TriangleTube Smart Line, Smart 40, Smart 50, Smart 60, Smart 80 Installation And Maintenance Manual
...Page 1
Technical Specifications
Indirect Fired Water Heater
L
I
S
T
E
D
Installation and Maintenance Guide
WARNING
• Before proceeding with installation and operation, read entire manual carefully. Failure to do so can cause injury or property damage.
• When receiving SMART Water Heaters, any claims for damage or short-
IMPORTANT
age in shipment must be filed immediately against the transportation
company by the consignee.
• Warranty Registration Card must be filled out by the customer and mailed
within thirty (30) days of installation in order to gain warranty coverage.
• Retain and affix this manual near the water heater for future reference
• Installation and service should only be performed by a qualified installer or
service technician.
• Installations and service should be performed by a license plumber or gas
fitter in the Commonwealth of Massachusetts.
Date Revised 01/8/12
2010-49 SMART IWH Manual
Page 2
Table of Contents
Product & Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Installation - Piping
Temperature & Pressure (T&P) Relief Valve . . . . . . . . . . . . . . . . . .4-5
Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Automatic Air Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Water Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Vacuum Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
General Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Domestic Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Thermostatic Mixing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Recirculation Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Multiple Water Heater Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Boiler Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Installation - Piping Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14
Installation - Wiring
Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Circulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Zone Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Snap-Set Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Installation - Wiring Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-21
Water Heater Start-Up
Filling the Inner (Domestic Water) Tank . . . . . . . . . . . . . . . . . . . . .22
Filling the Outer (Boiler Water) Tank . . . . . . . . . . . . . . . . . . . . . . .22
General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Adjusting the Water Heater Thermostat . . . . . . . . . . . . . . . . . . . . . .24
Water Heater Maintenance
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Filling Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Draining Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-27
Draining Inner (Domestic Water) Tank . . . . . . . . . . . . . . . . . . . . . . .26-27
Draining Outer (Boiler Water) Tank . . . . . . . . . . . . . . . . . . . . . . . . .27
Replacement Parts List
SMART Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28-29
Water Heater Specifications
SMART Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Performance SMART Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Page 3
Product & Safety Information
Following terms are used to bring attention to the
presence of various risk levels, or to important
information concerning product life.
DANGER
Indicates presence of a hazard which will
cause severe personal injury, death or substantial property damage if ignored.
WARNING
Indicates the presence of a hazard which
can cause severe personal injury, death or
substantial property damage if ignored.
CAUTION
Indicates the presence of a hazard which
will or can cause minor personal injury or
damage if ignored.
NOTICE
DANGER
Hot Water Can Scald!
• Water temperatures over 125ºF can cause
severe burns instantly or death from scalding.
• 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 anyone using hot water in the building fits
the above description or if local codes or state
laws require specific water temperatures at hot
water faucet, it is recommended:
- to install a thermostatic mixing valve at this
appliance or at each water faucet.
or
- to set the thermostat knob for the lowest temperature which satisfies your hot water
needs.
Indicates special instructions on installation, operation, or maintenance which are
important but not related to personal injury
hazards.
BEST PRACTICE
Indicates recommendations made by
Triangle Tube for the installers which will
help to ensure optimum operation and
longevity of the equipment
• Water drained from the system drain valves
may be extremely hot. To avoid injury:
– Make sure all connections are tight.
– Direct water flow away from any person.
CAUTION
Protection must be taken against excessive
temperature and pressure!
• Installation of a Temperature & Pressure
(T&P) relief valve is required.
CAUTION
To prevent damage to the inner tank, the
Installer must:
• Always fill inner tank prior to outer tank
and always drain outer tank prior to inner
tank.
• Relieve primary system pressure below 15
psig prior to draining inner tank.
1
Page 4
Pre-Installation
Codes Compliance
Water heater installation must conform with the
instructions in this manual and where applicable:
• local, state, provincial, and national codes,
laws, regulations and ordinances.
• in Canada - CAN / CGA B149.1 or B149.2
Installation Code.
SMART water heaters are exempt from ASME
Section VIII, Division 1 Code construction per
Interpretation VIII-86-136. Check with local codes
for applicability.
NOTICE
SMART Series water heaters will absorb
less than 200,000 BTU/hr when domestic
water outlet temperature is 210ºF and boiler
water supply temperature is 240ºF. Listed
outputs are based on ASME Section VIII
Interpretation VIII-1-86-136.
Where recommendations in this manual differ
from local, or national codes, the local or national
codes take precedence.
2. The pressure of the heat transfer medium is
maintained less than the normal minimum
operating pressure of the potable water system
Exception: Steam complying with sec-
tion #1 above.
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.
Other heat exchanger designs may be permitted
where approved by the Administrative Authority.
Operating Restrictions
• Maximum domestic hot water temperature
is 194ºF for commercial applications and
140ºF for residential applications.
• Maximum boiler water temperature is
210ºF.
• Maximum working pressure for inner
(domestic water) tank is 150 psig.
• Maximum working pressure for outer
(boiler water) tank is 45 psig.
• pH and chloride limits for water heaters
are:
Codes Restrictions
Single wall heat exchanger in the SMART water
heater complies with National Standard Plumbing
Code, provided that:
– boiler water (including additives) is practically
non-toxic, having toxicity rating or class of 1,
as listed in Clinical Toxicology of Commercial
Products, and
– boiler water 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. and L3.3
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.
- chloride, less than 150 mg/l (ppm)
- pH value min. 6 - max. 8
NOTICE
Any water conditioning system must be
installed and maintained in accordance with
manufacturer’s specifications.
NOTICE
Do not install the water heater on any application if the boiler piping contains non-oxygen barrier tubing or if the boiler piping is
considered an “open system”. Exposing the
outer tank of the water heater to oxygen
contamination will lead to premature tank
failure and denial of the warranty.
2
Page 5
Pre-Installation
Locating Water Heater
• This water heater is not intended for outdoor installations.
• Keep distance between boiler and water
heater to a minimum to:
– reduce piping heat loss
– provide minimal friction loss
• Locate water heater so that any leakage from
the tank or water connections will not cause
damage to the area adjoining the water heater
or to lower floors in the structure.
– When such a location is unavoidable, a
suitable drain pan with adequate drainage,
should be placed under the water heater.
• The SMART Series Water Heaters are designed
for vertical installation only.
Recommended Clearances
• Water heater should be installed to allow
adequate clearance for servicing.
• Zero clearance is permissible to any side of
the SMART Series water heater, but information labels may be hidden.
• Recommended top or vertical clearance is 12”
minimum.
• Refer to boiler manual for boiler clearances.
3
Page 6
Installation - Piping
Temperature & Pressure (T&P) Relief Valve
CAUTION
To reduce risk of excessive pressures and temperatures in the water heater, install temperature and pressure protective equipment
required by local codes, but no less than a combination temperature and pressure relief valve
certified by a nationally recognized testing laboratory that maintains periodic inspection of
production of listed equipment or materials, as
meeting the requirements for Relief Valves and
Automatic Gas Shutoff Devices for Hot Water
Supply Systems, ANSI Z21.22. This valve must
be marked with a maximum working pressure
of the water heater.
• Every SMART water heater must be protected
with a T&P relief valve.
• Determine T&P relief valve size by the following specifications, unless they conflict with
local codes:
Standard Installation
• Install T&P relief valve in the Auxiliary con-
nection located behind the air vent on the top of
the water heater (Figure 1 page 8).
or
• Install the T&P relief valve in the run (straight
through leg) of a tee located at the domestic hot
water outlet when using the Auxiliary connection for a recirculation return (Figure 2 page 8).
Commonwealth of Massachusetts Installation
Follow this procedure for jurisdictions requiring a
vacuum breaker to be installed on the domestic
cold water inlet.
• Install the T&P in the run (straight through leg)
of a tee located at the domestic hot water outlet. Use a long element T&P relief valve (Fig.
3B page 9).
T&P Relief Valve Discharge Piping
T&P relief valve discharge piping must be:
- SMART 30/40/50: 3/4”NPT with an AGA
Rating of 100,000 BTU/hr and a maximum
pressure rating of 150 psig. (Watts 100XL8 or equivalent).
- SMART 60/80/100/120: 3/4”NPT with an
AGA Rating of 200,000 BTU/hr and a maximum pressure rating of 150 psig. (Watts
40XL-8 or equivalent).
NOTICE
For proper operation of the T&P and to prevent the T&P from activating due to boiler
water temperature, use a T&P relief valve
with extended element. We recommended
an 8” minimum length to ensure element
senses domestic water.
- made of material serviceable for temperatures of 250ºF or greater.
- directed so that hot water flows away from
all persons.
- directed to a suitable place for disposal.
- installed so as to allow complete draining
of the T&P relief valve and discharge line.
T&P relief valve discharge piping must not
- excessively long. Using more than 2
elbows or 15 feet of piping can reduce discharge capacity.
- directly connected to a drain. Terminate
discharge piping within 6” from drain.
Refer to local codes.
- plugged, reduced or restricted.
- subject to freezing.
be:
4
Page 7
Installation - Piping
WARNING
Do not install any valve between T&P relief
valve and tank connection or on T&P relief
valve discharge piping. Do not plug T&P
relief valve or discharge piping. Improper
placement and piping of T&P relief valve
can cause severe personal injury, death or
substantial property damage.
Drain Valve
Drain valve and fittings are supplied by others.
Standard Installation
• Install a tee connection at the domestic cold
water inlet (Fig. 1 and 2 page 8 and Fig. 2A
on page 9).
• Pipe the drain piping with drain valve from
the tee connection to:
- a suitable place for disposal
or
- terminate within 12” of the floor
3. Once the tank is full and air has stop escaping and
air vent is seated and closed, screw the vent cap
completely close.
NOTICE
For proper operation of the air vent ensure
vent cap is tighten at all times. The air vent is
provided both a hygroscopic cap that prevents
leakage of water due to an internal membrane.
Thermal Expansion
If a backflow preventer, check valve or pressure
reducing valve is piped on cold water supply piping
of water heater, install an expansion tank on cold
water supply line to prevent normal thermal expansion from repeatedly forcing open T&P relief valve.
CAUTION
Commonwealth of Massachusetts Installation
• Thread a 3/4” close nipple onto the
Auxiliary connection and insert an openend dip tube into the Auxiliary connection
on top of water heater. As shown in Fig. 3A
page 9.
• Install a 3/4” NPT elbow to the Auxiliary
connection, see Fig. 3B page 10.
• Pipe the drain piping with drain valve from
the elbow connection to:
- a suitable place for disposal
or
- terminate within 12” of the floor
Automatic Air Vent
1. Remove plastic shipping cap from 1/2” NPT
pipe fitting on top center of water heater.
2. Install automatic air vent provided with water
heater, using suitable pipe dope or tape.
T&P relief valve is not intended for constant
duty, such as relief of pressure due to
repeated normal system expansion. Correct
this condition by installing a properly sized
expansion tank in domestic water system.
Refer to expansion tank manufacturer’s
installation instructions for proper sizing.
Water Hammer
Dishwashers, clothes washers and fast-closing positive shut-off valves incorporated in the system all
contribute to creating water shock. Install a water
hammer arrester to prevent damage to pipes and
appliances. See device manufacturer’s instructions
for application and installation.
5
Page 8
Installation - Piping
NOTICE
Water hammering within the domestic piping system can cause premature failure of
the inner tank of the water heater. This type
of failure is NOT covered under warranty.
Vacuum Breaker
Installing a vacuum breaker Watts N36-M1 or equivalent on the domestic cold water inlet will prevent
damage to the inner tank if a negative pressure is
developed in the domestic supply line. See manufacturer’s instructions for application and installation
of the vacuum breaker.
General Piping
• For domestic water piping diagrams, see pages 8
through 10.
• See pages 11 through 14 for:
- Boiler water piping.
• Use pipe dope or tape suitable for potable
water systems.
• Use isolation valves to isolate system components.
Domestic Piping
• Union on domestic hot water outlet should be
piped at a higher elevation than domestic water
drain valve. This will make draining the water
heater easier.
• Install unions for easy removal of water heater.
It is recommended to use dielectric unions or
couplings to protect hot and cold water fittings
from corrosion when connecting dissimilar
materials such as copper and galvanized iron
pipe.
• If copper pipe is used for domestic water connections, first solder pipe to a threaded adapter
and then screw adapter into cold water inlet on
top of water heater. Inlet contains an internal
plastic dip tube which can be damaged by heat
from soldering.
NOTICE
- Multiple water heater domestic and boiler
piping.
• See Chart 1 for domestic and boiler piping
connection sizes .
• All plumbing must meet or exceed all local,
state and national plumbing codes.
Do not apply heat to the cold water inlet
when making sweat connections to water
heater. Sweat tubing to adapter before fitting adapter to cold water inlet of heater. It
is imperative that no heat be applied to the
cold water inlet, as it contains a non metallic dip tube.
Chart 1
Connections (Inches) Recirculation Dip Tube Draining Dip Tube
Water
Heater
Model
SMART 30 3/4 NPT 1 NPSC 3/4 NPSC 34 3/4 34 3/4 1
SMART 40 3/4 NPT 1 NPSC 3/4 NPSC 43 3/4 43 3/4 1
SMART 50 3/4 NPT 1 1/4 NPSC 3/4 NPSC 25 3/4 52 3/4 1
SMART 60 3/4 NPT 1 1/4 NPSC 3/4 NPSC 34 3/4 62 3/4 1 1/4
SMART 80 1 1/2 NPT 1 1/2 NPSC 1 1/2 NPSC 25 1 1/2 48 1 1/2 1 1/4
SMART 100 1 1/2 NPT 1 1/2 NPSC 1 1/2 NPSC 32 1 1/2 61 1 1/2 1 1/2
SMART 120 1 1/2 NPT 2 NPSC 1 1/2 NPSC 32 1 1/2 61 1 1/2 1 1/2
Domestic
Water
Inlet/Outlet
Boiler Water
Supply/
Return
Auxiliary
Connection
Length
(Inches)
Diameter
(Inches)
Length
(Inches)
Diameter
(Inches)
Recommended
Minimum
Boiler Piping
Diameter
(Inches)
6
Page 9
Installation - Piping
• When the water supply pressure is higher than
70 psig, it is recommended to install a pressure
reducing valve on cold water supply line to
prevent water loss through T&P relief valve.
• If water heater will replace tankless coil in
boiler, disconnect piping to coil. Allow water
to drain from coil. Do not plug tankless coil.
DANGER
Plugging tankless coil inlet and outlet will
result in severe personal injury, death, or
substantial property damage.
Thermostatic Mixing Valve
• It is recommended to install an optional mixing
valve on the domestic hot water outlet.
• Mixing valve should comply with ASSE 1017
Recirculation Piping
• T&P relief valve must be installed in run
(straight through leg) of tee located at domestic
hot water outlet of water heater.
• It is recommended that the recirculation dip tube
be installed in auxiliary connection using a close
nipple assembly as shown Fig. 3A, page 9. See
Chart 1 page 6 for diameter and length of dip
tube.
DANGER
Failure to install automatic mixing valve
where recommended will result in severe
personal injury or death.
Boiler Piping
• If plastic pipe is used for boiler water piping, it
must have a maximum oxygen diffusion rate of
0.1 mg/liter-day for boiler and water heater
protection.
NOTICE
The Smart IDWH must be installed on a
closed type hydronic system. Failure to provide such a system will result in premature
failure of the outer tank and annulment of
warranty.
• Boiler water (including additives) must be
practically non-toxic, having toxicity rating or
class of 1, as listed in Clinical Toxicology of
Commercial Products.
If antifreeze is used in boiler system, local
codes may require a backflow preventer on
cold water supply line. Use antifreeze specifically intended for hydronic heating systems.
Inhibited propylene glycol is recommended at
a maximum 50/50 mixture.
• A stainless steel or bronze circulator is required
on potable water systems.
• Install automatic mixing valve either at the hot
water outlet of water heater or each hot water
faucet.
Multiple Water Heater Systems
• Parallel Pipe Recirculation Systems - Manifold
recirculation return to all water heaters.
• Series Piped Systems - Piped return to the leading (cold water inlet) water heater.
• Install automatic mixing valve either at the hot
water outlet of water heater or each hot water
faucet.
DANGER
Do not use automotive, ethylene glycol or
petroleum-based antifreeze. Do not use any
undiluted antifreeze. This can cause severe
personal injury, death or substantial property
damage.
7
Page 10
Cold Water
Inlet
6
1
12" min.
Heat Trap
Loop
(Optional)
12" min.
Heat Trap
Loop
(Optional)
1
5
5
1
8
7
4
10
M
H
C
Installation - Piping
7
Cold Water
Inlet
6
1
Recirculating
Loop
2
3
4
1
5
5
1
8
12" min.
Heat Trap
Loop
(Optional)
12" min.
Heat Trap
Loop
(Optional)
9
Fig. 1:
Standard Installation
Domestic Piping
SMART Series
Fig. 2:
Standard Installation
Domestic Piping with
Recirculation SMART Series
1. Shut-off valve
2. Recirculation Circulator
3. Flow Check Valve
4. T&P relief valve
5. Unions
6. Backflow preventer or pressure reducing valve(*)
7. Drain valve
8. Thermal expansion tank (potable)
9. Recirculation dip tube
10. Thermostatic mixing valve (*)
(*) Optional devices may be required by local codes.
8
Page 11
7
Cold Water
Inlet
6
1
Recirculating
Loop
2
3
4
1
5
5
1
8
12" min.
Heat Trap
Loop
(Optional)
12" min.
Heat Trap
Loop
(Optional)
Fig. 2A:
Optional Installation
Domestic Piping with
Recirculation SMART Series
1. Shut-off valve
2. Recirculation Circulator
3. Flow Check Valve
4. T&P relief valve
5. Unions
6. Backflow preventer or pressure reducing valve(*)
7. Drain valve
8. Thermal expansion tank (potable)
(*) Optional devices may be required by local codes.
9
Page 12
Installation - Piping
Cold Water
Inlet
6
1
12" min.
Heat Trap
Loop
(Optional)
12" min.
Heat Trap
Loop
(Optional)
4
1
5
5
8
9
11
10
M
H
C
7
Fig. 3A:
Fig. 3B:
Drain Tube AssemblyCommonwealth of
Massachusetts
Commonwealth of
Massachusetts Domestic
Piping SMART Series
1. Shut-off valves
4. T&P relief valve
5. Unions
6. Backflow preventer or pressure reducing valve (*)
7. Drain valve
8. Thermal expansion tank (potable)
9. Vacuum breaker
10. Mixing valve (*)
11. Dip tube - Draining per Chart 1
(*) Optional devices may be required by local codes.
10
Page 13
Installation -Piping
4
1
3
2
2-Port
Priority Valve
(normally open)
2-Port
Priority Valve
(normally close)
1
6
5
Cold water
inlet
1
2
4
1
3- Port
Priority
Valve
3
1
6
Cold water
inlet
5
Fig. 4:
Fig. 5:
SMART System Piping with 3-Port Zone Valve
(Domestic Priority)
SMART System Piping with 2-Port Zone Valves
(Domestic Priority)
1. Shut-off valves
2. Circulator
3. Expansion tank
4. Drain valve
5. Feed valve
6. Air separator
11
Page 14
9
1
1
2
Zone
valve
Zone Valve
1
4
7
6
Cold water
inlet
9
1
1
3
2
2
2
Zone
Circulator
Zone Circulator
3
3
4
1
7
6
Cold water
inlet
Installation - Piping
Fig. 6:
SMART System Piping with Zone Valves
(Non Domestic Priority)
Fig. 7:
SMART System Piping with Zone Circulators
1. Shut-off valves
2. Circulator
3. Flow check valve
4. Expansion tank
5. Drain valve
6. Feed valve
7. Air separator
12
Page 15
Installation - Piping
Circulator
Recirculated
Water
Automatic
Mixing Valve
Hot Water
Outlet
Cold Water
Inlet
T&P
Relief
Valve
Cold Water
Inlet
Isolation
Valve
Circulator
Automatic
Mixing Valve
Hot Water
Outlet
Cold Water
Inlet
T&P
Relief
Valve
Cold Water
Inlet
Isolation
Valve
Recirculated
Water
Fig. 8:
Multiple SMART Series Water Heater
System Domestic Piping - Parallel
• Recommended for most applications.
• Any one water heater tank thermostat may be
utilized to control system temperature.
• Install automatic mixing valve at either the hot
water outlet of the water heater system or at
each hot water fixture.
• Each tank should be piped with a drain as
shown in Fig. 1.
Fig. 9:
Multiple SMART Series Water Heater
System Domestic Piping - Series
• Recommended for applications in which there is a
large water consumption in short period of time.
• A maximum of 3 water heaters may be piped in series.
• Utilize the lead (hot water outlet) SMART tank thermostat to control system temperature.
• Install automatic mixing valve at either the hot water
outlet of the water heater system or at each hot water
fixture.
• Each tank should be piped with a drain as shown in
Fig. 1.
13
Page 16
2
3
5
4
1
7
Cold
water
inlet
6
1
1
2
3
5
4
1
7
Cold
water
inlet
6
Installation - Piping
Fig. 10:
Fig. 11:
Multiple SMART Series Water Heater System Boiler
Piping Reverse Return Balanced Flow
Multiple SMART Series Water Heater System Boiler Piping - Manifold
1. Shut-off valves
2. Circulator
3. Flow check valve
4. Expansion tank
5. Drain valve
6. Feed valve
7. Air separator
14
Page 17
Installation - Wiring
Connect to
outer 2 terminals
Wiring Requirements
WARNING
Electrical shock hazard can cause severe
personal injury, death or substantial property damage. Disconnect power before
installing and/or servicing.
1. All wiring must be a minimum of 18 gauge
and installed in accordance with:
• U.S.A. - National Electrical Code and any
other national, state or local code requirements having jurisdiction.
• Canada - C.S.A. C22.1 Canadian Electrical
Code Part 1 and any other national, provincial and local code requirements having
jurisdiction.
2. If original wire supplied with appliance must
be replaced, Type 90ºC or its equivalent must
be used.
Circulators
• Priority relay must be sized for total amp draw
of all circulators.
Zone Valves
• Transformer must be sized for maximum load
of all zone valves.
Snap Set Connection
• For easy wiring between water heater thermostat and boiler controls see Installation Wiring
section pages 15 through 18.
• Make sure snap set is firmly snapped together
after wiring.
Snap Set Wiring
3. Refer to control component instructions
packed with boiler for application information.
4. An optional service switch may be installed in
water heater electrical circuit. This switch
would only shut off the water heater, not the
home heating system. Do not shut off water
heater if there is a chance of freezing.
5. All electrical contacts shown do not have
power applied - off the shelf condition. See
pages 15 thru 18.
15
Page 18
Fig. 12:
Optima Zone Panel SZC5 with Zone Pumps Wiring
16
Page 19
Fig. 13:
Optima Zone Panel SCZ5 with Zone Valves Wiring
17
Page 20
H
N
High Vo l t a g e
120
V
.A.C.
24
V.A.C.
Room
Thermostat
Zone 1
Additional zones
Additional zones may
be added as shown above
Transformer
(Power)
Zone Valve
Zone Valve
1
2
C
W
ater Heater
Thermostat
Snap-Set
Water
Heater
Z
one
*Isolation Relay
Boiler
Thermostat
Terminals
* Use isolation relay on
3-wire zone valves with
non-isolated end switches.
Transformer and boiler
control can burn out if
isolation relay is not used
Priority
Relay
H
N
High Voltage
120
V.A.C.
24
V
.A.C.
Room
Thermostat
Zone 1
Additional zones
Additional zones may
be added as shown above
Transformer
(
Power)
Zone Valve
Zone Valve
1
2C
W
ater Heater
Thermostat
Snap-Set
W
ater
Heater
Z
one
Boiler
Thermostat
Terminals
High Voltage
Low Voltage
Boiler Low Voltage
Priority
Relay
Installation - Wiring
Fig. 14:
Typical 4-wire Zone Valve Zoning,
with Domestic Priority
Fig. 15:
Typical 3-wire Zone Valve Zoning,
with Domestic Priority
18
Page 21
Installation - Wiring
H
N
High Voltage
120
V
.A.C.
24
V.A.C.
Room
Thermostat
Room
Thermostat
Zone 1
Zone 2
Additional zones
Additional zones may
be added as shown above
Transformer
(Power)
Z
one Valve
Zone Valve
Zone Valve
1
2
C
Water Heater
Thermostat
S
nap-Set
W
ater
H
eater
Z
one
*Isolation Relay
Boiler
Thermostat
Terminals
* Use isolation relay on
3-wire zone valves with
non-isolated end switches.
Transformer and boiler
control can burn out if
isolation relay is not used
H
N
High Voltage
120
V.A.C.
2
4
V.A.C.
Room
Thermostat
Room
Thermostat
Zone 1
Zone 2
Additional zones
Additional zones may
be added as shown above
T
ransformer
(Power)
Zone Valve
Zone Valve
Zone Valve
1
2C
W
ater Heater
T
hermostat
Snap-Set
W
ater
Heater
Zone
Boiler
Thermostat
Terminals
High Voltage
Low Voltage
Boiler Low Voltage
Fig. 16:
Typical 4-wire Zone Valve Zoning,
without Domestic Priority
Fig. 17:
Typical 3-wire Zone Valve Zoning,
without Domestic Priority
19
Page 22
2
T
T
1
4
3
5
6
Circulator
Z
one 1
Thermostat
zone 1
Honeywell
R845A
R
elay
120
H
V
A C
N
2
T
T
1
4
3
6
Circulator
Zone 2
Thermostat
z
one 2
5
2
T
T
1
4
3
6
Water
Heater
Circulator
Water Heater
Thermostat
Snap-Set
5
1
2
C
Boiler
Thermostat
Terminals
Priority Relay
2
T
T
1
4
3
5
6
Circulator
Zone 1
Thermostat
zone 1
Honeywell
R845A
R
elay
120
H
V
A C
N
2
T
T
1
4
3
6
Circulator
Zone 2
T
hermostat
zone 2
5
2
T
T
1
4
3
6
Water
Heater
Circulator
Water Heater
Thermostat
Snap-Set
5
1
2
C
High Vo l t a g e
Low Vo l t a g e
Boiler
Thermostat
Terminals
Installation - Wiring
Fig. 18: Fig. 19:
Typical Circulator Zoning
with Domestic Priority
Typical Circulator Zoning
without Domestic Priority
20
Page 23
Installation - Wiring
T
T
1
4
3
5
6
Circulator
Z
one 1
T
hermostat
zone 1
Honeywell
R
845A
C
irculator
Relay
120
H
VAC
N
2
T
T
1
4
3
6
Circulator
Zone 2
Circulator
Zone 3
T
hermostat
zone 2
Thermostat
zone 3
5
2
T
T
1
4
3
6
5
High Voltage
Low Voltage
To Boiler 24 VAC
Thermostat Leads
2
ON
PRIORITY
ZONING CIRCULATOR
CIRC
ON
PR1
LIVE
NEUT
TT
2
1
C
Water Heater
Thermostat Snap Set
Priority Zone
Circulator
Fig. 20:
Priority Zone Circulator Wiring
Note: Maximum of 4 total circulator
zone when wiring 1 zone for priority.
21
Page 24
A
B
Water Heater Start-Up
Filling the Inner (Domestic Water) Tank
CAUTION
• Never use water heater unless inner and
outer tanks are completely filled with water.
• Inner tank must be completely filled and
pressurized before pressurizing outer tank.
1. Close domestic water drain valve.
2. Open domestic water isolation valves for
water heater.
3. Vent air from inner (domestic water) tank by
opening nearest hot water faucet. Fill
domestic water tank completely by allowing
water to run until there is a constant flow of
water.
4. Close hot water faucet.
5. When tank is full, air will stop escaping,
and the automatic air vent will close. If air
vent does not seat properly (water leaks
out), remove cap A. Briefly push in valve B
and release it to clean valve seat. Screw cap
A on completely, See Fig. 19.
NOTICE
For proper operation of the air vent ensure
vent cap is tightened at all times. The air
vent is provided with a hydroscopic cap that
prevents leakage of water due to internal
membrane.
6. If antifreeze is used in boiler water, check
concentration. Boiler water (including additives) must be practically non-toxic, having
toxicity rating or class of 1, as listed in
Clinical Toxicology of Commercial Products
.
Filling the Outer (Boiler Water) Tank
CAUTION
• Never use water heater unless inner and
outer tanks are completely filled with water.
• Inner tank must be completely filled and
pressurized before pressurizing outer tank.
1. Close boiler water drain valve at boiler water
outlet of water heater.
2. Open water heater’s boiler water isolation
valves.
3. Allow air to escape from outer (boiler water)
tank by opening vent cap A on automatic air
vent, located on top of water heater. See Fig.
19.
4. Follow instructions furnished with boiler to
fill with water.
WARNING
Do not use automotive, ethylene glycol or
petroleum-based antifreeze. Do not use any
undiluted antifreeze. This can cause severe
personal injury, death or substantial property
damage.
22
Fig. 21:
Automatic Air Vent
Page 25
Water Heater Start-Up
DANGER
HOT WATER CAN SCALD!
• Water temperatures over 125ºF can cause
severe burns instantly, or death from scalds.
• Feel water before bathing or showering.
• Consumer Product Safety Commission and
some states recommend temperatures settings of 130ºF or less. Setting thermostat
higher than 130ºF will increase risk of scald
injury and cause severe personal injury or
death.
• Water heated to a temperature suitable for
clothes washing, dish washing and other sanitizing needs will scald and cause permanent
injury.
• Children and elderly, infirm, or physically
handicapped persons are more likely to be
injured by hot water. Never leave them
unattended in or near a bathtub. If anyone
using hot water in the building fits this
description, or if state laws or local codes
require certain water temperatures at hot
water faucets, take special precautions.
General Notes
• Household water usage patterns will affect
water temperature at any faucet or shower.
Occasionally check temperature at each point
of use, then adjust thermostat accordingly.
Always recheck temperature after adjusting
thermostat.
• When hot water is used in repeated small quantities, a “stacking” effect can develop in the
water heater. The upper layer of water in tank
can be hotter than lower layer.
• Lowering the thermostat setting or installing
automatic mixing valves as indicated in these
instructions will reduce water temperature levels.
Consult your installer or service technician.
WARNING
At no time should boiler limit control be set
above 210ºF. This can cause severe personal injury, death or substantial property
damage if ignored.
- Install an automatic mixing valve at
water heater or at each hot water faucet,
bath and shower outlet. Selection and
installation must comply with valve
manufacturer’s recommendation and
instructions.
- Use the lowest practical temperature setting.
- Check water temperature after any
adjustment. You must follow
“Adjusting the Water Heater
Thermostat” procedures.
23
Page 26
Temperature
Up
Temperature
Down
Water Heater Start-up
Adjusting the Water Heater Thermostat
Water heater thermostat is factory set to its
lowest temperature. This may or may not be
suitable for your needs.
Turn thermostat knob clockwise to
increase water temperature.
Turn thermostat knob counter-clockwise
to decrease water temperature.
WARNING
Studies have indicated that dangerous bacteria, including legionella, pneumophila, can
form in the potable water distribution system if certain minimum water temperatures
are not maintained. Contact your local
health department for more information.
• Check water temperature at a hot water faucet
immediately after first heating cycle. Further
temperature adjustment may be necessary as
water heating system is used. Recheck water
temperature at faucet after adjustment.
• When adjusting thermostat, be sure boiler limit
control is set a minimum of 20ºF higher.
SMART Series Knob
24
Page 27
Water Heater Maintenance
Maintenance Schedule
Annual service by qualified service technician
should include the following:
Any procedure required by local codes.
Check air vent operation.
Verify system pressure. Air venting procedure may require adding water to bring system up to pressure, typically 12 psig.
Manually operate T&P relief valve at least
once a year. This will release some hot water.
WARNING
Before operating T&P relief valve, make
sure no one is in front of or around T&P
relief valve discharge piping. Hot discharge
water can cause severe personal injury or
substantial property damage.
Move operating lever to open position for a
few seconds and then move it back, allowing it
to snap closed. After T&P relief valve is operated, if it continues to release water, close cold
water inlet to water heater immediately.
Follow draining instructions, to relieve pressure from the inner tank and replace T&P relief
valve. If T&P relief valve weeps periodically,
it may be due to thermal expansion see
Thermal Expansion, page 5. Do not plug T&P
relief valve or discharge piping.
DANGER
Plugging T&P relief valve or discharge piping can cause excessive pressure in water
heater, resulting in severe personal injury,
death, or substantial property damage.
Follow instructions on circulator to oil it, if
required.
Check mixing valve, valves, pipes and fittings for leaks.
Check function of field-installed controls
and valves. See component manufacturer’s
instructions.
Review homeowner’s maintenance responsibilities and their frequencies, including any
not listed in the following section.
Homeowner monthly maintenance to include:
Check air vent operation.
• Automatic air vent - remove hygroscopic
cap. Briefly push in valve and release it to
clean valve seat. Screw cap on completely.
If air vent does not operate, call qualified
service technician.
Visually check valves, pipes and fittings for
leaks. Call qualified service technician to
repair leaks.
Filling Water Heater
See “Filling the Inner (Domestic Water) Tank and
“Filling the Outer (Boiler Water) Tank” on page 22.
Draining Water Heater
Drain water heater if it will be shut off and exposed
to freezing temperatures. Freezing water will
expand and damage water heater.
• If boiler water contains sufficient
antifreeze, then only the domestic water
needs to be drained.
WARNING
Close boiler water isolation valves and
relieve system pressure to below 15 psig in
outer tank before draining inner tank to
prevent damage to inner tank.
• If boiler water does not contain sufficient
antifreeze, then the boiler water and
domestic water must be drained.
If antifreeze is used in boiler water, check concentration. Boiler water (including additives) must be
practically non-toxic, having toxicity rating or
class of 1, as listed in Clinical Toxicology of
Commercial Products. A maximum 50/50 mixture
of inhibited propylene glycol is recommended.
Follow antifreeze manufacturer’s instruction.
25
Page 28
Water Heater Maintenance
WARNING
Do not use automotive, ethylene glycol or
petroleum-based antifreeze. Do not use
any undiluted antifreeze. This can cause
severe personal injury, death or substantial
property damage.
WARNING
Water from opened drain valves, unions
and other connections may be extremely
hot. To avoid severe personal injury, death
or substantial property damage:
- Tighten all drain hose connections.
- Direct hot water away from all persons.
Draining Inner (Domestic Water) Tank
BEST PRACTICE
There are 3 methods typically used in the
draining of the inner tank. The first method
outlined as Option 1 is to siphon the water
out. This method is typically the easiest to
perform, but may be lengthly in time to complete. The second method, shown as Option 2,
uses compressed air. This method is more
complicated however it is generally quicker
in draining the tank. The final method,
Option 3, use a pump to drain the tank. As
with Option 2, Option 3 is generally more
complicated, but is quicker in draining the
tank.
NOTICE
Prior to draining the inner tank, ensure the
following is completed:
1. The snap-set wiring connection at the
water heater is disconnected.
2. The DHW system supply isolation valve
is closed.
3. The outer (boiler water) tank pressure is
less than 15 psig.
Reference domestic piping diagrams Figs. 1,
2 and 3B on page 8 and 9.
Draining Inner Tank - Option 1
1. Connect a hose to the domestic water drain
valve at the cold water inlet. The hose should
extend to a drain at floor level to allow siphoning of the domestic inner tank.
2. Open a hot water faucet at the highest point
above the water heater.
3. Open the domestic water drain valve to start
the siphoning of the domestic inner tank.
4. When draining is complete, close the hot
water faucet and the domestic drain valve.
Draining Inner Tank - Option 2
1. Connect a hose to the domestic water drain
valve at the cold water inlet. Direct the hose to
a proper drain/suitable place for drainage.
2. Close the isolation valve on the DHW system
hot outlet of the water heater.
3. On the hot water outlet piping between the
water heater and the isolation valve install a
shrader (air tank) valve or some other fitting or
means that allows connection of an air hose
from a compressor.
4. Open the domestic water drain valve on the
cold water inlet.
26
Page 29
5. Apply compressed air at a maximum regulated
pressure of 40 psig.
6. When draining is complete, remove the air
hose and fittings needed to connect the air
hose.
Draining Outer (Boiler Water) Tank
1. Disconnect snap set wiring connection at
water.
2. Close boiler water isolation valves between
boiler and water heater.
7. Close the domestic water drain valve on the
cold water inlet and open the isolation valve on
the hot water outlet.
Draining Inner Tank - Option 3
1. Connect the suction side of the pump to the
domestic water drain valve using a hose and/or
piping fittings.
2. Connect a hose to the discharge side of the
pump. Direct the hose to a proper drain or a
suitable place for drainage.
3. Open a hot water faucet at the highest point
above the water heater.
4. Open the domestic water drain valve and start
the pump to begin draining the inner tank.
5. When draining is complete stop the pump,
close the hot water faucet and close the domestic drain valve. Remove the pump and all
hoses and fittings.
3. Connect hose to boiler water drain valve at
water heater. Open and drain water to a safe
place.
4. To speed draining procedure, loosen air vent
on top of tank.
5. When draining is complete, close drain valve
and retighten air vent.
27
Page 30
Replacement Parts
SMART Series
Item Part # Models Description
1 P3KITAV01 All Air vent, automatic
2
3
4
5
6
7
(Not shown)
8 P3KITWRS01 All Snap-set wire harness
9 P3KNB02 All Knob
10 P3CVR04 All Cover plate
P3KITTH01 All Aquastat - 160ºF residential
P3KITTH03 All Aquastat - 194ºF commercial
P3KITBTM02 SMART 30, 40, 50 60
Bottom capP3KITBTM03 SMART 80, 100
P3KITBTM04 SMART 120
P3KITTOP02 SMART 30, 40, 50 60
Top capP3KITTOP03 SMART 80, 100
P3KITTOP04 SMART 120
P3DW05 SMART 30
P3DW01 SMART 40
P3DW02 SMART 50
P3DW03
P3DW04
P3WKITDT01 SMART 30
P3WKITDT02 SMART 40
P3WKITDT03 SMART 50
P3WKITDT04 SMART 60
P3WKITDT08
P3WKITDT09 SMART 120
P3WKITDT01 SMART 30
P3WKITDT02 SMART 40
P3WKITDT02 SMART 50
P3WKITDT01 SMART 60
P3WKITDT08
(cut to length)
SMART 60
SMART 80
SMART 100
SMART 120
SMART 80
SMART 100
SMART 80
SMART 100
SMART 120
Drywell
Dip tube
Dip Tube - recirculation (optional)
28
Page 31
Replacement Parts
10
2
8
9
Thermostat
Cover Plate
Assembly
Located Below Thermostat
Cover Plate Assembly
6
3
4
5
SMART
Thermostat Cover Plate Assembly
29
Page 32
Water Heater Specifications
E
F
Hot Water
Outlet
Cold Water
Inlet
Auxiliary
Connection
Thermostat
& Cover Plate
Air Vent
B
A
C
D
C
old Water
I
nlet
Hot Water
Outlet
Auxiliary
Boiler
Return
Boiler
Supply
Top View
Rear View
30
Page 33
Performances
MODEL
oiler Heating
B
Capacity MBH
eak Flow
P
gal./ 10 min.
st Hour Flow
1
Gal./Hour
ontinuous Flow
C
Gal./ Hour
irculator
C
Min. GPM
SMART 30 87 40 140 115 5
SMART 40 112 50 180 150 7
SMART 50 140 65 220 185 8
SMART 60 270 100 410 360 16
SMART 80 300 125 460 400 18
SMART 100 337 150 525 450 25
SMART 120 420 190 650 560 28
Conditions:
- 50ºF Domestic cold water inlet temperature
- 140ºF Domestic hot water outlet temperature
- 200ºF Boiler water supply temperature
MODEL
Boiler Heating
Capacity MBH
SMART 30 115 60 235 210 8
Peak Flow
gal./ 10 min.
1st Hour Flow
Gal./Hour
Continuous Flow
Gal./ Hour
Circulator
Min. GPM
SMART 40 130 70 270 240 9
SMART 50 180 95 370 330 12
SMART 60 320 145 635 590 21
SMART 80 340 165 690 630 24
SMART 100 380 185 775 700 26
SMART 120 445 235 915 820 30
Conditions:
- 50ºF Domestic cold water inlet temperature
- 115ºF Domestic hot water outlet temperature
- 200ºF Boiler water supply temperature
31
Page 34
Additional quality water heating equipment available from: Triangle Tube
An
Company
Prestige Condensing Wall Mounted Boiler
- 96% AFUE - Energy Star
- Fully modulating
- Natural gas or propane
- Stainless Steel Contruction
- Direct vent PVC, CPVC, PP and SS
- Outdoor Reset
- Low NOx
Challenger Solo
- Up to 95% AFUE
- Fully modulating
- Natural gas propane
- Combination copper water tube/aluminum block
heat exchanger
- Direct vent, PVC, CPVC, PP and SS
- Outdoor reset
- Low NOx
Optima Controls
- SCC4 Multiple modulatin boiler control
- SCCX6 Multiple boiler control extension
- SZC5 Zone control panel
- S3S Three stage boiler control
- SMV Mixing valve control
- SIM Injection mixing control
- SSM Snow melt control
Freeway Center - 1 Triangle Lane - Blackwood, NJ 08012
(856) 228 8881 Fax (856) 228 3584
www.triangletube.com / sales@triangletube.com.
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