THERMO 2000 VOLTMAX 36, VOLTMAX 27, VOLTMAX 30, VOLTMAX 41, VOLTMAX 50 Installation And Operation Manual

...

VOLTMAX Electric Boiler

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

INSTALLATION AND OPERATION MANUAL

TABLE OF CONTENTS

SECTION 1 : TECHNICAL SPECIFICATIONS ............................................................... 4

SECTION 2 : INTRODUCTION ....................................................................................... 9

2.1 LOCAL INSTALLATION REGULATIONS ............................................................................. 9

2.2 CORROSIVE ENVIRONMENT.............................................................................................. 9

2.3 INSPECTION UPON RECEPTION ....................................................................................... 9

2.4 TO BE CHECKED ................................................................................................................. 9

SECTION 3 : INSTALLATION ...................................................................................... 10

3.1 SAFETY MEASURES .......................................................................................................... 10

3.2 LOCATION........................................................................................................................... 10

3.3 CLEARANCES .................................................................................................................... 10

3.4 PIPING INSTALLATION ...................................................................................................... 10

3.4.1 Boiler piping connection ............................................................................................... 11

3.4.2 Auxiliary boiler piping connection ................................................................................. 11

3.4.3 Safety valve .................................................................................................................. 11

3.4.4 System pressure control and expansion tank .............................................................. 12

3.4.5 Water pressure makeup regulator ................................................................................ 12

3.4.6 Air bleeder .................................................................................................................... 12

3.4.7 Circulating pump .......................................................................................................... 12

3.4.8 Drain faucet .................................................................................................................. 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

4.2.1 Boiler status .................................................................................................................. 29

4.2.2 Boiler configuration ....................................................................................................... 29

4.2.3 User setting .................................................................................................................. 29

4.2.4 Clock setting ................................................................................................................. 30

4.2.5 Consumption ................................................................................................................ 30

4.3 BOILER SETTINGS ............................................................................................................. 30

4.3.1 Heating mode W1 ......................................................................................................... 31

4.3.2 Heating mode W2/DHW ............................................................................................... 31

4.3.3 Pump setting................................................................................................................. 32

4.3.4 Capacity limiting ........................................................................................................... 32

4.3.5 Auxiliary boiler .............................................................................................................. 33

4.3.6 Limit setting .................................................................................................................. 34

4.3.7 Alarm ............................................................................................................................ 34

4.3.8 Communication............................................................................................................. 35

4.3.9 Occupation ................................................................................................................... 36

4.3.10 BOOST Mode ............................................................................................................. 36

4.3.11 Warm weather shutdown ............................................................................................ 37

4.3.12 Change password ...................................................................................................... 37

4.4 INTERNET ........................................................................................................................... 37

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 2.

4.4.1 Website ......................................................................................................................... 37

4.4.2 Email ............................................................................................................................. 37

4.5 BOILER STATUS DISPLAY SETTINGS ............................................................................. 39

4.6 HEATING MODE W1 SETTINGS ....................................................................................... 41

4.6.1 FIXED MODE ............................................................................................................... 41

4.6.2 OUTDOOR RESET MODE .......................................................................................... 42

4.6.3 Mode : DDC 0-10VDC .................................................................................................. 43

4.7 W2 MODE SET-POINT TEMPERATURE SETTINGS ........................................................ 44

4.7.1 W2 MODE .................................................................................................................... 44

4.7.2 DHW MODE ................................................................................................................. 44

4.8 PUMP CONFIGURATION MENU SETTINGS .................................................................... 44

4.8.1 PUMP 1 ........................................................................................................................ 44

4.8.2 PUMP 2 ........................................................................................................................ 44

SPECIFIC PARAMETERS FOR THE CAPACITY LIMITING MENU .................................... 45

4.8.3 MANUAL MODE ........................................................................................................... 45

4.8.4 MODE: 0-10 VDC ......................................................................................................... 45

4.9 POWER LIMITATION MENU SETTINGS ........................................................................... 46

4.9.1 MANUAL MODE ........................................................................................................... 46

4.9.2 0-10 VDC MODE .......................................................................................................... 46

4.9.3 T. ext MODE ................................................................................................................. 47

4.9.4 Schedule MODE ........................................................................................................... 48

4.10 AUXILIARY 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 PARAMETERS .......................... 54

5.3 STARTUP PROCEDURE .................................................................................................... 54

SECTION 6 : TROUBLESHOOTING ............................................................................ 56

6.1 WARNING LIGHTS ............................................................................................................. 56

6.2 OPERATING PROBLEM IDENTIFICATION ....................................................................... 56

6.2.1 External HL / LWCO ............................................................................................... 56

6.2.2 Sensor ( SE ) .......................................................................................................... 56

6.2.3 Low limit ( LL ) ........................................................................................................ 56

6.2.4 Flow ( F ) ................................................................................................................ 56

6.2.5 Current ( A ) ............................................................................................................ 56

6.2.6 HL temperature ( HL ) ............................................................................................ 57

6.2.7 Low pressure ( P ) .................................................................................................. 57

6.2.8 High pressure ( P ) ................................................................................................. 57

6.2.9 Lock out .................................................................................................................. 57

SECTION 7 : MAINTENANCE ...................................................................................... 58

7.1 BOILER WATER PIPING .................................................................................................... 58

7.2 PRESSURE RELIEF VALVE ............................................................................................... 58

7.3 AIR PURGE ......................................................................................................................... 58

7.4 ELECTRICAL INSPECTION................................................................................................ 58

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 3.

Capacity

STG

Series

SCR Series

Model

BTU/h

Amps

Electrical

element(s) 240 V

Stage Relay

SCR

Stage

VOLTMAX 23

22,5

76 770

108,4

6 x 5 kW

3 x 7,5 kW

2 x 7,5 kW

1 x 7,5 kW

VOLTMAX 27

92 124

130,1

6 x 6 kW

3 x 9 kW

2 x 9 kW

1 x 9 kW

VOLTMAX 30

102 360

144,5

8 x 5 kW

4 x 7,5 kW

3 x 7,5 kW

1 x 7,5 kW

VOLTMAX 36

122 832

173,4

8 x 6 kW

4 x 9 kW

3 x 9 kW

1 x 9 kW

VOLTMAX 41

139 892

198,7

5 x 5 kW + 5 x 6 kW

5 x 8,25 kW

4 x 8,25 kW

1 x 8,25 kW

VOLTMAX 45

153 540

216,8

10 x 6 kW

5 x 9 kW

4 x 9 kW

1 x 9 kW

VOLTMAX 50

49,5

168 894

238,4

6 x 5 kW + 6 x 6 kW

6 x 8,25 kW

5 x 8,25 kW

1 x 8,25 kW

VOLTMAX 54

184 248

260,1

12 x 6 kW

6 x 9 kW

5 x 9 kW

1 x 9 kW

Capacity

STG

Series

SCR Series

Model

BTU/h

Amps

Electrical

element(s) 240 V

Stage Relay

SCR

Stage

VOLTMAX 30

102 360

125

6 x 5 kW

3 x 10 kW

2 x 10 kW

1 x 10 kW

VOLTMAX 36

122 832

150

6 x 6 kW

3 x 12 kW

2 x 12 kW

1 x 12 kW

VOLTMAX 40

136 480

166,7

8 x 5 kW

4 x 10 kW

3 x 10 kW

1 x 10 kW

VOLTMAX 48

163 776

200

8 x 6 kW

4 x 12 kW

3 x 12 kW

1 x 12 kW

VOLTMAX 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

204 720

250

10 x 6 kW

5 x 12 kW

4 x 12 kW

1 x 12 kW

VOLTMAX 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

245 664

300

12 x 6 kW

6 x 12 kW

5 x 12 kW

1 x 12 kW

Puissance

STG Series

SCR Series

Model

BTU/h

Amps

Electrical

element(s)

240 V

Stage Relay

SCR Stage

VOLTMAX 23

22,5

76 770

62,6

6 x 5 kW

2 x 11,25 kW

1 x 11,25 kW

VOLTMAX 27

92 124

75,1

6 x 6 kW

2 x 13,5 kW

1 x 13,5 kW

VOLTMAX 34

116 008

93,9

9 x 5 kW

3 x 11,25 kW

2 x 11,25 kW

1 x 11,25 kW

VOLTMAX 41

40,5

138 186

112,6

9 x 6 kW

3 x 13,5 kW

2 x 13,5 kW

1 x 13,5 kW

VOLTMAX 45

153 540

125,1

12 x 5 kW

4 x 11,25 kW

3 x 11,25 kW

1 x 11,25 kW

VOLTMAX 54

184 248

150,2

12 x 6 kW

4 x 13,5 kW

3 x 13,5 kW

1 x 13,5 kW

VOLTMAX 56

191 072

156,4

15 x 5 kW

5 x 11,25 kW

4 x 11,25 kW

1 x 11,25 kW

VOLTMAX 68

67,5

230 310

187,7

15 x 6 kW

5 x 13,5 kW

4 x 13,5 kW

1 x 13,5 kW

SECTION 1 : TECHNICAL SPECIFICATIONS

Table 1: VOLTMAX 208 VAC / 60 Hz / Single-Phase1

Electrical supply 208 V - 1 phase (L1-L2) with 2 conductors 90°C with a ground.

Table 2: VOLTMAX 240 VAC / 60 Hz / 1 Phase1

Electrical supply 240 V - 1 phase (L1-L2) with 2 conductors 90°C with a ground.

Table 3 : VOLTMAX 208 VAC / 60 Hz / 3 Phase1

Electrical supply 208 V - 1 phase (L1-L2) with 2 conductors 90°C with a ground.

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 4.

Capacity

STG

Series

SCR Series

Model

BTU/h

Amps

Electrical

element(s) 240 V

Stage Relay

Model

VOLTMAX 30

102 360

6 x 5 kW

2 x 15 kW

1 x 15 kW

VOLTMAX 36

122 832

86,6

6 x 6 kW

2 x 18 kW

1 x 18 kW

VOLTMAX 45

153 540

108,3

9 x 5 kW

3 x 15 kW

2 x 15 kW

1 x 15 kW

VOLTMAX 54

184 248

129,9

9 x 6 kW

3 x 18 kW

2 x 18 kW

1 x 18 kW

VOLTMAX 60

204 720

144,3

12 x 5 kW

4 x 15 kW

3 x 15 kW

1 x 15 kW

VOLTMAX 72

245 664

173,2

12 x 6 kW

4 x 18 kW

3 x 18 kW

1 x 18 kW

VOLTMAX 75

255 900

180,4

15 x 5 kW

5 x 15 kW

4 x 15 kW

1 x 15 kW

Capacity

STG Series

SCR Series

Model

BTU/h

Amps

Electrical

element(s)

240 V

Stage Relay

Model

VOLTMAX 30

102 360

36,1

6 x 5 kW

2 x 15 kW

1 x 15 kW

VOLTMAX 36

122 832

43,3

6 x 6 kW

2 x 18 kW

1 x 18 kW

VOLTMAX 45

153 540

54,1

9 x 5 kW

3 x 15 kW

2 x 15 kW

1 x 15 kW

VOLTMAX 54

184 248

9 x 6 kW

3 x 18 kW

2 x 18 kW

1 x 18 kW

VOLTMAX 60

204 720

72,2

12 x 5 kW

4 x 15 kW

3 x 15 kW

1 x 18 kW

VOLTMAX 72

245 664

86,6

12 x 6 kW

4 x 18 kW

3 x 18 kW

1 x 18 kW

VOLTMAX 75

255 900

90,2

15 x 5 kW

5 x 15 kW

4 x 15 kW

1 x 15 kW

VOLTMAX 90

307 80

108,3

15 x 6 kW

5 x 18 kW

4 x 18 kW

1 x 18 kW

VOLTMAX 99

337 788

119,1

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

129,9

18 x 6 kW

3 x 36 kW

2 x 36 kW

1 x 36 kW

VOLTMAX 120

120

409 440

144,3

24 x 5 kW

4 x 30 kW

3 x 30 kW

1 x 30 kW

VOLTMAX 132

132

450 384

158,8

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

173,2

24 x 6 kW

4 x 36 kW

3 x 36 kW

1 x 36 kW

VOLTMAX 150

150

511 800

180,4

30 x 5 kW

5 x 30 kW

4 x 30 kW

1 x 30 kW

VOLTMAX 165

165

562 980

198,5

15 x 5 kW + 15 x 6 kW

5 x 33 kW

4 x 33 kW

1 x 33 kW

VOLTMAX 180

180

614 160

216,5

30 x 6 kW

5 x 36 kW

4 x 36 kW

1 x 36 kW

Table 4 : VOLTMAX 240 VAC / 60 Hz / 3 Phases1

Electrical supply 240 V - 1 phase (L1-L2) with 2 conductors 90°C with a ground.

Table 5 : VOLTMAX 480 VAC / 60 Hz / 3 Phases1

Electrical supply 480 V - 1 phase (L1-L2-L3) with 3 conductors 90°C with a ground.

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 5.

Capacity

STG Series

SCR Series

Model

BTU/h

Amps

Electrical

element(s)

240 V

Stage Relay

Model

VOLTMAX 30

102 360

28,9

6 x 5 kW

2 x 15 kW

1 x 15 kW

VOLTMAX 36

122 832

34,6

6 x 6 kW

2 x 18 kW

1 x 18 kW

VOLTMAX 45

153 540

43,3

9 x 5 kW

3 x 15 kW

2 x 15 kW

1 x 15 kW

VOLTMAX 54

184 248

9 x 6 kW

3 x 18 kW

2 x 18 kW

1 x 18 kW

VOLTMAX 60

204 720

57,7

12 x 5 kW

4 x 15 kW

3 x 15 kW

1 x 18 kW

VOLTMAX 72

245 664

69,3

12 x 6 kW

4 x 18 kW

3 x 18 kW

1 x 18 kW

VOLTMAX 75

255 900

72,2

15 x 5 kW

5 x 15 kW

4 x 15 kW

1 x 15 kW

VOLTMAX 90

307 80

86,6

15 x 6 kW

5 x 18 kW

4 x 18 kW

1 x 18 kW

VOLTMAX 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 kW

4 x 30 kW

1 x 30 kW

VOLTMAX 165

165

562 980

158,8

15 x 5 kW +

15 x 6 kW

5 x 33 kW

4 x 33 kW

1 x 33 kW

VOLTMAX 180

180

614 160

173,2

30 x 6 kW

5 x 36 kW

4 x 36 kW

1 x 36 kW

VOLTMAX

90 kW and less

More than 90 kW

Maximum operating pressure

30 PSI

60 PSI

Optional maximum operating pressure

70 PSI*

125 PSI

Table 6 : VOLTMAX 600 VAC / 60 Hz / 3 Phases1

Electrical supply 600 V - 1 phase (L1-L2-L3) with 3 conductors 90°C with a ground.

Tableau 7 : Maximal service pressure

* Model from 23 to 90 kW are available at a maximum operating pressure of 125 PSI, but size of the unit will be the same as model of more than 90 kW.

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 6.

BOILER CONNECTIONS

Boiler outlet

1 1/2" NPT M

Boiler inlet

1 1/2" NPT M

Pressure relief valve

3/4" NPT F

Drain valve

3/4" NPT F

Access to the 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

310lbs / 141kg

Water Volume

11 Us gal. / 41.6 liters

Max. operating

pressure

STANDARD: 30psi

OPTION: 70 PSI *

COMPONENTS IDENTIFICATION

Electrical main supply

Boiler controller

"On/Off" switch

D**

Disconnect switch & rotary handle

Fuses for controls

F***

Solid state SCR relay

G****

Low water cut-off, test button and indicator lights

Electrical control access door

Door handle for electric access with lock

Electrical control wires access holes

Access door power circuit

Access cover to Heating elements

Heating elements

BOILER DIMENSIONS AND CHARACTERISTIC: MODELS 90KW OR LESS

* Return sensor available with the " SCR SERIES " configuration. ** Optional disconnect switch available on " THREE-PHASE " models. *** Solid state SCR relay available with the " SCR SERIES " configuration. **** Low water cut-off is optional.

*Available at 125PSI (See Shop Drawing 99-180KW)

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 7.

BOILER CONNECTIONS

Boiler outlet

1 1/2" NPT M

Boiler inlet

1 1/2" NPT M

Pressure relief valve

3/4" NPT F

Drain valve

3/4" NPT F

Access to the 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

Electrical main supply

Boiler controller

"On/Off" switch

D**

Disconnect switch & rotary handle

Fuses for controls

F***

Solid state SCR relay

G****

Low water cut-off, test button and indicator lights

Electrical control access door

Door handle for electric access with lock

Electrical control wires access holes

Access door power circuit

Access cover to Heating elements

Heating elements

BOILER DIMENSIONS AND CHARACTERISTIC: MODELS 90KW TO 180KW

* Return sensor available with the " SCR Series " configuration. ** Optional disconnect switch *** Solid state SCR relay available with the " SCR Series " configuration. **** Low water cut-off is standard for models 120 kW and more.

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 8.

List of components shipped with the unit:

• Pressure relief valve

• Drain valve

• Outdoor temperature sensor ¸

(Located inside the control panel of the unit)

AVERTISSEMENT

WARNING

General Safety Precautions

Be sure to read and understand the entire Installation & operation manual before attempting to install or to operate this water heater. Pay 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

These important safeguards and instruction appearing in this manual are not meant to cover all possible conditions and situations that may occur. Common sense, caution and care are factors that 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 electric boiler must be installed in accordance with these instructions and in conformity with local codes, or in the absence of local codes, with the National Plumbing Code and the National Electric 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 RECEPTION

Inspect the electric boiler for possible shipping

damage. The manufacturer’s responsibility

ceases upon delivery of goods to the carrier in good condition. The Consignee must file any claims for damage, shortage in shipments, or non-delivery immediately against the carrier.

2.4 TO BE CHECKED

Please refer to the rating plate on the unit to ensure that you have the correct model and voltage in hand.

The electric boiler should not be installed where it may damage the adjacent structures or lower floors in the event of leakage of the tank or connections. If this cannot be avoided, install a nonflammable tray or bowl under the boiler to collect and drain water from leaks.

NOTE: Any tray or cuvette MUST conform to local codes.

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 9.

Sides**

3 inches / 76 mm

Bottom

0 inches / 0 mm

Top*

32 inches / 813 mm

Front

24 inches / 610 mm

Back

3 inches / 76 mm

MISE EN GARDE

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 boiler 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

Any commercial installation will be equipped with a safety valve that limits the maximum working pressure to the maximum design pressure of the tank. The maximum operating pressure of the VOLTMAX Boiler with a power of 90kW and less is 30 psi or 70 psi, depending on the options chosen. The maximum operating pressure of the VOLTMAX boiler with a power of more than 90kW is 60 psi or 125 psi, depending on the options selected. See boiler data sheet for maximum operating pressure.

The boiler is equipped with an automatic high limit temperature control set at 210°F (99°C) and a second manual high limit temperature settable.

This electric boiler is designed to operate at a maximum operating temperature of 200 ° F (93 ° C). The boiler is designed for use in a hot water heating system only.

The heat transfer fluid must be water or an antifreeze water / propylene glycol solution or an antifreeze water / ethylene glycol solution specially designed for heating systems. The maximum concentration of solution must be a maximum of 50%.

3.2 LOCATION

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 as from moving vehicles, flooding, etc.

The location must have sufficient ventilation to maintain an ambient temperature not exceeding 80°F (27°C).

To prevent condensation on the boiler walls, boiler temperature should not be maintained below the condensation temperature (dewpoint temperature) of the ambient. The operating temperature of the boiler must not be lower than the condensation temperature (dew temperature) relative to the ambient humidity content.

3.3 CLEARANCES

For adequate inspection and servicing the following minimum clearance is necessary:

Table 8 : Boiler Clearances

* A minimum clearance of 32 inches. For units equipped with 18 kW elements (25 in. For 15 kW elements) is required for possible replacement of heating elements.

** The left side of the control panel, where the boiler ON / OFF switch is located, must remain visible after installation. Otherwise, a label indicating its location must be affixed to the control panel indicating its position.

3.4 PIPING INSTALLATION

The location of the inlet and outlet piping shall conform to the various configurations shown in Figure 1. You will find typical connection diagrams to the Figure 3, Figure 4 and Figure 5.

The VOLTMAX boiler is designed to be operated on a closed circuit piping system. Therefore, it should not be used to heat open air tanks

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 10.

Figure 1 : Possible pipe flow configurations

3.4.1 BOILER PIPING CONNECTION

The boiler is equipped with two fittings on each side of the unit. One of the bottom connections must be used for the heating return (inlet) and one of the top connections must be used for supplying the heating system (outlet). The outlet and inlet size are 1½ "NPTM threaded steel pipes, for the VOLTMAX with a power of 90kW and less and 2½ "NPTM threaded steel pipes for the VOLTMAX with a power of More than 90kW.

Installation of plugs on the inlet and exhaust ducts is required to facilitate the disconnection and maintenance of the boiler.

When connecting different types of pipes (galvanized steel and copper), use dielectric joints (insulation) to protect the boiler and piping.

Use only new and clean pipes as piping connection to the boiler. Local codes or regulations may dictate the exact type of material to be used.

Insulate all piping containing hot water, especially in an unheated environment.

Install faucets for easy maintenance. Install a thermometer on the inlet and outlet

duct(s). Close the unused openings on the boiler. Do not

block the safety valve, this may cause loss, damage or injury.

3.4.2 AUXILIARY BOILER PIPING CONNECTION

When an auxiliary boiler used as back up is twinned to the VOLTMAX boiler to act as a backup 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 the boiler as indicated on its registration and identification plate. The valve must comply with the ASME Boiler and Pressure Vessel Code and limit the boiler maximum operating pressure. The safety valve is a security component, not a control component.

The capacity of the safety valve expressed in BTU / hour must equal or exceed the rating on the nameplate of the boiler (s).

A safety valve adjusted to the maximum design pressure of the boiler has been installed at the factory. The latter can be replaced by a valve with a lower trigger pressure, but its BTU / hour capacity must not be lower than the maximum boiler power.

Connect the exhaust of the safety valve to a drain line. The lower end of this conduit shall be at least 6" (15 cm) from the floor drain away from any electrical component. The drain line must be directed downwards from the exhaust of the safety valve to ensure complete drainage by gravity. The diameter of the drainpipe must not be less than that of the exhaust of the valve. The end of the conduit must not be threaded or hidden and must be protected from freezing. No

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 11.

valves, valves or valves shall be installed on the pipe. The installation of the safety valves is governed by the local code.

3.4.4 SYSTEM PRESSURE CONTROL AND EXPANSION TANK

Pressure control devices within the system ensure that each component operates within minimum and maximum allowable pressures and maintain minimum pressure for all normal operating temperatures. They also allow air bleeding, prevent cavitation at the pump inlet and prevent water from boiling within the system; all this is accomplished with minimal addition of new water.

The increase in boiler water volume resulting from higher temperature is stored in the expansion tank during periods of high operating temperature and is returned to the system when the temperature decreases.

The expansion tank must be able to store the required volume of boiler water during maximum design operating temperature without exceeding the maximum allowable operating pressure, and to maintain the required minimum pressure when the system is cold. Contact your installing contractor, plumbing supply house, or local plumbing inspector for assistance. The point where the expansion tank is connected should be carefully selected to avoid the possibility that normal operation of automatic check or manual valves will isolate the tank from a hot boiler or any part of the system.

The expansion tank should preferably be located on the suction or intake side of the pump.

3.4.5 WATER PRESSURE MAKEUP REGULATOR

Make-up systems must be employed as required by codes. An automatic fill valve (automatic pressure regulator) must be used with a backflow preventer as required, 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.

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 boiler.

Installation of manual or automatic air vents is required to eliminate all air from the boiler and the heating distribution system.

The main air eliminator must be installed near the outlet of the boiler on the highest point of the main supply piping. It is imperative to ensure that all air possibly located in the boiler be eliminated at all time.

Regularly purge air from the pipes and beware that the heated water does not cause injury or damage.

If the boiler is located at a location higher than the heat distribution system such as a heated floor, an automatic air eliminator should be installed close to the boiler outlet.

3.4.7 CIRCULATING PUMP

The pump capacity required is determined in relation to the capacity of the boiler installed and the type of heating distribution system on which it will be connected.

They are generally designed for an operation at a differential of temperature (Delta T0) of 10 to 20F between the supplies and return temperature to the boiler.

Use the following equation to determine the required water flow.

Pump flow rate = Boiler power ÷ Delta T ÷ 500

 Pump flow rate is expressed in US 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 loop to meet the heating load.

 Delta T: The boiler water temperature drop For example, an electric boiler rated at 180KW

has an output capacity of 614 160 BTU per hour. The system is designed for a temperature drop of 20°F.

Required pump flow rate = 614,160  20  500 = 61,4 GPM

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MODEL

DELTA T0

10oF

20oF

30oF

40oF

VOLTMAX 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

22.5

15.0

11.3

VOLTMAX 72

49.1

24.6

16.4

12.3

VOLTMAX 75

51.2

25.6

17.1

12.8

VOLTMAX 90

61.7

30.8

20.6

15.4

VOLTMAX 99

67.8

33.9

22.6

17.0

VOLTMAX 108

73.7

36.8

24.6

18.4

VOLTMAX 120

82.2

41.1

27.4

16.1

VOLTMAX 132

90.5

45.2

30.2

22.6

VOLTMAX 144

98.7

49.3

32.9

24.7

VOLTMAX 150

102.4

51.2

34.1

25.6

VOLTMAX 165

112.6

56.3

37.5

28.1

VOLTMAX 180

122.8

61.4

40.9

30.7

For example, an 180kW electric boiler has a power of 614,160 BTU/h. The system is designed for a drop-in temperature (Delta T) of 20°F.

Flow required = 614,160  20  500 = 61.4 GPM N.B. To achieve proper operation, a minimum

flow must be present when a heating request is applied and the heating elements are in operation. See the table below for the recommended minimum flow depending on the boiler output. Installation of a flow switch is not mandatory

The following table lists the required pump flow rate in relation to the boiler capacity and Delta T.

Table 9 : Temperature rise vs flow rate (GPM)

3.4.8 DRAIN FAUCET

A drain valve is installed behind the unit. It allows the boiler to be emptied, to make possible the replacement of defective components.

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 13.

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)

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VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 15.

Figure 3 : Basic installation

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Figure 4 : Basic installation with indirect water heater and radiator

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Figure 5 : Dual-Energy installation with a condensing boiler

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Figure 6 : Multiple boiler parallel installation

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Figure 7 : Basic installation with auxiliary boiler for production of domestic hot water and heating

3.5 ELECTRICAL CONNECTIONS

Wiring must be conform to the National Electrical Code and to state or local code requirements.

The electric boiler must be electrically grounded in accordance with local codes, or, in the absence of local codes, with the National Electrical Code.

3.5.1 MAIN ELECTRICAL SUPPLY

The power supply must be a 208 or 240-volt circuit (single-phase or three-phase, 60Hz), 480 volts (three-phase, 60 Hz) or 600 volts (threephase, 60 Hz) protected by an appropriately sized breaker.

Refer to the boiler rating plate to select the breaker capacity and wiring rating

3.5.2 PUMP SUPPLY

The VOLTMAX Electric boiler (SCR models) can control 1 or 2 pumps of the distribution system. According to the VOLTMAX configuration, the contact of the pump will function differently.

During a heat demand on W1 or W2, the contact between Pc and P1 or Pc and P2 will be used to start an external pump relay (maximum of 3 amps.). Depending on the configurations selected in the controller, the pump P2 can have priority over the pump P1.

N.B. The VOLTMAX boiler is not designed to heat without a water circulation in its tank. Therefore, if external pump controls are used, they must be interlocked with the operating authorization on W1or W2 of the controller.

3.5.3 CONNECTION OF EXTERNAL SIGNALS TO THE CONTROLLER

The connection of all external signals is made directly on the boiler controller on terminals located on top of it. See the connection diagram on Figure 8 and Figure 9.

Cables used for the connections shall resist temperature 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 the circulation pumps running.

On heating systems when water circulation is continuous, the heat demand control can be connected to the 24V+ and W1 terminals. The heating elements will then be active and available only when there is a request (dry contact).

If the heating system is designed to keep water warm with continuous circulation, a jumper (jumper) must be installed on the 24V+ and W1 terminals to maintain the boiler in demand. The boiler will then attempt to maintain the water temperature at the set-point.

Operation with an upper fixed set-point W2 can be established by connecting the auxiliary heating demand signal (Dry contact) of a thermostat to the 24V+ and W2 of the terminal block.

In all operating modes of the controller, a heat demand on W1 and W2/DHW (close contact) must be present to DI1 or DI2 to allow the operation of the boiler. The only exception is in domestic hot water mode (DHW) with an indirect water heater where the minimum boiler temperature shall be maintained.

3.5.3.2 Connecting au auxiliary boiler

(Available only on SCR models)

The boiler controller is designed to allow the operation of a second boiler or an auxiliary boiler according to two different mode of operation “Auxiliary Backup” or Dual-Energy”.

To do so, connect the TT terminals of the auxiliary boiler to terminals AUX of the VOLTMAX. The maximum capacity of this contact is 3A/120Vac.

See section 3.4.5 for details.

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 20.

3.5.3.3 Connection of an “Unoccupied signal”

of the building.

This function allows dropping the boiler temperature during periods where the building is not used and this without having to lower all the room thermostats of the building. To do so, a signal (dry contact) will have to be connected to terminal OCC. (SCR model only) The contact shall be close during the periods of temperature drop. You can also manage the periods of temperature drop by setting a schedule in the controller.

3.5.3.4 Connection of an indirect domestic

hot water heater

The VOLTMAX electric boiler can be used not only to fill the heating requirements of the building but also to fill its domestic hot water needs using an indirect domestic hot water heater such as our TURBOMAX series. To do so, connect the signal (dry contact) of indirect water heater temperature control to the terminal 24V+ and W2/DHW (SCR model only. This will activate the circulating pump supplying the water heater (if properly installed).

On STG models, the pumps can be controlled by an external pump controller with the same characteristics

3.5.3.5 Connection of a dual-energy signal

(SCR model only)

The VOLTMAX can be operated in a dual-energy mode with an auxiliary boiler.

To do so, connect the normally close contact of the dual energy controller to terminals 24V+ & BI-

E to operate with the electric boiler. See section

4.3.4.5 for more details on the sequence of

operation in dual energy.

3.5.3.6 Connection of an outdoor temperature

sensor

If you wish to modulate the boiler water temperature according to the outdoor temperature (Outdoor Reset, ORST) and also wish to stop the operation of the boiler when the outdoor temp. reaches a selected value, then the outdoor 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 not used.

Outdoor sensor location

o Outside the building at a location that best

represents the heat demand of the building (a wall facing north for most of the buildings and on a south one on buildings with large windows facing south).

o It should not be exposed to external heat

sources (dryer outlet, window openings, noninsulated walls).

o It should not be installed in a location where it

could be covered with snow.

3.5.3.7 Remote controller used to determine the target boiler temperature (SCR model only)

An external controller (such as a central building energy management system) can be used to determine the boiler target temperature required for the building. To do so, the external controller shall give a 0 to 10VDC signal connected to terminals 0-10Vdc G & 0-10Vdc T° of the controller.

3.5.3.8 Limit Capacity 0-10VDC (SCR model only)

An external controller providing a 0-10Vdc signal could be used to manage the capacity (kW) of the boiler. Example: An application where the main electrical service supply of the building is limited or when the electricity rate is billed according to the maximum peak loads of the building. To do so, the external controller shall be connected to terminals 0-10Vdc G & 0-10V cap. The capacity of the boiler could be manually limited by adjusting some of the controller parameters. See

section 4.3.4 for more details.

3.5.3.9 External alarm contact (SCR model only)

An alarm signal (dry contact) is available on the boiler to advise the user of an alarm situation. The capacity of the contact is 3A resistive/1A inductive on terminal AL/AL.

An internal audible alarm inside the controller is available on all models. Just activate it in the settings.

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VOLTMAX ELECTRIC BOILER Installation 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)

Heating request 1 : On

Heating request 2 : On

Pump 1 : On

Pump 2 : On

BIE

Boiler in Bi-Energy mode

VOLTMAX Boiler : On

Auxiliary boiler : On

Boost mode : On

Warm Weather Shut Down : On

An alarm is active

The boiler is in lock out mode

High temperature limit condition at the boiler outlet

Low temperature limit conditions (lack of capacity)

Alarm due to a pressure problem

Alarm due to an electrical problem

Alarm due to a flow problem

Alarm due to a sensor problem

T° SETPOINT

Actual set-point temperature

T° BOILER

Water temperature at the outlet of the boiler

CAP (%)

Percentage of power used according to boiler rated power

T° EXT

Outdoor temperature measured using the outdoor sensor

KW ACT

Actual power calculated by the boiler

PRESS.

Pressure inside the boiler

STAGE

Status of active stage

SECTION 4 : CONTROLLER OPERATION

4.1 USER INTERFACE

The control of the boiler is ensured by a controller TM171PFE03 of the company Schneider Electric. The LCD display of the controller provides an interface for configuring and displaying the boiler parameters.

A communication module also allows you to integrate the controller with an intelligent building management system (BACnet protocol). It is also equipped with an Ethernet connection. Allowing the connection to the Internet network of the building allowing to read and modify locally or remotely the boiler setting. It can be configured to send alarm messages via e-mail.

Icons will also display to indicate the boiler’s current operating status. Temperature can be displayed in Celsius or Fahrenheit and text can be set to either English or French.

The controller has a backlight function. It is also equipped with three indicator lights (Green / Yellow / Red). The green light indicates normal operation of the unit; the yellow light indicates that the controller has diagnosed and anomaly which requires verification by a technician. The red light 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.

Boiler operating mode

Alarm symbol

Operating state of the boiler

Figure 10 : Illustration of the display

4.1.1 SYMBOL DESCRIPTION

The main display shows most the boiler operation status information. The explanation of the main display is shown below.

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 23.

2 3 4

4.1.2 CONTROL PANEL

Figure 11 : Control panel

On the left side of the appliance, an on / off switch (# 3) is used to operate the appliance and to reset the boiler.

An indicator light showing the status of the low water level cut off and a test button (# 1) is standard for models 120 kW and above. The control circuit fuses (# 2) are accessible from the left side of the unit.

4.1.3 NAVIGATION AND ADJUSTEMENTS

The 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 to edit a parameter. Only highlighted box can be modified. To modify an option, select the box to modify with the arrow keys and press OK. The black box or one of its values will flash and can be changed. Change the values using the arrows and confirm the change by pressing OK.

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 24.

4.1.4 MAIN MENU NAVIGATION

Press one of the 5 buttons on the main display to access the main menu

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 25.

Figure 12 : Main menu navigation

4.1.5 NAVIGATION IN BOILER SETTING

Figure 13 : Navigation in boiler setting menu (1/3)

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 26.

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)

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 27.

Figure 15 : Navigation in boiler setting menu (3/3)

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 28.

Contents

Boiler status

Detailed information on the boiler condition

Boiler setting

Configuration of the boiler operating mode and parameters.

User setting

Configuration of the controller display option

Clock setting

Configuration of the internal clock

Consumption

Power consumption of the boiler

Parameters

Description

Language

Select English or French version

Temperature unit

Select the temperature units, either Celsius (C) or Fahrenheit (F)

Flow unit

Select the flow unit, either US gallons per minute (USgpm) or liters per second (L / sec)

Backlight

Setting the backlight mode:

- Off

- 30 secondes

- Always On

Internal buzzer

Setting of the internal buzzer

4.2 MAIN MENU

The main menu is accessible to the user, no access code is required. The main menu is accessed by pressing one of the 5 pushbuttons. Navigation between menu is done with the arrows (up, down, left and right).

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 access code gives access to advanced operating parameters that are not accessible to the installer and the user.

4.2.3 USER SETTING

Configuration of the controller display option

This menu allows the modification of different display parameters.

4.2.1 BOILER STATUS

Detailed information on the boiler condition

This menu allows the display of data not included in the main display. The boiler status menu display the measurements of temperature, 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

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 29.

HEATING

MODE W1

Boiler heating mode W1 configuration according to the type of application

HEATING

MODE

W2/DHW

Boiler heating mode W2 or DHW configuration according to the type of application

PUMP

SETTING

Pump contact configurations

CAPACITY

LIMITING

Capacity limiting mode configuration

AUXILIARY

BOILER

Auxiliary boiler mode configuration (if needed)

4.2.4 CLOCK SETTING

Internal clock configuration

Use this menu to adjust the controller’s internal clock. To set the clock correctly, you must adjust the time, minutes, and date.

This adjustment is necessary in order for these modes to function properly:

- The boiler’s power consumption

- Limiting the boiler’s power capacity according to a schedule

- The boiler’s occupation mode Battery life for the clock is at least 1 year when

the controller is unpowered (at 25°C). N.B. The date and day of the week must be set

correctly to ensure the controller automatically changes to daylight savings time.

4.2.5 CONSUMPTION

Boiler consumption cycle 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 consumption values are approximate and should not be used as a comparison with actual consumption data charged by the electricity distributor.

4.3 BOILER SETTINGS

In order to be able to configure the boiler, it is necessary to authenticate yourself with an installer or manufacturer code.

The default "Installer" access code is

1111 and can be changed in the

Change password menu.

This menu allows visualization of the boiler power consumption report. First, you must activate the beginning of the consumption cycle with the Start key. The consumption report can be saved using the Save 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.

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 30.

LIMIT SETTING

Configuration of the boiler operating limits

ALARM

Configuration of the alarms

COMMUNICATION

Configuration of the boiler communication parameter (Web, Email, Bacnet)

OCCUPATION

Configuration of the occupation parameter mode

MODE BOOST

Enable Boost mode

WARM WEATHER

SHUTD.

Enable warm weather shut-down function

CHANGE

PASSWORD

Changing the Installer password

FIXED

Fixed boiler set-point

DDC 010 VDC

Modulation of the boiler set-point using a 0-10VDC signal

OUTD RESET

Modulation of the boiler set-point using the outdoor temperature

STOP

No heating demand on W1

4.3.1 HEATING MODE W1 Selection of the operating mode

In this menu you must select an operating mode for selecting the desired setpoint temperature depending on the application. A heat demand or a demand must be present on W1 and/or W2/DHW so that the boiler can heat up. 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:

4.3.1.1 Fixe

This mode is used for an installation where it is desired to have a fixed set-point temperature. If the boiler is thermostat-controlled with a heat demand signal on W1, the boiler uses the

corresponding set-point (T. Set-point W1) as the 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 010VDC 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 reset

This operating mode makes it possible to modulate the boiler output set-point temperature as a function of the outdoor temperature. The outdoor temperature signal comes from the temperature sensor supplied with the boiler, which will be connected to the boiler controller.

The details of the parameters are presented in

Section 4.6.2 .

4.3.1.4 Stop

Select this mode to stop the boiler. The heating elements will not operate on a W1 demand.

4.3.2 HEATING MODE W2/DHW

This mode allows you to configure a second heating demand (W2) or a demand from an indirect domestic water heater (DHW). Select none if none of these functions are used. These modes are presented in detail in Section

4.7.

This mode allows the W2-DHW input to be used to receive a signal (dry contact) from a 2nd stage of heating. When the contact on W2-DHW closes, the setpoint temperature changes to the set value (T. Set-point W2), even if there is no demand on W1.

DHW

This mode allows you to configure the demand for an indirect domestic water heater. When the DHW mode is selected, the boiler is kept at a minimum temperature (T. Min Boiler) and when contact W2 closes (Dry contact) the set-point rises to T. DHW Set-point. In addition, the PID curve is more aggressive.

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 31.

On W1 Dem.

Contact of pump 1 is activated only when there is a demand on W1.

On W2 Dem.

Contact of pump 2 is activated only when there is a demand in W2.

Priority over P1

When there is a request on W2, contact of pump 2 is activated and contact of pump 1 is deactivated.

Always On

The selected pump is always on (contact is always on).

Stop

The selected pump is always deactivated (contact is always off).

Off Delay

The delay in seconds before the contact of the pump is deactivated.

4.3.3 PUMP SETTING

Configuring pump contact activation (Available only on SCR model)

The system allows the control of up to two pumps. Each of these pumps can be activated using a contact. Each pump can be activated according to different modes.

If the amperage of each of the pumps exceeds

3A, external pump relays must be used.

Pump Configuration Options

N.B. External pump relays can also be used as

an alternative to the boiler pump controller. If this alternative is used, a dry contact of this controller must be connected to W1 or / and W2 to allow the 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 to disconnect one of

the power relays inside the VOLTMAX boiler to accomplish this function.

N.B: On the STG models, the maximum power chosen must correspond to the power of the stages of the boiler since there is no power modulation relay on these models.

4.3.4.1 NONE

The boiler is not limited in power, the maximum power it can deliver is equivalent to its maximum rated power.

4.3.4.2 MANUAL

The maximum capacity permitted of the boiler is configured in a fixed mode.

Details of the variables in this mode are presented in Section 4.9.1

4.3.4.3 DCC 0-10 VDC

(Available only on SCR model)

A 0-10 VDC signal from a building management system can be used. The signal is treated as a function in order to limit the maximum power. In order to configure this mode, you must connect the 0-10 VDC signal to the terminal block 0-10Vdc Cap. and 0-10Vdc G.

Details of the variables in this mode are presented in Section 4.9.2

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 32.

None

No auxiliary boiler is present

Backup Aux.

This mode allows the adjustment of a second boiler to play a Backup role

Ext Contact

Select the heating source using electrical contact to the BI-E terminal.

BiE (BI-

Energy)

Select the heating source using electrical contact to the BI-E terminal

with the possibility of support mode of the auxiliary boiler.

Manual

Manually select the system operation mode (Electrical or Auxiliary).

4.3.4.4 T. EXT

The maximum permitted power can be adjusted according to the outside temperature sensor. The outdoor temperature is used in order to limit the maximum authorized power.

Details of the variables in this mode are presented in Section 4.9.3 .

This mode of operation is particularly advantageous in applications where the boiler is connected to an electrical network taking account of demand peaks in order to determine the cost of use (demand meter). Since the boiler will thus be limited to a maximum power which will have to be established as a function of the heating requirements of the building and the outside temperature, it will thus be possible to avoid peaks of power not required to satisfy the heating needs in periods of cold weather.

4.3.4.5 Schedule

The maximum authorized boiler power can be programmed according to a schedule. See section 4.9.4 for an explanation of how to modify a schedule.

4.3.5 AUXILIARY BOILER (Available only on SCR model)

The controller program has been designed to allow the operation of a second boiler or auxiliary boilier.

4.3.5.1 Select setpoint source for Auxiliary Boiler

The source of the set-point temperature control can be configured by selecting STPT source Aux. consequently.

In the Internal mode, the terminal contact Aux closes when there is a request for W1 or W2/DHW and the VOLTMAX output temperature is below the setpoint temperature. In addition, the Aux contact is opened when the output

temperature is higher 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:

N.B. The auxiliary boiler can only be switched on when a heat demand is present on W1 or / and W2 / DHW.

4.3.5.2 None

This mode must be active when there is no auxiliary boiler on the hydronic heating system.

4.3.5.3 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 compensate. The lack of capacity is defined by the fact that the boiler output temperature is less than X degrees (Delta T. Start Aux.) relative to the setpoint for duration of X min. (Auxiliary Start Delay). The auxiliary boiler will be deactivated when the temperature differential between the water outlet temperature and the set-point temperature is lower than Delta T. Off Aux. The calculation of the delay begins only when the electric boiler reaches its maximum power (or maximum power allowed).

The value of "Delta T." should be a negative value.

Details of the variables in this mode are presented in Section 4.10.1

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 33.

An alarm is active

The boiler is in lock mode

The high limit temperature has been reached

Low limit (Lack of capacity)

Pressure problem alarm

Electrical problem alarm

Flow problem alarm

Sensor problem alarm

4.3.5.4 Contact Ext.

This configuration mode makes it possible to operate the electric boiler or the auxiliary boiler according to a contact. During a close contact at

the BI-E terminals, the electric boiler ( ) is activated. When the contact is open, the

auxiliary boiler ( ) will be on. The auxiliary boiler will not be allowed to operate if the electric boiler lacks capacity. Details of the variables in this mode are presented in Section 0

4.3.5.5 BiE (BI-Energy)

The Bi-Energy mode allows the auxiliary boiler to operate when there is a lack of capacity.

Upon receipt of an electrical signal (contact closed at Bi-E) and a request at the terminal of W1 or W2, the contact at the terminal of AUX

will be opened and thus the electric boiler ( ) is allowed to operate and the auxiliary boiler is deactivated.

When an electrical signal is absent (contact open at Bi-E) and a request is present at the terminals of W1 or W2, the contact will close at the terminal of AUX, in order to operate the

boiler Auxiliary ( ) and not the electric boiler. Details 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 configuration options are presented in detail in Section 4.11.

4.3.7 ALARM

Alarm Mode Configuration

When an alarm is active, it will be displayed on the main display as a symbol.

Ex: If P and Se are displayed at the same time, this indicates a pressure sensor problem

A summary of active alarms is also available in the Boiler status menu. An alarm report is available under the Alarm log menu. Information about date, time and alarm code is available in this menu. The internal clock must be adjusted beforehand so that the alarm registers correctly. Section 6 - Troubleshooting details alarm codes and settings specific to this menu.

Details about this menu’s operation are available

in Section 4.12

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 34.

Address IP

10.0.0.100

User

administrator

Password

password

IP address

192.168.0.1

User

admin

Password

admin

4.3.8 COMMUNICATION

The boiler controller can be connected via an Ethernet network communication port and using a RS485 (BACnet)l. The boiler web portal can be accessed in a variety of ways. You will be able to modify the parameters remotely on a web portal and to visualize the boiler status.

Direct connection between the controller and a computer.

1. Connect the boiler controller to your local network or directly to your computer in an internet port using an RJ45 network cable. The communication port is located on the back of the controller. Refer to the wiring diagram, if you have any questions.

2. Open the Network and sharing center, then Change adapter setting on a windows operating system. Open the Local area

connection properties, then Internet Protocole Version 4 (TCP/IPv4).

3. Replace the parameters by those show on the following figure.

4. Open a web browser and enter the IP address (available in the Communication

menu / Ethernet) of the controller in the web address bar.

5. Enter your username and password.

Default

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 TPLINK model TL-WR810N.

1. Plug the router into an electrical outlet.

2. Connect the network cable to the RJ45 socket on the controller and the LAN / WAN jack on the router.

3. Use a computer to connect to the wireless network generated by TL-WR810N. (by default).

4. Open a web browser and your wireless

network’s web configuration page at

http://tplinkwifi.net, or use the router’s default address.

Default

Remote connection using a network connection

1. Enter a compatible IP address and subnet mask compatible with the network you want to connect to. Note: Select a free IP address that is compatible with the network (pay attention to the IP addresses of printers and other modules.)

2. Restart the controller to apply the

changes.

3. Plug the network cable into the controller and into an Ethernet port (wall outlet or directly into the router)

4. Open a web browser and enter the previously selected IP address.

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 35.

4.3.8.1 BACnet

The BACnet menu allows you to view the configuration and change the BACnet parameters. In order to configure the VOLTMAX boiler to your BACnet management system, you must activate the function.

You must then enter the correct baud rate. Ex: For a BACnet MS / TP communication protocol with a Metasys system the default baud rate is

38400. You must enter the correct MS / TP address. Ex : For a BACnet MS / TP communication with a Metasys system, the address is 5.

The names of the BACnet variables used by the program are listed in the tables below. Variables beginning with AV and BV are read variables, while variables beginning with "W" are editable.

For more information on the BACnet protocol, please refer to the appropriate documentation.

4.3.9 OCCUPATION

Setting the temperature-lowering period.

Ex: When the contact (switch) is open at the OCC terminal, then the boiler will be in temperature-lowering mode. (Night mode) When the contact (switch) is closed, it will be in normal occupancy mode (Day mode).

Force is used to force the boiler to operate normally (day mode).

A weekly schedule can be programmed under the Schedule setting to modify the occupation hours of the building.

4.3.9.2 SCHEDULE CONFIGURATION

Changing a Schedule

Use this menu to configure the building’s

occupation schedule. The schedule works on a weekly schedule (Monday - Sunday) and allow only 1 lowering Set point periods. The first hour represents the start of the occupancy period and the second hour represents the innocupancy periods.

4.3.9.1 Occupation setting

This function allows the boiler water temperature to be lowered for defined periods without having to lower all the thermostats of the building. This function can be activated 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) 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: In the case currently displayed between 07:00 and 17:59, the set-point temperature will not be affected. On the other hand, from 18:00 to 06:59, the set temperature will be lowered.

When the building is not occupied for a full day, you must enter this information as follows, so that the stpt stay in the lowering mode.

4.3.10 BOOST MODE

Enable Boost Mode

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 36.

This mode operates with the Fixed Set-point and Outdoor reset mode. This menu allows the Boost mode to be activated, this mode increase the set-point temperature when the heating load of the building exceeds the capacity generated by the current water temperature determined by the boiler. This mode is activated after a period of 30 min if the heat demand is maintained for 30 consecutive minutes on W1. After this period, the set temperature will start to rise until a predetermined maximum temperature is reached depending on the heating mode until the demand is filled. This temperature increase is temporary and has a maximum duration of 120 minutes or when the request is terminated on W1.

N.B. The BOOST mode is particularly interesting for applications such as: o Applications with a programmable thermostat

with automatic lowering of the building temperature.

o Return to normal heat demand after a

prolonged period of sunshine where there have been no long-term demands and, therefore, heating floors will take a long time to provide heat at d Normal water.

4.3.11 WARM WEATHER SHUTDOWN Shuts down the boiler when the outside temperature reaches an established 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.

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 when the boiler is properly connected to an internet or Ethernet network. The various setting parameters and the protocol for connecting the boiler to a network are available in the Communication menu and Section

4.3.8.

4.4.1 WEBSITE

In order to access the boiler remotely via the internet, the boiler controller must be correctly connected.

The web portal has 3 main menus, the User, Installer and Manufacturer menu. The structure of the web portal is the same as the controller; please refer to the previous sections, if you have any questions.

Ex: The user can obtain information concerning the boiler status, in the menu Operations /

N.B. The password to acces the installater section of the website is 1111. He is independent of the boiler password.

4.4.2 EMAIL

In order to configure the alarm by e-mail, you must:

1. You must first ensure that you enter the correct information in the controller (depending on your network) under the following options:

a. IP address

You must restart the device for the changes to take place.

2. Access the Boiler Web Portal.

3. Click on the Installer / Communication

b. Default Gateway c. Subnet mask d. Primary DNS e. Secondary DNS

menu.

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 37.

4. Enter your e-mail under Recipient. You can

also use your own mail server by entering the necessary data.

5. Then select the types of alarms you want to receive by e-mail.

If you want to send alarms to different e-mail addresses, simply enter a list of e-mails.

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, do not accept unencrypted communications. In order to work around the problem, there are relay services such as SMTP2GO: https://www.smtp2go.com, to relay between controller communication and your messaging system. This service is free for up to 1000 emails per month.

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 38.

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 39.

4.5 BOILER STATUS DISPLAY SETTINGS

Display

Description

BACnet Variable

BACnet Description

T. Set point

The set-point temperature of the boiler. The boiler will activate its elements accordingly in order to modulate its water outlet temperature.

AV_TSet-point

---

T. Out Boiler

The temperature at the outlet of the VOLTMAX boiler.

AV_BoilerTOut

---

T. In Boiler

The temperature at the inlet of the VOLTMAX boiler. This sensor is only available on SCR models.

AV_BoilerTIn

---

T. Outdoor

This variable allows the outdoor temperature to be displayed in real time when the outdoor temperature sensor is correctly connected.

AV_OutdoorT

---

Boiler Pressure

This variable allows the reading of the pressure sensor inside the boiler.

AV_SensorPressureSignal

---

Actual power

The actual power used in kilowatt

AV_ActualPower

---

% max authorized power

The maximum permissible power as a percentage 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_HeatingW1

0 = No W1 demand 1 = W1 demand

Demand W2/DHW

When requesting heating on W2 or DHW, allowing the operation of the heating elements.

BV_HeatingW2

0 = No W2 demand 1 = W2 demand

Pump W1

During a closed contact of the terminal block of the pump 1

BV_ContactPump1

0 = Pump 1 open contact 1 = Pump 1 closed contact

Pump W2/DHW

During a closed contact of the terminal block of the pump 2

BV_ContactPump2

0 = Pump 2 open contact 1 = Pump 2 closed contact

Flow

The theoretical flow calculated according to the power used, T. Out Boiler and T. In BoilerT. Available on SCR models only.

AV_WaterFlow

---

SCR Modulation %

Percentages of the SCR relay utilisation. (For SCR model only)

AV_ModSCR

Stage #1

Operation of stage #1 (For STG model only)

BV_RelStage1

0 = Stage 1 not working

VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 40.

1 = Operation of stage 1

Stage #2

Operation of stage #2

BV_RelStage2

0 = Stage 2 not working 1 = Operation of stage 2

Stage #3

Operation of stage #3

BV_RelStage3

0 = Stage 3 not working 1 = Operation of stage 3

Stage #4

Operation of stage #4

BV_RelStage4

0 = Stage 4 not working 1 = Operation of stage 4

Stage #5

Operation of stage #5

BV_RelStage5

0 = Stage 5 not working 1 = Operation of stage 5

Stage #6

Operation of stage #6

BV_RelStage6

0 = Stage 6 not working 1 = Operation of stage 6

Alarm HL/LWCO Alarm

Alarm triggered because of a high limit and low water level manual alarm.

BV_StatusAlarmHL/LW