TriangleTube SMART 30 Product manual

Technical Specifications
Installation and Maintenance Guide
• Before proceeding with installation and operation, read entire manual care-
fully. Failure to do so can cause injury or property damage.
• When receiving SMART Water Heaters, any claims for damage or short-
age in shipment must be filed immediately against the transportation
company by the consignee.
2010-49 SMART IWH Manual
• Warranty Registration Card must be filled out by the customer and mailed
within thirty (30) days of installation in order to gain warranty coverage.
• 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.
Indirect Fired Water Heater
Date Revised 7/30/15
WARNING
IMPORTANT
L
I
S
T
E
D
661A0300 - Rev C

Table of Contents
661A0300 - Rev C
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
i

1
Definitions
Following terms are used to bring attention to the
presence of various risk levels, or to important
information concerning product life.
Indicates presence of a hazard which will
cause severe personal injury, death or sub-
stantial property damage if ignored.
Indicates the presence of a hazard which
can cause severe personal injury, death or
substantial property damage if ignored.
Indicates the presence of a hazard which
will or can cause minor personal injury or
damage if ignored.
Indicates special instructions on installa-
tion, operation, or maintenance which are
important but not related to personal
injury hazards.
Indicates recommendations made by ACV-
Triangle Tube for the installers which will
help to ensure optimum operation and
longevity of the equipment.
ACV-Triangle Tube reserves the right to
modify the technical specifications and
components of its products without prior
notice.
Hot Water Can Scald!
• Water temperatures over 125ºF can cause
severe burns instantly or death from scalding.
• Children, disabled and elderly are at highest
risk of being scalded.
• Never leave them unattended in or near show-
er, bathtub or sink.
• Never allow small children to use a hot water
faucet or draw their own bath.
• If anyone using hot water in the building fits
the above description or if local codes or state
laws require specific water temperatures at hot
water faucet, it is recommended:
- to install a thermostatic mixing valve at this
appliance or at each water faucet.
or
- to set the thermostat knob for the lowest
temperature which satisfies your hot water
needs.
• Water drained from the system drain valves
may be extremely hot. To avoid injury:
– Make sure all connections are tight.
– Direct water flow away from any person.
Protection must be taken against excessive
temperature and pressure!
• Installation of a Temperature & Pressure
(T&P) relief valve is required.
To prevent damage to the inner tank, the
Installer must:
• Always fill inner tank prior to outer tank
and always drain outer tank prior to inner
tank.
• Relieve primary system pressure below 15
psig prior to draining inner tank.
WARNING
DANGER
DANGER
CAUTION
CAUTION
CAUTION
NOTICE
BEST PRACTICE
NOTICE
Product & Safety Information
661A0300 - Rev C

Pre-Installation
661A0300 - Rev C 2
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.
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.
2. The pressure of the heat transfer medium is main-
tained less than the normal minimum operating
pressure of the potable water system
Exception: Steam complying with sec-
tion #1 above.
3. The equipment is permanently labeled to indi-
cate 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 (domes-
tic 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.
- Total Dissolved Solids (TDS), less than
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.
In hard water areas (more than 7 grains of
hardness) soften the cold domestic supply
water to the appliance to prevent scaling.
NOTICE
BEST PRACTICE

661A0300 - Rev C
Pre-Installation
3
Any water conditioning system must be
installed and maintained in accordance
with manufacturer’s specifications.
Do not install the water heater on any appli-
cation if the boiler piping contains non-oxy-
gen 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 out-
door 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 infor-
mation labels may be hidden.
• Recommended top or vertical clearance is 12”
minimum.
• Refer to boiler manual for boiler clearances.
NOTICE
NOTICE

Installation - Piping
661A0300 - Rev C 4
Temperature & Pressure (T&P) Relief Valve
To reduce risk of excessive pressures and tem-
peratures in the water heater, install tempera-
ture and pressure protective equipment
required by local codes, but no less than a com-
bination temperature and pressure relief valve
certified by a nationally recognized testing lab-
oratory 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, A SI 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 follow-
ing 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 maxi-
mum pressure rating of 150 psig. (Watts
40XL-8 or equivalent).
For proper operation of the T&P and to pre-
vent 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 con-
nection located behind the air vent on the top of
the water heater (Figure 1 page 8).
or
• Install the T&P relief valve in the run (straight
through leg) of a tee located at the domestic hot
water outlet when using the Auxiliary connec-
tion 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 out-
let. 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:
- made of material serviceable for tempera-
tures of 250ºF or greater.
- directed so that hot water flows away from
all persons.
- directed to a suitable place for disposal.
- installed so as to allow complete draining
of the T&P relief valve and discharge line.
T&P relief valve discharge piping must not be:
- excessively long. Using more than 2
elbows or 15 feet of piping can reduce dis-
charge capacity.
- directly connected to a drain. Terminate
discharge piping within 6” from drain.
Refer to local codes.
- plugged, reduced or restricted.
- subject to freezing.
CAUTION
NOTICE

661A0300 - Rev C
Installation - Piping
5
Do not install any valve between T&P relief
valve and tank connection or on T&P relief
valve discharge piping. Do not plug T&P
relief valve or discharge piping. Improper
placement and piping of T&P relief valve
can cause severe personal injury, death or
substantial property damage.
Drain Valve
Drain valve and fittings are supplied by others.
Standard Installation
• Install a tee connection at the domestic cold
water inlet (Fig. 1 and 2 page 8 and Fig. 3
on page 9).
• Pipe the drain piping with drain valve from
the tee connection to:
- a suitable place for disposal
or
- terminate within 12” of the floor
Commonwealth of Massachusetts Installation
• Thread a 3/4” close nipple onto the
Auxiliary connection and insert an open-
end 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.
• Pipe the drain piping with drain valve from
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 man-
ual air vent.
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 expan-
sion from repeatedly forcing open T&P relief valve.
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 pos-
itive 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.
Water hammering within the domestic pip-
ing 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 equiv-
alent 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 manu-
facturer’s instructions for application and installation
of the vacuum breaker.
CAUTION
WARNING
NOTICE

Installation - Piping
661A0300 - Rev C 6
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.
• See Chart 1 for domestic and boiler piping
connection sizes .
• 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.
Domestic Piping
• Union on domestic hot water outlet should be
piped at a higher elevation than domestic water
drain valve. This will make draining the water
heater easier.
• Install unions for easy removal of water heater. It
is recommended to use dielectric unions or cou-
plings to protect hot and cold water fittings from
corrosion when connecting dissimilar materials
such as copper and galvanized iron pipe.
• If copper pipe is used for domestic water con-
nections, first solder pipe to a threaded adapter
and then screw adapter into cold water inlet on
top of water heater. Inlet contains an internal
plastic dip tube which can be damaged by heat
from soldering.
Do not apply heat to the cold water inlet
when making sweat connections to water
heater. Sweat tubing to adapter before fit-
ting adapter to cold water inlet of heater. It
is imperative that no heat be applied to the
cold water inlet, as it contains a non metal-
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.
• If water heater will replace tankless coil in
boiler, disconnect piping to coil. Allow water
to drain from coil. Do not plug tankless coil.
Plugging tankless coil inlet and outlet will
result in severe personal injury, death, or
substantial property damage.
NOTICE
DANGER
Chart 1
Water
Heater
Model
Connections (Inches) Recirculation Dip Tube Drainin Dip Tube Recommended
Minimum
Boiler Pipin
Domestic
Water
Inlet/Outlet
Boiler Water
Supply/
Return
Auxiliary
Connection
Len th
(Inches)
Diameter
(Inches)
Len th
(Inches)
Diameter
(Inches) Diameter
(Inches)
SMART 30 3/4 NPT 1 NPSC 3/4 NPSC 34 3/4 34 3/4 1
SMART 40 3/4 NPT 1 NPSC 3/4 NPSC 43 3/4 43 3/4 1
SMART 50 3/4 NPT 1 1/4 NPSC 3/4 NPSC 25 3/4 52 3/4 1
SMART 60 3/4 NPT 1 1/4 NPSC 3/4 NPSC 34 3/4 62 3/4 1 1/4
SMART 80 1 1/2 NPT 1 1/2 NPSC 1 1/2 NPSC 25 1 1/2 48 1 1/2 1 1/4
SMART 100 1 1/2 NPT 1 1/2 NPSC 1 1/2 NPSC 32 1 1/2 61 1 1/2 1 1/2
SMART 120 1 1/2 NPT 2 NPSC 1 1/2 NPSC 32 1 1/2 61 1 1/2 1 1/2

661A0300 - Rev C
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.
• It is recommended that the recirculation dip tube
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
• Parallel Pipe Recirculation Systems - Manifold
recirculation return to all water heaters.
• Series Piped Systems - Piped return to the lead-
ing (cold water inlet) water heater.
• Install automatic mixing valve either at the hot
water outlet of water heater or each hot water
faucet.
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.
The Smart IDWH must be installed on a
closed type hydronic system. Failure to pro-
vide 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 specifi-
cally intended for hydronic heating systems.
Inhibited propylene glycol is recommended at
a maximum 50/50 mixture.
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.
DANGER
DANGER
NOTICE
7

Cold Water
Inlet
6 1
12" min.
Heat Trap
Loop
(Optional)
12" min.
Heat Trap
Loop
(Optional)
1 5
5 1
8
7
4
10
M H
C
661A0300 - Rev C
Installation - Piping
7
Cold Water
Inlet
6 1
Recirculating
Loop
2 3
4
1 5
5 1
8
12" min.
Heat Trap
Loop
(Optional)
12" min.
Heat Trap
Loop
(Optional)
9
Standard Installation
Domestic Piping with
Recirculation SMART Series
8
1. Shut-off valve
2. Recirculation Circulator
3. Flow Check Valve
4. T&P relief valve
5. Unions
6. Backflow preventer or pressure reducing valve(*)
7. Drain valve
8. Thermal expansion tank (potable)
9. Recirculation dip tube
10. Thermostatic mixing valve (*)
(*) Optional devices may be required by local codes.
Standard Installation
Domestic Piping
SMART Series
Fig. 1:
Fig. 2:

661A0300 - Rev C
7
Cold Water
Inlet
61
Recirculating
Loop
23
4
15
51
8
12" min.
Heat Trap
Loop
(Optional)
12" min.
Heat Trap
Loop
(Optional)
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.
Fig. 3:
9
Installation - Piping

661A0300 - Rev C
Installation - Piping
10
Cold Water
Inlet
6 1
12" min.
Heat Trap
Loop
(Optional)
12" min.
Heat Trap
Loop
(Optional)
4
1 5
5
8
9
11
10
M H
C 7
1. Shut-off valves
4. T&P relief valve
5. Unions
6. Backflow preventer or pressure reducing valve (*)
7. Drain valve
8. Thermal expansion tank (potable)
9. Vacuum breaker
10. Mixing valve (*)
11. Dip tube - Draining per Chart 1
(*) Optional devices may be required by local codes.
Drain Tube Assembly-
Commonwealth of
Massachusetts
Fig. 4:
Commonwealth of
Massachusetts Domestic
Piping SMART Series
Fig. 5:

Installation -Piping
11
4
1
3
2
2-Port
Priority Valve
(normally open)
2-Port
Priority Valve
(normally close)
1
6
5
Cold water
inlet
1
2
4
1
3- Port
Priority
Valve
31
6
Cold water
inlet
5
Fig. 7:
1. Shut-off valves
2. Circulator
3. Expansion tank
4. Drain valve
5. Feed valve
6. Air separator
Fig. 6: SMART System Piping with 3-Port Zone Valve
(Domestic Priority)
SMART System Piping with 2-Port Zone Valves
(Domestic Priority)
661A0300 - Rev C

661A0300 - Rev C
Fig. 9:
Fig. 8:
1. Shut-off valves
2. Circulator
3. Flow check valve
4. Expansion tank
5. Drain valve
6. Feed valve
7. Air separator
SMART System Piping with Zone Valves
( on Domestic Priority)
SMART System Piping with Zone Circulators
12
Installation - Piping

Installation - Piping
• Recommended for applications in which there is a
large water consumption in short period of time.
•A maximum of 3 water heaters may be piped in series.
• Utilize the lead (hot water outlet) SMART tank ther-
mostat to control system temperature.
• Install automatic mixing valve at either the hot water
outlet of the water heater system or at each hot water
fixture.
• Each tank should be piped with a drain as shown in
Fig. 1.
13
Multiple SMART Series Water Heater
System Domestic Piping - Parallel
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
water outlet of the water heater system or at
each hot water fixture.
• Each tank should be piped with a drain as
shown in Fig. 1.
Fig. 10:
Fig. 11:
661A0300 - Rev C

661A0300 - Rev C 14
1. Shut-off valves
2. Circulator
3. Flow check valve
4. Expansion tank
5. Drain valve
6. Feed valve
7. Air separator
Fig. 12: Multiple SMART Series Water Heater System Boiler
Piping Reverse Return Balanced Flow
Multiple SMART Series Water Heater System Boiler Piping - Manifold
Fig. 13:
Installation - Piping

Installation - Wiring
15
Wiring Requirements
Electrical shock hazard can cause severe
personal injury, death or substantial prop-
erty 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 require-
ments having jurisdiction.
• Canada - C.S.A. C22.1 Canadian Electrical
Code Part 1 and any other national, provin-
cial 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.
Circulators
• Priority relay must be sized for total amp draw
of all circulators.
Zone Valves
• Transformer must be sized for maximum load
of all zone valves.
Snap Set Connection
• For easy wiring between water heater thermo-
stat and boiler controls see Installation Wiring
section pages 15 through 19.
• Make sure snap set is firmly snapped together
after wiring.
WARNING
Snap Set Wiring
661A0300 - Rev C

661A0300 - Rev C 16
HN
High Vo l t a g e
120
V.A.C.
24
V.A.C.
Room
Thermostat
Zone 1
Additional zones Additional zones may
be added as shown above
Transformer
(Power)
Zone Valve
Zone Valve
1
2
C
Water Heater
Thermostat
Snap-Set
Water
Heater
Zone
*Isolation Relay
Boiler
Thermostat
Terminals
* Use isolation relay on
3-wire zone valves with
non-isolated end switches.
Transformer and boiler
control can burn out if
isolation relay is not used
Priority
Relay
HN
High Voltage
120
V.A.C.
24
V.A.C.
Room
Thermostat
Zone 1
Additional zones Additional zones may
be added as shown above
Transformer
(Power)
Zone Valve
Zone Valve
1
2C
Water Heater
Thermostat
Snap-Set
Water
Heater
Zone
Boiler
Thermostat
Terminals
High Voltage
Low Voltage
Boiler Low Voltage
Priority
Relay
Typical 3-wire Zone Valve Zoning,
with Domestic Priority
Typical 4-wire Zone Valve Zoning,
with Domestic Priority
Fig. 14: Fig. 15:
Installation - Wiring

Installation - Wiring
HN
High Vo l t a g e
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
Zone Valve
1
2
C
Water Heater
Thermostat
Snap-Set
Water
Heater
Zone
*Isolation Relay
Boiler
Thermostat
Terminals
* Use isolation relay on
3-wire zone valves with
non-isolated end switches.
Transformer and boiler
control can burn out if
isolation relay is not used
17
Typical 3-wire Zone Valve Zoning,
without Domestic Priority
HN
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
Zone Valve
1
2C
Water Heater
Thermostat
Snap-Set
Water
Heater
Zone
Boiler
Thermostat
Terminals
High Voltage
Low Voltage
Boiler Low Voltage
Typical 4-wire Zone Valve Zoning,
without Domestic Priority
Fig. 16: Fig. 17:
661A0300 - Rev C

661A0300 - Rev C
2
TT
14356
Circulator
Zone 1
Thermostat
zone 1
Honeywell
R845A
Relay
120
H
VA C
N
2
TT
1436
Circulator
Zone 2
Thermostat
zone 2
5
2
TT
1436
Water
Heater
Circulator
Water Heater
Thermostat
Snap-Set
5
1
2
C
Boiler
Thermostat
Terminals
Priority Relay
18
Typical Circulator Zoning
with Domestic Priority
2
TT
14356
Circulator
Zone 1
Thermostat
zone 1
Honeywell
R845A
Relay
120
H
VA C
N
2
TT
1436
Circulator
Zone 2
Thermostat
zone 2
5
2
TT
1436
Water
Heater
Circulator
Water Heater
Thermostat
Snap-Set
5
1
2
C
High Vo l t a g e
Low Vo l t a g e
Boiler
Thermostat
Terminals
Typical Circulator Zoning
without Domestic Priority
Fig. 18: Fig. 19:
Installation - Wiring