Delta 45 User Manual

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The

F-25/30/35/40& 45

Combination Heaters

 

CONFORMS TO

 

ANSI Z 21-10-3/UL732

 

CERTIFIED TO

90870

CSA B 140.12

CGA/CAN 1-4.3-M85

 

 

 

- Input from 100,000 to 199,000 Btu/hr -

* I N S T A L L A T I O N A N D M A I N T E N A N C E *

M A N U A L

Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installa- NOTICE tion in order to gain warranty coverage.

When receiving Triangle Tube units, any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

Leave all documentation received with appliance with owner for future reference.

WARNING If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

For Your Safety

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

-Do not try to light any appliance

-Do not touch any electrical switch; do not use any phone in your building.

-Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

-If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier

2004-7Delta Elite Manual

Table of Contents

PRODUCT AND SAFETY INFORMATION

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Product Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Operating Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Code Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION I - PRE-INSTALLATIONITEMS

Code Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Determining Product Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Boiler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Recommended Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Flooring and Foundation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Residential Garage Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION II - COMBUSTION AIR AND VENTING

Providing Air for Combustion and Ventilation . . . . . . . . . . . . . . . . . . . . . 7-8Removal of an Existing Boiler from a Common Vent . . . . . . . . . . . . . . . . 8

SECTION III - UNIT PREPARATION

Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Hydrostatic Pressure Test

Hydrostatic Test Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Hydrostatic Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

Completion of Hydrostatic Test and Draining . . . . . . . . . . . . . . . . 10

SECTION IV - DOMESTIC PIPING

General Piping Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Domestic Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Thermal Expansion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Water Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Temperature / Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12

Thermostatic Mixing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

i

Table of Contents

U-TubeAssembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13

Domestic Drain Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Multiple Units Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Storage Tank Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

TR/Smart Series Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Domestic Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16

SECTION V - PRIMARY PIPING

General Piping Requirements

Low Water Cut-offDevice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Backflow Preventer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Primary System Piping Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Expansion Tank and Makeup Water

Diaphragm (Bladder) Expansion Tank. . . . . . . . . . . . . . . . . . . . . . 17 Closed-Type(Standard) Expansion Tank . . . . . . . . . . . . . . . . . . . . 17 Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Closet (Zero Clearance) Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Sizing Primary Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 System Piping - Zone Circulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 System Piping - Zone Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

System Piping - Radiant Heating with Mixing Valves. . . . . . . . . . . . . . . . 18-19System Piping - Multiple Units Installation. . . . . . . . . . . . . . . . . . . . . . . . 19 Primary Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-23

SECTION VI - VENTING

General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Oil Vent Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25

Oil Vent -DirectVent Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Gas Venting - General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Masonry and Metal Chimneys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Type B Vent Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Vent Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Common Vent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SECTION VII - FUEL PIPING

Gas Supply Piping Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Pipe sizing -NaturalGas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Natural Gas Supply Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . 29

ii

Table of Contents

Pipe Sizing - Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Propane Gas Supply Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . 30

General Oil Piping Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SECTION VIII - INTERNAL WIRING

General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Internal Control Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-32

SECTION IX - EXTERNAL WIRING

Installation Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Thermostat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Outdoor Temperature Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

External Control Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-36

SECTION X - START-UPPREPARATION

Check System and Domestic Water Chemistry

Water pH Level 6.0 to 8.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Water Hardness Less Than 7 Grains . . . . . . . . . . . . . . . . . . . . . . . 37 Chloride Concentration Less Than 80mg/L . . . . . . . . . . . . . . . . . . 37 Chlorinated Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Flush Primary and Domestic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Check and Test Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Use of Antifreeze in the Primary System . . . . . . . . . . . . . . . . . . . . . . . . . 38 Filling the Inner (Domestic) Tank and System . . . . . . . . . . . . . . . . . . . . . 38 Filling the Outer (Primary) Tank and System . . . . . . . . . . . . . . . . . . . . . . 38-39Check Low WaterCut-offDevice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Check for Gas Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Check Thermostat Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

SECTION XI - START-UPPROCEDURES

Final Checks Before Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

ELITE Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-41

iii

Table of Contents

SECTION XII - TEMPERATURE LIMITS

Setting Primary Thermostat Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Adjustment of Secondary Thermostat Limit . . . . . . . . . . . . . . . . . . . . . . . 42

Setting the Thermostatic Mixing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

SECTION XIII - CHECK-OUTPROCEDURES

Check-outProcedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

SECTION XIV - INSTALLATION RECORD

Installation Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

SECTION XVII - REPLACEMENT PARTS

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-49

PRODUCT SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-51

iv

Product & Safety Information

The following terms are used throughout this manual to bring attention to the presence of potential hazards or to important information concerning the product.

DANGER

NOTICE

Indicates the presence of a hazardous situation which, if ignored, will result in death, serious injury or substantial property damage.

Indicates special instructions on installation, operation or maintenance, which are important to equipment but not related to personal injury hazards.

WARNING

Indicates a potentially hazardous situation which, if ignored, can result in death, serious injury or substantial property damage.

CAUTION

Indicates a potentially hazardous situation which, if ignored, may result in minor injury or property damage.

BEST PRACTICES

Indicates recommendations made by Triangle Tube for the installers which will help to ensure optimum operation and longevity of the equipment

NOTICE

Triangle Tube reserves the right to modify the technical specifications and components of its products without prior notice.

1

Product & Safety Information

WARNING

Bacteria can develop in the domestic water system if certain minimum water temperatures are not maintained.

DANGER

Water temperature over 125ºF can cause severe burns instantly or death from scalds.

Children, disabled and elderly are at highest risk of being scalded.

-Never leave them unattended in or near shower, bathtub or sink.

-Never allow small children to use a hot water faucet or draw their own bath.

If any one using hot water in the building fits this description or codes require specific water temperatures at hot water faucet, we recommend:

a)ensure the factory installed thermostatic mixing valve is working properly.

b)to set the thermostatic mixing valve for the lowest temperature which satisfies your hot water need.

CAUTION

.

Protection must be taken against excessive temperature and pressure!

TO PROTECT AGAINST EXCESSIVE TEMPERATURE AND PRESSURE

Check if the Temperature and Pressure (T&P) relief valve is in the location provided. (Domestic Water)

Check if the 30 psi relief valve supplied is in the location provided. (Primary water)

To avoid injury, install the relief devices to comply with local code requirements.

HOT

BURN

2

Product & Safety Information

DANGER

WARNING

 

Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system which has been under water.

DANGER

WHAT TO DO IF YOU SMELL GAS - Do not try to light any appliance

Should overheating occur or the gas supply fails to shut off, turn OFF the manual gas control valve external to the appliance.

CAUTION

To prevent damage to inner tank, installer must:

-Do not touch any electrical switch; do not use any phone in your building.

-Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

-If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

Fill inner tank prior to outer tank during start-up.

Relieve primary system pressure below 15 psig prior to draining inner tank.

WARNING

 

 

 

NOTICE

 

 

 

 

 

 

 

Qualified Installer:

 

 

Please reference the unit’s model num-

Prior to installing this product

read all

ber and the serial number from the rat-

ing label when inquiring about service or

instructions included

in this

manual.

 

Perform all installation steps required in this

 

 

troubleshooting.

 

 

 

 

 

 

 

 

manual in the proper order given. Failure to

 

 

 

 

 

 

adhere to the guidelines within this manual

 

 

NOTICE

 

 

 

can result in severe personal injury, death or

 

 

 

 

 

 

 

 

 

 

 

substantial property damage.

 

 

Triangle Tube accepts no liability for any

 

 

 

 

 

 

 

 

 

 

 

 

damage resulting from incorrect instal-

 

 

Homeowner:

 

 

lation or from the use of components or

 

 

 

 

fittings not specified by Triangle Tube.

 

 

-Thisproduct should be maintained / ser-

 

 

 

 

 

 

 

 

 

 

viced and inspected annually by a qual-

 

 

 

 

 

 

ified service technician.

 

 

 

 

 

 

- This manual is intended for use by a

 

 

 

 

 

 

qualified Installer/Service Technician.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

Product & Safety Information

OPERATING RESTRICTIONS

Maximum working pressure for inner (domestic water) tank is 150 psig.

Maximum working pressure for outer (primary water) tank is 45 psig.

Inner tank has factory installed Temperature & Pressure Relief Valve with an AGA rating of 100,000 Btu/hr for PG-25and 200,000 Btu/hr for PG30/35/40/45.

Outer tank has a factory installed 30 psig relief valve rated at 535,000 Btu/hr

Electrical rating:120 V, 60 Hz, less than 12 amperes

pH & chloride limits for the ELITE are:

-Chloride, less than 80 mg/l.

-pH, 6.0 - 8.0.

NOTICE

Any water conditioning system must be installed and maintained in accordance with manufacturer’s specifications.

180º Maximum operating temperature - primary side.

120º Maximum outlet/mixed temperature - domestic side.

CODE RESTRICTIONS

Single wall heat exchanger in the ELITE complies with National Standard Plumbing Code, provided that:

-Outer tank water (including additives) is practically non-toxic,having toxicity rating or Class of 1, as listed in Clinical Toxicology of Commercial Products,

-Outer tank pressure is limited to maximum 30 psig by approved relief valve.

Single wall heat exchangers are permitted under the Uniform Plumbing code - Paragraph L3.2. if they satisfy all of the following requirements.

1.The heat transfer medium is potable water or contains only substances which are recognized as safe by the U.S. Food and Drug Administration.

2.The pressure of the heat transfer medium is maintained less than the normal minimum operating pressure of the potable water system

3.The equipment is permanently labeled to indicate that only additives recognized as safe by the FDAshall be used in the heat transfer medium.

Or, per Uniform Plumbing Code paragraph L3.3 as follows:

Other heat exchanger designs may be permitted where approved by the Administrative Authority.

4

Pre-InstallationItems

SECTION I - Pre-InstallationItems

Code Compliance

This product must be installed in accordance to the following:

All applicable local, state, national and provincial codes, ordinances, regulations and laws.

The National Fuel Gas Code NFPA54/ ANSI Z332.1 - Latest edition.

Installation of Oil Burning Equipment NFPA 31 - Latest Edition

National Electric Code ANSI/NFPA 70.

For installations in Canada -“InstallationCode for Gas Burning Equipment” CGA/B149.

For installations in Canada - Installation code for Oil Burning Equipment - CSA/B139.

Determining Product Location

Before locating the ELITE check for convenient locations to:

-Domestic water supply piping

-Heating system piping

-Venting

-Gas or oil supply piping

-Electrical service

Ensure the area chosen for the installation of the ELITE is free of any combustible materials, gasoline and other flammable liquids.

WARNING

Failure to remove or maintain the area free of combustible materials, gasoline and other flammable liquids or vapors can result in severe personal injury, death or substantial property damage.

Ensure the ELITE and its controls are protected from dripping or spraying water during normal operation or service.

The ELITE should be installed in a location so that any water leaking from the tank or piping connections or relief valves will not cause damage to the area surrounding the unit or any lower floors in the structure.

-When such a location is unavoidable a suitable drain pan with adequate drainage should be placed under the unit. The drain pan must not restrict the flow of combustion air to the unit.

Boiler Replacement

If the ELITE is replacing an existing boiler / hot water heater system, the following items should be checked and corrected prior to installation:

Primary and domestic piping leaks and corrosion.

Improper location and sizing of the expansion tank on the primary heating loop.

Improper sizing of the thermal expansion tank (if used) on the domestic supply line.

Vent condition and sizing.

Recommended Clearances

The ELITE is approved for zero clearance to combustibles, excluding the vent hood and vent piping.

Vent hood and vent piping - 6 inches from combustible materials when using type “L” double wall vent.

Vent Piping - 18 inches from combustible materials when using single wall vent.

Primary and domestic hot water piping - 1 inch from combustible material.

5