THERMO 2000 TURBOMAX 109 User Manual

TURBOMAX
®
Instantaneous Indirect Water Heater
USE & CARE MANUAL
WITH INSTALLATION INSTRUCTIONS FOR THE CONTRACTOR
Your TURBOMAX
®
Instantaneous Indirect Water Heater has been carefully assembled and
factory tested to provide years of trouble-free service. In order to insure the service intended,
the following information is provided to enable proper installation, operation, safety
precautions and maintenance of this product.
It is imperative that all persons who are expected to install, operate or adjust this water heater
read the instructions carefully so that they may understand how to do so.
Any questions regarding the operation, maintenance, service or warranty of this water heater
should be directed to the entity from whom it was purchased.
When all installation steps have been completed, replace this installation manual in its original
envelope, and keep in a safe place for future reference.
Note: Copyright 2005. Thermo 2000 Inc. All rights reserved. Turbomax® is a registered trademark of Thermo 2000 Inc.
Thermo 2000 reserves the right to modify at any time and without notice colors, components, materials, specifications or
model described in or shown in this document.
Revision : July 2014
THERMO 2000 INC.

THERMO 2000 TURBOMAX 109 Specifications

General

Brand	THERMO 2000
Model	TURBOMAX 109
Category	Water Heater
Language	English

Summary

TURBOMAX Use & Care Manual

General Safety Introduction

Emphasizes reading and following all warnings for safe operation.

TURBOMAX Specifications

Product Description and Key Features

Details the internal copper heat exchanger, materials, pressure ratings, and insulation.

Model Specifications Table

Provides a table of model specifications including tank volume, heat transfer area, flow rate, dimensions, and weight.

General Safety Precautions

Water Temperature and Scald Risk

Warns that water over 125°F can cause severe burns or death, highlighting risks to vulnerable groups.

Energy Conservation and Temperature Settings

Advises setting the lowest temperature that satisfies needs for energy efficiency.

Introduction and Installation Considerations

Local Installation Regulations and Decisions

States installation must conform to codes and covers pre-installation decisions on valves and output.

Location Requirements

Specifies installing the unit vertically in a clean, dry location, protected from damage and freezing.

Installation Guidelines and Components Checklist

Installation Clearances and Special Locations

Details clearances, catch pans, restaurant elevation, and corrosive atmosphere avoidance.

Mechanical Components Checklist

Provides a checklist of essential mechanical components for proper installation.

Installation Procedures

Warnings, Shipment Inspection, and Water Connections

Warns against unauthorized attachments, covers shipment checks, and details water line connections.

Expansion Tank for Potable Water

Explains the purpose of an expansion tank to prevent pressure build-up in closed systems.

Piping Schematics and Requirements

Zone Valve Zoning Schematic

Provides a basic piping schematic for zone valve zoning with a Turbomax and boiler.

Piping Schematic Requirements

Outlines requirements for installation, including code conformity and safety valve installation.

Radiant Floor System Piping

Buffer Tank Schematic and Requirements

Illustrates a schematic for using Turbomax as a buffer tank and details its installation requirements.

Multi-Unit Piping Schematics

Two Water Heaters Schematic and Requirements

Presents a schematic for two units and outlines requirements for multi-unit installations.

Light Commercial System Piping

Thermal Mass Tank Schematic and Requirements

Illustrates a schematic for light commercial use with a thermal mass tank and its requirements.

Component and Zoning Details

Pressure Relief Valve and Mixing Valve

Explains the function and installation of safety relief valves and thermostatic mixing valves.

Boiler Connections and Zoning Recommendations

Covers boiler water connections, circulator zoning, and zone valve zoning.

Pump and Pipe Sizing

Boiler Water Temperature Drop and Pump Flow Rate

Details calculating temperature drop and pump flow rate for system design.

Pipe Sizing and Friction Loss

Pipe Sizing Criteria and Pressure Loss in Pipes

Covers pipe sizing principles, velocity limits, and calculating pressure loss in pipes.

Pressure Loss and Pump Selection

Pressure Loss Calculations and System Drop

Details pressure loss calculations for components and the total system for pump selection.

Pump or Circulator Selection Guidance

Provides guidance on selecting the appropriate pump based on system requirements.

Piping System Pressurization and Expansion Tank Sizing

Pressurization Objectives and Tank Sizing

Explains system pressure goals and how to size an expansion tank for system safety.

Wiring and Temperature Control

Wiring Requirements and Temperature Control Settings

Outlines electrical wiring standards and temperature adjustment for the aquastat.

Wiring Schematics

Circulator and Zone Valve Wiring Diagrams

Shows wiring diagrams for separate circulators and 3-wire/4-wire zone valves.

Circulator Zoning Wiring

Domestic Priority Circulator Zoning

Details wiring for circulator zoning with an emphasis on domestic hot water priority.

Circulator Zoning Wiring (Continued)

Circulator Zoning Diagram with Priority Relay

Presents a wiring diagram for circulator zoning, including priority relay logic.

Gas Boiler Circulator Zoning Wiring

Gas Boiler Zoning Schematic with Domestic Priority

Illustrates zoning wiring for a gas boiler with domestic hot water priority.

Steam Installation

Steam Boiler Piping Precautions and Wiring

Provides precautions for steam boiler piping and wiring recommendations for steam systems.

Low Pressure Steam Boiler Piping Schematic

Steam Boiler Condensate Schematic and Requirements

Shows a schematic for steam boilers with condensate and lists installation requirements.

Steam Boiler Wiring Schematics

Steam Boiler Wiring Methods A and B

Provides two different wiring schematic options for low-pressure steam boilers.

Operation

Pre-Operation Safety and Filling Procedures

Covers safety precautions before operation and the steps for filling the heater coils.

Operating the Water Heater

Explains how to start and operate the water heater after installation and purging.

Advanced Operation and Settings

Boiler Start-up and Aquastat Adjustment

Describes boiler start-up sequences and aquastat adjustment for optimal temperature.

Thermostatic Mixing Valve Operation

Details how to operate a thermostatic mixing valve for safe and consistent water temperature.

Maintenance

Piping Inspection and Safety Valve Checks

Outlines yearly piping inspections and monthly checks of safety valves for proper function.

Scale Prevention and Cleaning Procedures

Discusses scale build-up issues, prevention methods, and chemical cleaning procedures.

Troubleshooting System Problems

Troubleshooting Hot Water Issues

Addresses common causes and solutions for insufficient or no hot water.

Troubleshooting Temperature and Noise Issues

Covers problems like water being too hot, boiler over-cycling, and water hammer noise.

Parts and Component Replacement

Replacement Parts List and Aquastat Replacement

Lists available parts and provides detailed steps for replacing the aquastat.

Pump Sizing Spreadsheet

System Flow Rate and Friction Loss Calculations

Spreadsheet section for calculating system flow rate and friction losses.

Pump Selection Worksheet

Spreadsheet section for selecting the appropriate pump based on calculated system parameters.

Expansion Tank Sizing Spreadsheet

Boiler Water Volume Calculation and Tank Selection

Spreadsheet for calculating system water volume and selecting the correct expansion tank.

TURBOMAX Limited Warranty

Warranty Coverage Details

Outlines warranty coverage for residential and commercial installations.

Warranty Exclusions and Limitations

Lists conditions under which the warranty is void or limited.