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THERMO 2000
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VOLTMAX 40

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

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1
VOLTMAX Electric Boiler
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
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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
kW
BTU/h
Amps
Electrical
element(s) 240 V
Stage Relay
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
27
92 124
130,1
6 x 6 kW
3 x 9 kW
2 x 9 kW
1 x 9 kW
VOLTMAX 30
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
36
122 832
173,4
8 x 6 kW
4 x 9 kW
3 x 9 kW
1 x 9 kW
VOLTMAX 41
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
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
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
kW
BTU/h
Amps
Electrical
element(s) 240 V
Stage Relay
Stage Relay
SCR
Stage
VOLTMAX 30
30
102 360
125
6 x 5 kW
3 x 10 kW
2 x 10 kW
1 x 10 kW
VOLTMAX 36
36
122 832
150
6 x 6 kW
3 x 12 kW
2 x 12 kW
1 x 12 kW
VOLTMAX 40
40
136 480
166,7
8 x 5 kW
4 x 10 kW
3 x 10 kW
1 x 10 kW
VOLTMAX 48
48
163 776
200
8 x 6 kW
4 x 12 kW
3 x 12 kW
1 x 12 kW
VOLTMAX 55
55
187 660
229,2
5 x 5 kW + 5 x 6 kW
5 x 11 kW
4 x 11 kW
1 x 11 kW
VOLTMAX 60
60
204 720
250
10 x 6 kW
5 x 12 kW
4 x 12 kW
1 x 12 kW
VOLTMAX 66
66
225 192
275
6 x 5 kW + 6 x 6 kW
6 x 11 kW
5 x 11 kW
1 x 11 kW
VOLTMAX 72
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
kW
BTU/h
Amps
Electrical
element(s)
240 V
Stage Relay
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
1 x 11,25 kW
VOLTMAX 27
27
92 124
75,1
6 x 6 kW
2 x 13,5 kW
1 x 13,5 kW
1 x 13,5 kW
VOLTMAX 34
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
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
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
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
1
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
1
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
1
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
kW
BTU/h
Amps
Electrical
element(s) 240 V
Stage Relay
Model
kW
VOLTMAX 30
30
102 360
72
6 x 5 kW
2 x 15 kW
1 x 15 kW
1 x 15 kW
VOLTMAX 36
36
122 832
86,6
6 x 6 kW
2 x 18 kW
1 x 18 kW
1 x 18 kW
VOLTMAX 45
45
153 540
108,3
9 x 5 kW
3 x 15 kW
2 x 15 kW
1 x 15 kW
VOLTMAX 54
54
184 248
129,9
9 x 6 kW
3 x 18 kW
2 x 18 kW
1 x 18 kW
VOLTMAX 60
60
204 720
144,3
12 x 5 kW
4 x 15 kW
3 x 15 kW
1 x 15 kW
VOLTMAX 72
72
245 664
173,2
12 x 6 kW
4 x 18 kW
3 x 18 kW
1 x 18 kW
VOLTMAX 75
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
kW
BTU/h
Amps
Electrical
element(s)
240 V
Stage Relay
Model
kW
VOLTMAX 30
30
102 360
36,1
6 x 5 kW
2 x 15 kW
1 x 15 kW
1 x 15 kW
VOLTMAX 36
36
122 832
43,3
6 x 6 kW
2 x 18 kW
1 x 18 kW
1 x 18 kW
VOLTMAX 45
45
153 540
54,1
9 x 5 kW
3 x 15 kW
2 x 15 kW
1 x 15 kW
VOLTMAX 54
54
184 248
65
9 x 6 kW
3 x 18 kW
2 x 18 kW
1 x 18 kW
VOLTMAX 60
60
204 720
72,2
12 x 5 kW
4 x 15 kW
3 x 15 kW
1 x 18 kW
VOLTMAX 72
72
245 664
86,6
12 x 6 kW
4 x 18 kW
3 x 18 kW
1 x 18 kW
VOLTMAX 75
75
255 900
90,2
15 x 5 kW
5 x 15 kW
4 x 15 kW
1 x 15 kW
VOLTMAX 90
90
307 80
108,3
15 x 6 kW
5 x 18 kW
4 x 18 kW
1 x 18 kW
VOLTMAX 99
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
1
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
1
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
kW
BTU/h
Amps
Electrical
element(s)
240 V
Stage Relay
Model
kW
VOLTMAX 30
30
102 360
28,9
6 x 5 kW
2 x 15 kW
1 x 15 kW
1 x 15 kW
VOLTMAX 36
36
122 832
34,6
6 x 6 kW
2 x 18 kW
1 x 18 kW
1 x 18 kW
VOLTMAX 45
45
153 540
43,3
9 x 5 kW
3 x 15 kW
2 x 15 kW
1 x 15 kW
VOLTMAX 54
54
184 248
52
9 x 6 kW
3 x 18 kW
2 x 18 kW
1 x 18 kW
VOLTMAX 60
60
204 720
57,7
12 x 5 kW
4 x 15 kW
3 x 15 kW
1 x 18 kW
VOLTMAX 72
72
245 664
69,3
12 x 6 kW
4 x 18 kW
3 x 18 kW
1 x 18 kW
VOLTMAX 75
75
255 900
72,2
15 x 5 kW
5 x 15 kW
4 x 15 kW
1 x 15 kW
VOLTMAX 90
90
307 80
86,6
15 x 6 kW
5 x 18 kW
4 x 18 kW
1 x 18 kW
VOLTMAX 99
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
1
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
1
Boiler outlet
1 1/2" NPT M
2
Boiler inlet
1 1/2" NPT M
3
Pressure relief valve
3/4" NPT F
4
Drain valve
3/4" NPT F
5*
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
A
Electrical main supply
B
Boiler controller
C
"On/Off" switch
D**
Disconnect switch & rotary handle
E
Fuses for controls
F***
Solid state SCR relay
G****
Low water cut-off, test button and indicator lights
H
Electrical control access door
I
Door handle for electric access with lock
J
Electrical control wires access holes
K
Access door power circuit
L
Access cover to Heating elements
M
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
1
Boiler outlet
1 1/2" NPT M
2
Boiler inlet
1 1/2" NPT M
3
Pressure relief valve
3/4" NPT F
4
Drain valve
3/4" NPT F
5*
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
A
Electrical main supply
B
Boiler controller
C
"On/Off" switch
D**
Disconnect switch & rotary handle
E
Fuses for controls
F***
Solid state SCR relay
G****
Low water cut-off, test button and indicator lights
H
Electrical control access door
I
Door handle for electric access with lock
J
Electrical control wires access holes
K
Access door power circuit
L
Access cover to Heating elements
M
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
VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 12.
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)
VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 14.
VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 15.
Figure 3 : Basic installation
VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 16.
Figure 4 : Basic installation with indirect water heater and radiator
VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 17.
Figure 5 : Dual-Energy installation with a condensing boiler
VOLTMAX ELECTRIC BOILER Installation and Operation Manual (Revised August 2017), Page 18.
Figure 6 : Multiple boiler parallel installation
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