The F-25/30/35/40 & 45 Combination Heaters 90870 CONFORMS TO ANSI Z 21-10-3/UL 732 CERTIFIED TO CSA B 140.12 CGA/CAN 1-4.3-M85 - Input from 100,000 to 199,000 Btu/hr - * I N S TALLAT I O N AN D MAI N T E NAN C E * M A N U A L NOTICE Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installation in order to gain warranty coverage.
Table of Contents PRODUCT AND SAFETY INFORMATION Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Product Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Operating Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Code Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents U-Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13 Domestic Drain Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Multiple Units Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Storage Tank Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 TR/Smart Series Application. . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product & Safety Information The following terms are used throughout this manual to bring attention to the presence of potential hazards or to important information concerning the product. DANGER NOTICE Indicates the presence of a hazardous situation which, if ignored, will result in death, serious injury or substantial property damage. Indicates special instructions on installation, operation or maintenance, which are important to equipment but not related to personal injury hazards.
Product & Safety Information WARNING . Protection must be taken against excessive temperature and pressure! Bacteria can develop in the domestic water system if certain minimum water temperatures are not maintained. TO PROTECT AGAINST EXCESSIVE TEMPERATURE AND PRESSURE DANGER Water temperature over 125ºF can cause severe burns instantly or death from scalds. • • Children, disabled and elderly are at highest risk of being scalded. - Never leave them unattended in or near shower, bathtub or sink.
Product & Safety Information DANGER WARNING Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system which has been under water. Should overheating occur or the gas supply fails to shut off, turn OFF the manual gas control valve external to the appliance.
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.
Pre-Installation Items SECTION I - Pre-Installation Items Ensure the ELITE and its controls are protected from dripping or spraying water during normal operation or service. 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.
Pre-Installation Items BEST PRACTICES Installer should provide a solid brick or concrete foundation pad, at least 2 inches above the floor level if: To provide serviceability to the unit it is recommended that the following clearances be maintained: - 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. Top and vent hood area - 36 inches.
Combustion Air and Venting SECTION II - Providing Air 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.
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 ance not connected to the common vent system.
Unit Preparation SECTION III - Unit Preparation NOTICE Handling Instructions The ELITE is generally easier to handle and maneuver once removed from the shipping carton and pallet. 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.
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. 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. WARNING Leaks must be repaired immediately when detected.
Domestic Piping SECTION IV - Domestic Piping CAUTION 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. • The Temperature / Pressure relief valve is not intended for constant duty, such as relief of pressure due to normal thermal expansion.
Domestic Piping 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. • WARNING DO NOT install any valves between the T&P relief valve and the discharge piping.
Domestic Piping 3. Solder the U-Tube Assembly onto the adapter. (See Fig. 1) 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. 4.
Domestic Piping TR/SMART Series Application The primary piping to the TR/SMART Series tank must comply with the piping methods details in SECTION V - Primary Piping or with other recognized piping methods. For applications requiring large volumes of domestic hot water over an extended period, the installer may include a Triangle Tube TR/SMART Indirect Water Heater in conjunction with the ELITE. (See Fig.
Domestic Piping Optional recirculation line 3 7 2 3 1 To dishwasher if permitted by codes 12" Heat trap 3 9 Cold water inlet 3 4 6 Note: All shut off valves shown in this figure must be closed when siphon draining the ELITE 8 Fig. 3: ELITE With Recirculation 7 Optional recirculation line 2 3 1 12" Heat trap 3 9 4 3 6 8 Fig. 4: 1. 2. 3. 4.
Domestic Piping Domestic Piping 3 2 7 12" Heat trap 1 To dishwasher if permitted by codes 3 9 4 3 Cold water inlet 6 3 8 2 7 Fig. 5 : ELITE with Storage Tank 3 7 2 3 12" Heat trap 1 To dishwasher if permitted by codes 3 9 4 6 8 Fig. 6: 1. 2. 3. 4. ELITE with TR/SMART Indirect Water Heater Mixing valve with check valve Flow check valve Shut off valve Backflow preventer or pressure reducing valve* 6. 7. 8. 9.
Primary Piping SECTION V - Primary Piping Expansion Tank and Makeup Water General Piping Requirements Ensure the expansion tank is properly sized for the outer tank volume (22 gallons) and the system volume and temperature. Low Water Cutoff Device - The ELITE is equipped with a factory installed pressure switch style Low Water Cut Off device. - The minimum operating system pressure allowable with this device is 10 psig.
Primary Piping Install a separate circulator for each zone of space heating. CAUTION DO NOT install automatic air vents on a closed-type expansion tank system. Air must remain in the system and be returned to the expansion tank to provide an air cushion. An automatic air vent would cause air to be vented from the system resulting in a water-logged expansion tank. To control the zone circulators refer to Fig. 19, page 35.
Primary Piping NOTICE NOTICE If the radiant system tubing contains no oxygen barrier, a stainless steel heat exchanger must be used. Failure to install a heat exchanger could lead to premature failure of the outer tank and void any warranty claim. To ensure adequate flow rate through the ELITE, maintain a minimum 1 inch diameter on the system piping connecting the unit to and from the primary / secondary connection.
Primary Piping Near Appliance Piping 12" Max. 2 6 2 7 To system From system 4 2 Supply flow 2 Cold Water fill supply 3 1 3 8 12" Max. 2 5 2 4 2 Cold Water fill supply From system 7 To system Supply flow Return flow 2 1 8 2 Return flow 2 Fig. 7 : To system Near Appliance Primary Piping with a Diaphragm Type Expansion Tank 12" Max. 2 Supply flow Fig.
Primary Piping 2 6 3 3 2 2 L O A D 12" max. 2 6 1 L O A D • Size primary manifold for total flow of all circulators • Size each circulator to individual circuit requirements • Install balancing valves to adjust flow to distribute heat to all zones 2 2 2 3 3 5 2 Fig. 8: Primary piping - Zoning with Circulators 6 2 4 4 12" max. 1 2 2 L O A D • L O A D 2 Install balancing valves to adjust flow to distribute heat to all zones 2 2 5 Fig.
Primary Piping 2 LOAD 6 M H C 3 7 5 2 8 1 5 Note: Adjust system temperature valve to establish maximum supply/return temperature differential of 30ºF and a minimum 130ºF return water temperature to the ELITE 2 Fig. 10: Primary Piping - Low Temperature Radiant System 2 Baseboard Load 6 2 12" Max. 3 2 1 7 2 12" Max. H 6 M Radiant Load C 8 3 2 6 2 12" Max. 2 3 2 Air Handler Load Fig. 11: Primary Piping - Multi Temperature System 1. 2. 3. 4.
Pu sh B u t t o Re set Switch Dom es II - Pha Primary Temperature/Pressure 23 as e IIIP-has Primary Heating 2 e IIIP-has as Domestic Heating Pu sh B u t t o Re set Switch Hot Water Specialists TriangleTube Primary Temperature/Pressure Fig. 12: Primary Piping - Multi Units Installation Unit Circulator Shut Off Valves Flow Check Valve System Circulator Hot Water Specialists TriangleTube 1 as e IIIP-has Primary Heating heS 1. 2. 3. 4.
Venting SECTION VI - Venting The chimney must extend a minimum 3 feet above the highest point where it passes through the roof and 2 feet higher than any portion of the building within 10 feet. Oil Vent - General Requirements WARNING The cross sectional area of the chimney and the height must be increased at minimum 4% per 1,000 feet of elevation above sea level.
Venting Install a barometric control device in the vent connector as shown in Fig. 13 and 13A and adjust per the manufacturer’s instruction when excess draft needs to be relieved or when applicable codes require a device. - Note that prevailing winds could cause nuisance lockouts, freezing of condensate and water/ice build-up may occur on buildings, plants and roofs.
Venting Gas Venting -General Requirements BEST PRACTICE The venting system must be installed in accordance with: - NFPA 54 National Fuel Gas Code, ANSI Z223.1. - NFPA 211 Standard for Chimneys, Vent and Solid Fuel Burning Appliances. For installations in Canada the venting system must be installed in accordance with: - CGA / B149 Installation Code for Gas Burning Equipment.
Venting Vent Connectors - - When a vent connector must be located in or pass through an un-conditioned space, attic or crawl space, that portion of the vent connector must be listed as Type B or other approved material having equivalent insulation qualities. The minimum clearance to combustibles for Type B vent connectors shall be 1 inch or per vent manufacturer’s instructions.
Fuel Piping SECTION VII - Fuel Piping WARNING Gas Supply Piping Connection Do not check for gas leaks with an open flame. Use a gas detection device or bubble test. Failure to check for gas leaks can cause severe personal injury, death or substantial property damage. NOTICE The gas supply piping must be installed in accordance to all applicable local, state and national codes and utility requirements. 5. Use pipe dope compatible with natural and propane gases.
Fuel Piping Pipe Sizing - Natural Gas Pipe Sizing - Propane Gas 1. Refer to Table 1 for pipe length and diameter requirements. Based on rated ELITE input (divide by 1,000 to obtain cubic feet per hour). 1. Contact the local propane gas supplier for recommended sizing of piping, tanks and 100% lockup gas regulator. - - Table 1 is based on Natural Gas with a specific gravity of 0.60 and a pressure drop through the gas piping of 0.30”w.c.. Propane Gas Supply Pressure Requirements 1.
Fuel Piping the spillage of oil in the event of an oil line break. Support oil line as required by local codes. General Oil Piping Guidelines Location and installation of oil tanks, oil piping and burners must comply with: - NFPA 31, Standard for the Installation of Oil-Burning Equipment - Local codes and regulations - Manufacturer’s information provided with the burner and oil pump.
Internal Wiring General Requirements SECTION VIII - Internal Wiring WARNING ELECTRICAL SHOCK HAZARD. For your safety, disconnect electrical power supply to the unit before servicing or making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. - Wiring must be N.E.C Class 1. - If original wiring as supplied with the unit must be replaced, use only type 90ºC wire or equivalent.
Internal Wiring Room T-Stat Snap-Set C LWCO Burner Circulator 1 B B W B B Relay R1 BL BL 1 3 4 6 Wire Color Code Y B Relay R2 1 3 4 6 Transformer BL B B B B W V T T R G BL Y BL Y V 14 13 12 11 10 9 8 7 B B B V T 6 5 3 4 2 1 G W T G Y O P P 2 G V Y BL C 1 Secondary T-Stat B G G C G 120V Incoming N H Supply Wiring Manual Reset Safety Limit 2 G C 1 Auto Reset Safety Limit 2 1 Primary T-Stat 120V Field Wiring (by others) 120V Factory
External Wiring ences of heat and cold, i.e. water pipes, areas of draft, lighting fixtures and fireplaces. SECTION IX - External Wiring Installation Compliance 4. Set the thermostat anticipator (if applicable) as follows: All field wiring made during installation must comply with: - - National Electrical Code NFPA 70 and any other national, state, provincial or local codes or requirements. - Set for 0.2 amps when wired directly to the Room Thermostat Snap-set.
External Wiring 4 Wire Zone Valve V.A.C. High Voltage Transformer (Power) 24 V.A.C. Room Thermostat Zone Valve Zone 1 Room Thermostat Zone 2 Zone Valve Additional zones may be added as shown above Additional zones C 1 To ELITE "Room Thermostat" Snap Set 3 Wire Zone Valve Transformer (Power) H 120 H V.A.C. High Voltage 24 V.A.C. Room Thermostat Zone Valve *Use isolation relay on 3-wire zone valve with non-isolated end switch.
External Wiring Thermostat zone 1 Honeywell R845A Relay T T T 2 1 120 VAC H N 4 3 5 6 Circulator Zone 1 Thermostat zone 2 T T 2 1 4 3 5 6 Circulator Zone 2 Additional zones may be added as shown above C 1 To ELITE " Room Thermostat" Snap Set Fig. 19: Field wiring with zone circulators.
External Wiring Thermostat Zone 2 Thermostat Zone 1 R L2 ZC L1 X1 X2 N H 120V C C Thermostat Zone 3 T1 T1 T2 T2 T3 T3 PR PR C1 C1 C2 C2 C3 C3 1 ELITE "Room Thermostat" Snap-Set Zone 1 Circulator Zone 2 Circulator Fig. 20: Typical Zone Relay Panel Wiring Storage Tank Thermostat T T T 120 VAC H N Honeywell R845A Relay 2 1 4 Bronze Circulator Fig.
Start-Up Preparation 4. Set the primary thermostat to the highest possible setting. NOTICE SECTION X - Start Up Preparation Check System Chemistry and Domestic Any water conditioning system must be installed and maintained in accordance with the water conditioner’s manufacturer’s specifications and within the operating guidelines of the ELITE. Water WARNING Do not use petroleum-base cleaning or sealing compounds in the primary system.
Start-Up Preparation Filling the Inner (Domestic) Tank and System NOTICE System water including additives must be practically non-toxic, having a toxicity rating or Class of 1, as listed in Clinical Toxicology of Commercial Products. WARNING Proceed with filling instructions for the inner and outer tanks only after ensuring the water meets the requirements listed in this installation manual. Failure to comply could result in damage and improper operation of the unit.
Start-Up Preparation 3. Fill the outer tank to correct system pressure. Correct pressure will vary with each application. WARNING Propane installations only - The propane supplier mixes an odorant with the propane to make its presence detectable. In some cases the odorant can fade and the gas may no longer have an odor. NOTICE Typical residential system fill pressure is 12 psi. System pressure will increase when system temperature increases. Operating pressure of the system should never exceed 25 psi.
Start-Up Procedures SECTION XI - Start-Up Procedures interfere with circulation creating heat distribution problems and system noise. Final Checks Before Start-up Check Vent Piping Verify the ELITE and the primary and domestic systems are full of water and all system components are correctly set for operation. Check for gas-tight seal at every connection and seam of the venting. Verify Start-up Preparation items outlined on pages 37 thru 39 have been completed.
Start-Up Procedures Measure Input - Natural Gas Only WARNING 1. Operate the unit for approximately 10 minutes. A combustion test must be performed after any burner adjustments are made. Allow the unit to operate for approximately 10 minutes after adjustment before measuring any combustion levels. Failure to comply with these procedures could result in severe personal injury, death or substantial property damage. 2. Turn off all gas appliances within the building. 3.
Temperature Limits SECTION XII - Temperature Limits NOTICE DANGER To adjust the thermostat settings: Studies have indicated that dangerous bacteria can form in the potable water distribution system if certain minimum water temperatures are not maintained. For prevention of this, it is recommended that the Secondary Thermostat be set as shown in Fig. 23 and maintained at 130ºF to 140ºF.
Temperature Limits Setting the Thermostatic Mixing Valve NOTICE To calibrate the outlet temperature, allow the water to run for approximately 2 minutes and measure the water with a thermometer. To adjust the valve setting, rotate the knob clockwise to decrease the water temperature or counter-clockwise to increase the water temperature. NOTICE The thermostatic mixing valve controls the outlet hot water temperature delivered to the faucets.
Check-Out Procedures SECTION XIII- Check-Out Procedures Adjusted balancing valves and system limit controls to provide design temperatures to the primary space heating system. NOTICE Perform the following check-out procedures as outlined and check off items as completed. When procedures are completed, the installer should complete the installation record on page 45. In multiple zone applications, adjusted for correct flow of primary heating water to each zone.
Installation Record SECTION XIV - Installation Record Measured Rate of Input: Thermostatic Mixing Valve Setting: Measured Domestic Outlet Temperature: Combustion Readings: CO2 % Nozzle Size O2 % Nozzle Angle CO ppm Pump Pressure gph psig The following items were completed during installation: Installation instructions have been followed and completed Check-out procedures have been followed and completed Information regarding the unit and installation received and left with owner / maintenance pe
Replacements Parts SECTION XVII - Replacement Parts NOTICE Replacement Parts Refer to pages 47 and 49 for description and replacement part numbers. WARNING Replacement parts can be ordered and purchased through a local Triangle Tube distributor. When ordering parts, specify the Model Number and Serial Number. Include a description of the part and a replacement part number. Using modified or other manufacturer parts will not be covered by warranty and may damage or cause improper function of the unit.
Replacements Parts 2 4 6 1 3 8 5 7 Item Part No. Fig.
Replacements Parts 9 8 7 10 11 7 Fig. 25: Control Panel Components Item Part No.
Replacements Parts 12B 12A 24V Circuit 14 13 12 11 1 0 9 13 8 7 6 5 4 3 2 1 G 120 V Circuit Fig. 26: Electrical Panel Components Item Part No. Description 12A PGRKIT19 12B PGRKIT 19 13 PGRKIT18 R1 Relay - Controls Burner Function R2 Relay - Controls Domestic Priority & Circulator Part No.
Specifications 10 E 3 4 Domestic cold 5 Domestic 6 hot G A D F 1 13" Approx. 2 H 11" B C Fig. 27: Side view J Fig. 28: Rear view 6 4 7 3 10 5 8 Fig. 29: Top view of ELITE 1. Primary circuit, ø 1” NPT 7. Manual reset safety sensor & pressure indicator sensor, ø 3/4” NPT 2. Primary circuit drain valve connection, ø 1/2” NPT 3. Domestic temperature/pressure relief valve (150 psi), ø 3/4” NPT 8.
Specifications Table 3: Dimensional Data Type Input Nat. Gas Inner Tank Capacity Outer Tank Capacity Dimensions A B C D E F G H J Vent size Connections: TP Valve (domestic) Domestic water Primary connection Drain Empty weight Heat exchanger surface Btu/hr Gal Gal Inches ø ø ø lb Sq. Ft. F-25 100,000 20 22 F-30 120,000 20 22 F-35 140,000 20 22 F-40 165,000 22 18 F-45 199,000 22 18 59 21 22 54.5 14 54 8 11.5 5 5 59 21 22 54.5 14 54 8 11.5 5 5 59 21 22 54.5 14 54 8 11.5 5 5 67 21 22 60.5 14 62.
Additional quality water heating equipment available from Triangle Tube/Phase III Phase III Indirect Fired Water Heaters - Exclusive “Tank-in-Tank” design Stainless steel construction Available in 8 sizes and 2 models Limited LIFETIME residential warranty 15 year limited commercial warranty Self cleaning/self descaling design - For domestic water, snow melting, radiant floor, refrigeration Plates made of stainless steel, with a 99.