THERMO 2000 VOLTMAX 23 Installation And Operation Manual
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THERMO 2000 VOLTMAX 23 Installation And Operation Manual

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VOLTMAX
Electric Boiler
INSTALLATION AND OPERATION MANUAL
mo
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
1

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Summary of Contents for THERMO 2000 VOLTMAX 23

  • Page 1 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...

  • Page 2: Table Of Contents

    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 ......................
  • Page 3 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 ............

  • Page 4: Section 1 : Technical Specifications

    Series Electrical Stage Stage Model BTU/h Amps element(s) 240 V Relay Relay 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...
  • Page 5 Table 4 : VOLTMAX 240 VAC / 60 Hz / 3 Phases Capacity SCR Series Series Electrical Stage Model BTU/h Amps Model element(s) 240 V Relay VOLTMAX 30 102 360 6 x 5 kW 2 x 15 kW 1 x 15 kW 1 x 15 kW VOLTMAX 36 122 832...
  • Page 6 Table 6 : VOLTMAX 600 VAC / 60 Hz / 3 Phases Capacity STG Series SCR Series Electrical Model BTU/h Amps element(s) Stage Relay Model 240 V VOLTMAX 30 102 360 28,9 6 x 5 kW 2 x 15 kW 1 x 15 kW 1 x 15 kW VOLTMAX 36...
  • Page 7 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.
  • Page 8 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. BOILER CONNECTIONS Boiler outlet 1 1/2"...

  • Page 9: Section 2 : Introduction

    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.

  • Page 10: Section 3 : Installation

    SECTION 3 : INSTALLATION MISE EN GARDE 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.

  • Page 11: Boiler Piping Connection

    Figure 1 : Possible pipe flow configurations 3.4.1 BOILER PIPING CONNECTION 3.4.2 AUXILIARY BOILER PIPING The boiler is equipped with two fittings on each CONNECTION side of the unit. One of the bottom connections When an auxiliary boiler used as back up is must be used for the heating return (inlet) and twinned to the VOLTMAX boiler to act as a back- one of the top connections must be used for...

  • Page 12: System Pressure Control And Expansion Tank

    valves, valves or valves shall be installed on the 3.4.6 AIR BLEEDER pipe. The installation of the safety valves is The air contained in the heated water must be governed by the local code. removed from the system to allow the proper functioning of the heating system and the boiler.

  • Page 13: Drain Faucet

    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) DELTA T MODEL VOLTMAX 23 15.7 18.4 VOLTMAX 20.5 10.2 VOLTMAX 24.6 12.3...

  • Page 14: Pressure Loss

    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 ( , Page Revised August 2017)
  • Page 15 Figure 3 : Basic installation VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised August 2017)
  • Page 16 Figure 4 : Basic installation with indirect water heater and radiator VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised August 2017)
  • Page 17 Figure 5 : Dual-Energy installation with a condensing boiler VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised August 2017)
  • Page 18 Figure 6 : Multiple boiler parallel installation VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised August 2017)
  • Page 19 Figure 7 : Basic installation with auxiliary boiler for production of domestic hot water and heating VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised August 2017)

  • Page 20: Electrical Connections

    3.5 ELECTRICAL CONNECTIONS 3.5.3.1 Connecting the building heat demand signal Wiring must be conform to the National Electrical Upon reception of a closed contact connected to Code and to state or local code requirements. terminals 24V+ and W1 or W2, the corresponding circulating pump P1 or P2 will start and the boiler The electric boiler must be electrically grounded will be allowed to operate.
  • Page 21 unless you want to use the Warm weather 3.5.3.3 Connection of an “Unoccupied signal” Shutdown function. of the building. This function allows dropping boiler N.B. Do not install a jumper if the outside sensor temperature during periods where the building is is not used.
  • 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) VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised August 2017)

  • Page 23: Section 4 : Controller Operation

    SECTION 4 : CONTROLLER OPERATION 4.1 USER INTERFACE The control of the boiler is ensured by a Boiler operating mode controller TM171PFE03 company Heating request 1 : On Schneider Electric. The LCD display of the Heating request 2 : On controller provides an interface for configuring and displaying the boiler parameters.

  • Page 24: Control Panel

    4.1.2 CONTROL PANEL 4.1.3 NAVIGATION AND ADJUSTEMENTS The navigation within the display is done with the five pushbuttons on the right of the screen. Figure 11 : Control panel Navigation between the elements is done with the up and down arrows. Use the right key to change the page in the menus.

  • Page 25: Main Menu Navigation

    4.1.4 MAIN MENU NAVIGATION Press one of the 5 buttons on the main display to access the main menu Figure 12 : Main menu navigation VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised August 2017)

  • Page 26: Navigation In Boiler Setting

    4.1.5 NAVIGATION IN BOILER SETTING Figure 13 : Navigation in boiler setting menu (1/3) VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised August 2017)
  • Page 27 You can switch from page by using the left or right arrow (Ex : 1/3 to 2/3 by using the right arrow) Figure 14 : Navigation in boiler setting menu (2/3) VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised August 2017)
  • Page 28 Figure 15 : Navigation in boiler setting menu (3/3) VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised August 2017)

  • Page 29: Main Menu

    4.2 MAIN MENU 4.2.2 BOILER CONFIGURATION The main menu is accessible to the user, no Configuration of the boiler operating mode access code is required. The main menu is accessed by pressing one of This menu is accessible only to the installer or to the 5 pushbuttons.

  • Page 30: Clock Setting

    4.2.4 CLOCK SETTING N.B. For the STG model, the calculation of power consumption is based on a theoretical Internal clock configuration 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...

  • Page 31: Heating Mode W1

    corresponding set-point (T. Set-point W1) as the supply temperature. Configuration of the LIMIT SETTING boiler operating limits 4.3.1.2 DDC 0-10 VDC Configuration of the ALARM (Available only on SCR model) alarms This operating mode allows modulating the Configuration of the boiler set-point temperature according to a 0- boiler communication COMMUNICATION...

  • Page 32: Pump Setting

    4.3.3 PUMP SETTING 4.3.4 CAPACITY LIMITING Configuring pump contact activation Adjusting the maximum authorized power (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.

  • Page 33: Auxiliary Boiler

    4.3.4.4 T. EXT temperature higher than setpoint The maximum permitted power can be adjusted temperature. according to the outside temperature sensor. The outdoor temperature is used in order to limit In External mode, the Aux contact closes when the maximum authorized power. there is a request on W1 or W2 / DHW regardless of the boiler output temperature Details of the variables in this mode are...

  • Page 34: Limit Setting

    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.

  • Page 35: Communication

    4.3.8 COMMUNICATION menu / Ethernet) of the controller in the web address bar. The boiler controller can be connected via an 5. Enter your username and password. Ethernet network communication port and using a RS485 (BACnet)l. The boiler web portal can Default be accessed in a variety of ways.

  • Page 36: Occupation

    4.3.8.1 BACnet Ex: When the contact (switch) is open at the The BACnet menu allows you to view the OCC terminal, then the boiler will be in configuration change BACnet temperature-lowering mode. (Night mode) When parameters. the contact (switch) is closed, it will be in normal In order to configure the VOLTMAX boiler to occupancy mode (Day mode).

  • Page 37: Warm Weather Shutdown

    This mode operates with the Fixed Set-point This menu allows you to change the installer and Outdoor reset mode. account password This menu allows the Boost mode to be activated, this mode increase the set-point 4.4 INTERNET temperature when the heating load of the The settings available on the controller are also building exceeds the capacity generated by the available remotely on a web portal.
  • Page 38 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.

  • Page 39: Boiler Status Display Settings

    4.5 BOILER STATUS DISPLAY SETTINGS Display Description BACnet Variable BACnet Description The set-point temperature of the boiler. The boiler will T. Set point activate its elements accordingly in order to modulate its AV_TSet-point water outlet temperature. T. Out Boiler The temperature at the outlet of the VOLTMAX boiler. AV_BoilerTOut The temperature at the inlet of the VOLTMAX boiler.
  • Page 40 1 = Operation of stage 1 Operation of stage #2 0 = Stage 2 not working Stage #2 BV_RelStage2 1 = Operation of stage 2 Operation of stage #3 0 = Stage 3 not working Stage #3 BV_RelStage3 1 = Operation of stage 3 Operation of stage #4 0 = Stage 4 not working Stage #4...

  • Page 41: Heating Mode W1 Settings

    4.6 HEATING MODE W1 SETTINGS Display BACnet variable Description Parameters Default 0 = Stop WP_HeatingMod Selects the power limitation mode between Stop, 1 = Outdoor Reset Operating Mode Fixed Modulation T. Ext, DCC 0-10VDC and Fixed. 2 = DCC 0-10VDC 3 = Fixed 4.6.1 FIXED MODE Configure the fixed set-point temperature...

  • Page 42: Outdoor Reset Mode

    4.6.2 OUTDOOR RESET MODE Adjust the set-point temperature according to the outside temperature This mode allows modulating the boiler output set-point temperature as a function of the outdoor temperature. The outdoor temperature value comes from a temperature sensor connected to the boiler controller. If the outdoor sensor is not connected or if its circuit is open, an alarm signal will be displayed on the display (SE).

  • Page 43: Mode : Ddc 0-10Vdc

    4.6.3 MODE : DDC 0-10VDC Modulation of the set-point temperature as a function of 0-10 VDC (Available only on SCR model) This operating mode allows to modulate the set-point temperature of the water outlet of the boiler according to a 0-10VDC signal applied to the terminal block 0-10Vdc T and 0-10Vdc G from an external controller (Ex: An energy management software).

  • Page 44: W2 Mode Set-Point Temperature Settings

    4.7 W2 MODE SET-POINT TEMPERATURE SETTINGS Display BACnet Variable Description Selection Default 0 = W2 Select the boiler’s operating mode during demand on W2 (None, W2 WP_HeatingMod Operating Mode 1 = DHW None and DHW) 2 = None 4.7.1 W2 MODE Configures the fixed set-point temperature during demand on W2 Display BACnet Variable...

  • Page 45: Specific Parameters For The Capacity Limiting Menu

    SPECIFIC PARAMETERS FOR THE CAPACITY LIMITING MENU The boiler authorizes a maximal power use. The configuration of these modes is shown below. 4.8.3 MANUAL MODE The maximum power is determined manually Display BACnet variable Description Parameters Default Max capacity Configure the maximum electrical power the boiler will use. 0 to maximum (kW) rated power...

  • Page 46: Power Limitation Menu Settings

    4.9 POWER LIMITATION MENU SETTINGS You can control the boiler power with different modes. Their configuration is below. Display BACnet Variable Description Selection Default 0 = None 1 = Manual WP_CapLimitMo Select the power limitation between Limitation Mode 2 = DCC 0-10VDC None, Manual, DCC 0-10VDC,T.

  • Page 47: Ext Mode

    4.9.3 T. EXT MODE Maximum power modulation based outside temperature. Power modulation is shown below. If the external sensor is not connected or there is a problem with the sensor, then the power will be limited according to Cap. At T. Ext.

  • Page 48: Schedule Mode

    4.9.4 SCHEDULE MODE Power can be modulated according to a fixed schedule. This can be programmed in the Schedule Setting menu. Display BACnet variable Description Parameters Default Max capacity AV_ActualCapLi Maximum capacity allowed at present time. 0 to maximum rated (kW) mitkW power...

  • Page 49: Auxiliary Boiler Settings

    4.10 AUXILIARY BOILER SETTINGS (Only available on SCR model) The system allows control of an auxiliary boiler to the system. The different configuration options are shown below. In order for the boiler to start, two conditions must be met: The water outlet temperature of the Voltmax boiler must be below the start-up temperature Aux.

  • Page 50: External Contact Mode

    4.10.2 EXTERNAL CONTACT MODE This mode selects the hydronic system heating source (VOLTMAX boiler or auxiliary boiler) using the BI-E terminal’s electrical switch. BACnet Display Description Settings Default Variable Selects the source used to control the set-point temperature. External means that the set-point will be determined by the auxiliary WP_STPTSourc boiler.

  • Page 51: Limit Configuration Menu Settings

    4.11 LIMIT CONFIGURATION MENU SETTINGS Display BACnet variable Description Settings Default Adjusts the temperature high limit at which the alarm triggers. If the water temperature leaving the boiler 0 to 92 °C exceeds the alarm’s high limit, it will trigger an HL Haute Limite T WP_HighLimitTemp 180 °F...

  • Page 52: Config. Alarm Menu Settings

    4.12 CONFIG. ALARM MENU SETTINGS Display BACnet Variable Description Possible Settings Default Displays the external alarm status. The external Status: 0 = Off BV_StatusExtAlarm alarm contact is activated only if a high limit or low HL/LWCO alarm 1 = On water level alarm occurs.

  • Page 53: Boost Menu Settings

    4.14 BOOST MENU SETTINGS Display BACnet Variable Description Possible Settings Default This option enables the BOOST functionality. 0 = Off Mode BOOST WP_ActivateModeBoost 1 = On 4.15 WARM WEATHER SHUTDOWN MENU SETTINGS Display BACnet Variable Description Possible Settings Default Shuts down the boiler when the outside temperature Warm Weather reaches a specific temperature.

  • Page 54: Section 5 : Boiler Start Up

    SECTION 5 : BOILER START UP WARNING Before operating this boiler, be sure to read and follow these instructions, as well warnings printed in this manual. Failure to do so can result unsafe operation boiler resulting in property damage, bodily injury, or death. Should you have any problems reading, following or difficulty understanding the instructions in this manual, STOP, and...
  • Page 55 7) When the boiler capacity has reached 100% 9) When the heating request is completed, the as displayed on the controller, measure the circulating pump can continue to operate amperage and voltage values drawn by the (depending on the operating mode or the unit.

  • Page 56: Section 6 : Troubleshooting

    SECTION 6 : TROUBLESHOOTING The troubleshooting section shows the various error messages that can occur during abnormal operation of the boiler. It is possible to change the limits of some alarms on the controller in the Limit Setting. 6.1 WARNING LIGHTS The LEDs above the navigation buttons indicate 3 different boiler states.

  • Page 57: Hl Temperature ( Hl )

    model) and the calculated theoretical current. limit (depending maximum boiler This may indicate an electrical problem from a pressure) wrong connection. 6.2.9 LOCK OUT 6.2.6 HL TEMPERATURE ( HL ) The outlet temperature of the boiler is above the high limit allowed. This alarm triggers the deactivation of the heating elements of the boiler.

  • Page 58: Section 7 : Maintenance

    SECTION 7 : MAINTENANCE Properly maintained, your boiler will provide years of dependable, trouble free service. It is recommended that a regular routine maintenance program be established and followed by the user. Components are subject to eventual failure that requires service. Failure to use the correct procedures or parts in these circumstances may make the unit unsafe or reduce the life of the boiler.

  • Page 59: Voltmax Electric Boiler Installation And Operation Manual ( Revised August 2017) , Page

    Units on which the serial number is removed or obliterated. consumer purchaser. Thermo 2000 reserves its rights to make changes in the details of design, construction, or material, as shall in its judgment constitute an improvement of former practices.

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