TriangleTube SMART 120 is an indirect fired water heater designed to provide efficient and reliable hot water for residential and commercial applications. With its unique heat exchanger design, it utilizes an external boiler to heat potable water, delivering up to 120 gallons of hot water at temperatures up to 194°F. Its compact size and zero-clearance installation allow for flexible placement, while its advanced features ensure safety and durability.
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Indirect Fired Water Heater
L
I
S T E D
Technical Specifications
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.
IMPORTANT
Date Revised 7/30/15
• When receiving SMART Water Heaters, any claims for damage or shortage 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.
2010-49 SMART IWH Manual
661A0300 - Rev C
Table of Contents
Product & Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Installation - Piping
Temperature & Pressure (T&P) Relief Valve . . . . . . . . . . . . . . . . . .4-5
Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Manual Air Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Water Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Vacuum Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
General Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Domestic Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-19
Water Heater Start-Up
Filling the Inner (Domestic Water) Tank . . . . . . . . . . . . . . . . . . . . .20
Filling the Outer (Boiler Water) Tank . . . . . . . . . . . . . . . . . . . . . . .20
General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Adjusting the Water Heater Thermostat . . . . . . . . . . . . . . . . . . . . . .22
Water Heater Maintenance
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Filling Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Draining Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23-25
Draining Inner (Domestic Water) Tank . . . . . . . . . . . . . . . . . . . . . . .24-25
Draining Outer (Boiler Water) Tank . . . . . . . . . . . . . . . . . . . . . . . . .25
Replacement Parts List
SMART Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-27
Water Heater Specifications
SMART Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
SMART Series Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
661A0300 - Rev C i
Product & Safety Information
Definitions
Following terms are used to bring attention to the presence of various risk levels, or to important information concerning product life.
DANGER
Hot Water Can Scald!
• Water temperatures over 125ºF can cause severe burns instantly or death from scalding.
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
Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.
• 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.
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.
– Make sure all connections are tight.
– Direct water flow away from any person.
BEST PRACTICE
Indicates recommendations made by ACV-
Triangle Tube for the installers which will help to ensure optimum operation and longevity of the equipment.
CAUTION
Protection must be taken against excessive temperature and pressure!
• Installation of a Temperature & Pressure
(T&P) relief valve is required.
NOTICE
ACV-Triangle Tube reserves the right to modify the technical specifications and components of its products without prior notice.
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.
1 661A0300 - Rev C
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.
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.
661A0300 - Rev C 2
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 section #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.
• Water quality limitations (based on E.P.A
National Secondary Drinking Water
Regulations):
- Chloride, less than 150 ppm or mg/l
- pH value min. 6, max. 8
- Total hardness 3 - 7 grains/gallon or 50-120 ppm or mg/l.
- Iron less than 0.3 ppm or mg/l.
- Aluminum, less than 0.2 ppm or mg/l.
- Copper, less than 1 ppm or mg/l.
- Manganese, less than 0.05 ppm or mg/l.
- Zinc, less than 5 ppm or mg/l.
BEST PRACTICE
In hard water areas (more than 7 grains of hardness) soften the cold domestic supply water to the appliance to prevent scaling.
Pre-Installation
NOTICE
Any water conditioning system must be installed and maintained in accordance with manufacturer’s specifications.
NOTICE cation 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.
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 661A0300 - Rev C
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:
- 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 100XL-
8 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.
Standard Installation
• Install T&P relief valve in the Auxiliary connection 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.
5 page 10).
T&P Relief Valve Discharge Piping
T&P relief valve discharge piping must be:
- 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 be:
- 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.
661A0300 - Rev C 4
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
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 water inlet (Fig. 1 and 2 page 8 and Fig. 3 on page 9).
the tee connection to:
- a suitable place for disposal or
- terminate within 12” of the floor
Commonwealth of Massachusetts Installation
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.
Auxiliary connection and insert an openend dip tube into the Auxiliary connection on top of water heater. As shown in Fig. 4 page 10.
• Install a 3/4” NPT elbow to the Auxiliary connection, see Fig. 5 page 10.
NOTICE the elbow connection to:
- a suitable place for disposal or
- terminate within 12” of the floor
Manual Air Vent
1. A manual air vent is factory installed.
2. Open manual air vent. Once the tank is full and air has stopped escaping, close the manual air vent.
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.
5 661A0300 - Rev C
Installation - Piping
General Piping
• For domestic water piping diagrams, see pages 8 through 10.
• See pages 11 through 14 for:
- Boiler water piping.
- Multiple water heater domestic and boiler piping.
• All plumbing must meet or exceed all local, state and national plumbing codes.
• Use pipe dope or tape suitable for potable water systems
• Use isolation valves to isolate system components.
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
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 lic dip tube.
• 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.
Domestic Piping 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 such as copper and galvanized iron pipe.
• If copper pipe is used for domestic water connections, first solder pipe to a threaded adapter boiler, disconnect piping to coil. Allow water to drain from coil. Do not plug tankless coil.
DANGER result in severe personal injury, death, or substantial property damage.
Chart 1
Water
Heater
Model
Connections (Inches)
Domestic
Water
Inlet/Outlet
Boiler Water
Supply/
Return
Auxiliary
Connection
Recirculation Dip Tube Draining Dip Tube Recommended
Minimum
Boiler Piping
Length
(Inches)
Diameter
(Inches)
Length
(Inches)
Diameter
(Inches)
Diameter
(Inches)
SMART 30 3/4 NPT
SMART 40 3/4 NPT
1 NPSC 3/4 NPSC
1 NPSC 3/4 NPSC
SMART 50 3/4 NPT 1 1/4 NPSC 3/4 NPSC
SMART 60 3/4 NPT 1 1/4 NPSC 3/4 NPSC
SMART 80 1 1/2 NPT 1 1/2 NPSC 1 1/2 NPSC
SMART 100 1 1/2 NPT 1 1/2 NPSC 1 1/2 NPSC
25
32
SMART 120 1 1/2 NPT 2 NPSC 1 1/2 NPSC 32
34
43
25
34
3/4
3/4
3/4
3/4
1 1/2
1 1/2
1 1/2
34
43
52
62
48
61
61
3/4
3/4
3/4
3/4
1 1/2
1 1/2
1 1/2
1
1
1
1 1/4
1 1/4
1 1/2
1 1/2
661A0300 - Rev C 6
Installation - Piping
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.
be installed in auxiliary connection using a close nipple assembly as shown Fig. 2, page 8. See
Chart 1 page 6 for diameter and length of dip tube.
• 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
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.
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.
• 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
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.
7 661A0300 - Rev C
Installation - Piping
Heat Trap
(Optional)
M
10
H
1
C
5
4
5
Loop
(Optional)
7
1
8
6 1
Cold Water
Inlet
Fig. 1: Standard Installation
Domestic Piping
SMART Series
Recirculating
Loop
2 3
4
1 5
5
Loop
(Optional)
1
7
8
6 1
Cold Water
Inlet
9
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(*)
661A0300 - Rev C 8
7. Drain valve
8. Thermal expansion tank (potable)
9. Recirculation dip tube
10. Thermostatic mixing valve (*)
(*) Optional devices may be required by local codes.
Installation - Piping
Recirculating
Loop
12" min.
Heat Trap
2
1 5
Heat Trap
(Optional)
3
4
5 1
7
8
6 1
Cold Water
Inlet
Fig. 3: 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 661A0300 - Rev C
Installation - Piping
Fig. 4: Drain Tube Assembly-
Commonwealth of
Massachusetts
Loop
(Optional)
4
1
M
10
H
C
5
5
Heat Trap
(Optional)
7
9
8
6 1
Cold Water
Inlet
11
Fig. 5: 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
661A0300 - Rev C 10
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.
Installation -Piping
1
3
6
2
5
1
1
Cold water inlet
4
Fig. 6: SMART System Piping with 3-Port Zone Valve
(Domestic Priority)
6
3
2
5
1
1
Cold water inlet
4
Fig. 7: 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 661A0300 - Rev C
Installation - Piping
Fig. 8: SMART System Piping with Zone Valves
(Non Domestic Priority)
Fig. 9: SMART System Piping with Zone Circulators
1. Shut-off valves
2. Circulator
3. Flow check valve
4. Expansion tank
661A0300 - Rev C 12
5. Drain valve
6. Feed valve
7. Air separator
Installation - Piping
Fig. 10: Multiple SMART Series Water Heater
System Domestic Piping - Parallel
Fig. 11: Multiple SMART Series Water Heater
System Domestic Piping - Series
• 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
• each hot water fixture.
shown in Fig. 1.
13
• Recommended for applications in which there is a
• A maximum of 3 water heaters may be piped in series.
• Utilize the lead (hot water outlet) SMART tank ther-
• Install automatic mixing valve at either the hot water fixture.
• Each tank should be piped with a drain as shown in
661A0300 - Rev C
Installation - Piping
Fig. 12: Multiple SMART Series Water Heater System Boiler
Piping Reverse Return Balanced Flow
Fig. 13: 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
661A0300 - Rev C 14
Installation - Wiring
Wiring Requirements Circulators
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.
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 19.
Zone Valves
• Transformer must be sized for maximum load of all zone valves.
Snap Set Connection
• For easy wiring between water heater thermosection pages 15 through 19.
• Make sure snap set is firmly snapped together after wiring.
Snap Set Wiring
15 661A0300 - Rev C
Installation - Wiring
Fig. 14: Typical 4-wire Zone Valve Zoning, with Domestic Priority
Water
Heater
Zone
Transformer
(Power)
H 120
V.A.C.
N
High Voltage
24
V.A.C.
Water Heater
Thermostat
Snap-Set
C
1
2
Zone Valve
Priority
Relay
Zone 1
Room
Thermostat Zone Valve
Additional zones
Additional zones may be added as shown above
High Voltage
Low Voltage
Boiler Low Voltage
Boiler
Thermostat
Terminals
Fig. 15: Typical 3-wire Zone Valve Zoning, with Domestic Priority
Water
Heater
Zone
Transformer
(Power)
H 120
V.A.C.
N
High Voltage
24
V.A.C.
Water Heater
Thermostat
Snap-Set
C
1
2
Zone Valve
Zone 1
Priority
Relay
Room
Thermostat Zone Valve
Additional zones Additional zones may be added as shown above
*Isolation Relay
* 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
Boiler
Thermostat
Terminals
661A0300 - Rev C 16
Installation - Wiring
Fig. 16: Typical 4-wire Zone Valve Zoning, without Domestic Priority
Water
Heater
Zone
Transformer
(Power)
H 120
V.A.C.
N
High Voltage
24
V.A.C.
Water Heater
Thermostat
Snap-Set
C
1
2
Zone Valve
Zone 1
Room
Thermostat
Zone Valve
Zone 2
Room
Thermostat Zone Valve
Additional zones
Additional zones may be added as shown above
High Voltage
Low Voltage
Boiler Low Voltage
Boiler
Thermostat
Terminals
Fig. 17: Typical 3-wire Zone Valve Zoning, without Domestic Priority
Water
Heater
Zone
Transformer
(Power)
H 120
V.A.C.
N
High Voltage
24
V.A.C.
Water Heater
Thermostat
Snap-Set
C
1
2
Zone Valve
Zone 1
Room
Thermostat
Zone Valve
Zone 2
Room
Thermostat Zone Valve
Additional zones
Additional zones may be added as shown above
*Isolation Relay
* 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
Boiler
Thermostat
Terminals
17 661A0300 - Rev C
Installation - Wiring
Fig. 18: Typical Circulator Zoning with Domestic Priority
120
H
VAC
N
Honeywell
R845A
Relay
T T
Thermostat zone 1
2 1 4 3 5 6
Circulator
Zone 1
T T
Thermostat zone 2
2 1 4 3 5 6
Water Heater
Thermostat
Snap-Set
C
2
1
T T
Circulator
Zone 2
2 1 4 3 5 6
Priority Relay
Fig. 19: Typical Circulator Zoning without Domestic Priority
120
H
VAC
N
Honeywell
R845A
Relay
T T
Thermostat zone 1
2 1 4 3 5 6
Circulator
Zone 1
T T
Thermostat zone 2
2 1 4 3 5 6
Water Heater
Thermostat
Snap-Set
C
2
1
T T
Circulator
Zone 2
2 1 4 3 5 6
Water
Heater
Circulator
Boiler
Thermostat
Terminals
High Voltage
Low Voltage
Water
Heater
Circulator
Boiler
Thermostat
Terminals
661A0300 - Rev C 18
Installation - Wiring
Fig. 20: Priority Zone Circulator Wiring
Note: Maximum of 4 total circulator zone when wiring 1 zone for priority.
120
H
VAC
N
Honeywell
R845A
Circulator
Relay
T T
Thermostat zone 1
2 1 4 3 5 6
Circulator
Zone 1
T T
Thermostat zone 2
Low Voltage
High Voltage
Water Heater
Thermostat Snap Set
2
C
1
CIRC
ON
Priority Zone
Circulator
ON
2 1 4 3 5 6
T T
Thermostat zone 3
Circulator
Zone 2
PR1 LIVE NEUT
T T
2 1 4 3 5 6
Circulator
Zone 3
To Boiler 24 VAC
Thermostat Leads
19 661A0300 - Rev C
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.
Filling the Outer (Boiler Water) Tank
CAUTION
• Never use water heater unless inner and outer tanks are completely filled with water.
5. When tank is full, and air stops escaping, close the manual air vent.
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.
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.
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 manual air vent, located on top of water heater.
4. Follow instructions furnished with boiler to fill with water.
661A0300 - Rev C 20
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 sethigher 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 unattended in or near a bathtub. If anyone using hot water in the building fits this description, or if state laws or local codes water faucets, take special precautions.
- 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.
General Notes
• Household water usage patterns will affect water temperature at any faucet or shower.
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
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.
21 661A0300 - Rev C
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
increase water temperature.
Turn thermostat knob counter-clockwise to decrease water temperature.
to
• 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.
WARNING
Studies have indicated that dangerous bacteria, including legionella, pneumophila, can tem if certain minimum water temperatures are not maintained. Contact your local health department for more information.
Temperature
Up
Temperature
Down
SMART Series Knob
661A0300 - Rev C 22
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. Manual 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.
Review homeowner’s maintenance responsibilities and their frequencies, including any not listed in the following section.
Homeowner monthly maintenance to include:
Check for air.
• Manual air vent-open and close briefly to release any air.
• Visually check valves, pipes and fittings for leaks. Call qualified service technician to repair any leaks.
Filling Water Heater
See “Filling the Inner (Domestic Water) Tank and
“Filling the Outer (Boiler Water) Tank” on page 20.
Draining Water Heater
Drain water heater if it will be shut off and exposed expand and damage water heater.
• If boiler water contains sufficient needs to be drained.
WARNING 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 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.
23
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 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
Follow antifreeze manufacturer’s instruction.
661A0300 - Rev C
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
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 3 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.
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.
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.
661A0300 - Rev C 24
Water Heater Maintenance
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.
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.
Draining Outer (Boiler Water) Tank
1. Disconnect snap set wiring connection at water heater.
2. Close boiler water isolation valves between boiler and water heater.
3. Connect hose to boiler water drain valve at water heater. Open and drain water to a safe place.
4. To speed draining procedure, open manual air vent on top of tank.
5. When draining is complete, close drain valve and close manual air vent.
25 661A0300 - Rev C
Replacement Parts
SMART Series
Item
1
2
3
4
5
6
7
(Not shown)
8
9
10
Part #
P3KITAV02
P3KITTH01
P3KITTH03
Models
All
All
All
P3KITBTM02 SMART 30, 40, 50 60
P3KITBTM03 SMART 80, 100
P3KITBTM04 SMART 120
P3KITTOP02 SMART 30, 40, 50 60
P3KITTOP03 SMART 80, 100
P3KITTOP04 SMART 120
P3DW05
P3DW01
P3DW02
SMART 30
SMART 40
P3DW03
SMART 50
SMART 60
SMART 80
SMART 100
P3DW04
SMART 120
P3WKITDT01 SMART 30
P3WKITDT02 SMART 40
P3WKITDT03 SMART 50
P3WKITDT04 SMART 60
P3WKITDT08
SMART 80
SMART 100
P3WKITDT09 SMART 120
P3WKITDT01 SMART 30
P3WKITDT02 SMART 40
P3WKITDT02 SMART 50
P3WKITDT01 SMART 60
P3WKITDT08
(cut to length)
SMART 120
P3KITWRS01 All
P3KNB02
P3CVR04
SMART 80
SMART 100
All
All
Description
Air vent, manual
Aquastat - 160ºF residential
Aquastat - 194ºF commercial
Bottom cap
Top cap
Drywell
Dip tube
Dip Tube - recirculation (optional)
Snap-set wire harness
Knob
Cover plate
661A0300 - Rev C 26
Replacement Parts
4
6
Thermostat
Cover Plate
Assembly
5
Located Below Thermostat
Cover Plate Assembly
3
SMART
8
2
9
10
2
Thermostat Cover Plate Assembly
27 661A0300 - Rev C
Water Heater Specifications
Air Vent
Cold Water
Inlet
F
Hot Water
Outlet
E
Top View
Auxiliary
Connection
D
Rear View
Auxiliary
661A0300 - Rev C 28
Performances
MODEL
SMART 30
SMART 40
SMART 50
SMART 60
SMART 80
SMART 100
SMART 120
Boiler Heating
Capacity MBH
87
112
140
270
300
337
420
Peak Flow gal./ 10 min.
40
50
65
100
125
150
190
1st Hour Flow
Gal./Hour
Continuous Flow
Gal./ Hour
140
180
220
410
460
525
650
Conditions: - 50ºF Domestic cold water inlet temperature
- 140ºF Domestic hot water outlet temperature
- 200ºF Boiler water supply temperature
115
150
185
360
400
450
560
Circulator
Min. GPM
5
7
8
16
18
25
28
MODEL
SMART 30
SMART 40
SMART 50
SMART 60
SMART 80
SMART 100
SMART 120
Boiler Heating
Capacity MBH
115
130
180
320
340
380
445
Peak Flow gal./ 10 min.
60
70
95
145
165
185
235
1st Hour Flow
Gal./Hour
Continuous Flow
Gal./ Hour
235
270
370
635
690
775
915
210
240
330
590
630
700
820
Conditions: - 50ºF Domestic cold water inlet temperature
- 115ºF Domestic hot water outlet temperature
- 200ºF Boiler water supply temperature
Circulator
Min. GPM
8
9
12
21
24
26
30
29 661A0300 - Rev C
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- 95% 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 94% AFUE
- Fully modulating
- Natural gas or propane
- Combination copper water tube/aluminum block heat exchanger
- Direct vent, PVC, CPVC, PP and SS
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- Low NOx
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- Construction of high quality corrosion resistant stainless steel (AISI 316) or titanium
- Specially designed built-in flow restrictor to assure maximum heat exchange
- Compact and light weight
- Available in 5 sizes that can accommodate any size pool or spa
661A0300 - Rev C
Triangle Tube - 1 Triangle Lane - Blackwood, NJ 08012 - (856) 228 8881 Fax (856) 228 3584 www.triangletube.com / [email protected].
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