat to the relay
(Honeywell #RA-889, RA-89A, RA-845A). The
components must wired such that, upon a
heating signal from a thermostat, only the
corresponding circulator will be activated. See
figure below
Diagramme électrique/ Wiring diagram
Raccordement de multiples circulateurs/ Wiring for multiple circulators
Thermostat
Zone 1
T
T
12
3
5
4
6
Relais/Relay
RA832A
T
T
1
2 3
5
4
6
Relais/Relay
RA832A
L2L1
Thermostat
Zone 2
Circulateur/
circulator
Zone 1
Circulateur/
circulator
Zone 2
electrical service
120Vac
T T
Note 1
Note 1
Block terminal sur
panneau électrique COMBOMAX/
Terminal block : thermostat on
COMBOMAX electric pannel
3.10 BI-ENERGY SETUP
To take advantage of a special domestic electric
utility rate, your COMBOMAXMC boiler can be
combined with an existing oil or gas-fired
furnace. Please contact your utility to make sure
your building is eligible and to find out about the
new wiring configuration. Please refer to figures
7 and 8 for the set-up required.
The CBE-EM bi-energy switching control
(available as an option) is especially designed to
satisfy utility requirements. The CBE-EM control
selects the cheapest energy source according to
the outdoor temperature, the indoor temperature
setting and any signal provided by the utility.
The CBE-EM bi-energy control starts up the oil
burner upon receiving the appropriate signal,
even if the thermostat is sending no heating
signal. The oil burner stops when the boiler
reaches its high-limit point. For this reason, the
plumbing system must be equipped with a flow
check valve or zone valves.
If the CBE-EM control is used with a 3-way
motorized vale (1’’ NPT F), it will directs the
heating water flow to the oil burner or the
COMBOMAXMC unit depending on the signal
sent to it by the external bi-energy sensor. Thus,
your oil burner can cool down while eliminating
energy losses up the chimney or by conduction
in the furnace room .
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page
10.
Section 4 : Operation
Before operating this water heater, be sure to
read and follow these instructions, as well as
the warnings printed in this manual. Failure
to do so can result in unsafe operation of the
water heater resulting in property damage,
bodily injury, or death. Should you have any
problems reading, following or difficulty in
understanding the instructions in this
manual, STOP, and get help from a qualified
person.
Do not turn on the water heater unless it is
filled with water. Do not turn on water heater
if cold water supply shut-off valve is closed.
Once the plumbing and electrical connections
are completed, your COMBOMAXMC unit is
ready for automatic operation.
4.1 FILLING THE TANK
Open the outlet valve (in a zone valve system,
manually open the zone valves).
Open the boiler inlet valve. Bleed the air from
the boiler tank by opening the safety valve atop
the boiler while you are filling the tank.
Leave all valves open. Reset the zone valves to
automatic operation. Check for leaks and repair
if necessary.
Bleed the air from all zones if required. Check
the boiler pressure gauge. A pressure reading
between 15 and 20 psi is normal for most
installations.
4.2 FILLING THE HEATING COIL
Make sure all drain cocks are closed.
Open the nearest domestic hot water tap as well
as any control valve on the water heater outlet
(the copper tube atop the boiler).
Open the cold water inlet valve on the heater
inlet tube. (the copper tube on the left side of the
unit).
Close the domestic hot water tap as soon as
water flows out of it. Fix any leaks
Open all other hot water taps fed by this heating
coil to bleed the air trapped behind them.
4.3 ADJUSTING THE AQUASTATS
Once all air has been bled from the system and
all components (valves, bleeders, controls) have
been properly adjusted, the boiler can be put
into operation. Never operate the boiler before
these adjustments are complete.
Bear in mind safety and energy-saving
considerations when adjusting the boiler water
temperature with the aquastats. It is most
energy-efficient to set them as low as possible,
in a manner consistent with your heating needs.
However, a minimum temperature of 160°F is
recommended for domestic hot water
production.
Each aquastat controls a boiler stage (each
element has its own aquastat). Adjust the setting
of each aquastat by turning the dial scaled in
degrees Celsius and Fahrenheit. See figure 10
for aquastat identification.
Set the first aquastat to the highest outlet
temperature required by the heating system and
the domestic hot water. Thermo 2000 inc.
recommends a setting around 180F to get the
maximum capacity.
Adjust the second aquastat around 5F lower
than the first one and proceed in a similar
manner for the 3rd and 4th aquastats, Thus, the
number of elements in operation will increase as
the boiler temperature will decrease.
The domestic hot water priority aquastat should
be adjusted to a setting around 10oF below that
of the last stage or 4th aquastat.
Note: The maximum setting for the boiler outlet
temperature is 190°F.
4.4 STARTUP PROCEDURE
1. Fill tank and coil as described in
sections 4.1 and 4.2.
2. Adjust temperature levels as described
in section 4.3
3. Set building thermostat setting(s) below
room temperature.
4. Activate boiler main breakers.
SAFETY PRECAUTIONS !
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page
11.
5. The main boiler contactor should close
and all elements should turn on, along
with their pilot lights.
6. The circulator should start up and the 3way valve should be open on the B side.
7. Boiler temperature should rise.
8. Circulator should stops when boiler
temperature exceeds the setting of the
domestic hot water priority aquastat.
9. Boiler temperature continue to rise and
the elements and corresponding pilot
lights turn off one after the other as their
temperature setting is reached.
10. When all elements are off, increase the
setting of the building thermostat(s) to a
point above room temperature.
11. Circulator should start up and the three
way valve should open its A port and
close the B port. Heating elements
should turn back on as the boiler
temperature drops below their
corresponding aquastat setting. This
could take a few minutes.
12. Circulator runs as long as a demand
exists for heating. When circulator turns
off, the A side of the valve closes and
the B side opens.
13. Boiler temperature rises. Heating
elements and corresponding pilot lights
should turn off as their temperature
setting is reached.
14. If during the period of the building
heating demand, the boiler temperature
would drop below the set point of the
domestic hot water priority aquastat, the
pump would continue running but the
three way valve would change position.
A port would close and B port would
open.
Thus, boiler capacity will modulate in relation the
importance of the heating demand within the
building. If only one heating element is required
to satisfy the demand, only one is activated ; if
two are required, two are activated, etc ... You
thus avoid excessive wear and tear on the
components due to numerous on-off cycles and
reduce your total heating costs.
4.5 DOMESTIC HOT WATER STARTUP
Maximum boiler water temperature is 190°F.
This should be 20°F to 40°F above the desired
temperature for domestic hot water. In practice,
the boiler water temperature should be between
160°F and 180°F.
An excessively high setting can cause
scalding. Use the thermostatically controlled
mixing valve included with the unit to lower
the domestic hot water temperature and thus
the risk of injury.
When there is no heat demands from the
building, the 3-way valve is always open on the
B side and the circulator starts up when the
boiler temperature drops below the setting of the
domestic hot water priority aquastat.
The heating element will come ON when the
boiler temperature drops below their controlling
aquastat.
The heating elements remain ON until they
reach their set points on the corresponding
aquastat.
Considerable time may elapse from a cold start
to the moment when the highest set point is
reached. Check the domestic hot water
temperature when the first heating cycle is
completed.
Normally, the domestic hot water priority
aquastat is set to 10F below the lowest
heating element aquastat set point.
4.6 ADJUSTING THE MIXING VALVE
A thermostatically controlled mixing valve works
automatically thanks to the thermostatic element
controlling the mix of very hot and cold water as
required to provide safe domestic hot water
under variable conditions.
To adjust the mixing valve setting, carefully open
a hot water tap. Protect yourself against the
possibility of scalding. Measure the hot water
temperature and adjust it with the mixing valve,
following the manufacturer’s instructions..
A higher boiler water temperature setting is now
possible thanks to this moderating effect. The
boiler water in the COMBOMAXMC tank acts as a
buffer and increases the boiler efficiency as well
as the amount of domestic hot water produced.
To increase the hot water production capacity,
first adjust the domestic hot water priority
aquastat setting and heating element
aquastats.settings.
Some sanitary uses may require different setting
ranges or dedicated piping.
DANGER
!
THERMO 2OOO INC.
500, 9
ième
Avenue
, C.P. 639, RICHMOND (QUÉBEC) JOB 2HO
T
ÉL.:
(819) 826-5613 F
AX:
(819) 826-6370
Rev. September 2011
Section 5 : Maintenance
Regular boiler maintenance will ensure troublefree service for many years. It is recommended
that you set up and follow a maintenance
program. All components fail eventually. The use
of incorrect replacement parts or disregarding
safety procedures and warnings during repairs
may reduce the boiler safety level and shorten its
useful life.
The owner should set up the following
maintenance program.
5.1 BOILER WATER PIPING :
Annual visual inspection.
Check for leaks close to connections, unions and
valves. Repair as needed.
5.2 BOILER CIRCUIT SAFETY VALVE:
Monthly inspection.
To be checked manually to ensure safety and
proper operation. Air trapped in the boiler is bled.
Make sure the water is discharged to a floor drain
and that no bystander is splashed. Use the lever
to open the safety valve. Hot water should come
flowing out. Upon releasing the lever, the safety
valve should shut tight. If it does not, it must be
replaced by an identical or equivalent model.
Never plug a safety valve.
5.3 DOMESTIC PIPING :
Annual visual inspection.
Check for leaks close to connections, unions and
valves. Repair as needed.
5.4 DOMESTIC CIRCUIT SAFETY VALVE
(TEMPERATURE & PRESSURE):
Annual inspection.
To be checked manually to ensure safety and
proper operation. Air trapped in the boiler is bled.
Make sure the water is discharged to a floor drain
and that no bystander is splashed. Use the lever
to open the safety valve. Hot water should come
flowing out. Upon releasing the lever, the safety
valve should shut tight. If it does not, it must be
replaced by an identical or equivalent model.
Never plug a safety valve.
5.5 SCALE BUILD-UP :
Monthly inspection.
This problem occurs infrequently under very
specific conditions. The main symptom is a drop
in domestic water pressure. A water softener will
solve the problem.
A proper chemical cleaning is a more efficient
solution. A scale dissolving product may be used,
paying careful attention to the manufacturer’s
recommendations. Do not use muriatic or
hydrochloric acid-based products. Carefully flush
the products after use. Contact your plumber to
remove scale build-up from the coil.
The manufacturer’s warranty DOES NOT
cover problems caused by improper
installation or maintenance. If the safety valve
opens periodically, it may be due to the
expansion tank. Immediately call a qualified
technician to appraise and repair the problem.
NOTE: To prevent tank breakage, trapped air
must periodically be bled from it by opening
the safety valve.
Before manually opening the safety valve,
make sure no bystander will accidentally be
splashed by the hot water. The discharged
water should be directed to a floor drain to
prevent scalding and damage.
DANGER
!
WARNING
!
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page
13.
General Safety Precautions
Be sure to read and understand the entire Use & Care Manual before attempting to install
or operate this COMBOMAX
MC
unit. Pay particular attention to the following General Safety
Precautions. Failure to follow these warnings could cause property damage, bodily injury or
death. Should you have any problems understanding the instructions in this manual, STOP,
and get help from a qualified installer or technician.
To meet commercial hot water needs, the
aquastat on this water heater is adjustable up to
190°F. However, water temperatures over 125°F
can cause severe burns instantly or death from
scalds. 125°F is the preferred starting point for
setting the control to supply general-purpose hot
water.
Safety and energy conservation are factors to be
considered when setting the water temperature
on the aquastat. The most energy efficient
operation will result when the temperature
setting is the lowest that satisfies requirements.
Maximum water temperature occurs just after
burner or the energy 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.
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 TO SCALDING VS TEMPERATURE
RELATIONSHIP
Temperature Time to scalding
120°F Over 5 minutes
125°F 1-1/2 to 2 minutes
130°F About 30 seconds
135°F About 10 seconds
140°F Less than 5 seconds
145°F Less than 3 seconds
150°F About 1-1/2 second
155°F About 1 second
With kind permission from the Shriners Burn Institute
The temperature of the water in the heater can be
set by turning the temperature dial on the
aquastat. To comply with safety regulations the
aquastat was set at its lowest setting before water
heater was shipped from the factory.
There is a hot water scald potential if the
aquastat is set too high. When this water
heater is supplying general purpose hot water
requirements for use by individuals, a
thermostatically controlled mixing valve for
reducing point-of-use water temperature is
recommended to reduce the risk of scald
injury. Contact a licensed plumber or local
plumbing authority for further information.
DANGER
!
!
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page
14.
Figure 2 : General diagram, single zone
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page
15.
Figure 3 : General diagram, radiant floor application
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page
16.
Fig. 4 General diagram used on large heating water systems
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page
17.
Figure 5 : General diagram used on multi-zones systems
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page
18.
Figure 6 : General diagram Dual Energy system without trhee way valve.
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page
19.
Figure 7 : General diagram Dual Energy with three way valve :
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page
20.
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page
21.
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page
22.
Figure 7: Dual Energy controller CBE-EM wiring diagram
Noir/ Black
Brun/ Brown
Bleu/ Blue
L1 N
120 Vac
24 Vac
H
H
V3
V2
E1
E2
T1
T2
Bi-energie/ Dual energy
Electrique/ Electric
Mazout/ Oil
E2
V2
T
T
Relais chaudière
mazout/
Oil boiler Relay
Noir/ Black
V1
Brun/ Brown
Bleu/ Blue
B
AB
A
Electrique/ Electric
Mazout/ Oil
Interrupteur DPDT
Switch ON-OFF-ON
Sonde extérieur/
Outdoor sensor
Transfo
Lumière haut tarif/
High tarif light
Valve 3 voies optionnelle/
Optional 3-way valve
Cablage en usine/
Factory wiring
Cablage par l'installateur
Wiring by others
H H V1V2 V3 E1E2
Valve 3 voies optionnelle/
Optional 3-way valve
Sonde extérieure/
Outdoor sensor
Lumière haut tarif/
High tarif light
Transfo
120 Vac
24 Vac
Interrupteur DPDT
Switch ON-OFF-ON
Bi-energie/ Dual energy
Electrique/ Electric
Mazout/ Oil
DPST
Relais/
Relay
Chaudière mazout
Oil boiler
("T T" relais de combustion/
oil boiler burner)
DPST
Relais/ Relay
T6
T5
Relais Pompe Externe/
External Pump Relay
T
T
T3 T4
Thermostat 24V
T3 T4 T5 T6T1 T2
Thermostat 24V
Relais de pompe externe/
External pump relay
Diagramme électrique/ Wiring diagram
Contrôle Bi-énergy avec chaudière Combomax
Dual control energy CBE-EM with Combomax boiler
Relais BTH, DTH/
BTH, DTH Relay
Chaudière électrique Combomax
Electric boiler Combomax
("E2 V2" bornier 24 Vac/
terminal E2-V2)
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page
23.
Figure 8: Wiring diagram, single and multiple zones
COMBOMAXMC Electric boiler Set-up, use and care guide
(revised Oct 2015)
, Page
24.
Figure 10: Parts list : 240V models
THERMO 2OOO INC.
500, 9
ième
Avenue
, C.P. 639, RICHMOND (QUÉBEC) JOB 2HO
T
ÉL.:
(819) 826-5613 F
AX:
(819) 826-6370
Rev. September 2011
COMBOMAX
TM
LIMITED WARRANTY
Warranty Coverage for Residential Installation.
Thermo 2000 Inc. hereby warrants to the original residential purchaser that the
COMBOMAX tank and exchanger installed in a residential setting shall be free of
leaks during normal use and service for a period of fifteen (15) years from the date
of purchase as long as the original residential purchaser owns the home in which
the unit was originally installed. Residential setting shall mean usage in a singlefamily dwelling in which the consumer resides on a permanent basis. Also,
residential setting shall mean use in multiple family dwellings in which one (1)
COMBOMAX tank and exchanger is to be use in only one (1) dwelling. In the event
that a leak should develop and occur within this limited warranty period due to
defective material or workmanship, such leak having been verified by an authorized
company representative, Thermo 2000 inc. will repair or replace at our sole option
the failed unit with the nearest comparable model at the time of replacement.
The original residential purchaser is responsible for all costs associated with the
removal and reinstallation, shipping and handling to and from manufacturing plant.
The replacement unit will be warranted for the remaining portion of the original
Warranty.
Warranty Coverage for Commercial Installation.
Thermo 2000 Inc. hereby warrants to the original residential purchaser that the
COMBOMAX tank and exchanger (coil assembly) installed in a commercial setting
shall be free of leaks during normal use and service for a period of ten (10) years
from the date of purchase. Commercial setting shall mean use in other than
residential setting stated above in the residential setting definition. In the event that
a leak should develop and occur within this limited warranty period due to defective
material or workmanship, such leak having been verified by an authorized company
representative, Thermo 2000 inc. will repair or replace at our sole option the failed
unit with the nearest comparable model at the time of replacement.
The original purchaser is responsible for all costs associated with the removal and
reinstallation, shipping and handling to and from Manufacturer. The replacement
unit will be warranted for the remaining portion of the original Warranty.
Limited two years warranty on all COMBOMAX
components & parts
All other COMBOMAX components & parts are warranted for a period of two (2)
years against defects due to defective material or workmanship. The original
purchaser is responsible for all costs associated with the removal and reinstallation,
shipping 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:
A) Defects or malfunctions resulting from installation, repair, maintenance
and/or usage that are not done in conformity with the manufacturer’s
installation manual; or
B) Defects or malfunctions resulting from installation, maintenance, or
repair that are not done in accordance with regulations in force; or
C) Defects or malfunctions resulting from improper installation, maintenance or
repair done carelessly or resulting from consumer damage (improper
maintenance, misuse, abuse, accident or alteration); or
D) Installation in which a relief valve (pressure) 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; or
E) Installation in which liquid circulating in the tank does not remain in closed
circuit or installation in which piping is leaking; or
F) A polybutylene pipe or radiant panel installation without an oxygen absorption
barrier is used; or
G) Installation where the acidity of water is not within the normal Environmental
Protection Agency (EPA) (between pH 6.5 – 8.5) guidelines or the domestic
water contains abnormal levels of particulate matter or water exceeding 10.5
gpg; or
H) Your home contains any type of water softener system and the unit is not
installed and maintained in accordance with the manufacturer specifications;
or
I) When installed with a low pressure steam boiler, if sludge is allowed to
accumulate in the COMBOMAX tank and boiler water acidity is lower than pH
6.5 or higher than pH 8.5; or
J) The COMBOMAX unit is being subject to non authorized modifications; or
K) Defects or malfunction resulting of storing or handling done elsewhere than
Thermo 2000’s manufacturing plant; or
L) Units on which the serial number is removed or obliterated.
Limitations.
Thermo 2000 shall not 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 towards the consumer. The warranty does not cover cost of
removal, reinstallation or shipping to repair or replace the unit, nor administration fees
incurred by the original consumer purchaser.
Thermo 2000 reserves 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 COMBOMAX dealers are permitted to perform warranty obligations. The
owner or its contractor must provide Thermo 2000’s head office or authorized depot with
defect unit together with the following information: COMBOMAX model and serial number,
copy of the original sales receipt and owner’s identification certificate.
Loading...