THERMO 2000 VoltMax400 Installation And Operation Manual
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THERMO 2000 VoltMax400 Installation And Operation Manual

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VoltMax 400
Electric Boiler
INSTALLATION AND OPERATION MANUAL
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: march 2019
1

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Summary of Contents for THERMO 2000 VoltMax400

  • 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: march 2019...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TECHNICAL SPECIFICATIONS ....................4 INTRODUCTION ........................8 LOCAL INSTALLATION REGULATIONS ..................... 8 CORROSIVE ENVIRONMENT ......................8 INSPECTION UPON RECEPTION ...................... 8 TO BE CHECKED ..........................8 INSTALLATION ........................9 SAFETY MEASURES .......................... 9 LOCATION ............................9 CLEARANCES ............................. 9 PIPING INSTALLATION ........................
  • Page 3 W2 MODE ........................... 44 DHW MODE........................44 POWER LIMITATION MENU SETTINGS ..................44 MANUAL MODE ......................... 45 0-10 VDC MODE ........................ 45 T. ext MODE ........................46 Schedule MODE ......................... 47 AUXILIARY BOILER SETTINGS ......................47 BACKUP MODE ......................... 48 EXTERNAL CONTACT MODE ...................

  • Page 4: Technical Specifications

    TECHNICAL SPECIFICATIONS Table 1 : VoltMax 600 VAC / 60 Hz / 3 Phases max. power Model BTU/h Amps Elements 600V Stage supply (MCM) 8 x 15 kW 3 x 350 VoltMax 192 655 104 4 x 48 kW 4 x 18 kW 8 x 18 kW 3 x 350 VoltMax 204...
  • Page 5 Table 2 : VoltMax 480 VAC / 60 Hz / 3 Phases max. power Model BTU/h Amps Elements 480V Stage supply (MCM) 8 x 15 kW VoltMax 192 655 104 4 x 48 kW 3 x 350 4 x 18 kW 8 x 18 kW VoltMax 204 696 048...
  • Page 6 Table 5 : VoltMax 240 VAC / 60 Hz / 1 Phase max. power Model BTU/h Amps Elements 240V Stage supply (MCM) 7 x 5 kW 2 x 500 VoltMax 77 262 724 7 x 11 kW 7 x 6 kW 2 x 600 VoltMax 80 272 960...
  • Page 7 BOILER DIMENSIONS AND CHARACTERISTICS * Optional disconnect switch available on "THREE-PHASE" models. BOILER CONNECTIONS Boiler outlet 3 " NPT M COMPONENTS IDENTIFICATION Boiler inlet 3 " NPT M Electrical main supply Pressure relief valve 3/4" NPT F Boiler controller Drain valve 1 1/4 "...

  • Page 8: 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 9: Installation

    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 10: Boiler Piping Connection

    Figure 1 : Possible pipe flow configurations BOILER PIPING CONNECTION 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 one twinned to the VoltMax boiler to act as a back-up of the top connections must be used for supplying...

  • Page 11: System Pressure Control And Expansion Tank

    be protected from freezing. No valves, valves or AIR BLEEDER valves shall be installed on the pipe. The The air contained in the heated water must be installation of the safety valves is governed by the removed from the system to allow the proper local code.

  • Page 12: Drain Faucet

    For example, an 180kW electric boiler has a power Table 9 : Temperature rise vs flow rate of 614,160 BTU/h. The system is designed for a (GPM) drop-in temperature (Delta T) of 20°F. DELTA T MODEL Flow required = 614,160  20  500 = 61.4 GPM VoltMax 77 52,5 26,3...

  • Page 13: Pressure Loss

    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 March 2019)
  • Page 14 Figure 3 : Basic installation VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised March 2019)
  • Page 15 Figure 4 : Basic installation with indirect water heater and radiator VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised March 2019)
  • Page 16 Figure 5 : Dual-Energy installation with a condensing boiler VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised March 2019)
  • Page 17 Figure 6 : Multiple boiler parallel installation VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised March 2019)
  • Page 18 Figure 7 : Basic installation with auxiliary boiler for production of domestic hot water and heating VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised March 2019)

  • Page 19: Electrical Connections

    ELECTRICAL CONNECTIONS Connecting the building heat demand Wiring must conform to the National Electrical signal or running authorization Code and to state or local code requirements. Upon reception of a closed contact connected to terminals 24V+ and W1 or W2, the corresponding The electric boiler must be electrically grounded in circulating pump P1 or P2 will start and the boiler accordance with local codes, or, in the absence of...
  • Page 20 Connection of an “Unoccupied signal” Outdoor sensor location of the building. Outside the building at a location that best This function allows dropping boiler represents the heat demand of the building (a temperature during periods where the building is wall facing north for most of the buildings and not used and this without having to lower all the on a south one on buildings with large room thermostats of the building.
  • Page 21 External alarm contact An alarm signal (dry contact) is available on the boiler to advise the user of an alarm situation. The capacity of the contact is 5A resistive/1A inductive on terminal AL/AL. The dry contact between contactors AL/AL is normaly open and will close in the event that any of the following conditions appears: •...
  • Page 22 Figure 8 : ELECTRICAL CONNECTIONS OF THE INPUT AND OUTPUT SIGNALS TO THE CONTROLLER VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised March 2019)

  • Page 23: Controller Operation

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

  • Page 24: Control Panel

    CONTROL PANEL NAVIGATION AND ADJUSTEMENTS The navigation within the display is done with the five pushbuttons on the right of the screen. Figure 10 : 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

    MAIN MENU NAVIGATION Press one of the 5 buttons on the main display to access the main menu Figure 11 : Main menu navigation VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised March 2019)

  • Page 26: Navigation In Boiler Setting

    NAVIGATION IN BOILER SETTING Figure 12 : Navigation in boiler setting menu (1/3) VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised March 2019)
  • 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 13 : Navigation in boiler setting menu (2/3) VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised March 2019)
  • Page 28 Figure 14 : Navigation in boiler setting menu (3/3) VOLTMAX ELECTRIC BOILER Installation and Operation Manual ( , Page Revised March 2019)

  • Page 29: Main Menu

    MAIN MENU 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

    Parameters Description CONSUMPTION Select English or French Boiler consumption cycle report Language version Select the temperature units, Temperature either Celsius unit Fahrenheit (F) Select the flow unit, either US Flow unit gallons per minute (USgpm) or liters per second (L / sec) Setting the backlight mode: Backlight 30 secondes...

  • Page 31: Heating Mode W1

    Boiler heating mode W1 HEATING MODE W1 HEATING configuration according to Selection of the operating mode MODE W1 the type of application HEATING Boiler heating mode W2 or MODE DHW configuration according W2/DHW to the type of application CAPACITY Capacity limiting mode LIMITING configuration AUXILIARY...

  • Page 32: Heating Mode W2/Dhw

    Outdoor reset Manual This operating mode makes it possible to DDC 0-10 VDC modulate the boiler output set-point temperature T. Ext as a function of the outdoor temperature. Schedule The outdoor temperature signal comes from the temperature sensor supplied with the boiler, Details of each of these options are presented in which will be connected to the boiler controller.

  • Page 33: Auxiliary Boiler

    Schedule Manually select system The maximum authorized boiler power can be Manual operation mode (Electrical programmed according to a schedule. See Auxiliary). section 4.8.4 for an explanation of how to modify a schedule. N.B. The auxiliary boiler can only be switched on when a heat demand is present on W1 or / and AUXILIARY BOILER W2 / DHW.

  • Page 34: Limit Setting

    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.

  • Page 35: Config. Bacnet

    7. On a web browser, you may now directly write the chosen IP adress in the navigation bar (as if it was a website) and you will be redirected to the controlers webpage. By the default, the username and password are as givien in the next table.

  • Page 36: Occupation

    In order to configure the VoltMax boiler to your BACnet management system, you must activate The SCR model allows the connection of a the function. contact (OCC Contact) allowing the use of an The controller allows a BACnet IP or MSTP external timer to control the OCCUPATION communication.

  • Page 37: Boost Mode

    This mode stops the boiler’s heating production BOOST MODE when the outside temperature is higher than a Enable Boost Mode 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.
  • Page 38 You must restart the device for the changes to take place. 2. Access the Boiler Web Portal. 3. Click on the Installer / Communication menu. Enter your e-mail under Recipient. You can also use your own mail server by entering the necessary data.

  • Page 39: Boiler Status Display Settings

    BOILER STATUS DISPLAY SETTINGS (Variables beginning with AV and BV are read variables, while variables beginning with "W" are editable) Display Description BACnet Variable Instance BACnet Description The set-point temperature of the boiler. The boiler T. Set point will activate its elements accordingly in order to AV_TBoilerSTP 8388661 modulate its water outlet temperature.
  • Page 40 1 = Operation of stage 1 Status of stage #2 0 = Stage 2 not working Stage #2 BV_RelStage2 20971525 1 = Operation of stage 2 Status of stage #3 0 = Stage 3 not working Stage #3 BV_RelStage3 20971526 1 = Operation of stage 3 Status of stage #4 0 = Stage 4 not working...

  • Page 41: Heating Mode W1 Settings

    The controller’s program name and version. Program name HEATING MODE W1 SETTINGS (Variables beginning with AV and BV are read variables, while variables beginning with "W" are editable) Display BACnet variable Instance Description Parameters Default Head Allows to select W1 heating demand source. Local WP_HeatingW1 20971563...

  • Page 42: Outdoor Reset Mode

    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

    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

    W2 MODE SET-POINT TEMPERATURE SETTINGS (Variables beginning with AV and BV are read variables, while variables beginning with "W" are editable) Display BACnet Variable Instance Description Selection Default Heat Allows to select W1 heating demand source. Local demande WP_HeatingW2 20971564 Local BACnet or Local BACnet...

  • Page 45: Manual Mode

    MANUAL MODE The maximum power is set manually. Display BACnet Variable Instance Description Selection Default Current Configures the maximum electrical power that the WP_ManualCapL 0 to maximum rated authorized 8388640 boiler will use. imit power max kW 0-10 VDC MODE An external 0-10 VDC controller is used to adjust the maximum power.

  • Page 46: Ext Mode

    T. EXT MODE Maximum power modulation is based on the 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 47: Schedule Mode

    SCHEDULE MODE Power can be modulated according to a fixed schedule. This can be programmed in the Schedule Setting menu. Display BACnet variable Instance Description Parameters Default Current authorized The value of power (%) calculated based on the 0 to maximum AV_CapLimitPrc 8388662 current and the boiler’s nominal operating voltage...

  • Page 48: Backup Mode

    BACKUP MODE Configures a second boiler as a backup. Display BACnet variable Instance Description Parameters Default Selects the source used to control the set-point temperature. Auxiliary or Auxiliary means that the set-point will be VoltMax STPT WP_STPTSource determined by the auxiliary boiler. The VoltMax 20971542 VoltMax Source...

  • Page 49: Bi-Energy Mode

    BI-ENERGY MODE This mode selects the hydronic system heating source (VoltMax boiler or auxiliary boiler) using the BI-E terminal’s electrical switch. The benefit of this mode is that the system can operate the back-up boiler when needed. Display BACnet variable Instance Description Parameters...

  • Page 50: Limit Configuration Menu Settings

    LIMIT CONFIGURATION MENU SETTINGS (Variables beginning with AV and BV are read variables, while variables beginning with "W" are editable) Display BACnet variable Instance Description Settings Default Adjusts the temperature high limit at which the alarm triggers. If the water temperature leaving the WP_HighLimitTe 0 to 92 °C boiler exceeds the alarm’s high limit, it will trigger...

  • Page 51: Config. Alarm Menu Settings

    CONFIG. ALARM MENU SETTINGS (Variables beginning with AV and BV are read variables, while variables beginning with "W" are editable) Display BACnet Variable Instance Description Settings Default Occupation WP_Schedule_O Allows to select Bi-energy activation contact Local 20971566 Local mode source. BACnet or Local BACnet Status: Displays the external alarm status.

  • Page 52: Boost Menu Settings

    BOOST MENU SETTINGS (Variables beginning with AV and BV are read variables, while variables beginning with "W" are editable) Display BACnet Variable Instance Description Settings Default Mode WP_ActivateMod This option enables the BOOST functionality. 0 = Off 20971557 BOOST eBoost 1 = On WARM WEATHER SHUTDOWN MENU SETTINGS (Variables beginning with AV and BV are read variables, while variables beginning with "W"...

  • Page 53: Boiler Start Up

    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 in unsafe operation of the boiler resulting in property damage, bodily injury, or death. Should you have any problems reading, following or difficulty in understanding the instructions in this manual, STOP, and get help from a qualified person.

  • Page 54: Startup Procedure

    operation temperature selected. Proceed to 2) When the boiler capacity has reached 100% the adjustment of the mechanical high limit as displayed on the controller, measure the control localized on the right in the low amperage and voltage values drawn by the voltage electric compartiment.

  • Page 55: Troubleshooting

    TROUBLESHOOTING This alarm happens when one of the following contacts is open: the adjustable mechanical high The troubleshooting section shows the various limit, the manual reset high limit located in the error messages that can occur during abnormal heating elements compartiment, a low level of operation of the boiler.

  • Page 56: Flow (F)

    This function can detect a possible lack of power This condition triggered by a lack of flow does not from the boiler and therefore possible anomalies turn off the boiler but activates a yellow indicator of certain componants. This function is generaly light as long as the condition is active.
  • Page 57 Tableau 12 : Resistance (Ohm) according to the outdoor sensor measuring temperature Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance Ω Ω Ω Ω °F °C °F °C °F °C °F °C 490 813 46 218 7 334 1 689 405 710 39 913 6 532...

  • Page 58: Fuses

    (goes back de 0:00), the battery on the present. A Sieve or other accessorie preventing electronic controller needs to be changed. sediment deposits shall be installed. Contact thermo 2000 technical support for the battery replacement procedure. TEMPERATURE SENSOR Water outlet sensor:...

  • Page 59: Maintenance

    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 60 This warranty is valid only for installations made within the territorial limits Thermo 2000 Inc. will repair or replace at our sole option the failed unit with of Canada and the United States.

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