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TriangleTube Delta, Installation And Maintenance Manual

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The MODULATING DELTA must be vented and supplied with combustion
and ventilation air as detailed in the MODULATING DELTA Vent
Supplement, which is included in the installation envelope. Once installation is
completed, inspect the vent and combustion air system thoroughly to ensure
systems are leak free, tight and comply with the instructions given in the
MODULATING DELTA Vent Supplement and are within all requirements of
applicable codes. Failure to comply with the installation requirements on the
venting and combustion air piping  and ventilation will cause severe personal
injury or death.

DANGER

Summary of Contents for Delta

Page 1: ...dulating Delta If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or death FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone...

Page 2: ...ion is completed inspect the vent and combustion air system thoroughly to ensure systems are leak free tight and comply with the instructions given in the MODULATING DELTA Vent Supplement and are within all requirements of applicable codes Failure to comply with the installation requirements on the venting and combustion air piping and ventilation will cause severe personal injury or death DANGER ...

Page 3: ...llations 6 Freeze Protection Feature 6 SECTION II APPLIANCE PREPARATION Handling Instructions 7 SECTION III DOMESTIC PIPING General Piping Requirements 8 Domestic Supply Pressure 8 Thermal Expansion 8 Water Hammer 8 Temperature Pressure Relief Valve 8 9 Thermostatic Mixing Valve 9 Mixing Valve Installation 9 Domestic Cold Water Supply Piping Assembly Installation 9 U Tube Assembly 9 10 Domestic Dr...

Page 4: ...adiant Heating with Mixing Valves 16 17 System Piping Multiple Appliances Installation 17 Primary Piping Diagrams 18 21 SECTION V GAS PIPING Gas Supply Piping Connection 22 Natural Gas Pipe Sizing Natural Gas 23 Natural Gas Supply Pressure Requirements 23 Propane Gas Pipe Sizing Propane Gas 24 Propane Gas Supply Pressure Requirements 24 SECTION VI INTERNAL WIRING General Requirements 25 Wiring Dia...

Page 5: ...4 Check Thermostat Circuit 34 SECTION IX START UP PROCEDURES Final Checks Before Start up 35 Appliance Start up 35 If Appliance Does Not Start Correctly 35 Check the Appliance and System 35 36 Start Up Operating Instructions 37 Set Domestic DHW Temperature 38 Operation Verification Domestic Hot Water 38 39 Set Primary CH Target Temperature 39 Operation Verification Space Heating 39 40 Control Disp...

Page 6: ...on Air Piping 50 Check Primary System 50 Check Domestic System 50 Check Expansion Tank 50 Check Primary Relief Valve 51 Check Temperature Pressure Relief Valve 51 Inspection of Ignition Electrode 51 Check All Gaskets 51 Check Control Wiring 51 Check Parameter Limit Settings 51 Perform Start Up and Checkout Procedure 51 Check Burner Flame 52 Check Flame Signal 52 Check Combustion Levels 52 Review w...

Page 7: ...cial instructions on installa tion operation or maintenance which are important to equipment but not related to personal injury hazards Indicates recommendations made by Triangle Tube for the installers which will help to ensure optimum operation and longevity of the equipment BEST PRACTICES NOTICE CAUTION WARNING DANGER The following terms are used throughout this manual to bring attention to the...

Page 8: ... installer must Fill inner tank prior to outer tank during start up Relieve primary system pressure below 15 psig prior to draining inner tank CAUTION WARNING DANGER DANGER Qualified Installer Prior to installing this product read all instructions included in this manual Perform all installation steps required in this manual in the proper order given Failure to adhere to the guidelines within this...

Page 9: ...iption or codes require specific water temperatures at hot water faucet we recommend a ensure the factory equipped thermo static mixing valve is installed and working properly b to set the thermostatic mixing valve for the lowest temperature which sat isfies your hot water need Protection must be taken against excessive temperature and pressure TO PROTECT AGAINST EXCESSIVE TEMPERATURE AND PRESSURE...

Page 10: ...A complies with National Standard Plumbing Code provided that Outer tank water including additives is practically non toxic having toxici ty rating or Class of 1 as listed in Clinical Toxicology of Commercial Products Outer tank pressure is limited to max imum 30 psig by approved relief valve Single wall heat exchangers are permitted under the Uniform Plumbing code Paragraph L3 2 if they satisfy a...

Page 11: ...ing or spray ing water during normal operation or service The MODULATING DELTA should be installed in a location so that any water leaking from the tank or piping connections or relief valves will not cause damage to the area surrounding the appliance or any lower floors in the structure When such a location is unavoidable a suitable drain pan with adequate drainage should be placed under the appl...

Page 12: ... is dirt sand gravel or other loose material The flooring is severely uneven or sloped The minimum foundation size required is 24 inches x 23 inches Residential Garage Installations When installing the MODULATING DELTA in a residential garage the following special pre cautions per NFPA 54 ANSI Z223 1 must be taken Mount the appliance with a minimum 18 inches above the floor level of the garage Ens...

Page 13: ...on to remove the wood shipment insert b Lift the carton over the appliance to remove If ceiling height is limited the carton maybe cut open using care not to damage the exterior jacket of the appli ance c Remove the front burner hood to pre vent damage prior to lifting the appli ance from the shipping pallet When lifting or moving the appliance do not use the burner or its components as a means of...

Page 14: ...ther mal expansion tank manufacturer s instruc tions for further information on installation and sizing The Temperature Pressure relief valve is not intended for constant duty such as relief of pressure due to normal thermal expansion Water Hammer Water hammer is the effect of sudden pres sure changes occurring in the domestic pip ing These pressure changes are typically the result of fast acting ...

Page 15: ...an aquastat The maximum recom mended setting of the aquastat is 10ºF lower than the thermostatic mixing valve setting For proper operation of the thermostatic mixing valve and to prevent potential scalding hazards the recirculation loop should be controlled by an aquastat DO NOT use continuous recirculation or timers Mixing Valve Installation 1 Remove the jacket top panel by pushing up on the corn...

Page 16: ...ose to the floor to aid in the siphon action required to drain the inner tank Multiple Appliances Installation For applications using multiple appliances the domestic piping should be piped using a bal anced manifold arrangement The installer should remove the thermostatic mixing valve from the appliances and install a single thermostatic mixing valve at the outlet of the hot water manifold The th...

Page 17: ...quired by local codes or installation requirements SMART Series Application For applications requiring large volumes of domestic hot water over an extended period the installer may include a Triangle Tube SMART Indirect Water Heater in conjunction with the MODULATING DELTA See Fig 6 page 13 The domestic system recirculation if used is directed to the SMART Series Tank The circu lator should be con...

Page 18: ...educing valve 6 Thermal expansion tank 7 Circulator controlled by aquastat 8 Domestic drain valve 9 Vacuum breaker 10 Recirculation Aquastat Note All shut off valves shown in this figure must be closed when siphon draining the MODULATING DELTA Optional devices may be required by local codes or installation requirements Optional 12 Heat trap 8 1 To dishwashe permitted by 3 Cold water inlet 4 3 3 6 ...

Page 19: ...ptional recirculation line Fig 6 MODULATING DELTA with SMART Indirect Water Heater Fig 5 MODULATING DELTA with Storage Tank 1 Mixing valve with check valve 2 Flow check valve 3 Shut off valve 4 Backflow preventer or pressure reducing valve 6 Thermal expansion tank 7 7A Circulator controlled by aquastat 8 Domestic drain valve 9 Vacuum breaker 10 Recirculation aquastat 11 Tank aquastat Optional devi...

Page 20: ...eater Should not be subject to conditions where freezing could occur Should not contain any shut off valves or obstructions No shut off valve should be piped between the appliance and the relief valve Failure to comply with the guidelines on installing the pressure relief valve and discharge piping can result in personal injury death or substantial property damage Low Water Cutoff Device The MODUL...

Page 21: ...mary water Expansion Tank and Makeup Water Ensure the expansion tank is properly sized for the outer tank volume approximately 20 gallons and the system volume and temperature Undersized expansion tanks will cause sys tem water to be lost through the pressure relief valve and cause additional makeup water to be added to the system Eventual primary tank failure can result due to this excessive make...

Page 22: ... It must supply only the primary loop Install a separate circulator for each zone of space heating To control the zone circulators refer to Fig 16 page 30 or Fig 17 Page 31 To ensure adequate flow rate through the MODULATING DELTA maintain a minimum 1 inch diameter on the system piping connecting the appliance to and from the primary secondary connec tion System Piping Zone Valves Connect the MODU...

Page 23: ...liance will begin high fire rate and shut down the primary circulator to prevent con densation from occuring within the appliance Size the heating system piping and circula tor to provide the flow needed for the radiant system To control the zone circulators reference Figs 16 or 17 pages 30 31 To ensure adequate flow rate through the MODULATING DELTA maintain a minimum 1 inch diameter on the syste...

Page 24: ...5 Circulator 6 Air Separator 7 Expansion Tank Diaphragm 8 Automatic Fill Valve 9 Isolation Valve 10 Zone Valve 11 Bypass Valve 12 Flow Check Valve Notes 1 Install a minimum of 12 straight pipe diameters upstream of all circulators 2 Adjust bypass for a mini mum of 3 gpm under any operating condition 3 Verify primary circulator is properly sized to overcome the system pressure drop and provide adeq...

Page 25: ...nimum of 6 straight pipe diameters upstream and down stream of closely spaced tees 4 Adjust pressure differential bypass valve on the zone with highest pressure drop to avoid velocity noise 1 Modulating Delta 2 Pressure Relief Valve 3 Automatic Air Vent 4 Drain Purge Valve 5 Circulator 6 Air Separator 7 Expansion Tank Diaphragm 8 Automatic Fill Valve 9 Isolation Valve 10 Zone Valve 11 Bypass Valve...

Page 26: ... Separator 7 Expansion Tank Diaphragm 8 Automatic Fill Valve 9 Isolation Valve 10 Zone Valve 11 Bypass Valve 12 Flow Check Valve 13 Mixing Valve Notes 1 Install a minimum of 12 straight pipe diameters upstream of all circulators 2 Install closely spaced tees a maxi mum of 4 pipe diameters center to center 3 Install a minimum of 6 straight pipe diameters upstream and down stream of closely spaced t...

Page 27: ...sion Tank Diaphragm 8 Automatic Fill Valve 9 Isolation Valve 10 Zone Valve 11 Bypass Valve 12 Flow Check Valve Notes 1 Install a minimum of 12 straight pipe diameters upstream of all circula tors 2 Install closely spaced tees a maximum of 4 pipe diameters center to center 3 Install a minimum of 6 straight pipe diameters upstream and down stream of closely spaced tees Fig 10 Primary Piping Zoning w...

Page 28: ...isconnect the MODULATING DELTA and its gas valve from the gas supply piping during any pressure test greater than 13 w c Do not check for gas leaks with an open flame Use a gas detection device or bub ble test Failure to check for gas leaks can cause severe personal injury death or substantial property damage 5 Use pipe dope compatible with natural and propane gases Apply sparingly only to the mal...

Page 29: ...0 lockup gas pressure regulator in the gas supply line if inlet pressure can exceed 13 w c at any time Adjust the lock up pressure regulator for 13 w c maximum DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pres sure This setting is suitable for natural gas and propane and requires no field adjustment Attempts by the installer to a...

Page 30: ...al gas and propane and requires no field adjustment Attempts by the installer to adjust or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage Prior to start up ensure the appliance is set to fire propane Check the rating label for the type of fuel Check the gas valve for propane conversion label If...

Page 31: ...ath Prior to servicing label all wires before disconnection Wiring errors can cause improper and dangerous operation Verify proper operation after servicing General Requirements Wiring must be N E C Class 1 If original wiring installed in the appli ance must be replaced use only type T 90ºC wire or equivalent The MODULATING DELTA must be electrically grounded as required by National Electrical Cod...

Page 32: ... Note 24V Wire Terminal Key Wiring Legend 7 Thermostat T T 8 Thermostat T T 9 Outdoor Sensor 10 Outdoor Sensor 11 External Limit Manual Reset 12 External Limit Manual Reset 13 External Limit Auto Reset 14 External Limit Auto Reset Mating Side of Male Plug Location in 9 Pin Connector 120V Wire Terminal Key L Incoming Supply L N Incoming Supply N G Incoming Supply G Wire Color Code Key BK Black W Wh...

Page 33: ...oper operation install the room ther mostat on an inside wall away from influ ences of heat and cold i e water pipes areas of draft lighting fixtures and fire places 3 Set the thermostat anticipator if applica ble as follows Set for 0 2 amps when wired directly to terminals 7 and 8 on the low voltage terminal strip located behing the con trol cover Set to match the total electrical power requireme...

Page 34: ...ze the system circulator shown as Item 5 in Fig 8 page 19 reference Fig 14 Installer to provide a Transformer Relay such as Honeywell R8285 or equivalent and Zone Valves with isolated end switch such as Honewell V8043 or equivalent Storage Tank Recirculation To energize the recirculation circulator between the MODULATING DELTA and a storage tank as shown as Item 7A in Fig 6 page 13 reference Fig 1...

Page 35: ...Voltage Terminal Strip 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 Zone Valve Zone Valve Isolation relay 7 8 29 4 Wire Zone Valve Fig 15 Multiple Zone Field Wiring Using Zone Valves 3 Wire Zone Valve Use isolation relay on 3 wire zone valve with non isolated end switch Transformer ...

Page 36: ...ltage Terminal Strip Circulator Zone 1 Thermostat zone 1 Honeywell R845A Relay 120 H VAC N Circulator Zone 2 Thermostat zone 2 Additional zones may be added as shown above 7 8 6 2 1 4 3 5 6 2 1 4 3 5 T T T T Fig 16 Field Wiring Using Zone Circulators ...

Page 37: ...ne 2 Circulator Zone 3 Circulator Thermostat Zone 2 Thermostat Zone 3 R C T1 T1 T2 T2 T3 T3 C3 C3 C2 C2 C1 C1 PR PR X2 X1 L1 L2 ZC H 7 8 Fig 17 Typical Zone Relay Panel Wiring T T Bronze Circulator Storage Tank Thermostat Honeywell R845A Relay 120 H VAC N 6 2 1 4 3 5 T T Fig 18 Storage Tank Recirculation Wiring ...

Page 38: ...must be installed and maintained in accor dance with the water conditioner s manufacturer s specifications and within the operating guidelines of the MODULATING DELTA Chlorinated Water Do not use the MODULATING DELTA inner or outer tank to heat a swimming pool or spa directly Maintain the chlorine level of the water in the inner and outer tanks at levels consid ered safe for drinking Flush Primary...

Page 39: ...Clinical Toxicology of Commercial Products Filling the Inner Domestic Tank and System Proceed with filling instructions for the inner and outer tanks only after ensur ing the water meets the requirements listed in this installation manual Failure to comply could result in damage and improper operation of the appliance Never operate the MODULATING DELTA unless both the inner and outer tanks are com...

Page 40: ...nd propane and requires no field adjustment Attempts by the installer to adjust or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage 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 ...

Page 41: ... Appliance Does Not Start Correctly 1 Verify CH parameter 2 and DHW para meter 3 Systems are turned ON or set to 01 Read the Boiler Display Parameter Section of the manual on page 42 for more information 2 Check for loose electrical connections blown fuse external or internal to the MCBA Control or open service switch 3 Is the gas supply valve open at the appli ance and meter 4 Is incoming gas sup...

Page 42: ...uld be within the range listed in Table 3 The CO level should not exceed 100 ppm when combus tion is correct The combustion levels should be mea sured at high and low firing rates refer to page 40 on how to set the firing rates If the combustion levels are not within the range given in Table 3 for the firing rate shut the appliance down and con tact Triangle Tube s Engineering Department Failure t...

Page 43: ...nce below and call your service technician or gas supplier 11 Replace the front jacket panel Make sure the panel is seated firmly in place and all mounting screws are tightened If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life 1 Set the room thermostat to lowest setting 2 Turn the service switch on the control pan...

Page 44: ...rge cycle The blower becomes energized and the 10 second pre purge cycle begins 2 The burner will begin the ignition sequence The control module will energize and open the gas valve and begin the spark for ignition If the burner flame proves within 4 5 sec onds the burner will begin to modulate to full input rate after an approximate 10 second flame stabilization period If the burner flame is not ...

Page 45: ...e has been disabled Parameter 2 should read as 00 for a verification 2 Set the room thermostat to the lowest setting 3 Turn off power to the appliance wait a few seconds and turn on power to the appliance 4 The following displays should occur A Self check on power up 0 No call for heat 5 Initiate a call for heat by raising the set point of the room thermostat to the highest setting The following d...

Page 46: ...play Standby Mode After the appliance is turned on the control panel will display STANDBY mode as shown in the figure above This is the standard mode for the MODULAT ING DELTA The control automatically returns to this mode after 20 minutes if no keys have been pressed on the display Any parameters that were modified are then enabled The first character shows on left side of display the current sta...

Page 47: ...gher than supply temperature Burner will remain OFF until corrected Supply temperature increased too quickly Burner will remain OFF for a 10 minute period Burner will recycle increasing waiting period 1 minute for a max 15 minutes LWCO pressure device or external limit terminals 13 14 is OPEN Burner off for 150 seconds auto reset 0 1 2 3 4 5 6 7 9 18 b 19 b 24 b 25 b 26 b 2 Display Function No blo...

Page 48: ...been saved To activate the parameters you changed press MODE once more which brings you into INFORMATION mode However if you do not press a key the system returns to STAND BY mode after 20 minutes and automatically enables the changes Note 1 This parameter is factory set to 140ºF It is important to note the control adds 46ºF to this setting to establish the operating limit dur ing a DWH call for h...

Page 49: ...s pressed after parameter 9 the dis play will show A 32 NFO I Measured CH outlet supply water temperature Measured CH inlet return water temperature Measured DHW storage temperature Measured outdoor temperature Optional outdoor sensor required 1 2 3 4 STEP STEP STEP STEP This parameter is not used 22 5 STEP Key Display Description of parameters Rate of increase in the outlet water temperature F se...

Page 50: ...nition after 5 attempts Power supply lost after lockout occured Internal control failure Internal control failure E E 02 03 04 08 09 E E E Display Hard Lockout Internal control failure 05 E Internal control failure 06 E Internal control failure 07 E Flame detected prior to burner startup E 00 Internal control failure External limit terminals 11 12 control is OPEN Blower signal does not reset to ze...

Page 51: ...t temperature allow the water to run for approximate ly 2 minutes and measure the water with a thermometer To adjust the valve set ting rotate the knob clockwise to decrease the water temperature or counter clockwise to increase the water temperature Once the desired temperature is achieved remove the knob and refit the lock ring onto the valve aligning the ring indicator mark with the valve s Mix...

Page 52: ...c Measure the rate of input on Natural Gas as outlined on page 36 c Check the incoming gas pressure to ensure a minimum pressure of 5 w c during flow conditions to all appliances and a maximum pressure of 13 w c during flow and non flow conditions for Natural and Propane c The thermostatic mixing valve is adjusted to the desired domestic hot water outlet temperature c Adjusted balancing valves and...

Page 53: ...ompleted Check out procedures have been followed and completed Information regarding the unit and installation received and left with owner maintenance personal Installer Information Company Address Address Phone Number Btu hr ____________________________________________________________________ ____________________________________________________________________ ___________________________________...

Page 54: ...an baffles and flue ways Remove burner assembly and clean burner head using compressed air only Once the maintenance items are completed review the service with the owner Owner Maintenance Periodically Check the area around the appliance Check the combustion air inlet and ven tilation openings for blockage Check the pressure gauge Check the operation of the domestic mixing valve Monthly Check vent...

Page 55: ...ea Verify that the area surrounding the MOD ULATING DELTA is free of combustible flammable materials or flammable vapors or liquids Remove immediately if found Refer to the list of potential materials listed in the MODULATING DELTA Vent Supplement If any of these products are in the room from which the appliance takes its combustion air they must be removed immediately or the combustion air intake...

Page 56: ...ormance problems Inspect air vent and air separators in the system Remove the caps on automatic air vents and briefly depress the valve stem to flush vent Replace the cap when complet ed Ensure vents do not leak replace any leaking vents Check Domestic System Verify all system components are correctly installed and operating correctly Check the outlet domestic temperature of the mixing valve and c...

Page 57: ...er closing the valve the valve fails to seat properly or continually weeps replace the relief valve Ensure the cause of the weeping is the valve itself and not due to thermal expansion or a faulty or under pressurized thermal expansion tank Inspection of Ignition Electrode Remove the ignition electrode from the burner mounting plate Remove any white oxides accumulated on the electrode using fine g...

Page 58: ...Re assemble the venturi and gas valve onto the blower Ensure the venturi gasket is in good condition and positioned correctly Re assemble the burner head onto the burn er mounting plate Ensure the burner head gasket is in good condition and positioned correctly Secure burner mounting plate to the appli ance with two nuts Re assemble the elec trical quick connects to burner assembly control cover a...

Page 59: ...pproved respirator which meets OSHA requirements for cristobalite dust similar to N95 Contact NIOSH at 1 800 356 4676 or on the web at www cdc gov niosh for latest recommen dations 2 Wear long sleeved loose fitting clothing gloves and eyes protection 3 Assure adequate ventilation 4 Wash with soap and water after contact 5 Wash potentially contaminated clothes separately from other laundry and rins...

Page 60: ...KTMFL01 Control Cover Panel 7 HMCOV05 Burner Hood Panel 8 MDRKIT01 Domestic NTC Sensor 9 MDRKIT02 Air Switch 10 PSRKIT19 Transformer 11 MDRKIT03 Control Module 12 MDRKIT04 Controle Module Display 13 MDRKIT05 Primary NTC Sensor 14 MDRKIT06 Control Module Display Cover 15 MDRKIT07 Low Water Cut Off not shown 16 MDRKIT11 Flue Hood Gasket 1 13 11 2 6 7 14 5 8 13 3 4 10 12 9 Fig 19 Modulating Delta Rep...

Page 61: ... PSRKIT01 Gas Valve 3 Venturi 4 PGRKIT15 Gas Valve Rectifier Plug 5 MDRKIT08 Igniter with Gasket 6 PSRKIT14 Ignition Cable 7 MDRKIT09 Burner Plate Insulation Gasket 8 PSRKIT37 Burner Head 9 MDRKIT10 Sight Glass Assembly 2 3 1 9 6 4 7 8 5 Fig 20 Burner Assembly Replacement Parts ...

Page 62: ...2 Primary drain valve connection ø 1 2 NPT 3 Domestic temperature pressure relief valve 150 psi ø 3 4 NPT 4 Primary pressure relief valve 30 psi ø 3 4 NPT 5 Domestic cold water inlet ø 3 4 NPT 6 Domestic hot water outlet ø 3 4 NPT 7 Primary return air vent ø 1 NPT 8 Gas connection 3 4 NPT Note Minimum allowable flow rate at full input PG 150 PG PLUS 150 7 gpm PG 199 PG PLUS 199 10 gpm ...

Page 63: ...ph PG 150 PG PLUS 150 20 22 70 230 190 PG 199 PG PLUS 199 17 20 80 290 250 N ote 1 Input ratings are shown for sea level applications The appliance automatically derates the input at approximately 2 for every 1 000 feet of altitude No alterations to the appliance is required Note 2 Based on the given AFUE the MODULATING DELTA PG PLUS Models meet the energy efficiency guidelines established by Ener...

Page 64: ...ly 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 Phase III Indirect Fired Water Heaters Maxi flo Pool and Spa Heat Exchangers Freeway Center 1 Triangle Lane Blackwood NJ 08012 Tel 856 228 8881 Fax 856 228 3584 http www triangle tube com E mail Info triangle tube com Member of Group 96 Effici...

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