advertisement
L
I
S
T
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prestige
Solo 60
Solo 175
Solo 250
Solo 399
Water Boiler
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.
When receiving the PRESTIGE Solo unit, any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.
Leave all documentation received with appliance with owner for future reference.
WARNING
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 in your building.
- Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
- If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or the gas supplier.
Series III
2010-7 Manual Prestige Solo 60/175/250/399 - Revised 02/17/10
Table of Contents
PRODUCT AND SAFETY INFORMATION
Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Product and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION I - PRE-INSTALLATION ITEMS
Code Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Determining Product Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Boiler Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Recommended Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Residential Garage Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Boiler Freeze Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION II - COMBUSTION AIR AND VENTING
Combustion Air Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ventilation and Combustion Air Requirements - Direct Vent . . . . . . . . . . . 6
Ventilation and Combustion Air Requirements - Category IV . . . . . . . . . . 6
Methods of Accessing Combustion Air into a Space - Category IV . . . . . . 7
- Indoor Combustion Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Outdoor Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
- Combination of Indoor and Outdoor Combustion Air. . . . . . . . . . 8-9
Combustion Air and Vent Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal of an Existing Boiler from a Common Vent System . . . . . . . . . . 10
Commonwealth of Massachusetts Installation . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION III - UNIT PREPARATIONS
Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wall Mounting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wall Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Wall Bracket Installation - Stud Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wall Bracket Installation - Solid Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Boiler Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION IV - BOILER PIPING
General Piping Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Low Water Cut Off Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Additional Limit Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Backflow Preventer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 i
Table of Contents
Boiler System Piping Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Expansion Tank and Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17
Diaphragm Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Closed-Type Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Sizing Primary Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Domestic Hot Water System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System Piping - Zone Circulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Near Boiler Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
System Piping - Zone Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Piping - Through Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Piping - Radiant Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Piping - Special Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Piping - Multiple Units Installation . . . . . . . . . . . . . . . . . . . . . . . . . 19
DHW Boiler Piping with PRESTIGE Solo and SMART . . . . . . . . . . . . . . 20
Central Heating System Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24
SECTION V - INSTALLING VENT / COMBUSTION AIR & CONDENSATE DRAIN
Installing Vent and Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installing Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-26
SECTION VI - GAS PIPING
Gas Supply Piping Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Natural Gas
Pipe Sizing -Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Natural Gas Supply Pressure Requirements. . . . . . . . . . . . . . . . . . . 28
Propane Gas
Pipe Sizing - Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Propane Gas Supply Pressure Requirements . . . . . . . . . . . . . . . . . . 29
Gas Valve/Venturi Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION VII - INTERNAL WIRING
General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Control Module Circulator AMP Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Wiring Tool Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Internal Factory Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SECTION VIII - EXTERNAL WIRING
Installation Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Line Voltage Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ii
Table of Contents
Domestic Hot Water Aquastat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Thermostat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-34
CH and DHW Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
System Circulator - Zone Valve Application . . . . . . . . . . . . . . . . . . . . . . . . 34
External Modulating Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Outdoor Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Additional 24V Limit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
External Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-36
SECTION IX - START-UP PREPARATION
Check Boiler System Water Chemistry
Water pH Level 6.0 to 8.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Water Hardness Less Than 7 Grains. . . . . . . . . . . . . . . . . . . . . . . . . 37
Chlorinated Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Flush Boiler and Domestic System to Remove Sediment . . . . . . . . . . . . . . 37
Check and Test Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Use of Antifreeze in the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Filling the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Check Low Water Cut-Off Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Check for Gas Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Check Thermostat Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Inspection of Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 39
SECTION - START-UP PROCEDURES
Final Checks Before Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
PRESTIGE Solo Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
If PRESTIGE Solo Does Not Start Correctly . . . . . . . . . . . . . . . . . . . . . . . 40
Check the PRESTIGE Solo and System . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41
Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Set Boiler CH Target Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Operation Verification - Space Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-44
Operation Verification - Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . 44
Boiler Control Display
Standby Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-46
Setting the Boiler Parameters
Parameter Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Accessing Boiler Information
Information Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Error (Hard Lockout) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 iii
Table of Contents
SECTION XI - OUTDOOR RESET CONTROL
Mounting the Outdoor Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Wiring the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Summer/Winter Switch at Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Adjusting Outdoor Reset Curve
CH Maximum Boiler Operating Setpoint (Parameter 4) . . . . . . . . . 51
CH Minimum Boiler Operating Setpoint (Parameter 10) . . . . . . . . 51
CH Reset Curve Coldest Day (Parameter 11) . . . . . . . . . . . . . . . . . 51
CH Reset Curve Warmest Day (Parameter 12) . . . . . . . . . . . . . . . . 52
Entering MCBA Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Changing a Parameter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Outdoor Reset Curve Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
SECTION XII - EXTERNAL MODULATING CONTROL
Wiring the Modulating Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Parameter Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Programming of External Modulating Control . . . . . . . . . . . . . . . . . . . . . . 54
Factory Setting for Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SECTION XIII - CHECK-OUT PROCEDURES
Check-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
SECTION XIV - INSTALLATION RECORD
Installation Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SECTIONS XV - MAINTENANCE SCHEDULE
Service Technician - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Owner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SECTION XVI - MAINTENANCE PROCEDURES
Maintenance Procedures
Reported Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Check Surrounding Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Inspect Burner Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Check System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Clean Condensate Drain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 60
Check Ventilation Air Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 iv
Table of Contents
Inspect Vent and Combustion Air Piping . . . . . . . . . . . . . . . . . . . . . 60
Check Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Check Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Check Boiler Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Inspection of Ignition Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Check Ignition Wiring and Ground Wiring . . . . . . . . . . . . . . . . . . . 61
Check Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Check Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Perform Start-Up and Checkout Procedure . . . . . . . . . . . . . . . . . . . 62
Check Burner Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Check Flame Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Check Combustion Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Check Flue Gas Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Clean Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-64
Review with Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Handling Previously Fired Combustion Chamber Insulation . . . . . 64
REPLACEMENT PARTS
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-71
PRODUCT SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-81 v
Product & Safety Information
Definitions
The following terms are used throughout this manual to bring attention to the presence of potential hazards or 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.
WARNING
Indicates a potentially hazardous situation which, if ignored, can result in death, serious injury or substantial property damage.
BEST PRACTICE
Indicates recommendations made by
Triangle Tube for the installers which will help to ensure optimum operation and longevity of the equipment
CAUTION
Indicates a potentially hazardous situation which, if ignored, may result in minor injury or property damage.
NOTICE
Triangle Tube reserves the right to modify the technical specifications and components of its products without prior notice.
1
Product & Safety Information
DANGER
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.
WARNING
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 in your building.
- Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
- If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or the gas supplier.
WARNING
Should overheating occur or the gas supply fails to shut off, turn OFF the manual gas control valve external to the appliance.
WARNING
DO NOT add cold make up water when the boiler is hot. Thermal shock can cause potential cracks in the heat exchanger.
CAUTION
When servicing the boiler:
Avoid electrical shock by disconnecting the electrical supply prior to performing maintenance.
WARNING
Qualified Installer:
Prior to installing this product read all instructions included in this manual and all accompanying manuals/documents with this appliance. Perform all installation steps required in these manuals in the proper order given. Failure to adhere to the guidelines within these manuals can result in severe personal injury, death or substantial property damage.
Homeowner:
- This product should be maintained / serviced and inspected annually by a qualified service technician.
- This manual is intended for use by a qualified Installer/Service Technician.
2
NOTICE
Please reference the unit’s model number and the serial number from the rating label, on the backside of the control panel when inquiring about service or troubleshooting.
NOTICE
Triangle Tube accepts no liability for any damage resulting from incorrect installation or from the use of components or fittings not specified by Triangle Tube.
Pre-Installation Items
SECTION I - Pre-Installation Items
Code Compliance
This product must be installed in accordance to the following:
All applicable local, state, national and provincial codes, ordinances, regulations and laws.
For installations in Massachusetts, code requires the boiler to be installed by a licensed plumber or gas fitter, and if antifreeze is utilized, the installation of a reduced pressure backflow preventer device is required in the boiler’s cold water fill or make up water supply line.
For installation in Massachusetts all direct vented appliances must comply with the guidelines as outlined on page 11.
- The National Fuel Gas Code NFPA54/
ANSI Z 223.1 - Latest edition.
National Electric Code ANSI/NFPA 70.
- For installations in Canada -“Installation
Code for Gas Burning Equipment”
CGA/B149.1 or B149.2 Canadian
Electrical Code Part 1 CSA C22.1.
Standards for Controls and Safety
Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1, when required.
NOTICE
The PRESTIGE Solo boiler gas manifold and gas controls meet the safe lighting and other performance requirements as specified in ANSI Z21.13 latest edition.
Determining Product Location
Before locating the PRESTIGE SOLO check for convenient locations to:
Heating system piping
Venting
Gas supply piping
Electrical service
Ensure the boiler location allows the combustion air/vent piping to be routed directly through the building and terminate properly outside with a minimum amount of length and bends.
Ensure the area chosen for the installation of the
PRESTIGE Solo is free of any combustible materials, gasoline and other flammable liquids.
WARNING
Failure to remove or maintain the area free of combustible materials, gasoline and other flammable liquids or vapors can result in severe personal injury, death or substantial property damage.
Ensure the PRESTIGE Solo and its controls are protected from dripping or spraying water during normal operation or service.
The PRESTIGE Solo should be installed in a location so that any water leaking from the boiler or piping connections or relief valve will not cause damage to the area surrounding the unit or any lower floors in the structure.
Boiler Replacement
If the PRESTIGE Solo is replacing an existing boiler, the following items should be checked and corrected prior to installation:
Boiler piping leaks and corrosion.
- Improper location and sizing of the expansion tank on the boiler heating loop.
If applicable, level and quality of freeze protection within the boiler system.
Recommended Clearances
The PRESTIGE Solo is approved for zero clearance to combustibles, excluding vent and boiler piping.
Boiler Piping - 1/4 inch from combustible materials.
3
Pre-Installation Items
- Reference the appropriate vent supplement for clearance requirements.
BEST PRACTICE
To provide serviceability to the unit it is recommended that the following clearances be maintained:
Top boiler jacket - 24 inches [610 mm].
Front - 24 inches [610 mm].
Bottom boiler piping - 24 inches [610 mm].
Rear - 0 inches
Sides - 6 inches [153 mm]
WARNING
If the clearances listed above cannot be maintained or the enclosure in which the boiler is installed is less than 85 cubic feet, the space must be ventilated. See page 6 for ventilation requirements.
Residential Garage Installations
When installing the PRESTIGE Solo in a residential garage, the following special precautions per NFPA 54/ANSI Z223.1 must be taken:
Mount the unit a minimum 18 inches
[458 mm] above the floor level of the garage. Ensure the burner and ignition devices / controls are no less than 18 inches [458 mm] above the floor level.
Locate or protect the unit in a manner so it cannot be damaged by a moving vehicle.
Boiler Freeze Protection Feature
The boiler control has a freeze protection feature built in. This feature monitors the boiler temperature and responds as follows when no call for heat is present:
46ºF Boiler circulator is ON
38ºF Boiler circulator is ON and burner operates at low fire
50ºF Burner OFF and boiler circulator operates for approximately 10 minutes
NOTICE
When maintaining zero clearance or less than recommended clearances, some product labeling may become hidden and unreadable.
CAUTION
The boiler freeze protection feature is disabled during a hard lockout, however the CH circulator will operate.
WARNING
When installing the PRESTIGE Solo in a confined space, sufficient air must be provided for proper combustion and venting and to allow, under normal operating conditions, proper air flow around the product to maintain ambient temperatures within safe limits to comply with the National Fuel Gas Code NFPA 54 latest edition.
CAUTION
The boiler freeze protection feature is designed to protect the boiler. The boiler should be installed in a primary/secondary piping arrangement if it is installed in an unheated space or exposed to water temperatures of 46ºF or less. See Section IV for primary/secondary piping examples. See Section IX for antifreeze guides.
4
Combustion Air Venting
SECTION II - Combustion Air and
Venting
Combustion Air Contamination
WARNING
If the PRESTIGE Solo combustion air inlet is located in any area likely to cause or contain contamination, or if products, which would contaminate the air cannot be removed, the combustion air must be repiped and terminated to another location. Contaminated combustion air will damage the unit and its burner system, resulting in possible severe personal injury, death or substantial property damage.
WARNING
Do not operate a PRESTIGE Solo if its combustion air inlet is located near a laundry room or pool facility. These areas will always contain hazardous contaminants.
Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds.
When these chemicals pass through the burner and vent system, they can form strong acids. These acids can create corrosion of the heat exchanger, burner components and vent system, causing serious damage and presenting a possible threat of flue gas spillage or water leakage into the surrounding area.
Please read the information listed below.
If contaminating chemicals are located near the area of the combustion air inlet, the installer should pipe the combustion air inlet to an outside area free of these chemicals per SECTION V of this installation manual.
Potential contaminating products
Spray cans containing chloro/fluorocarbons
Permanent Wave Solutions
Chlorinated wax
Chlorine - based swimming pool chemicals / cleaners
Calcium Chloride used for thawing ice
Sodium Chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid / muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms
Adhesives used to fasten building products and other similar products
Areas likely to contain these products
Dry cleaning / laundry areas and establishments
Beauty salons
Metal fabrication shops
Swimming pools and health spas
Refrigeration Repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
5
Combustion Air Venting
Ventilation and Combustion Air
Requirements - Direct Vent
A Direct Vent appliance utilizes uncontamined outdoor air (piped directly to the appliance) for combustion.
For Direct Vent installations, involving only the PRESTIGE Solo, in which the minimum service clearances are maintained as listed on page 4, no ventilation openings are required.
For Direct Vent, zero clearance installations involving only the PRESTIGE Solo, the space
/ enclosure must provide two openings for ventilation. The openings must be sized to provide
1 square inch of free area per 1,000 BTUH of boiler input. The openings shall be placed 12 inches from the top of the space and 12 inches from the floor of the space.
For installations in which the PRESTIGE Solo shares the space with air movers (exhaust fan, clothes dryers, fireplaces, etc.) and other combustion equipment (gas or oil) the space must be provided with adequate air openings to provide ventilation and combustion air to the equipment. To properly size the ventilation / combustion air openings, the installer must comply with the National Fuel Gas Code
NFPA 54, ANSI Z223.1 for installations in the
U.S or CSA B149.1 and B149.2 for installations in Canada.
WARNING
The space must be provided with ventilation / combustion air openings properly sized for all make-up air requirements
(exhaust fans, clothes dryers, fireplaces, etc.) and the total input of all appliances located in the same space as the PRES-
TIGE Solo, excluding the input of a
Direct Vent PRESTIGE Solo which uses combustion air directly from the outside, thus additional free area for the openings is not required. Failure to provide or properly size the openings could result in severe personal injury, death or substantial property damage.
Ventilation and Combustion Air
Requirements - Category IV
A Category IV appliance utilizes uncontaminated indoor or outdoor air (surrounding the appliance) for combustion.
BEST PRACTICE
In order to reduce the potential risks associated with indoor contaminates
(listed on page 5), flammable vapors and tight housing construction (little or no infiltration air), it is recommended to pipe uncontaminated combustion air directly from the outdoors to the appliance. This practice also promotes higher system efficiency by reducing heated indoor air from being exhausted from the house and replaced by cold infiltration air into the house.
For installations in which the PRESTIGE Solo shares the space with air movers (exhaust fan, clothes dryers, fireplaces, etc.) and other combustion equipment (gas or oil) the space must be provided with adequate air openings to provide ventilation and combustion air to the equipment.
To properly size the ventilation / combustion air openings, the installer must comply with the
National Fuel Gas Code NFPA 54, ANSI Z223.1
for installations in the U.S or CSA B149.1 and
B149.2 for installations in Canada, as referenced in this section of the manual and titled Methods of Accessing Combustion Air into a Space.
WARNING
The space must be provided with ventilation / combustion air openings properly sized for all make-up air requirements
(exhaust fans, clothes dryers, fireplaces, etc.) and the total input of all appliances, including the PRESTIGE Solo when located in the same space. Failure to provide or properly size the openings could result in severe personal injury, death or substantial property damage.
6
Combustion Air Venting
Methods of Accessing Combustion Air Into A
Space - Category IV
Indoor Combustion Air
NOTICE
The methods listed in this section for accessing Indoor Combustion Air assume that the infiltration rate is adequate and not less than .40 ACH. For infiltration rates less than .40 ACH, reference the NFPA 54 National Fuel Gas
Code for additional guidance.
Opening Size and Location
Openings used to connect indoor spaces shall be sized and located in accordance with the following see Fig. 1:
The minimum dimension of air openings shall be not less than 3 inches.
- Combining spaces in different stories.
The volumes of spaces in different stories shall be considered as communicating spaces where such spaces are connected by one or more openings in doors or floors having a total minimum free area of 2 sq. in./1000 Btu/hr of total input rating of all gas utilization equipment.
Outdoor Combustion Air
BEST PRACTICE
Isolating the combustion appliance room from the rest of the building and bringing in uncontaminated outside air for combustion and ventilation is always preferred.
Fig. 1:
All Combustion Air from Adjacent
Indoor Spaces Through Indoor
Combustion Openings
- Combining spaces on the same story.
Each opening shall have a minimum free area of 1 sq. in./1000 Btu/hr of the total input rating of all gas utilization equipment in the space, but not less than
100 sq. inches. One opening shall commence within 12 inches of the top, and one opening shall commence within 12 inches of the bottom of the enclosure.
Opening Size and Location
The minimum dimension of air openings shall be not less than 3 inches
Openings used to supply combustion and ventilation air shall be sized and located in accordance with the following:
One Permanent Opening Method. See Fig. 2
One permanent opening, commencing within 12 in. of the top of the enclosure, shall be provided.
The equipment shall have clearances of at least 1 inch from the sides and 6 in. from the front of the appliance. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of the following:
1sq. in./3000 Btu/hr of the total input rating of all equipment located in the enclosures, and
7
Combustion Air Venting
Fig. 2:
All Combustion Air from Outdoors
Through One Permanent Air
Opening
Not less than the sum of the areas of all vent connectors in the space.
Fig. 3: All Combustion Air from Outdoors
Through Ventilated Attic
Two Permanent Openings Method.
Two permanent openings, one commencing within 12 in. of the top and one commencing within 12 in. of the bottom of the enclosure, shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors, as follows:
Where directly communicating with the outdoors or where communication to the outdoors is through vertical ducts, each opening shall have a minimum free area of 1 sq. in./4000 Btu/hr of total input rating of all equipment in the enclosure.
See Fig.3.
Where communicating with the outdoors is through horizontal ducts, each opening shall have a minimum free area of not less than 1 sq.in./2000
Btu/hr of total input rating of all equipment in the enclosure. See Fig. 4.
Fig. 4:
All Combustion Air from Outdoors
Through Horizontal Ducts
Combination of Indoor and Outdoor
Combustion Air
Indoor Openings: Where used, openings connecting the interior spaces shall comply with the Indoor Combustion Air section on page 7.
8
Combustion Air Venting
Outdoor Opening(s) Location. Outdoor opening(s) shall be located in accordance with the
Outdoor Combustion Air section.
Outdoor Opening(s) Size. Outdoor opening(s) shall be calculated in accordance with the following:
- The ratio of the interior spaces shall be the available volume of all communicating spaces divided by the required volume.
- The outdoor size reduction factor shall be 1 minus the ratio of interior spaces.
- The minimum size of outdoor opening(s) calculated in accordance with the above outdoor air section multiplied by the reduction factor. The minimum dimension of air openings shall not be less than 3 in.
DANGER
Do not install the PRESTIGE Solo into a common vent with other gas or oil appliances. This may cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death or substantial property damage.
Combustion Air and Vent Piping
The PRESTIGE Solo requires a Category IV venting system, which is designed for pressurized venting and condensate.
The PRESTIGE Solo is certified per ANSI
Z21.13 as a Category IV or Direct Vent (sealed combustion) appliance. A Category IV appliance utilizes uncontamined indoor or outdoor air (surrounding the appliance) for combustion.
A Direct Vent appliance utilizes uncontaminated outdoor air (piped directly to the appliance) for combustion.
BEST PRACTICE
In order to reduce the potential risks associated with indoor contaminates
(listed on page 5), flammable vapors and tight housing construction (little or no infiltration air), it is recommended to pipe uncontaminated combustion air directly from the outdoors to the appliance. This practice also promotes higher system efficiency by reducing heated indoor air from being exhausted from the house and replaced by cold infiltration air into the house.
NOTICE
Install combustion air and vent pipe as detailed in the PRESTIGE Solo Vent
Supplement included in the boiler installation envelope. Refer to optional vent kit instructions for addition vent installation instructions.
DANGER
Verify installed combustion air and vent piping are sealed gas tight and meet all provided instructions and applicable codes, failure to comply will result in severe personal injury of death.
9
Combustion Air Venting
Removal of an Existing Boiler from a
Common Vent System
BEST PRACTICE
When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the remaining appliances. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
4. Place in operation the appliance being inspected. Follow the lighting instructions.
Adjust thermostat so appliance will operate continuously.
5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.
6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous condition of use.
7. Any improper operation of the common venting system should be corrected so the installation conforms with the National
Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CGA B149, Installation codes.
When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part II of the National Fuel
Gas Code ANSI Z223.1/NFPA 54 and/or
CAN/CGA B149, Installation codes.
DANGER
Do not install the PRESTIGE Solo into a common vent with other gas or oil appliances. This may cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death or substantial property damage.
10
Combustion Air Venting
Commonwealth of Massachusetts Installations Only
For direct-vent appliances, mechanicalvent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied:
1. If there is not one already present, on each floor level where there are bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply with NFPA 720 (2005 Edition).
2. A carbon monoxide detector shall also be located in the room that houses the appliance or equipment and shall: a. Be powered by the same electrical circuit as the appliance or equipment such that only one service switch services both the appliance and the carbon monoxide detector; b. Have battery back-up power; c. Meet ANSI/UL 2034 Standards and comply with NFPA 720 (2005
Edition); and d. Have been approved and listed by the Nationally Recognized Testing
Laboratory as recognized under 527
CMR.
3. A Product-approved vent terminal must be used, and if applicable, a Productapproved air intake must be used.
Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation.
4. A metal or plastic identification plate shall be mounted at the exterior of the building, four feet directly above the location of vent terminal. The plate shall be of sufficient size to be easily read from a distance of eight feet away, and read “Gas Vent Directly Below”.
NOTICE
Installer must provide tag identification plate and ensure the lettering meets code requirements.
For direct-vent appliances, mechanicalvent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake are installed above four feet above grade the following requirements must be satisfied:
1. If there is not one already present, on each floor level where there are bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply with NFPA 720 (2005 Edition).
2. A carbon monoxide detector shall: a. Be located in the room that houses the appliances or equipment; b. Be either hard wired or battery powered or both; and c. Shall comply with NFPA 720 (2005
Edition)
3. A Product-approved vent terminal must be used, and if applicable, a Productapproved air intake must be used.
Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation.
11
Unit Preparations
SECTION III - Unit Preparations
Handling Instructions
The PRESTIGE Solo is generally easier to handle and maneuver once removed from the shipping carton.
To remove the shipping carton:
CAUTION
Use care not to lift the unit from, or place the unit on the front plastic control panel, damage can occur. Use care not to drop, bump or rotate the boiler upside down, as damage to the boiler will result.
1. Remove any shipping straps and open the side of the shipping carton.
2. Slide the unit with the foam inserts out of the carton.
3. Discard all packing materials.
Wall Mounting Installation
The PRESTIGE Solo should be wall mounted using the bracket provided with the boiler. The
PRESTIGE Solo is not designed for floor installation. If floor installation is required an optional floor stand is available through
Triangle Tube.
NOTICE
The wall used for mounting the PRES-
TIGE Solo must be vertically plumbed and capable of supporting a minimum
130 pounds [59 kg] for the PRESTIGE
Solo 60, 175 pounds [80 kg] for PRES-
TIGE Solo 175/250 and 250 pounds [115
Kg] for PRESTIGE Solo 399. Failure to comply with these requirements could result in personal injury, death or substantial property damage.
Wall Mounting Guidelines
1. The wall-mounting bracket is designed for stud spacing of 12 inch or 16 inch on centers. For unconventional stud spacing, a solid / secure mounting surface must be provided for installation of the bracket.
2. For applications using wood studs, install the bracket using the lag screws provided with the boiler. Ensure both lag screws are installed securely in the studs.
3. For applications using metal studs, install the bracket to the studs using 3/16” toggle bolts and washers.
4. DO NOT mount or attempt to mount the wall bracket to hollow sheet rock or lath walls using anchors. Only install boiler to studs or equivalent wood structure.
5. For applications using solid walls (rock, concrete, brick, cinder block, etc.), install the wall bracket using anchors (double expansion shields) and bolts with washers provided with the boiler.
6. The boiler is too heavy and bulky for a single person to lift and attempt to mount; a minimum of 2 people is required for mounting the boiler.
NOTICE
Use extreme care not to drop the boiler or cause bodily injury while lifting or mounting the boiler onto the bracket.
Once mounted verify that the boiler is securely attached to the bracket and wall. Failure to comply with the above guidelines could result in property damage, personal injury or death.
12
Unit Preparations
PRESTIGE Solo 60/175/250 Stud Walls -
Installation
1. Locate the studs in the general area of the boiler placement.
2. Place the wall-mounting bracket on the wall centering the mounting slots with the stud centers and ensuring the upper edge of the bracket is away from the wall.
3. Level the bracket, while maintaining it’s centering with the studs and use a pencil to mark the location of the mounting slots.
4. Remove the bracket from the wall and drill
1/4” diameter hole by 3” deep positioned in the center of each mark. For applications using metal studs and 3/16” toggle bolts, drill the required clearance hole.
5. Reposition the bracket onto the wall and align mounting slots/holes. Insert the two lag screws provided (or toggle bolts for metal studs) through the mounting slots/holes and loosely tighten.
6. Level bracket and tighten screws (bolts for metal studs) securely making sure not to over-tighten to avoid damaging drywall or plaster.
Wall Bracket Installation - Solid Walls
1. Locate the general area of the boiler placement.
2. Place the wall-mounting bracket on the wall ensuring the upper edge of the bracket is away from the wall.
3. Level the bracket and use a pencil to mark the location of the mounting slots on the wall.
4. Remove the bracket from the wall and drill a 5/8” diameter hole by 1-3/8” deep positioned in the center of each mark.
5. Install the anchors (provided) flush or slightly recessed in the drilled holes with threaded side facing down.
6. Reposition the bracket on the wall and align mounting slots/holes. Insert the two bolts (provided) through the mounting slots/holes and loosely tighten.
7. Level bracket and tighten bolts securely.
Boiler Mounting
1. Obtain assistance in lifting the boiler onto the wall bracket.
2. Install the boiler making sure the boiler mounting lip located along the upper edge of the rear jacket panel engages the wallmounting bracket. Ensure the boiler is seated properly and is secure.
PRESTIGE Solo 399 Stud Walls -
Installation
1. To distribute the weight of the boiler evenly when mounting onto a stud wall it is recommended to use the PRESTIGE Solo
Wall Frame kit.
2. When using the wall frame to mount the boiler reference the kit installation instructions and ensure the frame is securely fastened to the wall.
3. If the structure of wall is questionable, in supporting a minimum weight of 250 pounds [115 kg.], it is recommended to use the optional floor stand.
13
Boiler Piping
SECTION IV - Boiler Piping
General Piping Requirements
- All plumbing must meet or exceed all local, state and national plumbing codes.
Support all piping using hangers. DO NOT support piping by the unit or its components.
Use isolation valves to isolate system components.
Install unions for easy removal of the
PRESTIGE Solo from the system piping.
- Should terminate with a plain end, not with a threaded end. The material of the piping should have a serviceable temperature rating of 250ºF or greater.
- 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 boiler and relief valve.
WARNING
Use a two wrench method when tightening piping onto the boiler connections.
Use one wrench to prevent the boiler piping from turning / twisting. Failure to support the boiler piping and connections in this manner could cause damage to the boiler and its components.
Pressure Relief Valve
1. The PRESTIGE Solo is supplied with a 30 psi pressure relief valve and must be piped using the PRV connection as shown in Fig.
5 page 15.
WARNING
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 PRESTIGE Solo is equipped with a factory installed pressure switch type Low Water
Cut Off device.
The minimum operating system pressure allowable with this device is 10 psig.
Check local codes if a Low Water Cutoff
Device is required. If so, determine if this device meets the requirements of the local codes.
2. To avoid potential water damage to the surrounding area or potential scalding hazard due to the operation of the relief valve, the discharge piping:
- Must be connected to the discharge outlet of the relief valve and directed to a safe place of disposal.
- Length should be as short and direct as possible. The size of the discharge line should not be reduced, maintain the same size as the outlet of the relief valve.
- Should be directed downward towards the floor at all times. The piping should terminate at least 6 inches [153 mm] above any drain connection to allow clear visibility of the discharge.
NOTICE
The PRESTIGE Solo control system also senses the system water temperatures entering and exiting the heat exchanger to provide protection against low water conditions Where local codes and jurisdiction do not accept a pressure device for low water protection, the jurisdictions may accept these PRESTIGE Solo integral control functions as a means of providing low water protection.
14
Boiler Piping
Pressure Relief Valve
(Supplied with Boiler)
3/4" Street Elbow
Air Vent
Drain Piping Directed to a Suitable
Place of Drainage
Boiler Supply
Connection
Fig. 5: Pressure Relief Valve and Boiler Drain Valve Installation
Boiler Return Connection with Tee Fitting and
Boiler Drain Valve
15
Boiler Piping
Additional Limit Control
If a separate LWCO device is required by certain local jurisdictions or when the boiler is installed above the system piping, the following guidelines must be followed:
- The LWCO device must be designed for water installations, electrode probetype is recommended.
- The LWCO device must be installed in a tee connection on the boiler supply piping above the boiler.
- Wiring of the LWCO device to the
PRESTIGE Solo is done directly onto the 24V terminal strip, reference Fig.
20 page 32 for available terminals for an external limit (manual or auto reset).
Boiler System Piping Applications
BEST PRACTICE
It is recommended on all piping applications to utilize a primary/secondary piping arrangement as a means to provide freeze protection of the boiler, which is an integral function of the boiler control.
Maintain the minimum boiler flow rate, see Graphs 2 through 5 on pages 72 & 73.
For other piping arrangements, consult the Engineering Department at Triangle
Tube or consult other approved/recognized design arrangements.
If the installation is to comply with ASME or
Canadian requirements, an additional high temperature limit may be needed. Consult local code requirements to determine compliance. The limit should be installed as follows:
- Install the limit in the boiler supply piping between the boiler and any isolation valve.
- Maximum set point for the limit is
194ºF.
- For wiring of the limit reference Fig. 20, page 32, using the external limit/manual reset terminals on the 24V terminal strip.
This will provide a "hard" lockout requiring a manual reset of the control.
Backflow Preventer
Use a backflow preventer valve in the make-up water supply to the unit as required by local codes.
BEST PRACTICE
On piping applications utilizing a single zone or other recognized piping design arrangements, it is recommended that the installer uses flow/check valves with weighted seats at or near the appliance to prevent gravity circulation.
Expansion Tank and Makeup Water
Ensure the expansion tank is properly sized for the boiler volume (3 gallons [12 L] for the
PRESTIGE Solo 60, 5 gallons [19 L] for the
PRESTIGE Solo 175/250, 7 gallons [26 L] for
PRESTIGE Solo 399) and the system volume and temperature.
CAUTION
Undersized expansion tanks will cause system water to be lost through the pressure relief valve and cause additional makeup water to be added to the system.
Eventual boiler heat exchanger failure can result due to this excessive makeup water addition.
16
Boiler Piping
The expansion tank must be located as shown in Fig. 6 and Fig. 7 on page 18 when using a primary/secondary piping arrangement or as per recognized design methods. Refer to the expansion tank manufacturer instructions for additional installation details.
Connect the expansion tank to an air separator only if the air separator is located on the suction side (inlet) of the system circulator.
Always locate and install the system fill connection at the same location as the expansion tank connection to the system.
Diaphragm Expansion Tank
Always install an automatic air vent on the top of the air separator to remove residual air from the system.
Closed-Type Expansion Tank
It is recommended to pitch any horizontal piping upwards toward the expansion tank 1 inch per 5 feet of piping. Use 3/4” piping for the expansion tank to allow air within the system to rise.
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.
Circulator
The PRESTIGE Solo must be supplied with a
Central Heating (CH) circulator. The circulator when wired directly to the PRESTIGE Solo will allow for domestic hot water priority and to provide circulation for the freeze protection feature of the boiler control. See Graphs 2 through 5 on pages 72 & 73 for pressure drop and minimum flow rate through the boiler.
Sizing Primary Piping
See Fig. 8 through 14, pages 20 - 24, for recommended piping arrangements based on various applications. Size the piping and system components required in the space heating system, using recognized design methods.
Domestic Hot Water System Piping
See Fig. 8 , page 20 for recommended piping to a DHW system. This recommended piping configuration ensures priority is given to the production and recovery of the DHW.
The piping for the DHW is separate from the boiler system piping and does not require a primary / secondary piping configuration.
To wire the DHW circulator to the boiler control module, reference Section VIII - External
Wiring.
System Piping - Zone Circulators
Connect the PRESTIGE Solo to the system piping as shown in Fig. 9 page 21 when zoning with zone circulators.
The installer must provide a separate circulator for each zone of space heating as well as the boiler circulator.
NOTICE
To ensure an adequate flow rate through the PRESTIGE Solo, the boiler supply and return piping size must be a minimum of 1 inch for the PRESTIGE Solo
60, 1-1/4 inch for the PRESTIGE Solo
175/250 and 1-1/2 inch for the PRES-
TIGE Solo 399.
17
Boiler Piping
System
Supply
2
12"
Max.
1
6
3
10
Cold
Water Fill
11
6
4
5
Boiler
Boiler
Supply Return
Fig. 6: Near Boiler Piping - Diaphragm Expansion Tank
12
6
System
Return
7
System
Supply
1
9
8
3
4
6
3/4" Piping
6
Cold
Water Fill
12"
Max.
10
11
6
System
Return
7
12
Boiler
Supply
Boiler
Return
Note: Pitch horizontal piping upwards (1” of pitch per 5 ft of piping) towards expansion tank.
Fig. 7 : Near Boiler Piping - Closed Type Expansion Tank
1. System circulator
2. Automatic air vent
3. Air separator
4. Automatic fill valve
5. Diaphragm expansion tank
6. Isolation valve
7. Drain/purge valve
8. Tank fitting
9. Closed type expansion tank
10. Primary/secondary connection
11. Boiler circulator
12. Flow/check valve
18
Boiler Piping
System Piping - Zone Valves
Connect the PRESTIGE Solo to the system piping as shown in Fig. 10 page 21 when zoning with zone valves. The primary / secondary piping ensures that the boiler loop has sufficient flow.
NOTICE
To ensure an adequate flow rate through the PRESTIGE Solo, the boiler supply and return piping size must be a minimum of 1 inch for the PRESTIGE Solo 60,
1-1/4 inch for the PRESTIGE Solo
175/250 and 1-1/2 inch for the PRESTIGE
Solo 399.
System Piping - Through Boiler
In new or retrofit applications in which primary/secondary arrangement is not utilized, the
PRESTIGE Solo allows this flexibility due to a lower boiler pressure drop, see Graphs 2 through
7 on pages 75 through 77.
Figure 11, page 22 illustrates a multiple zone valve system with a single system/boiler circulator. A by-pass loop with a pressure differential valve must be installed on the system piping.
Figure 12, page 22 illustrates a single zone utilizing the boiler circulator as the system circulator.
System Piping - Radiant Heating
The heat exchanger design of the PRESTIGE
Solo allows operation in a condensing mode.
This feature requires no regulation of the return water temperature back to the boiler in radiant heating applications.
The boiler water supply temperature can be maintained by the PRESTIGE Solo, eliminating the need for a mix system to achieve the desired temperature.
It is recommended for the installer to add a high temperature limit as shown in Fig.13 page
23. This will ensure that the primary supply temperature does not exceed the maximum allowable temperature for the radiant tubing.
BEST PRACTICE
The addition of the high temperature limit is important if the PRESTIGE Solo is connected to a domestic hot water system, which requires a high primary supply water temperature.
Size the system piping and circulator to provide the flow needed for the radiant system.
NOTICE
To ensure an adequate flow rate through the PRESTIGE Solo, the boiler supply and return piping size must be a minimum of 1 inch for the PRESTIGE Solo
60, 1-1/4 inch for the PRESTIGE Solo
175/250 and 1-1/2 inch for the PRES-
TIGE Solo 399.
System Piping - Special Application
If the boiler is used in conjunction with a chilled water/medium system, the boiler and chiller must be piped in parallel. Install flow/check valves to prevent the chilled medium from entering into the boiler.
If the boiler is used to supply hot water to the heating coils of an air handler where they may be exposed to chilled air circulation, install flow/check valves or other automatic means to prevent gravity circulation of the boiler water during cooling cycles.
System Piping - Multiple Units Installation
Use a balanced manifold system as the primary / secondary connection to the space heating piping as shown in Fig. 14 page 24.
Maintain a minimum of 6 inches [153 mm] of clearance between units to allow for servicing.
Refer to Figs. 6 and 7 page 18 to install air separator and expansion tank.
For the space heating piping refer to the applications mentioned in this manual or use recognized design methods.
19
Boiler Piping
8
System
Return
System
Supply
1
6
5
7
3
6
Domestic
Hot
Domestic
Cold
2
3
4
Fig. 8: DHW Boiler Piping with a PRESTIGE Solo and SMART
1. PRESTIGE Solo boiler
2. SMART water heater
3. Isolation valve
4. DHW circulator
5. CH circulator
6. Flow/check valve
7. Pressure relief valve
8. Drain/purge valve
NOTICE
The boiler system piping shown in Fig. 8 must be a “closed” system to avoid any oxygen contamination and potential failure of the outer tank of the Smart.
20
Boiler Piping
4
5
3 3
4
Additional
Zone Load
4
5
3 3
9
Zone Load
4
12"
Max.
4
8
7
1
4
11
10
2
Fig. 9: CH System Piping - Zoning with Zone Circulators
1. PRESTIGE Solo boiler
2. CH circulator
3. Flow/check valve
4 Isolation valve
5. Zone circulator
6. Drain/purge valve
3
7. Pressure relief valve
8. Air separator
9. Automatic air vent
10. Diaphragm expansion tank
11. Automatic fill valve
4
5
4
Additional
Zone Load
6
4
5
4
12
9
4
Zone Load
12"
Max.
4
8
7
1
4
11
10
2
Fig. 10: CH System Piping - Zoning with Zone Valves
1. PRESTIGE Solo boiler
2. CH circulator
3. Flow/check valve
4 Isolation valve
5. Zone valve
6. Drain/purge valve
3
7. Pressure relief valve
8. Air separator
9. Automatic air vent
10. Diaphragm expansion tank
11. Automatic fill valve
12. System circulator
6
21
4
6
6
Boiler Piping
4
P
12
5
4
5
7
Additional
Zone Load
Zone Load
4
4
Note: Verify CH circulator is properly sized to overcome the system pressure drop and provide adequate flow through the boiler system.
2
1
2
9
4
6
8
4
11
10
Fig. 11: CH System Piping - Multiple Zone Valve with Single System/Boiler Circulator
1. PRESTIGE Solo boiler
2. CH circulator
4 Isolation valve
5. Zone valve
6. Drain/purge valve
7. Pressure relief valve
8. Air separator
9. Automatic air vent
10. Diaphragm expansion tank
11. Automatic fill valve
12. Pressure Differential Valve
Single
Zone load
2
1
7
2
9
Note: Verify CH circulator is properly sized to overcome the system pressure drop and provide adequate flow through the boiler system.
3
4
6
8
4
11
10
Fig. 12: CH System Piping - Single Zone System with Single System/Boiler Circulator
1. PRESTIGE Solo boiler
2. CH circulator
3. Flow/check valve
4 Isolation valve
5. Zone valve
6. Drain/purge valve
7. Pressure relief valve
8. Air separator
9. Automatic air vent
10. Diaphragm expansion tank
11. Automatic fill valve
22
Boiler Piping
4
5
Additional
Radiant Zone
4
4
5
Radiant Zone
4
12
13
9
8
4
11
10
Note: Manifold mounted valve actuators may be used in lieu of zone valves.
4
12"
Max.
4
1
2
3
Fig. 13: CH System Piping - Radiant/Low Temp. Heating
7
6
1. PRESTIGE Solo boiler
2. CH circulator
3. Flow check valve
4 Isolation valve
5. Zone valve
6. Drain/purge valve
7. Pressure relief valve
8. Air separator
9. Automatic air vent
10. Diaphragm expansion tank
11. Automatic fill valve
12. System circulator
13. High temperature limit control
6
23
Boiler Piping
24
Installating Vent/Combustion Air & Condensate Drain
SECTION V - Installing Vent /
Combustion Air & Condensate Drain
Installing Vent and Combustion Air
DANGER
The PRESTIGE Solo must be vented and supplied with combustion air as shown in the PRESTIGE Solo Vent
Supplement, included in the boiler installation envelope. Refer to optional vent kit instructions for additional vent installation instructions. Once installation is completed, inspect the vent and combustion air system thoroughly to ensure systems are airtight and comply with the instructions given in the venting supplement and are within all requirements of applicable codes. Failure to comply with the installation requirements on the venting and combustion air piping will cause severe personal injury or death.
Installing Condensate Drain Assembly
1. Locate the condensate drain assembly and install as shown in Fig. 15 page 26.
WARNING
Ensure the condensate drain assembly contains the plastic seated ball. Do not install the condensate drain assembly if the ball is lost or missing, replace the entire assembly.
3. Remove the compression nut and rubber seal from the drain outlet.
4. Using 3/4” x 2’ flexible PVC tube provided, slide the compression nut and rubber seal over the pipe
NOTICE
The use of 3/4” PVC or CPVC pipe is also acceptable. If 3/4” pipe is used deburr and chamfer pipe to allow mating onto the drain assembly.
5. Thread the rubber seal into the compression nut to ease installation of the pipe to the drain assembly.
6. Seat the pipe onto the drain assembly and tighten the compression nut. Hand tight
only!
NOTICE
The installer may opt to using 13/16" ID tubing in lieu of rigid piping.
NOTICE
The installer may want to fill the condensate trap with water prior to assembling on the unit.
2. Remove the retaining nut and rubber seal from the condensate drain assembly and slide over the heat exchanger condensate drain nipple. Connect the condensate drain assembly to the retaining nut and tighten.
Hand tight only!
NOTICE
The drain line materials must be an approved material by the authority having jurisdiction. In absence of such authority, PVC and CPVC piping must comply with ASTM D1785 or D2845.
The cement and primer used on the piping must comply with ASME D2564 or
F493. For installations in Canada, use
CSA or ULC certified PVC or CPVC pipe, fittings and cement/primer.
7. Continue the pipe from the drain assembly to a floor drain or condensate pump.
25
Installating Vent/Combustion Air & Condensate Drain
NOTICE
When selecting and installing a condensate pump, ensure the pump is approved for use with condensing boilers and furnaces. The pump should be equipped with an overflow switch to prevent property damage from potential condensate spillage.
8. The PRESTIGE Solo will typically produce a condensate that is considered slightly acidic with a pH content below 3.0. Install a neutralizing filter if required by authority having jurisdiction.
CAUTION
The condensate drain must remain filled and unobstructed and allow unrestricted flow of condensate. The condensate should not be subject to conditions where freezing could occur. If the condensate is subjected to freezing or becomes obstructed , it can leak, resulting in potential water damage to the boiler and surrounding area.
Fill Plug with Vaccum
Break Port
Compression
Nut with Rubber Seal
Flexible Tubing
(or 3/4 PVC/
CPVC Piping to Drain)
Heat Exchanger
Condensate
Drain Nipple
Retaining Nut with Rubber Seal
(Hand Tight Only)
Plastic Ball
Condensate
Drain Assembly
Fig. 15: Condensate Drain Assembly
26
Gas Piping
SECTION VI - Gas Piping
Gas Supply Piping Connection
7. Use pipe dope compatible with natural and propane gases. Apply sparingly only to the male threads of pipe joints so that pipe dope does not block gas flow.
NOTICE
The gas supply piping must be installed in accordance to all applicable local, state and national codes and utility requirements.
WARNING
Failure to apply pipe dope as detailed above can result in severe personal injury, death or substantial property damage.
1. Install a 1/2” NPT for PRESTIGE Solo 60,
3/4” NPT for PRESTIGE Solo 175/250 or
1” NPT for PRESTIGE Solo 399 pipe union at the factory supplied gas nipple, for ease of service.
2. Install a manual shutoff valve in the gas supply piping as shown in Fig. 16. For installations in Canada the installer must tag and identify the main shutoff valve.
3. Install a sediment trap (drip leg) on the gas supply line prior to connecting to the PRES-
TIGE Solo gas train as shown in Fig. 16.
4. Support the gas piping using hangers. Do not support the piping by the unit or its components.
5. Purge all air from the gas supply piping.
6. Before placing the PRESTIGE Solo into operation, check and test all connections for leaks.
Close the manual shutoff valve during any pressure test with less than 13”w.c..
Disconnect the PRESTIGE Solo and its gas valve from the gas supply piping during any pressure test greater than
13”w.c..
WARNING
Use a two-wrench method of tightening gas piping near the unit and its gas piping connection. Use one wrench to prevent the boiler gas line connection from turning and the second to tighten adjacent piping. Failure to support the boiler gas piping connection could damage the gas line components.
External Manual
Gas Shut Off
Valve (Must Be
Within 6' of the
Boiler)
Gas Flow
Tee Fitting
Sediment
Trap Min.
Length of 3"
Cap
Union Fitting
WARNING
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.
Fig. 16: Recommended Gas Supply Piping
27
Gas Piping
NATURAL GAS
Pipe Sizing - Natural Gas
Refer to Table 1 for schedule 40 metallic pipe length and diameter requirements for natural gas, based on rated PRESTIGE Solo input
(divide by 1,000 to obtain cubic feet per hour).
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..
- For additional gas piping sizing information, refer to ANSI Z223.1. For Canadian installations refer to B149.1 or B149.2.
2. Install 100% lockup gas pressure regulator in the gas supply line if inlet pressure can exceed 13”w.c at any time. Adjust the lockup pressure regulator for 13”w.c maximum.
WARNING
DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural 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.
Natural Gas Supply Pressure Requirements
1. Pressure required at the gas valve inlet supply pressure port:
Maximum 13”w.c. at flow or no flow conditions to the burner.
Minimum 5”w.c. during flow conditions to the burner. Must be verified during start up and with all other gas appliances operating within the building.
NOTICE
The natural gas orifice requirements are:
PRESTIGE Solo 60: 0.204” (5.2 mm)
PRESTIGE Solo 175: None Required
PRESTIGE Solo 250: None Required
PRESTIGE Solo 399: 0.339” (8.6 mm)
Table 1: Gas Piping Sizing - Natural Gas
Length of Pipe in
Feet
Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per
Hour (based on 0.60 specific gravity, 0.30" w.c. pressure drop)
SCH 40
10
20
30
40
50
75
100
150
1/2"
132
92
73
63
56
45
38
31
3/4"
278
190
152
130
115
93
79
64
1"
520
350
285
245
215
175
150
120
1-1/4"
1050
730
590
500
440
360
305
250
1-1/2"
1600
1100
890
760
670
545
460
380
28
Gas Piping
PROPANE GAS
Pipe Sizing - Propane Gas
Contact the local propane gas supplier for recommended sizing of piping, tanks and 100% lockup gas regulator.
Propane Gas Supply Pressure Requirements
1. Adjust the propane supply regulator provided by the gas supplier for 13”w.c. maximum pressure
2. Pressure required at the gas valve inlet supply pressure port:
Maximum 13”w.c. at flow or no flow conditions to the burner
Minimum 5”w.c. during flow conditions to the burner. Must be verified during start up and with all other gas appliances operating within the building.
WARNING
Prior to start up, ensure the unit is set to fire propane. Check the rating label for the type of fuel. Check the gas valve for propane conversion label. If there is a conflict or doubt on the burner set up, remove the gas valve and check for the propane orifice, see Fig. 17 or 18, page
30. Failure to ensure proper burner setup could result in severe personal injury, death or substantial property damage.
NOTICE
The propane orifice requirements are:
PRESTIGE Solo 60: 0.120” (3.1 mm)
PRESTIGE Solo 175: 0.221” (5.6 mm)
PRESTIGE Solo 250: 0.250” (6.3 mm)
PRESTIGE Solo 399: 0.264” (6.7 mm)
WARNING
DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural 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.
29
Gas Piping
Venturi
Propane
Orifice
Inlet Supply
Pressure Port
Gas Valve
Gas Valve
Gasket
Gas Valve
Pipe Fitting
Fig. 17: Gas Valve / Venturi Assembly - PRESTIGE Solo 60/175/250
Gaskets
Orifice
Venturi Gas Valve
Fig. 18: Gas Valve / Venturi Assembly - PRESTIGE Solo 399
30
Internal Wiring
SECTION VII - 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.
CAUTION
Prior to servicing, label all wires before disconnecting. Wiring errors can cause improper and dangerous operation.
Verify proper wiring and operation after servicing.
General Requirements
Wiring must be N.E.C Class 1.
If original wiring as supplied with the unit must be replaced, use only Type T 90ºC wire or equivalent as a minimum.
The PRESTIGE Solo must be electrically grounded as required by National
Electrical Code ANSI/NFPA 70 - latest edition and / or the Canadian Electrical Code
Part 1, CSA C22.1, Electrical Code.
-
Control Module Circulator AMP Ratings
- AMP draw of the CH circulator not to exceed 2 amps.
AMP draw of the DHW circulator not to exceed 2 amps.
Wiring Tool Instructions
1. Locate the wiring tools on the PRESTIGE
Solo just below the MCBA control in a plastic bag and below the extra fuses.
2. Locate the terminal blocks on the PRES-
TIGE Solo below the MCBA control.
NOTICE
The 120V Terminals are located on the left set of Terminal Blocks. The 24V
Terminals are located on the right set of terminal blocks.
3. Carefully pull down on the lower half of the terminal block to remove.
4. Hook the wiring tool into the desired slot of the terminal block as shown in Fig.19.
5. Push wiring tool in towards the terminal block and insert wire in slot at bottom of terminal block.
6. Repeat steps 4 & 5 until all wiring is complete.
7. Re-connect the lower half of the terminal block to the upper half.
8. Place the wiring tool back into the plastic bag or leave tool hooked to a slot on the
24V terminal block.
Terminal Block
Wiring Tool
Fig. 19: Using the Wiring Tool on the
Terminal Blocks
BEST PRACTICE
When wiring the PRESTIGE Solo allow additional length of wire for the access panel to swing open during servicing.
31
Internal Wiring
Fig. 20: Prestige Solo Boiler Factory Wiring
32
External Wiring
SECTION VIII- External Wiring
Installation Compliance
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.
In Canada, CSA C22.1 Canadian
Electrical Code Part 1, and any other local codes.
Domestic Hot Water Aquastat Wiring
1. Connect the DHW thermostat (aquastat) to the 24V terminal strip on the wiring panel located below the PRESTIGE Solo control module as shown in Fig. 20, page 32.
2. Route all wiring through the provided openings, in the bottom jacket panel. Allow enough wire for access panel to swing open during servicing.
Thermostat Wiring
WARNING
ELECTRICAL SHOCK HAZARD.
Before making any electrical connections to the PRESTIGE Solo, disconnect electrical power supply at the service panel. Failure to comply can cause severe personal injury or death.
Line Voltage Connections
1. Connect a 120 VAC/15A service to the
120V terminal strip on the wiring panel below the PRESTIGE Solo control module, as shown in Fig. 20, page 32.
2. Route the incoming 120 VAC power wire through the provided openings in the bottom jacket panel.
3. The unit is provided with a service switch located on the front panel, check local code requirements for compliance.
NOTICE
If local electrical codes or conditions require an additional service switch, the installer must provide and install a fused disconnect or 15 amp (minimum) service switch.
NOTICE
Isolate 120V wiring from 24V wiring to prevent any potential electrical “noise”.
1. Connect room thermostat or the end switch
(isolated contact only) of a relay control panel to the 24V terminal strip on the wiring panel below the PRESTIGE Solo control module, as shown in Fig. 20, page
32.
2. For proper operation install the room thermostat on an inside wall away from influences of heat and cold, i.e. water pipes, areas of draft, lighting fixtures and fireplaces.
3. Set the thermostat anticipator (if applicable) as follows:
Set for 0.2 amps when wired directly to the PRESTIGE Solo.
Set to match the total electrical power requirements of the connected devices when wired to zone relays or other devices. Refer to the relay manufacturers’ specifications and the thermostat instructions for additional information on the anticipator setting.
33
External Wiring
NOTICE
When making low voltage connections to the Prestige, ensure no external voltage is present in the thermostat circuits. If external voltage is present, provide an isolated contact to prevent damage to the boiler control.
CH and DHW Circulator
External Modulating Control
The PRESTIGE Solo firing rate can be controlled by an external modulating boiler controller. See page 32 for wiring and Page 54 for control module setup.
Outdoor Reset Control
The PRESTIGE Solo may operate with a variable boiler operating temperature using the
Triangle Tube outdoor sensor, see pages 50 through 53 for installation and set-up.
1. Connect the CH primary circulator to the
PRESTIGE Solo 120 V terminals 1,2 and 3 as shown in Fig. 20, page 32.
2. Connect the DHW circulator to the PRES-
TIGE Solo 120 V terminals 4, 5 and 6 as shown in Fig. 20, page 32.
3. Maximum circulator continuous current draw is 2A for each circulator.
System Circulator - Zone Valve Application
To energize the system circulator shown as item 12 in Fig. 10 page 21 reference Fig. 21.
Installer to provide a Transformer / Relay such as Honeywell R8285 or equivalent and Zone
Valves with isolated end switch such as
Honeywell V8043 or equivalent.
NOTICE
If the installer opts for a fixed operating temperature for the boiler system, the outdoor sensor is not required and should not be installed.
Additional 24V Limit Wiring
The PRESTIGE Solo provides 24V terminal connections for additional limit controls as shown in Fig. 20 page 32. These limit terminal connections will provide a "hard" lockout requiring a manual reset of the PRESTIGE
Solo control, or a “soft” lockout in which the
PRESTIGE Solo will automatically reset.
Room Thermostats
24 V
Transformer by Others
Honeywell V8043
Zone Valves or Equivalent
H
120V
N
R
C
G
1
3 4
6
Honeywell R8285D
Transformer / Relay or Equivalent
7
8
To Prestige
24V Terminal Strip
24V Low Voltage Wiring
120V High Voltage Wiring
System Circulator
Fig. 21: Secondary System Circulator Wiring
34
External Wiring
4 Wire Zone Valve
Zone 1
H
120
V.A.C.
N
High Voltage
Transformer
(Power)
Room
Thermostat
24
V.A.C.
Zone Valve
Zone 2
Additional zones
Room
Thermostat
Zone
Valve
Additional zones may be added as shown above
7
8
To Prestige
24V Terminal Strip
3 Wire Zone Valve
Zone 1
Transformer
(Power)
H
120
V.A.C.
N
High Voltage
Room
Thermostat
24
V.A.C.
Zone Valve
Zone 2
Additional zones
Room
Thermostat
Zone
Valve
Additional zones may be added as shown above
NOTICE:
*Use isolation relay on
3-wire zone valve with non-isolated end switch.
Transformer and the Prestige
MCBA control can burn out if isolation relay is not used.
* Isolation relay
7
8
To Prestige
24V Terminal Strip
Fig. 22: Multiple Zone Field Wiring Using Zone Valves
35
External Wiring
Fig. 23: Field Wiring with Zone Circulators
Honeywell
R845A
Relay
T T
Thermostat zone 1
120
H
VAC
N
2
1
4 3 5 6
Circulator
Zone 1
T
T
Thermostat zone 2
2
1
4 3 5 6
Circulator
Zone 2
Additional zones may be added as shown above
Fig. 24: Typical Zone Relay Panel Wiring
Thermostat
Zone 1
Thermostat
Zone 2
7 8
To Prestige
24V Terminal Strip
Thermostat
Zone 3
R C T1 T1 T2 T2 T3 T3
L2 ZC L1 X1 X2
PR PR C1 C1 C2 C2
C3
C3
N H
120 VAC
7 8
To Prestige
24V Terminal Strip
Zone 1
Circulator
36
Zone 2
Circulator
Zone 3
Circulator
Start-Up Preparation
SECTION IX - Start-Up Preparation
Check Boiler System Water Chemistry
WARNING
Do not use petroleum-base cleaning or sealing compounds in the boiler system.
Damage to seals and gaskets in the system components could occur, resulting in substantial property damage.
Flush Boiler and Domestic System to
Remove Sediment
The installer must flush the boiler system to remove any sediment to allow proper operation of the PRESTIGE Solo .
Flush the systems until the water runs clean and is free of sediment.
For zoned systems, each zone should be flushed through a purge valve. Purge valves and isolation valves should be installed on each zone to allow proper flushing of the 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.
Water pH Level 6.0 to 8.0
Maintain the boiler water pH between 6.0 and
8.0. Check using litmus paper or contact a water treatment company for a chemical analysis.
If the pH does not meet this requirement, do not operate the PRESTIGE Solo or leave the unit filled until the condition is corrected.
Check and Test Antifreeze
For boiler systems containing antifreeze solutions, follow the antifreeze manufacturer’s instructions in verifying the inhibitor level and to ensure the fluid characteristics are within specification requirements.
Due to the degradation of inhibitors over time, antifreeze fluids must be periodically replaced.
Refer to the manufacturer of the antifreeze for additional instructions.
Water Hardness Less Than 7 Grains
For areas with unusually hard water (hardness above 7 grains) consult a water treatment company.
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.
Chlorinated Water
Do not use the PRESTIGE Solo to heat a swimming pool or spa directly.
Maintain the chlorine level of the water at levels considered safe for drinking.
37
Start-Up Preparation
Use of Antifreeze in the Boiler System
WARNING
NEVER use automotive or ethylene glycol antifreeze or undiluted antifreeze in the primary system as freeze protection.
This can cause severe personal injury, death or substantial property damage if ignored.
Determine the antifreeze fluid quantity using the system water content volume and following the antifreeze manufacturer instructions.
The water volume of the PRESTIGE Solo is approximately 3 gallons [12 L] for PRESTIGE
Solo 60 or 5 gallons [19 L] for PRESTIGE Solo
175/250 or 7 gallons [26 L] for PRESTIGE Solo
399 . Remember to include the volume of the expansion tank.
Check with local codes requirements for the installation of backflow preventers or actual disconnection from the boiler’s cold water fill or make up water supply line.
NOTICE
Massachusetts Code requires the installation of a backflow preventer if antifreeze is used.
Ensure the concentration of antifreeze to water does not exceed a 50/50 ratio.
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.
Filling the Boiler System
1. Close the boiler drain valve located on the bottom of the unit and any manual or automatic air vent in the system.
2. Open all system isolation valves.
3. Fill the boiler system to correct system pressure. Correct pressure will vary with each application.
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.
4. Purge air and sediment in each zone of the boiler system through the purge valve.
Open air vents to allow air to be purged in the zones.
5. Once the system is completely filled and purged of all air and sediment, check the system pressure and check/repair any leaks.
WARNING
Unrepaired system leaks will cause continual makeup water to be added to the boiler. Continual makeup water could cause mineral buildup within the heat exchanger, reducing the heat transfer, causing possible heat buildup and eventual heat exchanger failure.
Check Low Water Cut-Off Device
The PRESTIGE Solo is provided with a factory installed LWCO device that measures system pressure of more than 10 psi.
Remove the front jacket panel and check for continuity across the low water cut-off device wire terminals. The contacts should be closed when system pressure is greater than 10 psi. See item 6, on Fig. 27 page 66
(PRESTIGE Solo 60) or on Fig. 27A page
67 (PRESTIGE Solo 175/250) or Fig. 27B page 68 (PRESTIGE Solo 399) for location of the LWCO.
38
Start-Up Preparation
Check For Gas Leaks
WARNING
Prior to start-up and during initial operation, smell near the floor and around the unit for gas odorant or any unusual odor.
Do not proceed with the start-up if there is any indication of a gas leak. Any leaks found must be repaired immediately.
NOTICE
In systems using 3-wire zone valves, backfeed of voltage to the unit is a common problem. Use an isolation relay to prevent voltage from the external circuit entering the PRESTIGE Solo control panel.
Reconnect the external thermostat wires to the 24V terminal strip on the wiring panel.
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.
Prior to start-up of the unit and periodically after start-up have the propane supplier check and verify the odorant level.
Inspection of Condensate Drain Assembly
1. Inspect and ensure the Condensate Drain
Assembly is properly installed as described on page 25 and shown in Fig. 15 on page
26.
2. Remove the plug from the Condensate
Drain Assembly and fill with fresh water.
Check Thermostat Circuit
Disconnect the external thermostat wires from the 24V terminal strip on the wiring panel.
Connect a voltmeter across the wire ends of the external thermostat wiring.
Close each thermostat, zone valve and relay in the external circuit one zone at a time and check the voltage reading across the wire ends.
There should NEVER be voltage measured at the wire ends.
If voltage is measured at the panel under any condition, check and correct the external wiring.
NOTICE
The condensate drain assembly must be filled with water when the PRESTIGE
Solo is in operation. The condensate drain assembly prevents flue gas emissions from entering the condensate line.
Failure to ensure trap is filled with water could result in severe personal injury or death.
3. Re-Install plug in condensate drain assembly.
39
Start-Up Procedures
SECTION - Start-Up Procedures
Final Checks Before Start-Up
c c c c c c
Read page 45 through 48 regarding the operation of the PRESTIGE Solo control.
Verify the PRESTIGE Solo and the boiler system are full of water and all system components are correctly set for operation, including the minimum flow rate through the boiler, see pages 79 through 81.
Verify Start-up Preparation items outlined on pages 37 thru 39 have been completed.
Verify all electrical connections are correct and securely fastened.
Inspect vent and combustion air piping for signs of deterioration from corrosion, physical damage or sagging. Verify combustion air and vent piping are intact and correctly installed and supported. Reference the PRES-
TIGE Solo vent supplement.
Verify burner configuration - Propane only.
- Check for proper labeling on the gas valve and the rating label for propane configuration.
- If there is doubt on the burner configuration, remove the gas valve and check for proper propane gas orifice size: 0.120” or
3.1 mm for PRESTIGE Solo 60, 0.221” or
5.6mm for PRESTIGE Solo 175, 0.250” or
6.3 mm for PRESTIGE Solo 250 or 0.264” or 6.7 mm for PRESTIGE Solo 399. Refer to Figs. 17 & 18, page 30 for location of the propane gas orifice.
PRESTIGE Solo Start-Up
1. Turn the ON-OFF switch located on the front control panel to the OFF position. Turn ON the electrical supply/service to the unit.
2. Read and follow the Operating Instructions outlined on page 42.
If PRESTIGE Solo Does Not Start Correctly
1. Verify DHW (parameter 2) and CH (parameter 3) systems are turned ON or set to
“01”. Read the Boiler Display Standby and
Parameter Section of the manual starting on page 47 for more information.
2. Check for loose electrical connections, blown fuse (external or internal to the
MCBA Control) or open service switch.
3. Check continuity across the L.W.C.O
device for a closed circuit. See item 5 on
Fig. 27, page 66 and item 6 Fig. 27A, page
67 and Fig. 27B, page 68.
4. Is the external limit control (if applicable) open? Ensure the external limit is reset to the closed position.
5. Is the gas supply valve(s) open at the unit and meter?
6. Is incoming gas supply pressure at the unit more than 5”w.c. and less than 13” w.c. for natural or propane with all gas appliances
ON or OFF.
7. Are the heating thermostats set above room temperature?
If none of these conditions correct the problem, refer to the PRESTIGE Solo Trouble-Shooting
Guide or contact Triangle Tube Tech Service.
NOTICE
c
For natural gas applications the Prestige
60 requires an orifice: 0.204” (52mm), and the Prestige 399 requires and orifice:
0.330” (8.6 mm)
Ensure the vent Condensate Drain
Assembly is filled with water.
40
Check the PRESTIGE Solo and System
c
Check Boiler Piping.
Check Boiler system piping and components for leaks. If found, shut down the unit and repair immediately.
Purge any remaining air from the system piping. Air in the system piping will interfere with circulation creating heat distribution problems and system noise.
Start-Up Procedures
c
Check Vent Piping and Combustion Air
Piping.
Check for gas-tight seal at every connection and seam of the venting and combustion air piping.
Test for CO2 or O2 and for CO during high firing rate. To manually place the boiler into high fire mode, reference page 45. The combustion reading should be within the range listed in
Table 2. The CO level should not
exceed 100 ppm when combustion is correct.
WARNING
Venting system must be sealed gas-tight to prevent flue gas spillage and potential carbon monoxide emissions, which will result in severe personal injury or death.
c
Check Gas Piping
Check around the unit for gas odor following the procedure outlined in this manual on Page 39.
WARNING
If any gas leaks are found or suspected, shut the unit down immediately. Use a gas detection device or bubble test to locate the source of the gas leak and repair at once. Do not operate the unit until the leak is corrected. Failure to comply with this procedure could result in severe personal injury, death or substantial property damage.
c
Verify Flame Pattern and Combustion
Check the flame pattern through the inspection port of the heat exchanger.
The flame should be blue and stable.
The flame should be the length of the burner head openings.
WARNING
The combustion testing and adjustments must be performed by a qualified installer, service agency or the gas supplier. All combustion measurements must be performed with calibrated equipment to ensure proper reading and accuracy.
WARNING
The combustion levels should be measured at high firing rate, refer to page 45 of the PRESTIGE Solo control section on how to set the firing rate. If the combustion levels are not within the range given in Table 2 for the firing rate, shut the boiler down and contact Triangle
Tube Engineering Department. Failure to comply with this requirement could result in severe personal injury, death or substantial property damage.
Table 2: Recommended Combustion Levels
Natural Gas
All Models
O2 Min.
2.30%
Propane
Solo 60/175/250
2.70%
O2 Max.
5.30%
CO2 Min.
8.80%
CO2 Min.
10.50%
CO Max.
100 ppm
4.70%
10.70%
12.00%
100 ppm
Propane
Solo 399
3.70%
5.20%
10.00%
11.00%
100 ppm c
Measure Input - Natural Gas Only
1. Ensure the boiler is firing at maximum firing rate. To manually place the boiler into high fire mode, reference page 45.
2. Operate the unit for approximately 10 minutes.
3. Turn off all gas appliances within the building, except the PRESTIGE Solo.
4. At the gas meter, record the time required to use one cubic foot of gas.
41
Start-Up Procedures
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING
If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
A
. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. DO NOT try to light the burner by hand.
B. BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone in your building
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
C. Use only your hand to turn the external manual gas valve. Never use tools. If the valve will not turn by hand, don’t try to repair it; call a qualified service technician. Force or attempted repair may result in a fire or explosion.
D. 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 and any gas control which has been under water.
OPERATING INSTRUCTIONS
1.
STOP! Read the safety information above. This appliance is equipped with an ignition device which automatically lights the burner. DO NOT try to light the burner by hand.
7.
Turn the service switch on the PRESTIGE control panel “ON”.
8.
Set room thermostat(s) to desired setting(s).
2.
Set room thermostat(s) to lowest setting. Turn the external manual gas valve handle clockwise
“CLOSE” (valve handle shall be perpendicular to gas piping).
3.
Turn the service switch on the PRESTIGE control panel OFF.
9.
The PRESTIGE control panel display will show a sequence of numbers (0,1,2,3,4,etc.) as the left digit. Sequence digit 3 or 4 indicates the boiler is firing. Sequence digit 0 means there is no call for heat (all external thermostats are satisfied).
4.
Remove the front jacket panel on the unit.
5.
Turn the external manual gas valve handle counter clockwise to “OPEN” gas supply (valve handle shall be parallel to gas piping).
10. If the unit will not operate with a call for heat and the system piping is not hot, follow the instructions “To
Turn Off Gas to Appliance”, 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.
6.
Wait five (5) minutes to clear out any gas. If you then smell gas in the jacket enclosure or around the unit, STOP! Follow “B” in the safety information above. If you don’t smell gas, go to the next step.
TO TURN OFF GAS TO APPLIANCE
1.
Set the room thermostat to lowest setting.
3. Turn the external manual gas valve handle clockwise to “CLOSE”.
2.
Turn the service switch on the PRESTIGE control panel to “OFF”
42
Start-Up Procedures
5. Calculate Natural gas input using the following equation:
3600 x 1000 / number of second recorded for one cubic foot of gas = BTU/H.
6. The BTU/H calculated should approximate the input rating listed on the unit.
Set Boiler CH Set Point
1. Press the MODE button until the display shows PARA. This is the parameter mode of the control.
2. Press the STEP button until the first digit on the display shows "4". The last three digits on the display shows the CH
Maximum Boiler Operating Setpoint.
3. Press the "+" or "-" button to change the setting.
NOTICE
When an outdoor sensor is used, the setting of Parameter 4 is the CH setpoint when the outdoor temperature is at or below 0ºF. When the outdoor temperature is above 0ºF, the PRESTIGE Solo control will calculate the boiler setpoint between the minimum and maximum temperature settings.
4. Press the "STORE" button to save the setting.
Operation Verification - Space Heating
NOTICE
Digits and characters shown as [
0000
], in the following outline, represent the control panel display. The last three digits on the display represent the measured boiler water temperature and may differ from what is shown in the manual.
1. Disconnect the DHW (Domestic Hot
Water) thermostat wiring from the PRES-
TIGE Solo or turn down DHW tank aquastat (if used) to ensure the boiler does not receive a DHW call for heat.
2. Set the room thermostat to the lowest setting.
3. Turn off power to the boiler, wait a few seconds and turn on power to the boiler.
4. The following displays should occur:
[
U1.22
] Software version
[
A140
] Self check on power up
[
0140
] 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 display should occur.
[
5140
] This is a fan / air flow check. The burner blower will be energized momentarily prior to the prepurge cycle.
[
1140
] This is the prepurge cycle. The burner blower and the CH (Central
Heating) circulator become energized. The blower has a 10 second prepurge cycle.
[
2140
] This is the ignition cycle. The control module will energize and open the gas valve and begin the spark for ignition.
If the burner flame proves, the burner will continue to fire at the ignition fan speed for approximately 10 seconds to stabilize the flame.
If the burner flame is not proven the control module will repeat the ignition sequence. If the flame is not proven after five attempts the control will lockout and the display will show [
E-02
]
To verify flame failure lockout, close the manual shut off valve on the gas supply piping to the boiler and repeat ignition sequence. When verification is completed, ensure the manual shut off valve is returned to the open position.
[
3140
] This is the normal CH operation cycle. After the flame is proven and stabilized the burner will fire at low input for
43
Start-Up Procedures
approximately 1 minute. After this time period, the control module will begin to modulate the burner firing rate based on actual boiler outlet temperature and the set point temperature.
6. Allow the boiler to operate and allow the boiler outlet temperature to reach the set point temperature.
[
6180
] This begins the burner shutdown and post purge cycle. The CH circulator will continue to run until the room thermostat is satisfied.
7. Lower the room thermostat set point below the room temperature to end the call for heat.
[
1180
] This begins a post purge cycle.
When the room thermostat is satisfied, the boiler will shutdown. The control module will close the gas valve and the blower will continue for 30 seconds for a post purge cycle before shutting down. If another call for heat is initiated, the boiler will remain off for an additional 30 seconds before starting a new ignition sequence.
[
7180
] The CH circulator will continue to run for a 1 minute post pump cycle.
[
0180
]The boiler is in standby MODE waiting for a call for heat.
8. Verify the operation of the boiler by repeating the operational sequence several times.
9. Return the room thermostat to a desired setting. Reconnect the DHW wiring or return the DHW aquastat to desired setting, placing the DHW system into operation.
[
5140
] This is a fan / air flow check. The burner blower will be energized momentary prior to the prepurge cycle.
[
1180
] This is prepurge cycle. The burner blower and DHW circulator become energized and the 10 second prepurge cycle begins.
[
2180
] The boiler will begin the ignition sequence. The same sequence of establishing flame, trail for ignition and attempts for ignition as described in the space heating applies for domestic water heater.
[
4180
] This indicates normal operation for DHW. The burner will begin modulating its input to maintain the DHW set point.
The burner will not go into the low input rate for the 1 minute flame stabilization period that occurs in CH mode.
3. Lower the DHW aquastat to satisfy the call for heat.
[
1180
] The post purge cycle begins. The control module closes the gas valve and the blower continues for a 30 second post purge.
[
8180
] The DHW circulator will continue for a 30 second post pump cycle. If another DHW call for heat is initiated the boiler ignition sequence will begin immediately.
[
0180
] Boiler is in standby MODE waiting for a CH or DHW call for heat.
4. Verify the DHW operation of the boiler by repeating the outlined operation sequence several times.
5. Return the DHW aquastat and room thermostat to the desired setting.
Operation Verification - Domestic Hot
Water (if applicable)
1. As outlined in the verification for space heating, repeat STEPS 2 through 4.
2. Raise the DHW aquastat setting to initiate a call for heat. As in the space heating operation the display should show:
44
Start-Up Procedures
Boiler Control Display
Standby Mode
StbY
This is the standard mode for the PRESTIGE
Solo. 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 stored.
The first character shows (on left side of display) the current status of the boiler depending on the condition of both the boiler and the burner. The last 3 characters indicate the boiler supply temperature.
If the burner is blocked due to a “soft” lockout, the display alternates between a 9 followed by the boiler supply temperature and a “b” with a two digit error code.
TO DEACTIVATE THE HIGH OR LOW
FIRE TEST MODE: press the MODE button until “
StbY
” is displayed. Then press and hold both the “+” and “-” buttons simultaneously to deactivate the high or low fire test mode.
Display
H 180
L
180
Boiler function
Test function: Burner on, high fire mode
Test function: Burner on, low fire mode
TO TEMPORARILY PLACE THE BURN-
ER INTO HIGH FIRE TEST MODE: press the MODE button until “
StbY
” is displayed.
Then press and hold both the MODE and “+” buttons simultaneously until the first digit flashes “H”.
While in the test mode:
high limit will function
boiler CH circulator will function
domestic circulator will not function
the test mode will time out in approximately 10 minutes
NOTICE
If the “+” button is held in, the CH system
(parameter 3) will be turned OFF and the
display will show “
cOFF
”. Press and
hold the “+” button to turn the CH system back ON, the display will show “c” followed by CH set point. If the “-” but-
ton is held in while in the “
StbY
” mode,
domestic system (parameter 2) will be turned OFF and the display will show
“
dOFF
”. Press and hold “-” button to
turn the domestic system back ON, the display will show “d” followed by domestic set point temperature.
TO TEMPORARILY PLACE THE BURN-
ER INTO LOW FIRE TEST MODE: press the MODE button until “
StbY
” is displayed.
Then press and hold both MODE and “-” buttons simultaneously until the first digit flashes
“L”.
45
Start-Up Procedures
Standby Mode Display
b b
Display
0 180
1 180
2
180
3 180
4 180
5 180
6 180
7
180
8 180
9 180 b 18 b b b b b b b
19
24
25
26
8
2 9
30
33
38 b
35 b b
40
52 b 65 b b1
18
Boiler function
STANDBY, no demand for heat
Fan prepurge or post purge cycle
Ignition sequence
Burner ON for space heating (CH)
Burner ON for domestic hot water (DHW)
Pre-check for air flow prior to prepurge cycle
Burner OFF due to reaching temperature setpoint
Space Heating (CH) post pump cycle
Domestic hot water (DHW) post pump cycle
Burner blocked:
Supply temperature too high (202 F) . Burner will remain OFF until temperature drops below 200 F
Return temperature too high (202 F). Burner will remain OFF until temperature drops below 200 F
Return temperature is higher 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
Factory supplied LWCO device or external limit (terminals 15 & 16) is OPEN.
Burner off for 150 seconds, auto reset.
No blower signal
Blower signal present with no demand, Burner will remain OFF until condition terminates
Temperature difference between the supply and return is more than 72 F. Burner will remain OFF for 150 seconds. Burner will recycle increasing wating period 1 minute for a max. 20 cycle.
Indirect water heater temperature sensor is short-circuited. Burner OFF until corrected.
Indirect water heater temperature sensor is
“open” or disconnected. Burner OFF until corrected.
Flue temperature sensor is short-circuited.
Burner OFF until corrected
Flue temperature senor is “open” Burner OFF until corrected.
Flue temperature greater than 240 F but less than 250 F. Burner off for 150 seconds
Wait for the blower to start
Power frequency deviation
Flame current signal lost
46
Start-Up Procedures
Setting The Boiler Parameters
Parameter mode
P ARA
To access PARAMETER mode when the system is in STANDBY mode, press the MODE button once.
Key: Display
MODE
P ARA
Pressing MODE once
Note 1: This parameter is factory set to 140ºF.
It is important to note the control adds 46ºF to this setting, therefore the actual domestic hot water boiler setpoint is 140ºF + 46ºF = 186ºF.
Key: Display
STEP
STEP
STEP
STEP
2
3
4
.
.
.
01
01
Description of parameters
Domestic Hot Water Setting (See Note 1)
DHW Application Selection (See Note 2)
CH Application Selection (See Note 3)
CH Maximum Boiler Operating Setpoint
To scroll through the list of parameters, simply press the “STEP” button. The first digit is the parameter number followed by the parameter value. To modify a parameter value, use the + or - keys. Then press “STORE” to save the value you just changed. The display flashes once to confirm the data has been stored.
To activate the parameters you changed, press
“RESET”. However, if you do not press a key, the system returns to STANDBY mode after 20 minutes and automatically stores the changes.
Note 2: This parameter should not be changed from the factory setting of 01. The performance of the DHW will be affected and can become unreliable.
Note 3: This parameter should not be changed from the factory setting of 01. The performance of the CH (Central/Space Heating) will be affected and can become unreliable.
47
Start-Up Procedures
Accessing Boiler Information
Information mode
I NFO
To switch from STANDBY mode to INFOR-
MATION mode, press MODE twice.
Key: Display
MODE
MODE
P ARA
I
NFO
Pressing MODE once
Pressing MODE twice
Press STEP until the system displays the information you need. The first digit is the information item number followed by the items value.
The decimal point located behind the first position flashes to indicate that the boiler is in
INFO mode.
NOTICE
The ignition counters and burner hours are split into three two digit numbers.
For example:
J 12
.34
.56
Write the numbers down from left to right to arrive at 123,456 CH ignitions.
NOTICE
In the INFO Mode a temperature reading of -22 typically indicates an “open” circuit. A temperature reading of 240 typically indicates a short-circuit.
Display Digit
Segments
48
Start-Up Procedures
Error (Hard Lockout) Mode
If a serious fault occurs, the system enters a hard lockout condition which requires a manual reset by pressing the RESET button. A hard lock is indicated by displaying an E for the first digit, followed by the error code.
For a detailed description of the error codes, reference the PRESTIGE Solo Troubleshooting
Guide.
CAUTION
The boiler freeze protection feature is disabled during a Hard Lockout, however the CH circulator will operate.
CAUTION
During a hard lockout or low water condition the boiler will not re-start without service. If the heating system is left unattended in cold weather appropriate safeguards or alarms should be installed to prevent property damage.
Display
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E
E 13
E 14
15
16
17
18
19
25
28
29
31
32
35
36
37
40
44
52
E
60
61
E 65
E
1 13
E 1 15
E 1 22
E 1 23
E 1 24
E
E
E
E
E
E
E
E
E
E
E 00
02
03
04
05
06
07
08
09
11
12
Hard Lockout
Flame detected prior to burner startup
Failed ignition after 5 attempts
Gas valve harness not properly connected
Power supply lost after lockout occured
Internal control failure
Internal control failure
Internal control failure
Internal control failure
Internal control failure
Internal control failure
External limit (terminals 13 & 14) is OPEN
Internal control failure
Internal control failure
Internal control failure
Internal control failure
Internal control failure
Supply Temperature exceeds 212 F
Return Temperature exceeds 212 F
Supply Temperature increased too rapidly
No blower signal present
Blower signal does not reset to zero
Supply Temperature sensor is short circuited
Return Temperature sensor is short circuited
Flue Temperature sensor is short circuit
Supply Temperature sensor is OPEN
Return Temperature sensor is OPEN
Flue Temperature sensor is OPEN
Internal control failure
Flue Temperature exceeds 250 F
Internal control error - failure to read parameters
Internal control failure
Inadequate power supply to the fan
Invalid power frequency
Internal control failure
Supply or Return Temperature sensor drift
Supply or Return Temperature failure
Supply or Return Temperature not changing
49
Outdoor Reset Control
SECTION XI - Outdoor Reset Control
The boiler setpoint for a heating call can be fixed or vary with the outdoor temperature. If the application requires a constant supply temperature from the boiler, the outdoor temperature sensor should not be connected to the boiler. If an outdoor temperature sensor is connected to the boiler, the outdoor reset function is automatically enabled and will vary the CH setpoint with the change in outdoor temperature. The outdoor reset function has no affect on the DHW setpoint during a domestic call.
Fig. 25: Sensor Enclosure and Components
Mounting the Outdoor Sensor
4. Mount the sensor enclosure at an elevation on the exterior wall to prevent accidental damage or tampering.
5. Avoid mounting the enclosure in areas subjected to excessive moisture.
6. Once an area on the exterior wall has been determined, to affix the enclosure use the enclosure as a template to mark the location of the mounting screws.
7. Using a 3/16” drill bit, drill 2 pilot holes on the marked locations.
8. Tap the enclosed plastic anchors into the pilot holes. Use care not to damage the anchors.
9. Mount the sensor enclosure using the screws provided.
Wiring the Sensor
1. Remove the sealing nut and sealing gasket from the sensor enclosure.
2. Route two 18 gauge wires through the sealing nut and gasket. Connect the wires to the sensor terminals 1 and 2.
3. Re-insert the sealing gasket and tighten the sealing nut to the sensor enclosure.
4. Route the sensor wire back to the PRES-
TIGE Solo boiler, ensuring the wires are not run parallel to telephone or power cables.
1. Remove the front cover and mounting screws / anchors from the sensor enclosure.
2. When mounting the enclosure the exterior wall selected should represent the heat load of the building. Typically a northern or northeastern wall will suit most buildings.
A southern facing wall may suit buildings that have large glass walls or windows on the southern face.
3. Ensure the sensor enclosure is shielded from direct sunlight or the effects of heat or cold from other sources (exhaust fans, appliance vents...) to prevent false temperature sensing.
NOTICE
If the sensor wires are located in an area with sources of potential electromagnetic interference (EMI) the sensor wires should be shielded or the wires should be routed in a grounded metal conduit. If using shielded cable, the shielding should be connected to the common ground of the unit.
5. Connect the sensor wires to the outdoor sensor terminals on the 24V terminal strip located inside the boiler enclosure (see boiler wiring diagram, Fig. 20 page 32).
50
Outdoor Reset Control
Summer / Winter Switch at Boiler
If required the CH (Central Heating) system can be turned off at the boiler, similar to a manual summer / winter switch by pressing and holding the “+” button while in
the “StbY
” mode. The display will show “
cOFF
”. Pressing and holding the “+” button turns the CH system back on.
The display will show “c” followed by the CH set point temperature.
WARNING
If a parameter setting is changed but the
STORE button is not pressed to save the setting, the MCBA will automatically store the setting after 20 minutes. Ensure all parameters are at their factory settings or appropriately revised for the application prior to commissioning the boiler. Failure to comply could result in erratic or unreliable operation of the
Prestige boiler.
CH Maximum Boiler Operating Setpoint
(Parameter 4)
Factory Setting
186ºF
Minimum
Setting
86ºF
Maximum
Setting
194ºF
If an outdoor temperature sensor is not connected to the boiler, the boiler setpoint for a heating call will be set to the CH Maximum
Boiler Operating Setpoint. If an outdoor temperature sensor is connected, the CH
Maximum Boiler Operating Setpoint becomes the boiler setpoint on the CH Reset Curve
Coldest Day. The outdoor temperature can be monitored on the boiler display via item 4 of the INFO menu.
CH Minimum Boiler Operating Setpoint
(Parameter 10)
Factory Setting
Minimum
Setting
Maximum
Setting
86ºF
60ºF 140ºF
NOTICE
Once a parameter setting has been revised and stored pressing the STEP button will display the setting of the next parameter without showing P_XX. To avoid confusion, it is advisable to continue pressing the STEP button until
Parameter 46 is reached. The next press of the STEP button will cause the display to roll over to Parameter 1. Continue pressing the STEP button until the next parameter to be adjusted is reached and revise the setting.
Adjusting Outdoor Reset Curve
Parameters 4, 10, 11, & 12 define the settings of the outdoor reset curve. See Graph 1 and
Table 3, page 53 for an example of modifying the outdoor reset curve.
This parameter is not applicable if an outdoor sensor is not connected to the boiler. When an outdoor temperature sensor is connected, the
CH Minimum Boiler Operating Setpoint becomes the boiler setpoint on the CH Reset
Curve Warmest Day.
CH Reset Curve Coldest Day
(Parameter 11)
Factory Setting
Minimum
Setting
00ºF
(-)22ºF
Maximum
Setting
50ºF
This parameter is not applicable if an outdoor sensor is not connected to the boiler. When an outdoor temperature sensor is connected, the
CH Reset Curve Coldest Day is the coldest design temperature of the heating system.
51
Outdoor Reset Control
CH Reset Curve Warmest Day
(Parameter 12)
Factory Setting
64ºF
Minimum
Setting
60ºF
Maximum
Setting
78ºF
This parameter is not applicable if an outdoor sensor is not connected to the boiler. When an outdoor temperature sensor is connected, the
CH Reset Curve Warmest Day is the warmest design temperature of the heating system.
Entering MCBA Access Code
The installer must enter the MCBA Access
Code to adjust the advanced parameter settings of the MCBA. The Access Code can be entered as follows:
1. Press the MODE button until the display shows
STbY
.
2. Press and hold the MODE and STEP buttons together for 2 to 3 seconds until the display shows
CODE
.
3. Press the STEP button once and the display will show
C_
XX where XX represents a random number.
4. Press the “+” or “–“ buttons to change the number displayed to read
C_54
.
. Press and hold the “+” or “–“ button to rapidly change the number.
5. When the display reads
C_54
, press the
STORE button to save the Access Code.
The display should flash to indicate that the
Access Code was saved.
After the Access Code has been entered, the advanced parameters can be accessed by pressing the MODE button until the display shows
PARA
. Once the display shows
PARA
, press the STEP button to reach the appropriate parameter. The display should follow the following sequence:
Press STEP once-
1140
Press STEP x2 -
Press STEP x3 -
2_01
3_01
Press STEP x4 -
Press STEP x5 -
Press STEP x6 -
4186
P_10
P_11
Etc......
After Parameter 4, the display will show P followed by the parameter number. Once a particular parameter is reached, the display will change to show the current setting of that parameter.
NOTICE
The actual parameter values displayed on the display may vary depending on the application, but the sequence will always occur in the order shown.
Changing a Parameter Setting
1. Use the “+” or “–“ button to change the parameter setting.
2. Press the STORE button to save the change. The display should flash to indicate that the change was saved.
3. Press the RESET button to leave the Access
Code mode.
52
Outdoor Reset Control
180
140
Parameter 4 Set Point
100
86
60
Parameter 10
Set Point
20
90 70
64
50
30
10 0 -10
Outdoor Air Temperature ( F)
Graph 1: Outdoor Air Temperature Reset Curve (Example)
Table 3: Outdoor Air Temperature Reset (Example)
Outdoor
Temperature
0ºF or Lower
23ºF
40ºF
64ºF or Higher
Boiler target Temp.
Based on Outdoor Temp.
140ºF
122ºF
108ºF
86ºF
Graph 1 illustrates Parameter 4 adjusted to 140ºF target temperature at 0ºF outdoor air temperature
Note: Factory setting of Parameter 4 is 186ºF.
53
External Modulating Control
SECTION XII - External Modulating
Control
The boiler can directly accept an analog 0-10
VDC signal to control the firing rate from an external modulating boiler controller.
Wiring the Modulating Controller
Run two 18 gauge wires from the external modulating boiler controllers 0-10 VDC boiler output to the external input terminals on the low voltage terminal strip inside the boiler. (see boiler wiring diagram, Fig. 20 page 32). This signal will both enable and modulate the boiler. No wiring is required at the thermostat (T-
T) terminals 7 and 8 of the boiler.
NOTICE
Ensure that Parameter 4 is set above the highest setpoint of the external modulating control. Paramater 4 is a boiler high temperature limit when using an external modulating controller.
Programming of External Modulating
Control
The external modulating control must be programmed to send 1.8 VDC to enable the boiler and run it at low fire, and 10 VDC to run the boiler at high fire. Once the control enables the boiler, it must wait 2 minutes to allow the burner to stabilize before modulating the boiler.
NOTICE
Ensure that the polarity of the connections from the external modulating boiler controller to the boiler is correct.
Reversed polarity could lead to erratic and/or no response from the boiler controller.
Parameter Adjustment
The Prestige MCBA control module must be programmed to accept the 0-10 VDC signal from the external modulating boiler control.
CH Operating Signal Section
(Parameter 45)
Factory Setting
00
Revised
Setting
02
Follow the procedure for entering the MCBA
Access Code on page 52, and then change the setting of Paramater 45 from the factory setting of 00 to 02.
54
External Modulating Control
Factory Setting Parameters
39
40
41
42
21
32
33
38
43
45
46
18
19
20
12
13
3
4
1
2
10
11
46ºF
01 Minutes
03 x 10.2 Sec.
02ºF
06ºF
03 x 10.2 Sec.
00 x 10.2 Sec.
00 x 10.2 Sec.
00 Minutes
00
02
140ºF
01
01
186ºF
86ºF
00ºF
64ºF
-22ºF
32ºF
00 Minutes
00ºF
DHW Setting
DHW Application Selection
CH Application Selection
CH Maximum Boiler Operating Setpoint
CH Minimum Boiler Operating Setpoint
CH Reset Curve Coldest Day
CH Reset Curve Warmest Day
Frost Protection Setpoint
CH Block Temperature Setting
Boost Feature Setting
Parallel Shift Value
Setpoint Value Addition for DHW
CH Circulator Post Pump Time Period
DHW Circulator Post Pump Time Period
DHW On Differential
DHW Off Differential
CH Call Blocking Time
DHW Call Blocking Time
DHW to CH Call Blocking Time
DHW Priority Timeout
CH Operating Signal Selection
DHW Operating Signal Selection
55
Check-Out Procedures
SECTION XIII- Check-Out Procedures
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 57.
Check-Out Procedures
c
Boiler system water chemistry checked and verified as outlined on page 37.
c c
The boiler air vent and any automatic air vents placed within the system are open one full turn.
Air is purged from the heating zones and boiler system piping.
c c c c c
If applicable, confirm that the burner has been properly configured for Propane as outlined on page 29.
Thermostat circuit wiring checked and verified that no voltage is present to the low voltage terminals as outlined on page 39.
Operating Instructions on page 42 were followed during start-up.
Combustion levels and flame pattern verified as outlined on page 41.
Measured the rate of input on Natural Gas as outlined on page 41.
c c c
Checked the incoming gas pressure to the
PRESTIGE Solo to ensure a minimum pressure of 5”w.c during flow conditions to all gas appliances and a maximum pressure of 13”w.c during non-flow conditions for
Natural and Propane.
Adjusted balancing valves and system limit controls to provide design temperatures to the primary space heating system.
In multiple zone applications, adjusted for correct flow of boiler water to each zone.
c c c c c c
Checked and verified room thermostat(s) function properly and the thermostat(s) heat anticipator (if used) was properly set.
Observed several operating cycles for proper operation of the PRESTIGE Solo and the system.
Set the room thermostat(s) to the desired room temperature.
Reviewed all instructions shipped with the
PRESTIGE Solo with the homeowner or maintenance personnel.
Completed the Installation Record on page
57.
Ensure all manuals and other documents are returned to the Installation envelope and given to the owner for safekeeping.
56
Installation Record
SECTION XIV - Installation Record
PRESTIGE Model Number:
Serial Number:
Date of Installation:
Fuel: Natural Gas Propane
Measured Rate of Input:
Combustion Readings:
CO
2
%
O
2
%
CO ppm
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 personnel.
Installer Information
Btu/hr
(Company)
____________________________________________________________________
(Address)
____________________________________________________________________
(Address)
____________________________________________________________________
(Phone Number) _________________________________________________________________
57
Maintenance Schedule
SECTION XV - Maintenance Schedule
Service Technician
At least on an annual basis the following maintenance should be performed by a qualified service technician:
General
Attend to any reported problems.
Inspect the interior of the boiler jacket area; clean and vacuum if necessary.
Clean the condensate drain assembly and fill with fresh water.
Check for leaks: water, gas, flue and condensate.
Verify flue vent piping and air inlet piping are in good condition, sealed tight and properly supported.
Check boiler water pressure, piping and expansion tank.
Check control settings.
Check ignition electrode (sand off any white oxide; clean and reposition).
Check ignition wiring and ground wiring.
Check all control wiring and connections.
Check burner flame pattern (stable and uniform).
Additional items if combustion or performance is poor:
Clean heat exchanger and flue ways.
Remove burner assembly and clean burner head using compressed air only.
Owner Maintenance
Periodically:
Check the area around the unit.
Check and remove any blockage from the combustion air inlet and ventilation openings.
Check the temperature and pressure gauges.
Monthly:
Check vent piping.
Check combustion air inlet piping.
Check the pressure relief valve.
Check the condensate drain system.
Every 6 months:
Check boiler piping and gas supply piping for corrosion or potential signs of leakage.
Operate the pressure relief valve.
WARNING
Follow the maintenance procedures given throughout this manual. Failure to perform the service and maintenance or follow the directions in this manual could result in damage to the PRES-
TIGE Solo or in system components, resulting in severe personal injury, death or substantial property damage.
Once the maintenance items are completed, review the service with the owner.
58
Maintenance Procedures
SECTION XVI - Maintenance
Procedures
Maintenance Procedures
WARNING
The PRESTIGE Solo should be inspected and serviced annually, preferably at the start of the heating season, by a qualified service technician. In addition, the maintenance and care of the unit as outlined on page 58 and further explained on pages 59 through 64 should be performed to assure maximum efficiency and reliability of the unit. Failure to service and maintain the PRESTIGE Solo and the system components could result in equipment failure, causing possible severe personal injury, death or substantial property damage.
NOTICE
The following information provides detailed instruction for completing the maintenance items outline in the maintenance schedule on page 58. In addition to this maintenance, the PRESTIGE
Solo should be serviced at the beginning of the heating season by a qualified service technician.
Verify that combustion air inlet area is free of any contaminates. Refer to the materials listed on page 5 of this manual. If any of these products are in the area from which the unit takes its combustion air, they must be removed immediately or the combustion air intake must be relocated to another area.
Inspect Burner Area
Remove the boiler front jacket panel and venturi inlet elbow.
Vacuum any dirt or debris from the burner/blower components.
Re-install venturi inlet elbow and front jacket panel when completed.
WARNING
Do not use solvents to clean any of the burner components. The components could be damaged, resulting in unreliable or unsafe operation.
Check System Piping
Inspect all piping (water and gas) on the boiler system for leaks and verify that the piping is leak free and properly supported.
Inspect the fittings and components on the unit and verify they are leak free.
Reported Problems
Any problems reported by the owner should be checked, verified and corrected before proceeding with any maintenance procedures.
Check Surrounding Area
Verify that the area surrounding the PRES-
TIGE Solo is free of combustible / flammable materials or flammable vapors or liquids.
Remove immediately if found.
WARNING
Eliminate all boiler water system leaks.
Continual fresh make-up water will reduce the heat exchanger life causing boiler failure. Leaking water may also cause severe property damage to the surrounding area. Inspect the gas supply piping using the procedure outlined on
Page 41.
59
Maintenance Procedures
Clean Condensate Drain Assembly
1. Loosen the retaining nut from the condensate drain assembly and disconnect the assembly from the boiler.
2. Empty any water from the trap and drain assembly. Flush with fresh water as necessary to clean.
3. Check the drain piping from the condensate drain assembly to the drain. Flush to clean as necessary.
4. Reassemble the condensate drain assembly onto the boiler by tightening the retaining nut with rubber seal onto the boiler. Hand tight only.
5. Remove the fill plug on the condensate drain assembly and fill with water. See Fig. 15 on page 26.
6. Replace the fill plug on drain assembly.
Check Ventilation Air Openings
Verify that all ventilation openings to the mechanical room or building are open and unobstructed. Check the operation and wiring of any automatic ventilation dampers.
Check and verify the vent discharge and the combustion air intake are free of debris and obstructions.
Inspect Vent and Combustion Air Piping
Visually inspect the venting system and combustion air piping for blockage, deterioration or leakage. Repair any deficiencies.
Verify that the combustion air inlet piping is connected, sealed and properly supported.
WARNING
Failure to inspect the vent system and combustion air inlet piping and to have any conditions repaired, can result in severe personal injury or death.
Check Boiler System
Verify all system components are correctly installed and operating properly.
Check the cold fill pressure for the system, typical cold water fill pressure is 12 psig.
Verify the system pressure, as the unit operates at high temperature, to ensure the pressure does not exceed 25 psig. Excessive pressure reading indicates expansion tank sizing is incorrect or system performance 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 completed. Ensure vents do not leak, replace any leaking vents.
60
Maintenance Procedures
Check Expansion Tank
Refer to Section IV - Boiler Piping for recommended location of the expansion tank and air eliminators.
Closed -Type Tank:
Ensure tank is partially filled with water leaving an air gap as a cushion.
Refer to the manufacturer’s instruction for proper fill level.
Ensure the tank is fitted with a device that reduces gravity circulation of airsaturated tank water back into the system. This device prevents air from bubbling up through the water as it returns from the system.
Ensure no automatic air vents are used in the system. This will allow air to escape from the system instead of returning to the tank.
Diaphragm Tank:
Ensure the system contains a minimum of one automatic air vent. Recommended location of the air vent should be atop an air eliminator.
Remove the tank from the system and check the charge pressure. For residential applications the charge pressure is typically 12 psig. If tank does not hold a charge pressure, then the membrane is damaged and the tank should be replaced.
Check Boiler Relief Valve
Inspect the relief valve and lift the lever to verify flow at least annually or as recommended on the warning tag of the valve.
WARNING
Before manually operating the pressure relief valve, ensure the discharge piping is directed to a suitable place of disposal to avoid a potential scald hazard. The discharge piping must be full size without restriction and installed to permit complete drainage of both the valve and line.
If after closing the valve, the valve fails to seat properly or continually weeps, replace the relief valve. Ensure the cause of the relief valve to weep is the valve itself, not due to system over-pressurization caused by an expansion tank that is waterlogged or undersized.
Inspection of Ignition Electrode
Remove the ignition electrode from the burner mounting plate.
Remove any white oxides accumulated on the electrode using fine grit sandpaper or steel wool.
If the electrode does not clean to a satisfactory condition, replace the ignitor .
When replacing the ignition electrode, ensure the gasket is in good condition and correctly positioned, replace gasket if necessary.
Check Ignition Wiring and Ground Wiring
Inspect the burner wiring from the burner control module to the ground terminal behind the control panel.
Ensure wiring is in good condition and securely connected.
Check ground continuity of the wiring to the boiler jacket or piping using a continuity meter.
Replace and correct ground wire if ground continuity is not completed and satisfactory.
61
Maintenance Procedures
Check Control Wiring
Inspect all control wiring. Ensure wiring is in good condition and properly connected.
Check Control Settings
1. Set the control display to PARAMETER mode and check all boiler settings. Adjust setting as necessary see page 47.
2. Check any external limit control settings (if used). Adjust settings as necessary.
Perform Start-up and Checkout Procedures
Start the unit and perform the start-up procedure as listed in this manual.
Verify the cold water fill pressure is correct and the operating pressure of the boiler is within normal operating range.
Complete the checkout procedures as referenced in this manual.
Check Burner Flame
Inspect the burner flame through the observation port on the heat exchanger.
If flame pattern is not fully blue and covers the entire burner surface during high fire, shut the unit down and allow it to cool thoroughly before disassembly.
Close the external manual gas valve on the gas supply line and disconnect the gas piping and rectifier plug.
Disconnect the wiring harness connectors from the blower and remove the blower retaining screws or nuts. Remove the blower from the unit.
Remove the mounting nuts securing the burner mounting plate to the heat exchanger and set aside.
Carefully remove the burner mounting plate assembly from the heat exchanger. Ensure combustion chamber insulation is not damaged during removal of burner mounting plate assembly. See WARNING on page 64.
Remove the burner head mounting screws and remove the burner head. Inspect the burner head for deterioration. Use compressed air or a vacuum to clean the burner head.
Remove the venturi and gas valve assembly from the blower.
Use a vacuum cleaner or compressed air to clean the interior of the blower assembly.
Inspect the blower blades to ensure they are clean and not damaged.
Re-assemble the venturi and gas valve onto the blower. Ensure the venturi gasket is in good condition, positioned correctly and replace gasket if necessary.
Re-assemble the burner head onto the burner mounting plate. Ensure the burner head gasket is in good condition, positioned correctly and replace gasket if necessary.
Re-assemble the burner mounting plate assembly onto the heat exchanger. Ensure the burner plate gasket and combustion chamber insulation is in place and not damaged, replace gasket and insulation if necessary. See WARNING on page 64.
Re-assemble the blower onto the burner mounting plate and reconnect the wiring harness connectors.
Re-assemble the gas supply connection and rectifier to gas valve. Open the external manual gas valve. Check gas piping for any leaks as outlined on page 41 and repair if necessary.
Place the unit back into service.
62
Maintenance Procedures
Check Flame Signal
The flame signal can be read from item E of the information mode. It should be a min. 3μ Α −DC.
Check the ignitor for fouling or damaged insulation if a low flame signal is read.
Check ground wiring and continuity as a cause for low flame signal. Replace ignitor if conditions are satisfactory.
Check Combustion Levels
Refer to page 41 of this manual for measuring combustion levels and burner adjustments.
Check Flue Gas Temperature
1. Adjust the boiler to fire at HIGH fire, see page 45. Place the control display to INFOR-
MATION mode, see page 47 for procedures.
2. The flue gas temperature is indicated on the display when the first digit is 5. The measured temperature (shown as the last 3 digits) should not be more than 54ºF higher than the measured supply water temperature.
3. The measured supply water temperature is indicated on the information display when the first digit is 1 and the temperature shown as the last 3 digits.
4. If the measured flue gas temperature is higher than 54ºF over the supply water temperature, shut the boiler down and follow the procedures listed below to clean the heat exchanger.
Clean Heat Exchanger
1. Shut down the boiler:
- Follow the instructions on Page 42 "To
Turn Off Gas to Appliance"
- Do not drain the boiler unless the boiler will be subject to freezing conditions.
- Do not drain the boiler if freeze protection fluid is used in the system.
2. Allow the boiler to cool down to room temperature before servicing.
3. Disconnect the gas piping and rectifier plug to the gas valve.
4. Disconnect the wiring harness connectors from the blower and remove the blower retaining screws or nuts. Remove the blower from the unit.
5. Remove the mounting nuts securing the burner mounting plate to the heat exchanger and set aside.
6. Carefully remove the burner mounting plate assembly from the heat exchanger.
Ensure combustion chamber insulation is not damaged during removal of burner mounting plate assembly. See WARNING on page 64.
7. Carefully remove the combustion chamber insulation from the heat exchanger and set aside. See WARNING on page 64.
8. Use a vacuum cleaner, compressed air or water to remove any accumulation from the heat exchanger flue ways. Do not use any solvent.
9. Re-install the combustion chamber insulation onto the heat exchanger.
10. Re-assemble the burner mounting plate assembly onto the heat exchanger. Ensure the burner plate gasket and combustion chamber insulation is in place and not damaged, replace gasket and insulation if necessary. See WARNING on page 64.
11. Re-assemble the blower onto the burner mounting plate and reconnect the wiring harness connectors.
12. Reconnect the gas piping and rectifier to gas valve. Check for leaks, repair if necessary.
13. Close isolation valves on the boiler water piping to isolate the boiler from the heating system.
63
Maintenance Procedures
14. Attach a hose to the boiler drain valve and flush the boiler thoroughly with fresh water by using the purge valves to allow water to enter through the make-up water line to the boiler.
15. Once the boiler has been completely flushed, return the boiler and system piping back to operation.
16. Perform the required startup and checkout procedures as outlined on pages 37 to 57.
Review With Owner
Ensure the owner understands the importance to perform the maintenance schedule specified in this manual.
Remind the owner of the importance to call a licensed contractor should the unit or system exhibit any unusual behavior.
Handling Previously Fired Combustion Chamber Insulation
WARNING
The combustion chamber insulation contains ceramic fibers, which are classified as a possible human carcinogen.
When exposed to extremely high temperatures, the ceramic fibers, which contain crystalline silica, can be converted into cristobalite.
Avoid Breathing and Contact with Skin and Eyes
When removing or repairing the combustion chamber insulation follow these precaution measures:
1. Use a NIOSH approved 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 recommendations.
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 rinse washing machine thoroughly.
6. Discard used insulation in an air tight plastic bag.
NIOSH Stated First Aid:
Eye/Skin: Immediately irrigate
Breathing: Clean fresh air
64
Replacement Parts
5
6
7
2
3
5
9
1
1A
5
6
2
3
7
8
9
1
Fig. 26: PRESTIGE Solo Jacket Components
Item
8
Part #
PRESTIGE
Solo 60
--
PSJKT01B
Part #
PRESTIGE
Solo 175-250
PSCS01
PSJKT01F
PSJKT02S
PSJKT01T
PSJKT02T
--
PSJKT03B
PSJKT03T
PSJKT04T
PSJKT03
PSRKIT21
Part #
PRESTIGE
Solo 399
Description
Disply Control Panel
PSCS02 (Left)
PSCS03 (Right)
Display Control Panel Extensions (Not Shown)
PSJKT04B Base Panel
PSJKT02F Front Jacket Panel
PSJKT03S Side Jacket Panel (Left and Right)
PSJKT05T Top Jacket Panel
PSJKT06T Top Jacket Access Panel
PSJKT04 Control Cover Panel
Wall Mounting Braket with 1 Hardware
65
Replacement Parts
2
3
1
4
4
8
9
5
7
6
Fig. 27: PRESTIGE Solo 60 Internal Components
5
6
7
8
9
Item
1
2
3
4
Part # Description
PSRKIT01 Heat Exchanger Body
PSRKIT02 Vent Outlet Adapter
PSRKIT03 Combustion Air Inlet Adapter
PSRKIT04 NTC Sensor (NTC1, NTC2 and NTC5)
PGRKIT20 LWCO Pressure Device
PSRKIT05 Condensate Drain Assembly
PSRKIT06 Boiler Piping - Return Assembly
PSRKIT52 Boiler Piping - Supply Assembly
PSRKIT17 Pressure Gauge and Fitting
66
Replacement Parts
3
2
9
1
6
10
4
5
4
8
7
Fig. 27A: PRESTIGE Solo 175/250 Internal Components
Item
1
8
9
6
7
10
2
3
4
5
Part #
PRESTIGE
Solo 175/250
PSRKIT25
PSRKIT26
PSRKIT27
PSRKIT03
PSRKIT04
PSRKIT34
Description
Heat Exchanger Body Solo 175
Heat Exchanger Body Solo 250
Vent Outlet Adapter
Combustion Air Inlet Adapter
Supply & Return NTC Sensor (NTC1, NTC2)
Flue NTC Sensor (NTC5)
PGRKIT20 LWCO Pressure Device
PSRKIT05 Condensate Drain Assembly
PSRKIT28
PSRKIT29
PSRKIT17
Boiler Piping - Return Assembly
Boiler Piping - Supply
Pressure Gauge and Fitting
67
Replacement Parts
2
3
4
5
9
6
1
4
8
10
Fig. 27B: PRESTIGE Solo 399 Internal Components
7
Item
5
6
7
8
9
10
3
4
1
2
Part #
PRESTIGE
Solo 399
PSRKIT44
PSRKIT45
PSRKIT46
PSRKIT47
Description
Heat Exchanger Body
Vent Outlet Adapter
Combustion Air Inlet Adapter
Supply & Return NTC Sensor (NTC1, NTC2)
PSRKIT34 Flue NTC Sensor (NTC5)
PGRKIT20 LWCO Pressure Device
PSRKIT05
PSRKIT48
Condensate Drain Assembly
Boiler Piping - Return Assembly
PSRKIT49
PSRKIT17
Boiler Piping - Supply Assembly
Pressure Gauge and Fitting
68
Replacement Parts
9
8
7
6
5
4
3
2
1
Item
9
10
7
8
11
12
3
4
5
6
1
2
Fig. 28: PRESTIGE Solo 60/175/250 Burner Components
Part #
PRESTIGE
Solo 60
PSRKIT09
PSRKIT11
Part #
PRESTIGE
Solo 175-250
Description
PSRKIT30 Combustion Chamber Insulation
PSRKIT31 Burner Head with Gasket
PSRKIT12 PSRKIT32 Burner Plate
PSRKIT55 PSRKIT13 Blower with Gasket
PGRKIT01 Gas Valve
-Venturi - 055 (Solo 60) - 052 (Solo 175) - 051 (Solo 250)
PSRKIT14
PSRKIT15
PSRKIT16
--
--
PGRKIT15
Ignition Cable
Igniter with Gasket
Sight Glass Assembly (Glass, Gasket and Bracket)
Propane Orifice - Not Shown
Burner Plate Gasket - Not Shown
Gas Valve Rectifiier Plug - Not Shown
69
Replacement Parts
8
7
3
4
9
2
5
6
10
12
13
Item
7
8
5
6
9
1
2
3
4
10
11
12
13
1
Fig. 28A: PRESTIGE Solo 399 Burner Components
Part #
PRESTIGE Solo 399
PSRKIT37
PSRKIT38
PSRKIT39
PSRKIT40
PSRKIT41
--
PSRKIT14
PSRKIT15
PSRKIT16
--
--
PSRKIT42
PSRKIT43
Description
Combustion Chamber Insulation
Burner Head with Gasket
Burner Plate
Blower with Gasket
Gas Valve
Venturi
Ignition Cable
Igniter with Gasket
Sight Glass Assembly (Glass, Gasket and Bracket)
Propane Orifice - Not Shown
Burner Plate Gasket - Not Shown
Gas Valve Piping
Gas Supply Piping
70
Replacement Parts
3
Fig. 29: PRESTIGE Solo Electronic Components
Item
1
2
3
Part #
PSRKIT50 Prestige Control Module
Description
PSRKIT19 Transformer with Surge Protection
PSRKIT20 Prestige Control Module Display
71
Product Specifications
15.43” [392 mm]
9.87” [251 mm]
3” Vent Outlet
3” Combustion AIr Inlet
3”
[76 mm]
3/4” NPSC Pressure Relief Valve
Front View PRESTIGE Solo 60
19.75” [502 mm]
7.31” [186 mm]
9.87” [251 mm]
2.2”
[56 mm]
1 ” NPT Boiler Supply
1” NPT Boiler Return
1/2” NPT Gas Connection
72
Product Specifications
Front View PRESTIGE Solo 175/250
73
Product Specifications
24.70” [628 mm]
20.40” [516 mm]
18.60” [473 mm]
13.40” [340 mm]
4” Vent Outlet
3/4” NPSC Pressure Relief Valve
4” Combustion Air Inlet
Front View PRESTIGE Solo 399
9.25” [235 mm]
17.87” [454 mm]
3.27”
[83 mm]
1 1/2” NPT Boiler Return
1” Gas Connection
1 1/2” NPT Boiler Supply
74
Product Specifications
Side View PRESTIGE Solo 60
75
Product Specifications
Side View PRESTIGE Solo 175/250
76
Product Specifications
20.80” [529 mm]
15.40” [490 mm]
5.90” [150 mm]
3/4” NPSC Pressure Relief Valve
4” Vent Outlet
4” Combustion Air Inlet
Side View PRESTIGE Solo 399
14.72” [374 mm]
16.10” [409 mm]
1 1/2” NPT Boiler Supply
1 1/2” NPT Boiler Return
1” Gas Connection
77
Output
Note 4
157,500
225,500
Product Specifications
Boiler
Model
Fuel
SOLO 60
Natural
Propane
SOLO 175 Natural
Propane
SOLO 250
Natural
Propane
Input
Note 4
60,000
170,000
102,500
DOE
Heating Capacity
Note 1 & 4
54,000
110,000
154,000
245,000
102,500
223,000
110,000
Net IBR
Rating
Note 2
47,000
134,000
194,000
DOE Seasonal
Efficiency AFUE
Note 3
95%
95%
95%
95%
95%
95%
Shipping
Weight
Lbs / Kg
95 / 43
95 / 43
131 / 60
131 / 60
142 / 65
142 / 65
Boiler
Model
Fuel
SOLO 399 Natural
Propane
Input
Note 4
399,000
102,500
Output
Note 4
Note 5
379,000
110,000
Net IBR
Rating
Note 2
330,000
102,500
Combustion
Efficiency
94.1%
87,000
Thermal
Efficiency
95.1%
Shipping
Weight
Lbs / Kg
225 / 102
Note 1:
The heating capacity of the PRESTIGE Solo
60/175/250 is based on the test requirements of the U.S. Department of Energy.
Note 2:
The IBR rating is based on a piping and pick up allowance of 1.15. This allowance should be sufficient for the standard radiation requirements for a building load.
Note 3:
Based on the given AFUE the PRESTIGE
Solo 60/175/250 meets the energy efficiency guidelines established by Energy Star.
Note 4:
Input and output ratings are shown for sea level applications. The PRESTIGE Solo automatically derates the input at approximately 2% for every 1,000 Ft. of altitude. No alterations to the boiler or burner system is required.
Note 5:
PRESTIGE Solo 399 output rating is based off of the thermal efficiency.
DOE
78
Product Specifications
Pressure Drop Comparison -Grundfos
Graph 2: Pressure Loss Through Boiler-Grundfos Circulator
Pressure Drop Comparison -Taco
Graph 3: Pressure Loss Through Boiler-Taco Circulators
Note: Minimum allowable flow rate at full input:
- 3 gpm SOLO 60
79
Product Specifications
Graph 4: Pressure Loss Through Boiler - Grundfos Circulators
Graph 5: Pressure Loss Through Boiler - Taco Circulators
Note: Minimum allowable flow rate at full input:
- 8 gpm SOLO 175
- 12 gpm SOLO 250
80
Product Specifications
Graph 6: Pressure Loss Through Boiler - Grundfos Circulators
Graph 7: Pressure Loss Through Boiler - Taco Circulators
Note: Minimum allowable flow rate at full input:
- 19 gpm SOLO 399
81
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E-mail: Info@triangle tube.com
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Table of contents
- 7 Definitions
- 8 Product and Safety Information
- 9 Code Compliance
- 9 Determining Product Location
- 9 Boiler Replacement
- 9 Recommended Clearances
- 10 Residential Garage Installations
- 10 Boiler Freeze Protection Feature
- 11 Combustion Air Contamination
- 12 Ventilation and Combustion Air Requirements - Direct Vent
- 12 Ventilation and Combustion Air Requirements - Category IV
- 13 Methods of Accessing Combustion Air into a Space - Category IV
- 13 - Indoor Combustion Air
- 13 - Outdoor Combustion Air
- 14 - Combination of Indoor and Outdoor Combustion Air
- 15 Combustion Air and Vent Piping
- 16 Removal of an Existing Boiler from a Common Vent System
- 17 Commonwealth of Massachusetts Installation
- 18 Handling Instructions
- 18 Wall Mounting Installation
- 18 Wall Mounting Guidelines
- 19 Wall Bracket Installation - Stud Walls
- 19 Wall Bracket Installation - Solid Walls
- 19 Boiler Mounting
- 20 General Piping Requirements
- 20 Pressure Relief Valve
- 20 Low Water Cut Off Device
- 22 Additional Limit Control
- 22 Backflow Preventer
- 22 Boiler System Piping Applications
- 22 Expansion Tank and Makeup Water
- 23 Diaphragm Expansion Tank
- 23 Closed-Type Expansion Tank
- 23 Circulator
- 23 Sizing Primary Piping
- 23 Domestic Hot Water System Piping
- 23 System Piping - Zone Circulators
- 24 Near Boiler Piping Diagrams
- 25 System Piping - Zone Valves
- 25 System Piping - Through Boiler
- 25 System Piping - Radiant Heating
- 25 System Piping - Special Applications
- 25 System Piping - Multiple Units Installation
- 26 DHW Boiler Piping with PRESTIGE Solo and SMART
- 27 Central Heating System Piping Diagrams
- 31 Installing Vent and Combustion Air
- 31 Installing Condensate Drain Assembly
- 33 Gas Supply Piping Connection
- 34 Pipe Sizing -Natural Gas
- 34 Natural Gas Supply Pressure Requirements
- 35 Pipe Sizing - Propane Gas
- 35 Propane Gas Supply Pressure Requirements
- 36 Gas Valve/Venturi Assembly
- 37 General Requirements
- 37 Control Module Circulator AMP Ratings
- 37 Wiring Tool Instructions
- 38 Internal Factory Wiring Diagram
- 39 Installation Compliance
- 39 Line Voltage Connections
- 39 Domestic Hot Water Aquastat Wiring
- 39 Thermostat Wiring
- 40 CH and DHW Circulator
- 40 System Circulator - Zone Valve Application
- 40 External Modulating Control
- 40 Outdoor Reset Control
- 40 Additional 24V Limit Wiring
- 40 External Wiring Diagrams
- 43 Water pH Level 6.0 to
- 43 Water Hardness Less Than 7 Grains
- 43 Chlorinated Water
- 43 Flush Boiler and Domestic System to Remove Sediment
- 43 Check and Test Antifreeze
- 44 Use of Antifreeze in the Boiler System
- 44 Filling the Boiler System
- 44 Check Low Water Cut-Off Device
- 45 Check for Gas Leaks
- 45 Check Thermostat Circuit
- 45 Inspection of Condensate Drain Assembly
- 46 Final Checks Before Start-Up
- 46 PRESTIGE Solo Start-Up
- 46 If PRESTIGE Solo Does Not Start Correctly
- 46 Check the PRESTIGE Solo and System
- 48 Operating Instructions
- 49 Set Boiler CH Target Temperature
- 49 Operation Verification - Space Heating
- 50 Operation Verification - Domestic Hot Water
- 51 Standby Mode
- 54 Parameter Mode
- 54 Information Mode
- 55 Error (Hard Lockout) Mode
- 56 Mounting the Outdoor Sensor
- 56 Wiring the Sensor
- 57 Summer/Winter Switch at Boiler
- 57 CH Maximum Boiler Operating Setpoint (Parameter 4)
- 57 CH Minimum Boiler Operating Setpoint (Parameter 10)
- 57 CH Reset Curve Coldest Day (Parameter 11)
- 58 CH Reset Curve Warmest Day (Parameter 12)
- 58 Entering MCBA Access Code
- 58 Changing a Parameter Setting
- 59 Outdoor Reset Curve Example
- 60 Wiring the Modulating Controller
- 60 Parameter Adjustment
- 60 Programming of External Modulating Control
- 61 Factory Setting for Parameters
- 62 Check-Out Procedures
- 63 Installation Record
- 64 Service Technician - General
- 64 Owner Maintenance
- 65 Reported Problems
- 65 Check Surrounding Area
- 65 Inspect Burner Area
- 65 Check System Piping
- 66 Clean Condensate Drain Assembly
- 66 Check Ventilation Air Openings
- 66 Inspect Vent and Combustion Air Piping
- 66 Check Boiler System
- 67 Check Expansion Tank
- 67 Check Boiler Relief Valve
- 67 Inspection of Ignition Electrode
- 67 Check Ignition Wiring and Ground Wiring
- 68 Check Control Wiring
- 68 Check Control Settings
- 68 Perform Start-Up and Checkout Procedure
- 68 Check Burner Flame
- 69 Check Flame Signal
- 69 Check Combustion Levels
- 69 Check Flue Gas Temperature
- 69 Clean Heat Exchanger
- 70 Review with Owner
- 70 Handling Previously Fired Combustion Chamber Insulation
- 71 Replacement Parts
- 78 Specifications