Delta 45, F-25, 30, 35, 40 User Manual
2004-7 Delta Elite Manual
Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installation 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
* I N S
* I N S TTAALLLLAATT
I O N
I O N AA
N D M
N D M AA
I N
I N TT
E N
E N AA
N C E *
N C E *
M
M AA
N U
N U AALL
- Input from 100,000 to 199,000 Btu/hr -
NOTICE
F-25/30/35/40 & 45
Combination Heaters
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
The
CONFORMS TO
ANSI Z 21-10-3/UL 732
CERTIFIED TO
90870
CSA B 140.12
CGA/CAN 1-4.3-M85
Table of Contents
i
PRODUCT AND SAFETY INFORMATION
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Product Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Operating Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Code Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION I - PRE-INSTALLATION ITEMS
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 . . . . . . . . . . . . . . . . . . . . . 7-8
Removal 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
Table of Contents
ii
U-Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-off Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . 18-19
System Piping - Multiple Units Installation. . . . . . . . . . . . . . . . . . . . . . . . 19
Primary Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23
SECTION VI - VENTING
General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Oil Vent Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
Oil Vent -Direct Vent 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 -Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Natural Gas Supply Pressure Requirements . . . . . . . . . . . . . . . . . . . . . . . 29
iii
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-UP PREPARATION
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 . . . . . . . . . . . . . . . . . . . . . . 38-39
Check Low Water Cut-off Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Check for Gas Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Check Thermostat Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SECTION XI - START-UP PROCEDURES
Final Checks Before Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
ELITE Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41
iv
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-OUT PROCEDURES
Check-out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SECTION XIV - INSTALLATION RECORD
Installation Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SECTION XVII - REPLACEMENT PARTS
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-49
PRODUCT SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-51
Product & Safety Information
1
Indicates the presence of a hazardous
situation which, if ignored, will result
in death, serious injury or substantial
property damage.
Indicates a potentially hazardous situation which, if ignored, can result in
death, serious injury or substantial
property damage.
Indicates a potentially hazardous situation which, if ignored, may result in
minor injury or property damage.
Indicates special instructions on installation, operation or maintenance,
which are important to equipment but
not related to personal injury hazards.
Indicates recommendations made by
Triangle Tube for the installers which
will help to ensure optimum operation
and longevity of the equipment
BEST PRACTICES
NOTICE
CAUTION
WARNING
DANGER
The following terms are used throughout this manual to bring attention to the presence of
potential hazards or to important information concerning the product.
Triangle Tube reserves the right to modify the technical specifications and components of
its products without prior notice.
NOTICE
Product & Safety Information
2
Bacteria can develop in the domestic
water system if certain minimum water
temperatures are not maintained.
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 thermosta-
tic mixing valve is working properly.
b)to set the thermostatic mixing valve
for the lowest temperature which satisfies your hot water need.
.
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.
CAUTION
DANGER
WARNING
HOT
BURN
3
Product & Safety Information
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.
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.
Should overheating occur or the gas
supply fails to shut off, turn OFF the
manual gas control valve external to
the appliance.
To prevent damage to inner tank,
installer must:
• Fill inner tank prior to outer tank
during start-up.
• Relieve primary system pressure
below 15 psig prior to draining
inner tank.
CAUTION
WARNING
DANGER
DANGER
Qualified Installer:
Prior to installing this product read all
instructions included in this manual.
Perform all installation steps required in this
manual in the proper order given. Failure to
adhere to the guidelines within this manual
can result in severe personal injury, death or
substantial property damage.
Homeowner:
-This product should be maintained / serviced and inspected annually by a qualified service technician.
- This manual is intended for use by a
qualified Installer/Service Technician.
Please reference the unit’s model number and the serial number from the rating label when inquiring about service or
troubleshooting.
Triangle Tube accepts no liability for any
damage resulting from incorrect installation or from the use of components or
fittings not specified by Triangle Tube.
NOTICE
NOTICEWARNING
4
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-25 and 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.
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 FDA shall 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.
NOTICE
Pre-Installation Items
5
SECTION I - Pre-Installation Items
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 -“Installation
Code 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.
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.
WARNING
Pre-Installation Items
To provide serviceability to the unit it is
recommended that the following clearances be maintained:
Top and vent hood area - 36 inches.
Front and burner area - 24 inches.
Rear and primary piping areas - 12
inches.
When installing the ELITE in a confined
space, sufficient air must be provided for
proper combustion and venting and to
allow under normal operating condition,
proper air flow around the product to
maintain ambient temperatures within
safe limits to comply with the National
Fuel Gas Code NFPA 54 - latest edition.
Flooring and Foundation
The ELITE is approved for installation on
combustible floors, but never on carpeting.
Do not install the ELITE on carpeting
even with a metal or wood foundation
base. Fire can result causing severe personal injury, death or substantial property damage.
Installer should provide a solid brick or concrete foundation pad, at least 2 inches above
the floor level if:
- There is a potential for the floor to
become flooded. The height of the
foundation should be such to sufficiently elevate the unit.
- The floor is dirt, sand, gravel or other
loose material.
- The flooring is severely uneven or
sloped.
The minimum foundation size required is 24
inches x 23 inches.
Residential Garage Installations
When installing the ELITE in a residential
garage the following special precautions per
NFPA 54/ANSI Z223.1 must be taken:
- Mount the unit with a minimum 18
inches above the floor level of the
garage. Ensure the burner and ignition
devices / controls are no less than 18
inches above the floor level.
- Locate or protect the unit in a matter
so it cannot be damaged by a moving
vehicle.
WARNING
WARNING
BEST PRACTICES
6
Combustion Air and Venting
7
SECTION II - Providing Air for
Combustion and Ventilation
The installer must provide adequate
combustion and ventilation to the area in
which the ELITE is installed. Providing
adequate air ensures proper combustion
and reduces the potential risk of severe
personal injury or death from carbon
monoxide emissions if a flue gas leakage
occurred.
The installer should not install an
exhaust fan in the room with the ELITE.
The exhaust fan could affect the combustion of the burner or cause potential flue
gas leakage resulting in severe personal
injury or death.
The installer should take the condition
and age of the building when determining air for ventilation. Older building
(buildings with single pane windows and
minimal weather-stripping around doors
and windows) tend to have adequate natural infiltration and ventilation without
providing dedicated air openings.
Newer buildings (buildings with double
pane windows and weather-stripped
doors and windows) are unlikely to have
natural infiltration and ventilation, thus
must be provided with dedicated air
openings.
The installer must follow the requirements of
state, provincial or local codes when sizing and
locating adequate air openings for combustion
and ventilation.
In absence of the codes the installer may opt to
use the following guidelines when the ELITE
is installed in a confined room as defined by
NFPA 31 as a room with less than 7200 cubic
feet per 1 GPH of input of all appliances located in the area (7200 cubic feet is define as a
room with 8 foot ceiling and 33.5 ft x 33.5 ft in
dimension):
Two Permanent Openings - One opening
must commence within 12 inches of the ceiling
and the other opening within 12 inches of the
floor. The opening must have a minimum
height or length dimension of 3 inches, the
actual dimensions are based on:
Using Inside Air - Each opening must be connected freely to the areas having adequate infiltration from the outside. Each opening should
be at least 140 sq. inches per 1 GPH of input (1
sq. inch per 1000 BTU input). This input
should include all appliances (gas and/or oil)
plus any appliances that may draw air from the
room such as clothes dryers.
Using Outside Air - Each opening should be
connected directly or by ducts to the outdoors
or to a crawl space or attic area that is freely
connected with the outdoors. The openings
should be sized as follows:
Through outside wall or vertical ducts -
The openings should be a minimum 35 sq
inches per 1 GPH input (1 sq. inch per 4000
BTU input) of all appliances (gas and/or
oil) plus any appliances that may draw air
from the room such as clothes dryers.
Through horizontal ducts - The openings
should be a minimum 70 sq. inches per 1
GPH input (1 sq. inch per 2000 BTU input)
of all appliances (gas and/or oil) plus any
appliances that may draw air from the room
such as clothes dryers.
Where ducts are used, the size of the duct
should equal the free area of the opening in
which the duct is connected to.
NOTICE
WARNING
WARNING
8
Combustion Air and Venting
The installer should compensate for any louvers, grilles or screens when determining the
free air of the opening. The installer should
refer the louver or grille manufacturer’s
instruction for determining free area. In
absence of the manufacturer’s instructions the
installer should use the following as a guideline:
-Wood louvers will provide 20 to 25%
free area
-Metal louvers or grilles will provide 60
to 75% free air
Installers should lock louvers in the open position or provide an interlock system to prove the
louvers are in the open position prior to operation of the ELITE.
Removal of an Existing Boiler from a
Common Vent System
For installations in which the ELITE is
replacing an existing boiler / hot water
heater system, which was connected to a
common vent system with other appliances, the following steps shall be conducted with each remaining appliance
connected to the common venting system:
1. Any unused openings in the common
venting system must be sealed.
2. A visual inspection of the venting system must be conducted for proper sizing and horizontal pitch. The inspection should ensure no blockage or
restriction is within the vent system,
and there is no leakage, corrosion or
other items, which could cause an
unsafe condition.
3. To adequately test the venting system,
close all exterior doors and windows
and all doors between the area containing the remaining appliances connected
to the common vent system and other
areas of the building. Turn on any
clothes dryers and any other gas appli-
ance not connected to the common vent
system. Turn on all exhaust fans, i.e.
range hoods and bathroom exhaust
fans, preferably at maximum speed.
Close any fireplace dampers.
4. Place in operation the first appliance
being inspected that is connected to the
common vent system. The remaining
appliances should not be in operation.
Follow the appliance’s lighting instructions and adjust the thermostat to allow
the appliance to operate continuously.
5. Test for spillage at the draft hood relief
opening after 5 minutes of main burner
operation. Spillage can be detected
using the flame of a match or candle or
with smoke from a cigarette.
6. Once it has been determined that each
remaining appliance connected to the
common vent system is properly vented, return doors, windows, exhaust
fans, fireplace dampers and any operating gas appliance to their previous
condition.
Should any improper operation of the common
venting system be detected in the outlined test,
the condition should be corrected so the vent
system conforms with the National Fuel Gas
Code, NFPA 54/ ANSI Z223.1 - latest edition.
Canadian installations must conform with
B149.1 or 149.2 Installation Code.
BEST PRACTICES
9
Unit Preparation
SECTION III - Unit Preparation
Handling Instructions
The ELITE is generally easier to handle and
maneuver once removed from the shipping carton and pallet.
To remove the shipping carton and pallet:
a. Remove the shipping straps and open
the top of the shipping carton to remove
the wood shipment insert.
b. Lift the shipping carton over the unit to
remove. If ceiling height is limited the
carton maybe cut open using care not to
damage the exterior jacket of the unit.
c. Discard all packing materials.
Hydrostatic Pressure Test
Prior to permanently connecting water,
oil/gas supply or electrical supply, perform a pressure hydrostatic test of the
outer tank to ensure all piping connections were not damaged during shipment.
Hydrostatic Test Preparation
1. Mount the circulator on the supply pipe as
shown in Fig. 7 page 20.
2. Temporarily plug the primary return connections as shown in Fig. 7 page 20 using a
1” NPT pipe plug. Use pipe dope sparingly to allow removal of the plugs upon completion of the test.
3. On the outlet flange of the circulator pipe
install a 1” NPT nipple and shut-off valve.
Use pipe dope sparingly to allow removal
of the fittings upon completion of the test.
To avoid getting water onto the unit
and/or surrounding area additional piping from the shut-off to a catch bucket or
drain may be required.
4. Connect a hose to the primary circuit drain
valve located per Fig. 28 page 50, Item 2
and connect the other end to a fresh water
supply. Ensure the hose can be used as a
drain hose upon completion of the test.
Hydrostatic Test Procedures
1. Open the shut-off valve installed on the
outlet flange of the circulator.
2. Open the fresh water supply valve and then
open slowly the primary circuit drain valve
to fill the outer tank with water.
3. When the water within the outer tank
reaches the shut-off on the primary supply,
close the primary circuit drain valve.
4. Close the shut-off valve, on the top of the
circulator.
5. Slowly reopen the primary circuit drain
valve until the test pressure on the temperature / pressure gauge reaches 10 psig
maximum. Close the primary circuit drain
valve.
To prevent damage to the inner tank the
test pressure must not exceed 10 psig.
6. Allow the test pressure to remain for 10
minutes.
Do not leave the unit unattended while
pressurized. A cold water fill could
expand and cause excessive pressure,
resulting in severe personal injury, death
or substantial property damage.
WARNING
CAUTION
NOTICE
BEST PRACTICES
10
Unit Preparation
7. Ensure constant gauge pressure has been
maintained throughout the 10 minute test.
Check for leaks at all fitting joints. Repair
if found.
Leaks must be repaired immediately
when detected. Failure to repair leaks
can damage the unit, resulting in substantial property damage.
8. Check continuity using a voltmeter across
the terminals of the LWCO device. The
contacts on the LWCO should be closed.
See item 6 in Fig. 24 page 47 for location
of the LWCO.
Completion of Hydrostatic Test and Draining
1. Disconnect the fill hose from the fresh
water source and direct the hose to a suitable place of drainage.
2. Open the primary drain valve and completely drain the unit. To aid in draining, open the
shut-off valve on the primary supply.
3. Remove the hose from the primary drain
valve when draining is complete.
4. Remove the plugs, nipple, shut-off valve
and any other piping unless they will
remain for use in the system piping.
WARNING
11
Domestic Piping
SECTION IV - Domestic Piping
General Piping Requirements
• All plumbing must meet or exceed all
local, state and national plumbing codes.
• Use pipe dope or tape suitable for
potable water.
• Use isolation valves to isolate system
components.
• Install unions for easy removal of the
ELITE from the system piping.
Domestic Supply Pressure
For applications in which the domestic supply pressure exceeds 70 psig it is recommended to install a pressure reducing valve
on the cold water supply.
Maintaining the cold water supply at or
below 70 psig will prevent normal thermal
expansion from repeatedly forcing the T&P
relief valve open.
Thermal Expansion
If the cold water supply contains a backflow
preventer, check valve and / or a pressure
reducing valve, the installer must install a
domestic thermal expansion tank on the cold
water supply. (See Fig. 2 page 14)
Installing a thermal expansion tank will
prevent normal thermal expansion from
repeatedly forcing the T&P relief valve
open.
When installing a thermal expansion tank
ensure the charge pressure of the tank is
equal to the cold water supply pressure at
the point of installation. Consult the thermal expansion tank manufacturer’s instructions for further information on installation
and sizing.
The Temperature / Pressure relief valve
is not intended for constant duty, such as
relief of pressure due to normal thermal
expansion.
Water Hammer
Water hammer is the effect of sudden pressure changes occurring in the domestic piping. These pressure changes are typically
the result of “fast acting” positive shut-off
valves closing. These types of valves can
be typically found on dishwashers and
clothes washers.
The effects of water hammering can cause
damage to system components and tank
welds on the unit.
Installation of hammer arresters is recommended at these types of appliances, which
incorporate “fast-acting” positive shut-off
valves. Consult the manufacturer of water
hammer arresters for recommendation on
sizing and installation requirements.
Temperature / Pressure Relief Valve
The ELITE has a factory installed
Temperature / Pressure Relief valve.
Ensure the rating of the T&P relief valve is
correctly sized as follows per AGA:
CAUTION
Model AGA Rating
F-25 100,000 Btu/hr
F-30 200,000 Btu/hr
F-35 200,000 Btu/hr
F-40 200,000 Btu/hr
F-45 200,000 Btu/hr
Domestic Piping
12
The installer must install discharge piping
onto the T&P relief valve. The discharge
piping must be:
• Made of material serviceable for temperatures of 250ºF or greater.
• Directed so that any hot water discharge flows away from all persons.
• Directed to a suitable place of drainage.
• Installed as to allow complete draining
of the T&P relief valve and the discharge piping.
•Terminated with a plain end, not with
threads.
Failure to properly direct the discharge
piping of the T&P relief valve may result
in flooding of the area adjacent to the
unit and or lower floors in the structure
causing substantial property damage.
The installer must not install the T&P
relief valve discharge piping in a manner
that is:
• Excessively long: Using more than 2
elbows and/or 15 feet of discharge piping can reduce the discharge capacity.
•Terminated directly into a drain: The
discharge piping must terminate within
6 inches of the drain. Check with local
plumbing codes for termination guidelines.
• The discharge piping is plugged, reduced
in size or restricted in any manner.
• The discharge piping is subject to freezing.
DO NOT install any valves between the
T&P relief valve and the discharge piping. DO NOT plug the T&P relief valve
or the discharge piping. Improper placement and piping of the T&P relief valve
can cause severe personal injury, death
or substantial property damage.
Thermostatic Mixing Valve
The ELITE contains a factory installed thermostatic mixing valve with built-in check valve.
The operating range of the thermostatic mixing
is 90ºF to 120ºF.
For applications with a domestic recirculation
loop, the recirculation pump should be controlled by an aquastat. The maximum recommended setting of the aquastat is 10ºF lower
than the thermostatic mixing valve setting.
For proper operation of the thermostatic
mixing valve and to prevent potential
scalding hazards, the recirculation loop
should be controlled by an aquastat. DO
NOT use continuous recirculation.
U-Tube Assembly
The ELITE is supplied with a U-Tube
Assembly that directs cold water to the
thermostatic mixing valve.
To install the U-Tube Assembly the
installer must:
1. Disconnect the cold inlet adapter/union
from the thermostatic mixing valve.
2. Using needle-nose pliers remove the
plastic check valve assembly from the
adapter.
DANGER
WARNING
CAUTION
Domestic Piping
3. Solder the U-Tube Assembly onto the
adapter. (See Fig. 1)
4. Once the adapter has sufficiently
cooled, re-insert the check valve assembly making sure of orientation and
reconnect onto the mixing valve.
If the installation of the ELITE requires
domestic hot water for a commercial dishwasher, the installer may insert a tee connection between the unit and the mixing
valve to provide 140ºF domestic hot water.
The installer must reference local plumbing
codes to ensure if this type of application is
permissible.
The thermostatic mixing valve MUST be
installed and utilized on the ELITE.
Removal of the thermostatic mixing
valve will result in severe personal injury
or death.
The manual valve on the U-Tube assembly must remain in the full open position
for proper operation of the thermostatic
mixing valve.
Domestic Drain Valve
- The installer must install a drain valve
and drain leg as shown in Fig. 2 page
14 or Fig. 3 page 15.
- The drain valve should be positioned
close to the floor to aid in the siphon
action required to drain the inner tank.
Multiple Units Installation
For applications using multiple units the
domestic piping should be piped using a balanced manifold arrangement.
The installer should remove the thermostatic
mixing valve from the units and install a single
thermostatic mixing valve at the outlet of the
hot water manifold. The thermostatic mixing
valve should be sized according to the required
flow rate and pressure drop. Refer to the thermostat mixing valve manufacturer specification and installation instructions for more
details.
Reference Fig. 4, page 15 for piping diagram.
Storage Tank Application
For applications requiring large volumes of
domestic hot water in a relative short period,
the installer may include a storage type tank
(see Fig. 5 page 16) in the domestic piping.
The installer must:
1. Relocate the thermostatic mixing valve
from the ELITE to the outlet of the storage tank.
2. Provide recirculation from the storage
tank back to the ELITE using a bronze
type circulator. Maximum recommended flow rate is 5 to 10 gpm.
CAUTION
DANGER
13
Fig. 1: Mixing Valve Assembly
Check Valve
U-Tube Assembly
Adapter
Cold
Mixed
ot
H
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