TRIANGLE TUBE Prestige Excellence 110 Condensating Gas Boiler Water Heater User manual
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prestige
Excellence
Water Boiler
L
I
S T E D
Part 1 of 2
* I N S T A L L A T I O N A N D M A I N T E N A N C E *
M A N U A L
NOTICE
WARNING
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 Excellence 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.
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.
Revised Date: 12/15/15 2015-9 Prestige ACVMax Install Manual
Table of Contents
Section I - Pre-Installation Items
SECTION II - Combustion Air and Venting
2.2 Ventilation and Combustion Air Requirements - Direct Vent ..............................6
2.3 Ventilation and Combustion Air Requirements - Category IV.............................6
2.4 Methods of Accessing Combustion Air Into A Space - Category IV...................7
2.4.1 Indoor Combustion Air Opening Size and Location...................................7
2.4.2 Outdoor Combustion Air Opening Size and Location................................7
2.4.2.1 One Permanent Opening Method ...................................................7
2.4.2.2 Two Permanent Openings Method ................................................8
2.4.3 Combination of Indoor and Outdoor Combustion Air ..............................9
2.6 Removal of an Existing Boiler from a Common Vent System ............................10
2.7 Commonwealth of Massachusetts Installations Only...........................................11
SECTION III - Unit Preparations
i
Table of Contents
SECTION V - Installing Vent / Combustion Air & Condensate Drain
6.3.2 Propane Gas Supply Pressure Requirements ..............................................26
7.1 General Requirements...........................................................................................28
7.2 Fuse Locations ......................................................................................................28
SECTION VIII - External Wiring
ii
Table of Contents
9.7.6 Set Warm Weather Shutdown Temperature.................................................45
SECTION X - Start-Up Preparation
10.1.2 Boiler Fluid Hardness Less Than 7 Grains.................................................54
iii
Table of Contents
10.5 Check Thermostat Circuit.....................................................................................56
SECTION XI - Start-Up Procedures
SECTION XII - Outdoor Reset Control
SECTION XIII - External Modulating Control
SECTION XV - Installation Record
SECTION XV - Check-Out Procedures
SECTION XVI - Maintenance Schedule
SECTION XVII- Maintenance Procedures
iv
Table of Contents
17.23 Handling Previously Fired Combustion Chamber Insulation...............................73
17.24 Torque Specifications Table..................................................................................73
Section XVIII Product Specifications
PRESTIGE Excellence Front View.................................................................................74
PRESTIGE Excellence Right Side View.........................................................................75
PRESTIGE Excellence Top View....................................................................................76
Section XIX Notes
General Notes .........................................................................................................79
v
Product & Safety Information
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
Indicates the presence of a hazardous situation which, if ignored, will result in death, serious injury or substantial property damage.
NOTICE
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
ACV-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
ACV-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 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 peragency or the gas supplier.
WARNING
Qualified Installer:
Homeowner:
NOTICE
Please reference the unit’s model number
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 appliance is hot. Thermal shock can potentially cause cracks in the heat exchanger.
CAUTION
When servicing the appliance:
- Avoid electrical shock by disconnecting the electrical supply prior to performing maintenance.
WARNING
WARNING
2
1.0
Pre-Installation Items
SECTION I - PRE-INSTALLATION
ITEMS
1.1
Code Compliance
This product must be installed in accordance to the following:
- All applicable local, state, national and provincial codes, ordinances, regulations and laws.
Before locating the PRESTIGE Excellence check for convenient locations to:
- Heating system piping
- Venting
- Gas supply piping
- Electrical service
NOTICE
The PRESTIGE Solo boiler gas manifold
1.2
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. vented appliances must comply with the guidelines as outlined on page 11.
- 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
ANSI/ASME CSD-1, when required.
tion 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 Excellence and its controls are protected from dripping or spraying water during normal operation or service.
The PRESTIGE Excellence should be installed in a location so that any water leaking from the not cause damage to the area surrounding the unit or any lower floors in the structure.
Determining Product Location
NOTICE
The PRESTIGE boiler is certified for
ONLY.
1.3
Boiler Replacement
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 antifreeze within the boiler system.
3
1.0
Pre-Installation Items
1.4
Recommended Clearances
The PRESTIGE Excelence is approved for vent and boiler piping.
- Boiler Piping - 1/4 inch from combustible materials.
- Reference the appropriate vent supplement for clearance requirements.
BEST PRACTICE
To provide serviceability to the unit it is ances 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]
1.5
Residential Garage Installations
When installing the PRESTIGE Solo in a resiper NFPA 54/ANSI Z223.1 must be taken:
[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.
1.6
Boiler Freeze Protection Feature
WARNING 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.
NOTICE
When maintaining less than recommended serviceability clearances, some product labeling, including the rating able.
WARNING
When installing the PRESTIGE
Excellence 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
Code NFPA 54 - latest edition.
4 freeze protection feature built in. This feature monitors the boiler water temperature and responds as follows when no call for heat is present:
- 46ºF [8ºC] Pump outputs configured to respond to a CH1 Call are enabled.
- 42ºF [6ºC] Pump outputs configured to respond to a CH1 or CH2 Call are enabled, Burner operates at low fire.
- 60ºF [15ºC] Freeze protection ends.
Burner & all pumps turn off after completing CH Post Pump Time.
CAUTION
The boiler freeze protection feature is the circulators will operate.
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/secfor antifreeze guides.
2.0
Combustion Air & Venting
SECTION II - COMBUSTION AIR
AND VENTING
2.1
Combustion Air Contamination
WARNING tion 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 Excellence 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
2.0
Combustion Air Venting
2.2
Ventilation and Combustion Air
Requirements - Direct Vent
A Direct Vent appliance utilizes uncontaminated outdoor air (piped directly to the appliance) for combustion.
For Direct Vent installations, involving only the PRESTIGE Excellence, 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 Excellence, 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.
2.3
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 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 tion air into the house.
For installations in which the PRESTIGE
Excellence shares the space with air movers and other combustion equipment (gas or oil) the space must be provided with adequate air openings to provide ventilation and combusventilation / combustion air openings, the installer must comply with the National Fuel
Gas Code NFPA 54, ANSI Z223.1 for installainstallations in Canada.
WARNING tion / 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 Excellence 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 death or substantial property damage.
6
Excellence 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 man-
Combustion Air into a Space.
WARNING tion / combustion air openings properly sized for all make-up air requirements
(exhaust fans, clothes dryers, fireplaces, including the PRESTIGE Excellence when located in the same space. Failure to provide or properly size the openings death or substantial property damage.
2.0
Combustion Air Venting
2.4
Methods of Accessing Combustion
Air Into A Space - Category IV
2.4.1 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:
- Combining spaces on the same story.
Each opening shall have a minimum 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.
Fig. 1:
All Combustion Air from Adjacent
Indoor Spaces Through Indoor
Combustion Openings
- Combining spaces in different stories.
The volumes of spaces in different stoing 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.
2.4.2 Outdoor Combustion Air
BEST PRACTICE
Isolating the combustion appliance room from the rest of the building and bringcombustion and ventilation is always preferred.
Opening Size and Location
The minimum dimension of air openings shall be not less than 3 inches tilation air shall be sized and located in accordance with the following:
2.4.2.1 One Permanent Opening Method
One permanent opening, commencing within 12 in. of the top of the enclosure, shall be provided as shown in Fig 2 on page 8. 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
- Not less than the sum of the areas of all vent connectors in the space.
7
2.0
Combustion Air Venting
Fig. 2: All Combustion Air from Outdoors
Through One Permanent Air
Opening
2.4.2.2 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: 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 rat-
Fig. 3: All Combustion Air from Outdoors
Through Ventilated Attic
- 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
8
2.0
Combustion Air Venting
2.4.3 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.
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 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 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 Excellence
Vent Supplement included in the boiler installation envelope. Refer to optional vent kit instructions for additional 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.
into a common vent with other gas or oil appliances. This may cause flue gas spillage or appliance malfunction, resultdeath or substantial property damage.
2.5
Combustion Air and Vent Piping
The PRESTIGE Excellence requires a for pressurized venting and condensate.
The PRESTIGE Excellence is certified per
ANSI Z21.13 as a Category IV or Direct Vent
(sealed combustion) appliance. A Category IV appliance utilizes uncontaminated indoor or outdoor air (surrounding the appliance) for combustion. A Direct Vent appliance utilizes
9
2.0
Combustion Air Venting
2.6
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 conin operation.
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and horizontal pitch and deterleakage, corrosion and other deficiencies which could cause an unsafe condition.
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 comtested 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
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
CAN/CGA B149, Installation codes.
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.
inspected. Follow the lighting instructions.
Adjust thermostat so appliance will operate continuously.
DANGER
Do not install the PRESTIGE Excellence 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
2.0
Combustion Air Venting
2.7
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 carwith NFPA 720 (2005 Edition).
2. A carbon monoxide detector shall also 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 and d. Have been approved and listed by the
Nationally Recognized Testing
Laboratory as recognized under 527
CMR.
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 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: 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 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.
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
3.0
Unit Preparations
SECTION III - UNIT
PREPARATIONS
3.1
Handling Instructions
handle and maneuver once removed from the shipping carton.
To remove the shipping carton:
CAUTION boiler upside down, as damage to the boiler will result.
3.3
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
2. Slide the unit with the foam inserts out of the carton.
3. Discard all packing materials.
3.2
Wall Mounting Installation
The PRESTIGE Excellence should be wall mounted using the bracket provided with the boiler. The PRESTIGE Excellence is not designed for floor installation. If floor installation is required an optional floor stand is available through ACV-Triangle Tube.
NOTICE
The wall used for mounting the PRES-
TIGE Excellence must be vertically plumbed and capable of supporting a minimum 250 pounds [115 kg] for the
PRESTIGE Excellence. Failure to comply with these requirements could result in personal injury, death or substantial property damage.
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.
gle person to lift and attempt to mount; a minimum of 2 people is required for mounting the boiler.
NOTICE 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
3.0
Unit Preparations
3.4
Wall Bracket Installation - Stud
Walls
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.
boiler reference the kit installation instructions and ensure the frame is securely fastened to the wall.
3.6
Boiler Mounting
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.
in supporting a minimum weight of 265 pounds [120 kg.], it is recommended to use the optional floor stand.
3.5
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.
slightly recessed in the drilled holes with threaded side facing down.
align mounting slots/holes. Insert the two bolts (provided) through the mounting slots/holes and loosely tighten.
7. Level bracket and tighten bolts securely.
13
4.0
Boiler Piping
SECTION IV - BOILER PIPING
4.1
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.
above any drain connection to allow clear visibility of the discharge.
- Should terminate with a plain end, not with a threaded end. The material of
- Install unions for easy removal of the
PRESTIGE Excellence from the system piping.
- 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.
piping from turning / twisting. Failure to support the boiler piping and connections in this manner could cause damage to the boiler and its components.
4.2
Pressure Relief Valve
with a 30 psi pressure relief valve and must be piped using the PRV connection as shown in Fig. 5 page 15.
2. To avoid potential water damage to the surrounding area or potential scalding hazard
- 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
WARNING
Failure to comply with the guidelines on installing the pressure relief valve and discharge piping can result in personal damage.
4.3
Boiler Air Vent
NOTICE
This boiler is supplied with a special automatic air vent that will provide reliable operation in purging air from the boiler. The hygroscopic cap supplied with the automatic air vent MUST remain tight at all times on the air vent body. The hygroscopic cap has a membrane which expands upon contact with water and seals the air vent until the ing in the air vent.
- Should be directed downward towards terminate at least 6 inches [153 mm]
2. Never loosen the hygroscopic cap to allow the cap fully tightened in place.
3. If the hygroscopic cap is not fully tighttighten the cap securely.
14
4.0
Boiler Piping
Fig. 5: Pressure Relief Valve and Boiler Drain Valve Installation
4.4
Low Water Cutoff Device
- The PRESTIGE Excellence is equipped with a factory installed pressure sensor type Low
Water Cut Off device.
- The minimum operating system pressure allowable with this device is 10 psig.
4.5
Additional Limit Control
If a separate LWCO device is required by the local jurisdiction or when the boiler is installed
Device is required. If so, determine if this device meets the requirements of the local codes.
NOTICE
The PRESTIGE Excellence control system also senses the 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
Excellence integral control functions as a means of providing low water protection.
- 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 PRES-
TIGE Excellence is done directly onto the
15 page 29 for available terminals for an external limit (manual or auto reset).
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.
15
4.0
Boiler Piping
- Consult heat exchanger for maximum set point of limit.
- For wiring of the limit, reference Fig. 15, page 29, using the external manual reset strip. This will provide a "hard" lockout requiring a manual reset of the control.
4.6
Backflow Preventer
- Use a backflow preventer valve in the make-up water supply to the unit as required by local codes.
4.7
Boiler System Piping Applications
CAUTION
Undersized expansion tanks will cause
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 suc-
Always locate and install the system fill connection at the same location as the expansion tank connection to the system.
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 shown in Graphs 1 through 6 on pages 94 through 96. For other piping arrangements, contact ACV-Triangle Tube
Technical Support or consult other approved/recognized design arrangements.
4.8.1 Diaphragm Expansion Tank of the air separator to remove residual air from the system.
4.8.2 Closed-Type Expansion Tank
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.
4.8
Expansion Tank and Makeup
Water
the boiler volume (3 gallons [12 L]) and the system volume and temperature.
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 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.
4.9
Circulator
The PRESTIGE Excellence requires an external circulator to provide circulation through the boiler.
16
4.0
Boiler Piping
The circulator, when wired directly to the PRES-
TIGE Excellence, will allow for domestic hot water priority and provide circulation for the freeze protection feature of the boiler control. See
Graph 1 on page 78 for pressure drop and minimum flow rate through the boiler.
4.10 Sizing Primary Piping
See Fig. 7 through 10, pages 20 - 21, for recommended piping arrangements based on various applications. Size the piping and system comusing recognized design methods.
4.11 Domestic Hot Water System Piping
See Fig. 7 through 10, pages 20 - 21 for recommended piping to a DHW system. This recom-
The piping for the DHW is separate from the mary / secondary piping configuration.
To wire the DHW circulator to the boiler control module, reference Section VIII - External Wiring.
4.12 System Piping - Zone Circulators
tem piping as shown in Fig. 7 on page 20 when zoning with zone circulators.
NOTICE
To ensure an adequate flow rate through the PRESTIGE Excellence, the boiler supply and return piping size must be a minimum of 1 inch.
4.13 System Piping - Zone Valves
piping as shown in Fig. 11 on page 20 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 Excellence, the boiler supply and return piping size must be a minimum of 1 inch.
4.14 System Piping - Through Boiler
In applications in which primary/secondary arrangement is not utilized, the PRESTIGE
Excellence allows this flexibility due to a lower boiler pressure drop, see Graph 1 on pages 78.
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 10 on page 21 illustrates a single zone utilizing the boiler circulator as the system circulator.
for each zone of space heating as well as the boiler circulator.
4.15 System Piping - Radiant Heating
The heat exchanger design of the PRESTIGE allows operation in a condensing mode. This feature requires no regulation of the return temperature back to the boiler in radiant heating applications.
The design and construction of the PRESTIGE heat exchanger allows the installation of the boiler on systems with non - oxygen barrier tubing.
17 664A0100 - Rev. A
4.0
Boiler Piping
CAUTION
DO NOT install a SMART tank along maintained by the PRESTIGE, eliminating the need for a mix system to achieve the desired temperature.
It is recommended for the installer to install a high temperature limit to ensure that the primary supply temperature does not exceed the ant tubing.
Size the system piping and circulator to provide the flow needed for the radiant system.
4.16 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 um 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.
NOTICE
To ensure an adequate flow rate through the PRESTIGE Excellence, the boiler supply and return piping size must be a minimum of 1 inch.
NOTICE is important if the PRESTIGE is connected to a domestic hot water system, which requires a high primary supply water temperature.
664A0100 - Rev. A 18
4.0
Boiler Piping
Fig. 6: Piping Component Legend
664A0100 - Rev. A 19
4.0
Boiler Piping
Note: Reference Fig. 20, page 36 for
Prestige Wiring.
Fig. 7: System Piping - Zoning with Zone Circulators
Note: Reference Fig. 21, page 36 for
Prestige Wiring.
Fig. 8: System Piping - Zoning with Zone Valves
NOTICE
The boiler system piping shown must be a “closed” system to avoid any oxygen contamination and potential failure of the outer tank of the Smart.
20 664A0100 - Rev. A
4.0
Boiler Piping
Note: Reference Fig. 22, page 37 for
Prestige Wiring
.
Note: Verify CH circulator is properly sized to overcome the system pressure drop and provide adequate flow through the boiler system.
Fig. 9: System Piping - Multiple Zone Valve with Single System/Boiler Circulator
Note: Reference Fig. 23, page 37 for
Prestige Wiring.
Note: Verify CH circulaovercome the system pressure drop and provide ade-
Fig. 10: System Piping - Single Zone System with Single System/Boiler Circulator
NOTICE
664A0100 - Rev. A 21
5.0
Installing Vent/Combustion Air & Condensate Drain
SECTION V - INSTALLING VENT
/ COMBUSTION AIR &
CONDENSATE DRAIN
5.1
Installing Vent and Combustion Air
WARNING
Ensure installation of the condensate drain assembly included the metal washer. Failure to comply could result in the trap assembly dislocating from the boiler.
DANGER
The PRESTIGE Excellence must be vented and supplied with combustion air as shown in the PRESTIGE Excellence 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.
5.2
Installing Condensate Drain
Assembly ensure the metal washer is installed as shown in Fig. 11 on page 23.
NOTICE
The installer may want to fill the condensate trap with water prior to assembling on the unit.
2. Install the condensate drain assembly on the boiler condensate drain by pushing the condensate drain assembly up until it stops.
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.
4. Remove the compression nut and rubber seal from the condensate drain assembly drain outlet.
5. Using 3/4” x 2’ flexible PVC tube provided, slide the compression nut and rubber seal over the pipe
NOTICE also acceptable. If 3/4” pipe is used deburr and chamfer pipe to allow mating onto the drain assembly.
6. Thread the rubber seal into the compression nut to ease installation of the pipe to the drain assembly.
7. Seat the pipe onto the drain assembly and tighten the compression nut. Hand tight only!
NOTICE
The installer may opt to use 13/16" ID tubing in lieu of rigid piping.
3. Tighten the condensate drain assembly retaining nut with rubber seal.
22 664A0100 - Rev. A
5.0
Installing Vent/Combustion Air & Condensate Drain
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.
8. Continue the pipe from the drain assembly to a floor drain or condensate pump.
9. The PRESTIGE Excellence 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, resulter and surrounding area.
NOTICE
When selecting and installing a condensate pump, ensure the pump is approved naces. The pump should be equipped with an overflow switch to prevent property damage from potential condensate spillage.
Fig. 11: Condensate Drain Assembly
664A0100 - Rev. A 23
6.0
Gas Piping
SECTION VI - GAS PIPING
6.1
Gas Supply Piping Connection
NOTICE in accordance to all applicable local, state and national codes and utility requirements.
1. Install a 1/2” NPT for PRESTIGE
Excellence supply piping as shown in Fig. 12. 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 Excellence gas train as shown in Fig.
12.
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.
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 Excellence and its gas valve from the gas supply
7. Use pipe dope compatible with natural and propane gases. Apply sparingly only to the
WARNING
Failure to apply pipe dope as detailed above can result in severe personal
WARNING
Use a two-wrench method of tightening gas piping near the unit and its gas pipvent the boiler gas line connection from turning and the second to tighten adjacent piping. Failure to support the boilthe gas line components.
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. 12: Recommended Gas Supply Piping
24 664A0100 - Rev. A
6.0
Gas Piping
6.2
Natural Gas
6.2.1 Pipe Sizing length and diameter requirements for natural gas, based on rated PRESTIGE Excellence 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.
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 sure. 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.
6.2.2 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
NOTICE
The natural gas orifice requirements are:
Table 1: Gas Piping Sizing - Natural Gas
Length of Pipe in
Feet
SCH 40
10
20
30
40
50
75
100
150
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)
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
664A0100 - Rev. A 25
6.0
Gas Piping
6.3
Propane Gas
6.3.1 Pipe Sizing - Propane Gas
WARNING
The unit was shipped with a propane conversion kit which is located on the
This kit includes all the necessary parts and instruction to perform the conversion from natural to propane gas. If this conversion kit is missing, please contact
ACV-Triangle Tube Technical Support before installing unit for missing kit.
WARNING
Prior to start up, ensure the unit is set to fire propane. Check the rating label 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. 16 on page 27.
Failure to ensure proper burner setup could result in severe personal injury, death or substantial property damage.
Contact the local propane gas supplier for recommended sizing of piping, tanks and 100% lockup gas regulator.
6.3.2 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
DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve sure. This setting is suitable for natural gas and propane and requires no field adjustment. Attempts by the installer to pressure could result in damage to the valve, causing potential severe personal injury, death or substantial property damage.
NOTICE
The propane orifice requirements are:
PRESTIGE Excellence: 0.185” (4.7 mm)
26 664A0100 - Rev. A
6.0
Gas Piping
664A0100 - Rev. A
Fig. 13: Gas Valve / Venturi Assembly - PRESTIGE Excellence
27
7.0
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.
al injury or death.
CAUTION
Prior to servicing, label all wires before disconnecting. Wiring errors can cause improper and dangerous operation.
servicing.
7.1
General Requirements
- Wiring must be N.E.C Class 1.
- If original wiring as supplied with the unit
[90ºC] wire or equivalent as a minimum.
- The PRESTIGE 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.
Fig. 14: ACVMax Control Module Fuse Location
7.2
Fuse Locations
nal replaceable 5A fuses as shown in Figure
19.
The bottom fuse protects the P3, P4, and Alarm outputs.
Spare fuses are located on the back of the control module enclosure.
28 664A0100 - Rev. A
7.0
Internal Wiring
2
4
5
ACV MAX
Display
X13
6
7
8
9
10
3
4
5
1
2
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Cascade
Slave
1
2
3
4
5
6
W
W
W
W
W
W
Flame
L
G
N
P4 Pump
L
G
N
P3 Pump
L
G
N
DHW Pump
L
G
N
Power Supply
L
G
N
Alarm
L
G
N
L
G
N
10
11
12
13
14
15
4
5
6
1
2
3
7
8
9
19
20
21
16
17
18
BK
W
BK
W
W
BK
W
W
BK
BK
W
BK
Prestige Excellence Internal Wiring
GND
GND
GND
GND
CH Pump
1
2
DHW Sensor
CH2
Thermostat
System
Sensor
Modulation
Signal
CH1
Thermostat
Outdoor
Sensor
BK
BR
Modbus
X5
X6
X4
X7
Blower
Power Terminals
3
2
1
Blower
Blower
Signal Terminals
3-Way Valve M
C
D
A
B
4
5
1
2
R
BK
O
W
R
W
V
BK
Flue Temperature Sensor
Return Temperature Sensor
Supply Temperature Sensor
Wire Legend
- Low Voltage
- Line Voltage
- Ingnition Cable
Wire Color Legend
BK – Black
W – White
GR – Green
BL – Blue
R – Red
O – Orange
V – Violet
Y – Yellow
BR – Brown
GY – Gray
Manual Reset
Limit
Auto Reset
Limit
Mix
Sensor
1
2
3
4
1
2
O
O
BR
BR
BK
BK
Fig. 15: Prestige Solo Boiler Factory Wiring
664A0100 - Rev. A 29
On / Off
Switch
GND
1
2
3
4
5
6
7
8
9
10
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
ACV MAX
Control Board
X11
W
W
W
W
W
W
1
2
3
4
5
6
X15
W
BK
2
1
X10
W
BK
W
BK
4
3
2
1
X12
BK
W
BK
W
BK
W
4
3
2
1
6
5
P14
BK
W
3
2
1
P13
GND
BK
W
BK
W
2
1
6
5
X9
Water Pressure
Sensor
1
2
3
1
2
3
Cascade
Master
1
2
3
4
X16
R
W
V
BK
R
BK
O
W
6
11
12
5
2
8
7
1
X1
BK
BK
Y
Y
BL
BL
R
R
2
7
3
1
6
8
4
9
X3
BR
BR
O
O
W
BK
R
1
8
2
9
14
7
13
X2
A1002507
8.0
External Wiring
SECTION VIII - EXTERNAL
WIRING
8.1
Installation Compliance
All field wiring made during installation must comply with: other national, state, provincial or local codes or requirements.
WARNING
2. Route the incoming 120 VAC power wire tom jacket panel.
3. The unit is provided with a service switch requirements for compliance.
NOTICE
If local electrical codes or conditions require an additional service switch, the installer must provide and install a fused switch.
8.3
Circulator Wiring
1. The circulator connections used will depend on the systems piping layout.
Before making any electrical connections to the PRESTIGE, disconnect electrical power supply at the service panel.
sonal injury or death.
NOTICE
The line voltage terminals are located on the right set of terminals 23 through 40.
NOTICE fuse located on the main control board. The total combined amp draw of the circulators, alarm, and flame terminals must not exceed
5 amps at any time. Use an isolation relay to lower the total combined amp draw if exceeding this limits.
8.2
Line Voltage Connections
1. Connect a dedicated 120 VAC/15A service to the line voltage terminal on the terminal block, Fig. 20 on page 31, located internally
21.
age terminal on the terminal block, Fig. 15 on page 29, located internally in the lower right corner, as shown in Fig. 16. This circulator is typically used as the primary/boiler circulator to supply heat to the central/space heating loop.
Figure 16: Terminal Strip Location
30 voltage terminal on the terminal block, Fig.
15 on page 29, located internally in the lower right corner, as shown in Fig. 16. The
DHW circulator is enabled during a DHW call. This circulator is typically used to supply heat to an indirect hot water heater.
terminal on the terminal block, Fig. 15 on page 29, located internally in the lower right corner, as shown in Fig. 16. This circulator is typically used to circulate water in the
664A0100 - Rev. A
8.0
External Wiring
secondary CH loop when zoning with zone valves or as a dedicated circulator to a space heating zone.
5. Connect the P4 circulator to the line voltage terminal on the terminal block, Fig. 15 on corner, as shown in Fig. 16 on page 30. This circulator is typically used as a dedicated circulator to a second space heating zone.
8.4
Alarm Wiring
NOTICE
CH and DHW call connections to the
PRESTIGE require a dry contact with no external voltage present. Ensure no external voltage is present on each set of wires before connecting to the PRESTIGE. If external voltage is present, the use of an isolation relay is required to prevent damage to the ACVMax controller.
Prestige is in a soft or hard lockout. This dry contact can be connected to an external monitoring system or other indicator to alert the operator that the Prestige is locked out.
1. Connect the external monitoring device to the line voltage terminal on the terminal block, Fig. 15 on page 29, located internally on page 30.
NOTICE
The alarm contact is fused with a common
5A fuse located on the main control board.
lators, alarm, and flame terminals must not exceed 5 amps at any time. Use an isolation relay to lower the total combined amp draw if exceeding this limits.
8.5
Low Voltage Connections
NOTICE
Line and Low Voltage wiring should be separated to prevent possible electrical noise on the low voltage circuits. Line and Low Voltage wiring should use separate electrical knockouts on the PRES-
TIGE cabinet and should remain separated inside the PRESTIGE.
Figure 17: Low Voltage Connections
8.6
Thermostat Wiring
The ACVMax control has two thermostat call inputs for multiple zone / temperature systems.
WARNING
Simultaneous CH1 and CH2 calls will result in the PRESTIGE operating at the mixing device on the lower temperature zones such as the ACV-Triangle Tube
Optima Series SMV Control may be ture zones from damage.
1. Connect the room thermostat or dry contact end switch to the low voltage terminal strip located on the bottom of the main control board as shown in Fig. 14 on page 28 & Fig
17.
664A0100 - Rev. A 31
8.0
External Wiring
2. Follow thermostat manufacturer’s instructions for proper installation. Thermostat should be located on an inside wall away from any heat or cold influences such as drafts, lights, fireplaces, etc.
vide a “hard” lockout requiring a manual reset of the PRESTIGE or a “soft” lockout in which the PRESTIGE will automatically reset when the limit resets.
- Set for 0.2 amps when wired directly to the PRESTIGE.
- Set to match the electrical power requirements of the connected device devices. Refer to the relay manufacturer’s specifications and the thermostat instructions for additional information on anticipator setting.
NOTICE
The use of power stealing thermostats which draw their power from the PRES-
TIGE can lead to erratic or unpredictable operation.
NOTICE
Manual Reset Limit and Auto Reset require a dry contact with no external voltage present. Ensure no external voltconnecting to the PRESTIGE. If external voltage is present, the use of an isolation relay is required to prevent damage to the ACVMax controller.
1. Remove the factory installed jumper wire on the Manual Reset or Auto Reset termi-
8.7
The Outdoor Reset function and Warm
Weather Shutdown (WWSD) features require the connection of the included outdoor temperinstallation and setup.
8.8
Domestic Hot Water Wiring
An indiriect water heater sensor is prewired to the low voltage terminal strip on the wiring panel below he PRESTIGE control module.
8.9
Outdoor Sensor Wiring
Additional Boiler Limits
Additional boiler limits (High Limit, LWCO, etc.) can be wired into either the Manual Reset
2. Connect the additional boiler limit to the low voltage reset limit terminal strip located on the bottom right of the main control board as shown in Fig. 14 on page 28.
8.10 External Modulation Control
The PRESTIGE firing rate can be controlled by an external modulating boiler controller. See page 65 for external modulation signal wiring and setup.
8.11 System Sensor Wiring
An optional system temperature sensor can be placed on the central heating loop to control the temperature in the central heating loop instead of the boiler loop. When connected, the PRES-
TIGE will automatically modulate to maintain the target temperature in the central heating loop. The boiler supply temperature sensor will continue to be used as a high temperature limit.
32 664A0100 - Rev. A
8.0
External Wiring
CAUTION
Locate the system temperature sensor where it can accurately measure the supply temperature to the heating system.
Inaccurate system temperature readings could lead to overheating or under heating resulting in property damage.
8.12 Modbus Wiring
The ACVMax control includes the ability to communicate with building management sys-
Consult the PRESTIGE ACVMax Control
Supplement for more information.
the low voltage terminal strip on the wiring panel below the PRESTIGE control module, as shown in Fig. 14 on page 28 & Fig
17 on page 28.
664A0100 - Rev. A 33
8.0
External Wiring
Fig. 18: Multiple Zone Field Wiring Using Zone Valves & Zone Valve Panel
34 664A0100 - Rev. A
8.0
External Wiring
Fig. 19: Multiple Zone Field Wiring using Zone Circulators & Zone Relay Panel
664A0100 - Rev. A 35
8.0
External Wiring
Note: Reference Fig. 7, page 20 for
System Piping.
Fig. 20: Prestige Wiring - Zoning with Zone Circulators
Note: Reference Fig. 8, page 20 for
System Piping.
Fig. 21: Prestige Wiring - Zoning with Zone Valves
36 664A0100 - Rev. A
8.0
External Wiring
Note: Reference Fig. 9, page 21 for
System Piping.
Fig. 22: Prestige Wiring - Multiple Zone Valve with Single System/Boiler Circulator
Note: Reference Fig. 10, page 21 for
System Piping.
Fig. 23: Prestige Wiring - Single Zone System with Single System/Boiler Circulator
664A0100 - Rev. A 37
9.0
ACVMax Operation
SECTION IX - ACVMAX OPERATION
The ACVMax Boiler Management System is designed to be flexible yet easy to use. ACVMax monitors and controls the Prestige to provide heat as efficiently as possible. ACVMax includes many advanced features which previously were not available in the Prestige.
• Two central/space heating (CH) call inputs with separate outdoor reset curves.
• Domestic Hot Water (DHW) call input with optional priority.
• EZ Setup feature allows the installer to quickly customize ACVMax for each installation.
• Cascade function allows up to six Prestige boilers to operate together in a single heating system.
• Modbus interface for integrating with building management systems.
All ACVMax features are easy to use through a graphical display where information is presented
ACVMax display example of the Prestige fired for a domestic hot water demand.
Fig. 24: ACVMax User Interface
38 664A0100 - Rev. A
9.0
ACVMax Operation
9.1 ACVMax Navigation
Navigation is performed through four arrow buttons UP , DOWN , LEFT , RIGHT with a center
OK button for making selections and entering information. The INSTALLER button (the small round button) provides the installing contractor with full access to all available features after entering a password. Reference the ACVMax Control Supplement for Installer level functions.
Figure 25 – ACVMax Navigation Buttons
The Main Menu can be entered from the Home Screen by pressing the OK button. The menu system utilizes icons to represent each selection. The current selected menu is displayed as a reversed image with a text description shown at the top of the display. Menus can be entered by highlighting the desired icon and pressing the OK button. The Home Screen icon at the bottom of each screen returns to the Home Screen when selected. The Previous Screen icon at the bottom of each screen returns to the previous screen when selected.
664A0100 - Rev. A 39
9.0
ACVMax Operation
9.2 ACVMax Menu Structure
40 664A0100 - Rev. A
9.0
ACVMax Operation
9.3 Home Screen
The screen backlight will illuminate when any button is pressed and remain illuminated for five minutes. Press the UP or DOWN buttons to turn on the backlight while at the Home Screen without making any changes.
The screen contrast can be adjusted at the Home Screen by pressing and holding the OK button then pressing and holding the LEFT arrow along with the OK button. The contrast can then be increased by pressing the UP button or decreased by pressing the formed again to switch between increasing and decreasing contrast.
DOWN button while hold-
664A0100 - Rev. A 41
9.0
ACVMax Operation
9.4 Status Line Messages
Status Line Message
Standby
Description
Indicates that the Prestige is ready to respond when a demand is received.
CH Demand A central heating call has been received.
DHW Demand
CH / DHW Demand
DHW Priority
Priority Timeout
External Demand
Slave Operation
A domestic hot water call has been received.
Central heating and domestic hot water calls are being received simultaneously. Both calls are being satisfied simultaneously because domestic hot water priority has been disabled.
Central heating and domestic hot water calls are being received simultaneously. Domestic hot water call is being satisfied first because it has priority over central heating calls.
Central heating and domestic hot water calls are being received simultaneously. The domestic hot water priority time limit has been exceeded.
Priority will now switch back and forth between central heating and domestic hot water calls until one call is satisfied.
An external modulation call has been received.
The Prestige is a slave in a cascade system.
Manual Operation
CH Burner Delay
DHW Burner Delay
CH Setpoint Reached
DHW Setpoint Reached
CH Post Pump
DHW Post Pump
Freeze Protection
Boiler Protection
Lockout Description
The burner or circulators have manually been enabled in the Installer Menu.
The burner will not fire until the call blocking time has elapsed.
The burner will not fire until the call blocking time has elapsed.
The burner is not fired because the supply/system water temperature exceeds the setpoint. The central heating circulator continues to operate and the burner will fire again once the supply/system water temperature drops below the setpoint.
The burner is not fired because the supply/system water temperature exceeds the setpoint. The domestic circulator continues to operate and the burner will fire again once the supply/system water temperature drops below the setpoint.
The central heating circulator is running to remove heat from the Prestige at the completion of a call.
The domestic hot water circulator is running to remove heat from the
Prestige at the completion of a call.
The burner is fired because the freeze protection feature has been activated.
Freeze protection will end once the supply/system water temperature is raised to 60ºF [16ºC].
The burner firing rate is being reduced because of an excessive difference between the boiler supply and return temperatures. The firing rate will begin increasing once the temperature difference is less than 45ºF [25ºC].
The lockout which currently has the Prestige shut down is displayed.
42 664A0100 - Rev. A
9.0
ACVMax Operation
9.5 Main Menu
The Main Menu can be entered from the Home Screen by pressing the OK button. The menu system utilizes icons to represent each selection. The currently selected menu is displayed as an inversed image with a text description shown at the top of the display. Menus can be
664A0100 - Rev. A 43
9.0
ACVMax Operation
9.6 EZ Setup
The EZ Setup menus provide a simple way to quickly customize the
TriMax for each installation. EZ Setup prompts the user to make selections which allows the Prestige to be setup very quickly without searching through long lists of settings and manually making adjustments.
9.7 Heating EZ Setup
Navigation: Home Screen>Main Menu>EZ Setup>Heating EZ Setup ing settings for the application.
Select CH Demand prompts the installer to select how a CH Demand is generated. Press the UP or DOWN buttons to select the CH Demand type then press the OK button to store the setting. The Select CH Demand options are:
• Thermostat & Outd. Curve – This option is only displayed when the thermostat or zone panel will enable the Prestige and the setpoint will vary with the outdoor temperature for central heating calls.
• Thermostat & Setpoint - This option is only displayed when the outdoor temperature sensor is not connected. A central heating call from a thermostat or zone panel will enable the Prestige and the setpoint will be fixed for central heating calls
• Constant & Outdoor Curve - This option is only displayed when the outdoor temperature sensor is connected. The Prestige will maintain set-
• Constant & Setpoint for central heating calls.
- The Prestige will maintain setpoint without an
• 0-10V Modulation Signal – This option allows the Prestige firing rate to be controlled by an external control system.
9.7.2 CH1 Setpoint Default: 180°F [82°C]
CH1 Setpoint prompts the installer to enter the fixed setpoint for a CH1 heating call when a Setpoint option is chosen in Select CH Demand. Press the LEFT or RIGHT buttons to adjust the CH1 Setpoint then press the
OK button to store the setting.
9.7.3 CH2 Setpoint Default: 140°F [60°C]
CH2 Setpoint prompts the installer to enter the fixed setpoint for a CH2 heating call when a Setpoint option is chosen in Select CH Demand. Press
44 664A0100 - Rev. A
9.0
ACVMax Operation
the LEFT or RIGHT buttons to adjust the CH2 Setpoint then press the
OK button to store the setting.
9.7.4 Select CH1 Reset Curve Default: Finned Tube Baseboard
Select CH1 Reset Curve prompts the installer to select an outdoor reset curve
Demand. Outdoor reset curve presets are available to cover most applications. The outdoor reset curve can also be adjusted to any desired settings in the Installer Menu. Press the ton to store the setting.
UP or DOWN buttons to select the outdoor
OK but-
9.7.5 Select CH2 Reset Curve Default: Low Mass Radiant
Select CH2 Reset Curve prompts the installer to select an outdoor reset curve for a CH2 heating call when an Outdoor Reset option is chosen in Select CH
Demand. Outdoor reset curve presets are available to cover most applications. The outdoor reset curve can also be adjusted to any desired settings in
Table 2: Outdoor Reset Preset Selections
Preset
Low Mass Radiant
High Mass Radiant
Cast Iron Baseboard
Finned Tube Baseboard
Radiators
Fan Coil
Minimum Setpoint
80ºF [27ºC]
80ºF [27ºC]
100ºF [38ºC]
120ºF [49ºC]
120ºF [49ºC]
140ºF [60ºC]
Maximum Setpoint
140ºF [60ºC]
120ºF [49ºC]
170ºF [77ºC]
180ºF [82ºC]
170ºF [77ºC]
180ºF [82ºC] the Installer Menu. Press the UP or DOWN buttons to select the outdoor reset curve appropriate for the type of heating system then press the OK button to store the setting.
9.7.6 Set Warm Weather Shutdown Temperature Default: OFF
Warm Weather Shutdown prompts the installer to enter an optional outdoor temperature at which to disable the central heating function and any circulators placed into constant circulation with the Pump Constant Circulation setting. The Prestige will continue to respond to a domestic hot water call or a 0-10V Modulation Signal when the outdoor temperature exceeds the
Warm Weather Shutdown Temperature setting. Press the LEFT or
RIGHT buttons to adjust the Warm Weather Shutdown Temperature then press the OK button to store the setting. The Warm Weather Shutdown icon is displayed on the home screen when the outdoor temperature reaches the Warm Weather Shutdown Temperature.
9.7.7 CH EZ Setup Complete
EZ Setup Complete informs the installer upon completion of all necessary steps that the EZ setup is complete. Press the OK button to return to the
664A0100 - Rev. A 45
9.0
ACVMax Operation
9.8 Domestic Hot Water EZ Setup
Navigation: Home Screen>Main Menu>EZ Setup>DHW EZ Setup
Domestic Hot Water EZ Setup allows the installer to quickly customize the domestic hot water settings for the application.
9.8.1 Select DHW Demand Default: Switch
Select DHW Demand prompts the installer to select the type of device which will generate a DHW call. Press the UP or DOWN buttons to select the
DHW Demand type then press the OK button to store the setting. The Select
DHW Demand options are:
• Thermostat – A domestic hot water call from an aquastat or dry contact switch will enable the Prestige with a fixed setpoint for a domestic hot water call.
• Sensor – This option requires the use of Indirect Water Heater Sensor
PSRKIT22. The Prestige will monitor the DHW storage temperature and generate a domestic hot water call when the temperature drops below the DHW Storage Setpoint by 6ºF [3ºC].
9.8.2 Boiler DHW Setpoint Default: 186°F [86°C]
Boiler DHW Setpoint prompts the installer to enter the fixed boiler setpoint temperature during a Domestic hot water call when the Switch option is chosen in Select DHW Demand. Press the LEFT or RIGHT buttons to adjust the Boiler DHW Setpoint then press the OK button to store the setting.
Default: 140°F [60°C] storage setpoint temperature when the Sensor option is chosen in Select
DHW Demand. Press the LEFT or RIGHT buttons to adjust the DHW
Storage Setpoint then press the OK button to store the setting.
NOTICE
The Boiler DHW Setpoint will automatically be set 46°F [25°C] higher than the DHW Storage Setpoint setting.
46 664A0100 - Rev. A
9.0
ACVMax Operation
Default: Off that a domestic hot water call has priority over a central heating call. Press the LEFT or RIGHT buttons to adjust the DHW Priority Timeout then press the OK button to store the setting.
9.7.7 CH EZ Setup Complete
EZ Setup Complete informs the installer upon completion of all necessary steps that the EZ setup is complete. Press the OK button to return to the
9.9 EZ Setup Reset
Navigation: Home Screen>Main Menu>EZ Setup>EZ Setup Reset
EZ Setup Reset allows the installer to reset all EZ Setup settings back to the original factory defaults. Follow the onscreen instructions to reset all
EZ Setup settings back to the original factory defaults.
9.10 Display EZ Setup
Navigation: Home Screen>Main Menu>EZ Setup>Display EZ Setup
Display EZ Setup allows the installer to select the language used for all text as well as the type of temperature units displayed. Press the UP or
DOWN buttons to select then press the OK button to store the setting.
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9.0
ACVMax Operation
9.11 CH/DHW Operation
Navigation: Home Screen>Main Menu>CH / DHW Operation
CH / DHW Operation provides a simple way to disable either the central enabled and disabled by selecting the central heating or domestic hot water icon then pressing the OK button to toggle between enabled and disabled.
An icon with an X through it indicates that function has been disabled. The
9.12 Boiler Information
Information
Boiler Information provides real time operating information of the
Prestige. Each line contains an information item followed by its current value. Six information items are displayed on the screen at one time. Press the UP or DOWN buttons to scroll through additional information items.
See page 51 for a list of all information items.
9.12.1 Boiler Information Logging
Some information items include a logging function which records one sample every 12 minutes to produce a graph of the last 24 hours. Select the inforgraph. The following items have a logging function:
OK button to view its
• Boiler Firing Rate
• Ionization Current
• Boiler Setpoint
• Boiler Supply Temperature
• Boiler Return Temperature
• Boiler Flue Temperature
• Outdoor Temperature
• DHW Storage Temperature
• External Modulation Signal
• Pressure
48 664A0100 - Rev. A
9.0
ACVMax Operation
9.12.2
Information Items
Information Item
Boiler Status
Heating Call
DHW Call
Boiler Firing Rate
Ionization Current
Boiler Setpoint
Supply Temp.
Return Temp.
Boiler Flue Temp.
Outdoor Temp.
DHW Storage Temp.
Description
Displays the current operating state of the Prestige. This is the same as the status line on the home screen.
Displays if a central heating call is present.
Displays if a domestic hot water call is present.
Displays the current firing rate of the Prestige.
Displays the current flame ionization current from the ignitor.
Displays the current setpoint of the Prestige.
Displays the current supply temperature of the Prestige.
Displays the current return temperature to the Prestige.
Displays the current flue temperature of the Prestige.
Displays the current outdoor temperature.
Displays the current DHW storage temperature when Indirect Water
Heater Sensor PSRKIT22 is installed.
External Modulation Signal
Pressure
CH Ignitions
Displays the current external modulation signal being received from an external controller.
Displays the current system pressure.
Displays the number of central heating ignitions since the unit was installed. This counter increases in increments of twenty.
CH Runtime
DHW Ignitions
DHW Runtime
Mix Zone Temperature
Displays the number of hours the Prestige has run for a central heating call since the unit was installed.
Displays the number of domestic hot water ignitions since the unit was installed. This counter increases in increments of twenty.
Displays the number of hours the Prestige has run for a domestic hot water call since the unit was installed.
Displays the temperature of the low temperature mixed circuit.
664A0100 - Rev. A 49
9.0
ACVMax Operation
9.13 Lockout History
e b d b c d e f bb ab bc e f bb g a c d e f ab c d e f ab ab ab abc
de abc
de abc
de abc
de f bbb b abc
de f bb
Navigation: Home Screen>Main Menu>Boiler Information>Lockout
History
Lockout History records the last eight lockouts. Each line contains a lockout description followed by how long ago the lockout occurred. Six lockouts are displayed on the screen at one time. Press the UP or DOWN butlockouts and descriptions.
9.13.1 Lockout Details
Some information items are recorded at the time of a lockout to aid in diagnosing the cause of the lockout. Select the lockout description in Lockout
History then press the OK button to view the recorded information. Press the
UP or DOWN buttons to scroll through the recorded information. The following information items are recorded at the time of a lockout:
• Heating Call
• Domestic Call
• Boiler Firing Rate
• Flame Ionization Current
• Boiler Setpoint
• Boiler Supply Temperature
• Boiler Return Temperature
• Boiler Flue Temperature
• Outdoor Temperature
• System Temperature
50 664A0100 - Rev. A
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ACVMax Operation
9.13.2
Lockout Screen
The Lockout Screen replaces the Home Screen if a lockout occurs. The screen backlight will also illuminate constantly while the Prestige is locked out. Pressing any arrow button will return to the Home Screen so that additional troubleshooting can be performed. See pages 54
664A0100 - Rev. A 51
9.0
ACVMax Operation
Manual Reset Hard Lockouts
Code
E1
E2
E3
E5
E8
E9
Lockout Message
Failed Ignition
False Flame
Description
The burner failed to light after 5 ignition attempts.
A flame is being detected prior to ignition.
High Boiler Temperature Boiler temperature has reached 210°F [99ºC]
Blower Speed
Flame Circuit Error
Blower is not at correct speed or speed signal is not being received by control module.
Flame circuit test failed.
Gas Valve Circuit Error Gas valve circuit test failed.
E13
E15
E16
E17
E18
Reset Limit Reached
Sensor Drift
Supply Sensor Stuck
Return Sensor Stuck
Sensor Failure
Resets are limited to 5 every 15 minutes.
Supply or return sensor reading has drifted.
Supply sensor reading is not changing.
Return sensor reading is not changing.
Supply or return sensor reading changed very rapidly.
E21 Internal Control Fault A / D conversion error.
E30
E31
E43
E44
Supply Sensor Shorted
Supply Sensor Open
Return Sensor Shorted
Return Sensor Open
A short circuit has been detected in the boiler supply temperature sensor circuit.
An open circuit has been detected in the boiler supply temperature sensor circuit.
A short circuit has been detected in the boiler return temperature sensor circuit.
An open circuit has been detected in the boiler return temperature sensor circuit.
E47 Water Pressure Sensor Error Water pressure sensor is disconnected or broken.
E80
E87
Return > Supply
External Limit Open
Return temperature is higher than supply temperature.
An external manual reset limit has opened
52 664A0100 - Rev. A
E97
E98
E99
E91
E92
E93
E94
E95
E96
Code
E7
E12
E25
E32
E33
E34
E37
E45
E46
E76
E81
E89
E90
9.0
ACVMax Operation
Lockout Message
High Flue Temperature
Internal Control Fault
Internal Control Fault
DHW Sensor Shorted
DHW Sensor Open
Low Voltage
Low Water
Flue Sensor Shorted
Flue Sensor Open
External Limit Open
Sensor Drift
Incorrect Setting
Automatic Reset Soft Lockouts
Description
Flue temperature exceeds high limit.
EEPROM misconfiguration
CRC check error.
A short circuit has been detected in the DHW temperature sensor circuit.
An open circuit has been detected in the DHW temperature sensor circuit.
Line voltage has fallen below an acceptable operating level.
Water level has fallen below an acceptable operating level.
A short circuit has been detected in the boiler flue temperature sensor circuit.
An open circuit has been detected in the boiler flue temperature sensor circuit.
An external automatic reset boiler limit has opened.
Supply and return temperatures are not equal.
A parameter setting is in conflict with another setting.
Firmware Mismatch Control module and display firmware versions are incompatible.
System Sensor Shorted A short circuit has been detected in the system temperature sensor circuit.
System Sensor Open An open circuit has been detected in the system temperature sensor circuit.
Outdoor Sensor Shorted A short circuit has been detected in the outdoor temperature sensor circuit.
Internal Display Fault
Supply Sensor Error
Outdoor Sensor Open
Cascade Mismatch
Display memory error.
Supply sensor reading is invalid.
An open circuit has been detected in the outdoor temperature sensor circuit.
Cascade configuration has changed.
Cascade Bus Error
Controller Bus Error
Communication with other boilers has been lost.
Communication between boiler display and control module has been lost.
664A0100 - Rev. A 53
10.0 Start-Up Preparation
SECTION X - START-UP
PREPARATION
10.1.3 Chlorinated Water
Do not use the PRESTIGE Excellence to heat a swimming pool or spa directly.
NOTICE
Requirements below must be met for warranty coverage of Prestige heat existing system, using approved heating system cleaning agents is required prior to installation of the Prestige boiler.
System should be treated with an approved inhibitor after filling for long term protection.
10.1 Boiler System Fluid Requirements
WARNING sealing compounds in the boiler system.
Damage to seals and gaskets in the system components could occur, resulting in substantial property damage.
NOTICE practically non-toxic, having a toxicity rating or Class of 1, as listed in Clinical
Toxicology of Commercial Products.
10.1.1 Boiler Fluid pH Level 6.0 to 8.0
10.1.4 Flush Boiler to Remove Sediment
The installer must flush the boiler system to remove any sediment to allow proper operation of the PRESTIGE Excellence .
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.
10.1.5 Cleaning of Old Boiler/System:
• Drain the existing system.
• Fill system with fresh water and cleaner, all zones.
• Follow manufacturer’s instructions for proper cleaner concentration and proper cleaning time.
• Thoroughly drain and flush system with fresh water after cleaning.
• Install new boiler, fill system with fresh water and proper amount of inhibitor.
8.0. Check using litmus paper or contact a water treatment company for a chemical analysis.
not operate the PRESTIGE Excellence or leave the unit filled until the condition is corrected.
10.1.2 Boiler Fluid Hardness Less Than 7
Grains
For areas with unusually hard water (hardness above 7 grains) consult a water treatment company.
54 manufacturer’s specs; add inhibitor if necessary.
10.1.6 Cleaning of New Boiler/System:
• Install new boiler and flush system with cleaner water to remove any debris.
• Fill system with fresh water and proper amount of inhibitor.
manufacturer’s specs; add inhibitor if necessary.
664A0100 - Rev. A
10.0 Start-Up Preparation
10.1.7 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.
10.1.8 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 Excellence is approximately 5 gallons [19 L]. 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 instalantifreeze is used.
Ensure the concentration of antifreeze to water does not exceed a 50/50 ratio.
NOTICE practically non-toxic, having a toxicity rating or Class of 1, as listed in Clinical
Toxicology of Commercial Products.
10.2 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 will cause mineral buildup within the heat exchanger, reducing the heat transfer, causing possible heat buildup and eventual heat exchanger failure.
664A0100 - Rev. A 55
10.0 Start-Up Preparation
10.3 Check Low Water Cut-Off Device
- The PRESTIGE Excellence is provided with a factory installed LWCO device that monitors system pressure.
- Access the Boiler Information Menu by following instructions in Section 9.12 on page
48. Scroll down to see the current system pressure displayed and verify it is within the recommended numbers given in Section 10.2
on page 53.
10.4 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.
- If voltage is measured at the panel under any condition, check and correct the external wiring.
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 Excellence control panel.
- Reconnect the external thermostat wires to the low voltage terminal strip.
1. Inspect and ensure the Condensate Drain
Assembly is properly installed as described on page 22 and shown in Fig. 11 on page 23.
2. Remove the plug from the Condensate
Drain Assembly and fill with fresh water.
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.
10.5 Check Thermostat Circuit
- Disconnect the external thermostat wires from the low voltage terminal strip.
- 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.
NOTICE
The condensate drain assembly must be filled with water when the PRESTIGE
Excellence 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.
56 664A0100 - Rev. A
11.0 Start-Up Procedures
SECTION XI - START-UP
PROCEDURES
11.1 Final Checks Before Start-Up
c
Read Section IX regarding the operation of the ACVMax Boiler Management System.
c
Verify the PRESTIGE Excellence and the boiler system are full of water and all system components are correctly set for oper-
11.2 PRESTIGE Excellence Start-Up
1. Press the ON-OFF button 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 61.
c
Verify Start-up Preparation items outlined in
Section X have been completed.
c
Verify all electrical connections are correct and securely fastened.
c
Inspect vent and combustion air piping for signs of deterioration from corrosion, physical damage or sagging. Verify combustion air installed and supported. Reference the PRES-
TIGE Excellence vent supplement.
c
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
25 for orifice sizes. Refer to Fig. 13 on page 27 for location of the propane gas orifice.
1. Check for loose electrical connections, minals) or an open service switch.
2. Verify CH and DHW operation is enabled.
it indicates that function is disabled.
3. Check the system pressure in the Boiler
Information Menu by following the instructions in Section 9.12 on page 48.
4. Is an external limit control (if applicable) open? Ensure the external limit is reset to the closed position.
5. Are the gas supply valves 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 Excellence Trouble-
Shooting Guide or contact ACV-Triangle Tube
Technical Support.
NOTICE
Excellence requires an orifice: 0.242”
(6.15mm) c
Assembly is filled with water.
11.3 Check the PRESTIGE Excellence and System
c Check Boiler Piping.
Check Boiler system piping and components for leaks. If found, shut down the unit and repair immediately.
664A0100 - Rev. A 57
11.0 Start-Up Procedures
piping. Air in the system piping will interfere with circulation creating heat distribution problems and system noise.
c
Check Vent Piping and Combustion Air
Piping.
Check for gas-tight seal at every concombustion air piping.
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 61.
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
1. 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
2. Test for CO2 or O2 and for CO during high firing rate. The combustion readings should be within the range listed in
Table 3 on page 59. The CO level should not exceed 100 ppm when combustion is correct. Perform the following procedure to manually place the burner into high fire.
a. Press the round INSTALLER button.
b. Enter the installer access code “054” by using the LEFT and RIGHT buttons to select a digit and the UP and DOWN buttons to change the digit. Press the
OK button to enter the access code.
c. Press the RIGHT button to highlight the Manual Operation icon then press the OK button.
58 d. Press the OK button while the FAN burner and power the CH circulator.
NOTICE dissipate the heat generated during the combustion test. If an adequate CH load is not available, an indirect water heater can be used to dissipate the heat by creating a DHW call which will enable the
DHW circulator.
664A0100 - Rev. A
11.0 Start-Up Procedures
e. Press the LEFT and RIGHT buttons to
Hold down the LEFT or RIGHT button to rapidly increase or decrease the firing rate.
Table 3: Recommended Combustion Levels fire (1%) is not within +/- 0.2 of the combustion level measured at high fire, adjust the plastic OFFSET SCREW under the
Figs. 13 on page 27) according to Table 6.
O2 Min.
O2 Max.
CO2 Min.
CO2 Max.
CO Max.
Natural Gas
All Models
2.30%
5.30%
8.80%
10.50%
100 ppm
Propane
Excellence
2.70%
4.70%
10.70%
12.00%
100 ppm f. Press the OK button while the FAN icon
Direction
Clockwise
Counter-Clockwise
Exellence
Table 4: Throttle Screw - High Fire
Direction
Clockwise
Excellence g. Cycle power to the Prestige once comnormal operation.
WARNING
The combustion levels should be measured at high firing rate. If the combusin Table 4 for the firing rate, shut the boiler down and contact ACV-Triangle
Tube Technical Support. Failure to comply with this requirement could result in severe personal injury, death or substantial property damage.
Counter-Clockwise
Table 5: Offset Screw - Low Fire 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 58.
2. Operate the unit for approximately 10 minutes.
3. Turn off all gas appliances within the building, except the PRESTIGE Excellence.
FIRE (100%) is outside the recommended combustion settings adjust the THROT-
TLE SCREW (see Fig. 13 on page 27) according to Table 5.
3. Once the combustion level is set at high fire
(100%), manually place the boiler into low fire (1%) mode by pressing the LEFT button to adjust firing rate down.
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.
664A0100 - Rev. A 59
11.0 Start-Up Procedures
c
Test High Temperature Limit 8. Initiate a CH or DHW call and confirm that a High Boiler Temperature lockout occurs
The high temperature limit can be temporarily lowered from 210ºF [99ºC] to 102ºF [39ºC] for testing.
1. Press the round INSTALLER
Reference Fig. 25, page 39.
button.
using LEFT and RIGHT buttons to select a digit and the UP and DOWN buttons to change the digit. Press the OK button to enter the access code.
3. Press the OK button while CH & DHW
Settings icon is highlighted.
4. Press the DOWN button to highlight the
Boiler Settings icon then press the OK button.
5. Press the DOWN button to highlight button.
6. Press the UP button to highlight 102ºF
9. Press any ARROW button to return to the
Home Screen.
10. Press the round INSTALLER button.
11. Press the OK button while the CH & DHW
Settings icon
12. Press the button.
is highlighted.
DOWN button to highlight the
13. Press the DOWN button to highlight button.
14. Press the DOWN button to highlight 210ºF
15. Press the
OK
DOWN button.
button twice to highlight then press the
16. Press the OK button to reset the lockout and return the unit to service.
7. Press the
OK
DOWN button.
button twice to highlight then press the
60 664A0100 - Rev. A
11.0 Start-Up Procedures
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING
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.
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.
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).
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.
7. Turn the service switch on the PRESTIGE control panel “ON”.
8. Set room thermostat(s) to desired setting(s).
9. The PRESTIGE control panel display will show the current operating status on the Status Line at the bottom of the screen. “Standby” means there is no call for heat (all thermostats are satisfied). “CH
Demand” indicates a space heating call has been received. “DHW Demand” indicates a domestic hot water call has been received. A flame icon will be displayed when the unit is fired.
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.
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”
664A0100 - Rev. A 61
12.0 Outdoor Reset Control
SECTION XII - OUTDOOR RESET
CONTROL
4. Avoid mounting the outdoor sensor in areas subjected to excessive moisture.
5. Once an area on the exterior wall has been determined, follow the mounting instructions included with the outdoor sensor.
12.2 Wiring the Sensor
1. Connect 18 AWG 2-wire cable or similar cable to the outdoor sensor.
2. Route the cable back to the PRESTIGE parallel to telephone or power cables.
12.1 Mounting the Outdoor Sensor
1. The exterior wall selected for mounting the outdoor sensor should represent the heat load of the building. Typically a northern or northeastern wall will suit most buildings. A southern facing wall for those buildings, which may have large glass walls or windows on the southern face.
2. Ensure the outdoor sensor is shielded from direct sunlight or the effects of heat or cold from other sources (exhaust fans, appliance vents...) to prevent false temperature sensing.
3. Mount the outdoor sensor at an elevation on the exterior wall to prevent accidental damage or tampering.
NOTICE
If the sensor wires are located in an area with sources of potential electromagnetic should be shielded or the wires should be routed in a grounded metal conduit. If using shielded cable, the shielding ground of the unit.
3. Connect the outdoor sensor wires to the outdoor sensor terminals on the low voltage terminal strip located on the boiler control module inside the enclosure (see Fig. 15 on page 29 and Fig. 17 on page 31). The outdoor sensor wires do not have polarity.
IMPORTANT
In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.
THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOL-
LOWING CONDITIONS IS TRUE.
perature as the heating load decreases.
• This boiler is not used for any space heating
300,000 BTU/hr or greater.
• This boiler is equipped with a tankless coil.
62 664A0100 - Rev. A
13.0 External Modulating Control
SECTION XIII - EXTERNAL
MODULATING CONTROL
The boiler can directly accept an analog 0-10 external modulating boiler controller.
13.1 Wiring the Modulating Controller
Run two 18 gauge wires from the external modulating boiler controller’s 0-10 VDC boiler output to the modulation signal terminals on the low voltage terminal strip located on the boiler control module inside the enclosure (see
Fig. 15 on page 29 and Fig. 17 on page 31).
This signal will both enable and modulate the terminals.
13.2 ACVMax Adjustment
accept the 0-10 VDC signal from the external modulating boiler control.
1. Use the Heating EZ Setup function to set the CH Demand to 0-10V Modulation
Signal. Reference page 46 for the Heating
EZ Setup function.
13.3 Programming of External
Modulating Control
grammed to send 2 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 er to stabilize before modulating the boiler.
NOTICE
Ensure that the polarity of the connections from the external modulating boil-
Reversed polarity will lead to no response from the boiler.
664A0100 - Rev. A 63
13.0 External Modulating Control
Factory ACVMax Setting
HEATING SETTING
Heating Operation
Demand Type
Absolute Max CH Setpoint
CH1 Maximum Setpoint
CH1 Minimum Setpoint
Outdoor Curve Coldest Day
Outdoor Curve Warmest Day
CH2 Circuit
CH2 Maximum Setpoint
CH2 Minimum Setpoint
Warm Weather Shutdown
Circulation Pump Permanent
CH Post Pump Time
Freeze Protection
Frost Protection Setpoint
Parallel Shift Value
CH Call Blocking
FACTORY DEFAULT EZ SETUP RESET
Enabled
Thermostat &
Outd. Curve
188°F [87°C]
180°F [82°C]
120°F [49°C]
0°F [-18°C]
64°F [18°C]
Enabled
140°F [60°C]
80°F [27°C]
OFF
Disabled
5 Minute
Enabled
-22°F [-30°C]
0°F [0°C]
1 Minute
3
3
3
3
3
3
DOMESTIC SETTING
DHW Operation
Demand Type
Boiler DHW Setpoint
DHW Setpoint
DHW On Differential
DHW Storage Adder
DHW Post Pump Time
DHW Priority Timeout
DHW Priority
DHW Call Blocking
DHW to CH Call Blocking
Antilegionella Function
BOILER SETTING
Prestige Model
Lockout Temp.
Modbus Address
Pump Settings
Ignition Level NAT
FACTORY DEFAULT EZ SETUP RESET
Enabled
Thermostat (Solo)
Sensor (Excellence)
167°F [75°C]
140°F [60°C]
6°F [3°C]
28°F [15°C]
1 Minute
Off
Enabled
0 Minute
1 Minute
Disabled
3
3
3
FACTORY DEFAULT EZ SETUP RESET
Solo (2 pumps)
Solo/Excel. (3 way valve)
210°F [99°C]
0=BCST
Solo/Excellence 2
64
INSTALLER RESET
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
INSTALLER RESET
3
3
3
3
3
3
3
3
3
3
3
INSTALLER RESET
3
3
3
3
664A0100 - Rev. A
14.0 Check-Out Procedures
SECTION XIV- Check-Out Procedures
c
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 68.
Boiler system fluid chemistry checked and verified as outlined on page 56.
c remove any debris/sediment.
c
Any automatic air vents placed within the system are open one full turn.
c
Air is purged from the heating zones and boiler system piping.
c
If applicable, confirm that the burner has been properly configured for Propane as outlined on page 28.
c Thermostat circuit wiring checked and vervoltage terminals as outlined on page 58.
c lowed during start-up.
c
Combustion levels and flame pattern verified as outlined on page 60. c
Measured the rate of input on Natural Gas as outlined on page 61.
c
Test high temperature limit as outlined on page 62.
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.
c
Adjusted balancing valves and system limit controls to provide design temperatures to the primary space heating system.
c correct flow of boiler water to each zone.
c
Checked and verified room thermostat(s) c
Observed several operating cycles for c
Set the room thermostat(s) to the desired room temperature.
c
Reviewed all instructions shipped with the
PRESTIGE Excellence with the homeowner or maintenance personnel.
c
Completed the Installation Record on page c
68.
Ensure all manuals and other documents and given to the owner for safekeeping.
664A0100 - Rev. A 65
15.0 Installation Record
SECTION XV - INSTALLATION RECORD
PRESTIGE Model Number:
Serial Number:
Date of Installation:
Fuel: Natural Gas Propane
Measured Rate of Input: Btu/hr
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
(Company) ____________________________________________________________________
(Address) ____________________________________________________________________
(Address) ____________________________________________________________________
(Phone Number) _________________________________________________________________
66 664A0100 - Rev. A
16.0 Maintenance Schedule
SECTION XVI - MAINTENANCE
SCHEDULE
16.1 Service Technician
At least on an annual basis the following mainvice 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 boiler fluid pH on systems.
- Check for leaks: water, gas, flue and condensate.
- Verify flue vent piping/gaskets 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.
16.2 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 or follow the directions in this manual could result in damage to the PRES-
TIGE Excellence or in system components, resulting in severe personal injury, death or substantial property damage.
- Clean heat exchanger and flue ways.
664A0100 - Rev. A 67
17.0 Maintenance Procedures
SECTION XVII- MAINTENANCE
PROCEDURES
17.1 Maintenance Procedures
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.
WARNING 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 67 and further explained on pages 68 through 73 should be performed to assure maximum efficiency and reliability of the unit. Failure to service and maintain the PRESTIGE
Excellence and the system components could result in equipment failure, causdeath or substantial property damage.
17.4 Inspect Burner Area
Vacuum any dirt or debris from the burner/blower components.
Check the burner plate mounting nuts for tightness, see Section 17.24 on page 73 for torque specification.
Re-install venturi inlet elbow and front jacket panel when completed.
NOTICE
The following information provides detailed instruction for completing the nance schedule on page 67. In addition to this maintenance, the PRESTIGE
Excellence should be serviced at the qualified service technician.
system for leaks and verify that the piping is leak free and properly supported.
17.2 Reported Problems
Any problems reported by the owner should be checked, verified and corrected before proceeding with any maintenance procedures.
WARNING
Do not use solvents to clean any of the burner components. The components could be damaged, resulting in unreliable or unsafe operation.
17.5 Check System Piping
17.3 Check Surrounding Area
TIGE Excellence is free of combustible / flammable materials or flammable vapors or liquids. Remove immediately if found.
68
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 60.
664A0100 - Rev. A
17.0 Maintenance Procedures
17.6 Clean Condensate Drain
Assembly
Loosen the retaining nut from the condensate drain assembly and disconnect the assembly from the boiler.
Empty any water from the trap and drain assembly. Flush with fresh water as necessary to clean.
Check the drain piping from the condensate drain assembly to the drain. Flush to clean as necessary.
Reassemble the condensate drain assembly onto the boiler by tightening the retaining nut
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.
17.9 Check Boiler System
Verify all system components are correctly installed and operating properly.
Remove the fill plug on the condensate drain page 23.
Replace the fill plug on drain assembly.
17.7 Check Ventilation Air Openings
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.
17.8 Inspect Vent and Combustion Air
Piping
Visually inspect the venting system and combustion air piping for blockage, deterioration of gaskets or leakage. Repair any deficiencies.
Verify that the combustion air inlet piping is connected, sealed and properly supported.
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 vents do not leak, replace any leaking vents.
Verify boiler fluid pH level is between 6.0 and
8.0.
Check and verify inhibitor /antifreeze concentration within the boiler water meets
If necessary contact a boiler water treatment company for a chemical analysis.
664A0100 - Rev. A 69
17.0 Maintenance Procedures
17.10 Check Expansion Tank
ommended 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.
- 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
WARNING
Before manually operating the pressure relief valve, ensure the discharge piping is 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 valve to weep is the valve itself, not due to system over-pressurization caused by an expansion tank that is waterlogged or undersized.
17.12 Inspection of Ignitor
Remove the ignitor from the burner mounting plate.
Remove any white oxides accumulated on the ignitor using fine grit sandpaper or steel wool. If
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 residentypically 12 psig. If tank does not hold a charge pressure, then the membrane is damaged and the tank should be replaced.
17.11 Check Boiler Relief Valve
When replacing the ignitor, ensure the gasket is in good condition and correctly positioned.
Replace the gasket if necessary. Torque screws to specification in Section 17.24 on page 73.
17.13 Check Ignition Wiring and
Ground Wiring
Inspect the ignition cable from the ignitor to the ACVMax control module.
ify flow at least annually or as recommended on the warning tag of the valve.
70
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.
664A0100 - Rev. A
17.0 Maintenance Procedures
17.14 Check Control Wiring
Inspect all control wiring. Ensure wiring is in good condition and properly connected.
17.15 Check Control Settings
DHW EZ Setup menus. Adjust settings as necessary, see page 44-47
Carefully remove the burner plate assembly from the heat exchanger. Ensure that the combustion chamber 2-in-1 insulation is not damassembly. See WARNING on page 73.
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.
17.16 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.
17.17 Check Burner Flame
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.
blower. Ensure the venturi gasket or o-ring is in good condition, positioned correctly and replace gasket or o-ring 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 plate assembly onto the heat exchanger. Ensure the combustion tioned correctly, and not damaged, replace if necessary. See WARNING on page 73.
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.
supply line and disconnect the gas piping and gas valve wire harness connector.
the blower and remove the blower clamp.
Remove the blower from the unit.
Re-assemble the gas supply connection and wire harness to gas valve. Open the external manual gas valve. Check gas piping for any leaks as outlined on page 56 and repair if necessary.
Torque all screws, bolts, and nuts in accordance with specifications in Section 17.24 on page 73.
Place the unit back into service.
664A0100 - Rev. A 71
17.0 Maintenance Procedures
17.18 Check Flame Signal
The flame signal can be read from the Boiler
Information screen. It should be a min. 1
μ 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.
17.19 Check Combustion Levels
17.20 Check Flue Gas Temperature
Manually place the boiler into high fire. See page 58 for procedure.
observe the flue gas temperature. See page 48 for procedure.
Disconnect the wiring harness connectors from the blower and remove the blower clamp.
Remove the blower from the unit.
Remove the mounting nuts securing the burner plate to the heat exchanger and set aside.
Carefully remove the burner plate assembly from the heat exchanger. Ensure that the combustion chamber 2-in-1 insulation is not damassembly. See WARNING on page 73.
Use compressed air or water to remove any ways.
Re-assemble the burner plate assembly onto the heat exchanger. Ensure the combustion chamber 2-in-1 insulation is in place, positioned correctly, and not damaged, replace if necessary. See WARNING on page 73.
Re-assemble the blower onto the burner plate and reconnect the wiring harness connectors.
[30°C] above the supply water temperature, shut the boiler down and follow the heat exchanger cleaning procedure below.
17.21 Clean Heat Exchanger
Shut down the boiler:
- Follow the instructions on Page 61 "To
Turn Off Gas to Appliance"
Torque all screws, bolts, and nuts in accorpage 73.
Close isolation valves on the boiler water piptem.
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.
- Do not drain the boiler if freeze protection fluid is used in the system.
Allow the boiler to cool down to room temperature before servicing.
Disconnect the gas piping and gas valve wire harness connector.
return the boiler and system piping back to operation.
72 664A0100 - Rev. A
17.0 Maintenance Procedures
17.22 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.
WARNING
The combustion chamber insulation con-
17.23 Handling Previously Fired Combustion Chamber Insulation
When removing or repairing the combustion 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.
NIOSH Stated First Aid:
Eye/Skin: Immediately irrigate
Breathing: Clean fresh air separately from other laundry and rinse washing machine thoroughly.
17.24 Torque Specifications Table
Item
Burner Plate Nuts
Burner Head Bolts
Fan Clamp Screw
Gas Valve Screws
Venturi Screws
Ignitor Screws
664A0100 - Rev. A 73
Torque Req'd (in-lbs)
Min.
44
26.5
62
31
31
26.5
Max.
53
31
71
35
35
31
18.0 Product Specifications
SECTION XVIII PRODUCT SPECIFICATIONS
Boiler
Model
Fuel Input
DOE
Heating Capacity
Net AHRI
Rating
DOE Seasonal
Efficiency AFUE
Shipping
Weight
Lbs / Kg
Excellence
Natural
Propane
110,000 99,000 86,000 95% 250 / 115
Note 1: The heating capacity of the PRESTIGE
Excellence is based on the test requirements of the U.S. Department of Energy.
Note 2: The AHRI 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
Excellence meets the energy efficiency guidelines established by Energy Star.
Note 4: Input and output ratings are shown for sea level applications. The PRESTIGE
Excellence automatically derates the input at approximately 2% for every 1,000 Ft. of altitude. No alterations to the boiler or burner system is required.
DOE
74 664A0100 - Rev. A
18.0 Product Specifications
2-1/8” [52 mm]
3/4” NPSC Pressure
Relief Valve
24-7/8” [632 mm]
17” [432 mm]
10-1/4” [258 mm]
3” Vent Outlet
3” Combustion Air
Inlet
7-5/8”
15-7/8” [403 mm]
[191 mm]
20-7/8” [528 mm]
1” NPT Boiler Return
1/2” NPT Gas
Connection
1” NPT Boiler Supply
Fig. 26: Front View PRESTIGE Excellence
664A0100 - Rev. A 75
18.0 Product Specifications
23-5/8” [600 mm]
4-3/4”
[120 mm]
3”Vent Outlet
3” Combustion Air Inlet
9” [226 mm]
16-7/8” [428 mm]
Boiler Drain
1” NPT Boiler Supply
1” NPT Boiler Return
Fig. 27: Right Side View PRESTIGE Excellence
76 664A0100 - Rev. A
18.0 Product Specifications
10-3/8” [262 mm]
3/4” NPT DHW Outlet
7-5/8” [191 mm]
Manual Air Vent
4-3/4”
[121 mm]
3/4” NPSC Aux. Connection (Rear)
3/4” NPT DHW Inlet
Fig. 28: Top View PRESTIGE Excellence
664A0100 - Rev. A 77
18.0 Product Specifications
Graph 1: Pressure Loss Through Boiler - Taco Circulators
Note : Minimum allowable flow rate at full input: 5 gpm
78 664A0100 - Rev. A
19.0 Notes
SECTION XIX NOTES
664A0100 - Rev. A 79
19.0 Notes
80 664A0100 - Rev. A
19.0 Notes
664A0100 - Rev. A 81
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- Plates made of stainless steel, with a 99.9 % copper and brazed, ensuring a high resistance to corrosion
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Triangle Tube - 1 Triangle Lane - Blackwood, NJ 08012 - Tel: (856) 228 8881 - Fax: (856) 228 3584
E-mail: [email protected]
prestige
Excellence
Water Boiler
Part 2 of 2
L
I
S T E D
* I N S T A L L A T I O N A N D M A I N T E N A N C E *
M A N U A L
7/13/16
WARNING
IMPORTANT
• Before proceeding with installation and operation, read entire manual carefully. Failure to do so can cause injury or property damage.
• When receiving the PRESTIGE Excellence, any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.
• Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installation in order to gain warranty coverage.
• Retain and affix this manual near the water heater for future reference
• Installation and service should only be performed by a qualified installer or service technician.
• Installations and service should be performed by a license plumber or gas fitter in the Commonwealth of Massachusetts.
2011-61 Manual Prestige Excellence_IWH 664A0300 - Rev. B
Tables of Contents
Section I: Product & Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Section II: Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Section III: Installation - Domestic Piping
3.1 Temperature & Pressure (T&P) Relief Valve . . . . . . . . . . . . . . .5
3.2 Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.3 Automatic Air Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.4 Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.5 Water Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.6Vacuum Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.7 General Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.8 Domestic Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.9 Thermostatic Mixing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.10 Recirculation Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.11 Storage Tank Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Section IV: Installation - Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . .9-10
Section V: Water Heater Start-Up
5.1 Filling the Inner (Domestic Water) Tank . . . . . . . . . . . . . . . . . .11
5.2 Filling the Outer (Boiler Water) Tank . . . . . . . . . . . . . . . . . . . .11
5.3 Setting the Thermostatic Mixing Valve . . . . . . . . . . . . . . . . . . .11
5.4 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.5 Domestic Hot Water EZ Setup . . . . . . . . . . . . . . . . . . . . . . . . . .13
5.6 Additional DHW Feature
5.6.1 DHW Frost Protection . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.6.2 Factory Trimax Setting . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Section VI: Water Heater Maintenance
6.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
6.2 Filling Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
6.3 Draining Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17
6.4 Draining Outer (Boiler Water) Tank . . . . . . . . . . . . . . . . . . . . . .17
6.5 Draining Inner (Domestic Water) Tank . . . . . . . . . . . . . . . . . . .17
Section VII: Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Section VIII: Water Heater Specifications
8.1 Excellence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-21
Section IX: Performance
9.1 Excellence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
664A0300 - Rev. B i
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.
CAUTION
BEST PRACTICE
Indicates recommendations made by ACV-
Triangle Tube for the installers which will help to ensure optimum operation and longevity of the equipment
Indicates a potentially hazardous situation which, if ignored, may result in minor injury or property damage.
WARNING
NOTICE
ACV-Triangle Tube reserves the right to modify the technical specifications and components of its products without prior notice.
1 664A0300 - Rev. B
Product & Safety Information
WARNING
Bacteria can develop in the domestic water system if certain minimum water temperatures are not maintained.
DANGER
HOT WATER CAN SCALD!
Water temperature over 125ºF [52ºC] can cause severe burns instantly or death from scalds.
CAUTION
Protection must be taken against excessive temperature and pressure!
TO PROTECT AGAINST EXCESSIVE
TEMPERATURE AND PRESSURE
(T&P) relief valve is installed in the location provided (DHW Side).
• Check if the 30 psi relief valve supplied
Side)
• To avoid injury, install the relief devices to comply with local code requirements.
- Never leave them unattended in or near shower, bathtub or sink.
- Never allow small children to use a hot water faucet or draw their own bath.
• To avoid any potential scald hazard or if codes require specific water temperatures at the hot water faucet, the installer must:
- Install the factory supplied thermostatic mixing valve at this appliance and ensure it is working property
and
- Set the domestic storage temperature to the lowest temperature which satisfies your hot water needs.
- Feel and adjust water temperature before bathing or showering.
- Water drained from the system drain valves may be extremely hot.
TO AVOID INJURY:
- Make sure all connections are tight.
- Direct water flow away from any person.
CAUTION
To prevent damage to the inner tank, the
Installer must:
• Always fill inner tank prior to outer tank and always drain outer tank prior to inner tank.
• Relieve primary system pressure below 15 psig prior to draining inner tank.
664A0300 - Rev. B 2
Pre-Installation
Codes Compliance
Installation of the Excellence Water Heater must conform with the instructions in this manual and where applicable:
• local, state, provincial, and national codes, laws, regulations and ordinances.
• in Canada - CAN / CGA B149.1 or B149.2
Installation Code.
Excellence water heater is exempt from ASME
Section VIII, Division 1 Code construction per
Interpretation VIII-86-136. Check with local codes for applicability.
NOTICE
The Excellence water heater will absorb less than 200,000 BTU/hr when domestic water outlet temperature is 194ºF and boiler water supply temperature is 240ºF. Listed outputs are based on ASME Section VIII
Interpretation VIII-1-86-136.
Where recommendations in this manual differ from local, or national codes, the local or national codes take precedence.
Codes Restrictions
Single wall heat exchanger in the Excellence water heater complies with National Standard Plumbing
Code, provided that:
– boiler water (including additives) is practically non-toxic, having toxicity rating or class of 1, as listed in Clinical Toxicology of Commercial
Products, and
– boiler water pressure is limited to maximum
30 psig by approved relief valve.
Single wall heat exchangers are permitted under the
Uniform Plumbing Code - Paragraph L3.2. and L3.3
if they satisfy all of the following requirements.
1. The heat transfer medium is potable water or contains only substances which are recognized as safe by the U.S. Food and Drug
Administration.
3
2. The pressure of the heat transfer medium is maintained less than the normal minimum operating pressure of the potable water system
Exception: Steam complying with section #1 above.
3. The equipment is permanently labeled to indicate that only additives recognized as safe by the FDA shall be used in the heat transfer medium.
Other heat exchanger designs may be permitted where approved by the Administrative Authority.
Operating Restrictions
• Maximum DHW outlet temperature is
120ºF, when factory supplied mixing valve is installed.
• Maximum boiler water temperature rating is 210ºF.
• Maximum working pressure for inner
(domestic water) tank is 150 psig.
• Maximum working pressure for outer
(boiler water) tank is 30 psig.
• Water quality limitations (based on E.P.A
National Secondary Drinking Water
Regulations):
- Chloride, less than 150 ppm or mg/l
- pH value min. 6, max. 8
- Total Dissolved Solids (TDS), less than
120 ppm or mg/l.
- Iron less than 0.3 ppm or mg/l.
- Aluminum, less than 0.2 ppm or mg/l.
- Copper, less than 1 ppm or mg/l.
- Manganese, less than 0.05 ppm or mg/l.
- Zinc, less than 5 ppm or mg/l.
664A0300 - Rev. B
Pre-Installation
BEST PRACTICE
In hard water areas (more than 7 grains of hardness) soften the cold domestic supply water to the appliance to prevent scaling.
NOTICE
Any water conditioning system must be manufacturer’s specifications.
BEST PRACTICE
To provide serviceability to the unit it is recommended that the following clearances be maintained:
Top boiler jacket - 24 inches.
Front - 24 inches.
Bottom boiler piping - 24 inches.
Rear - 0 inches
Sides - 6 inches
NOTICE
Do not install the Excellence water heater on any application if the boiler piping contains non-oxygen barrier tubing or if the boiler piping is considered an “open system”.
Exposing the outer tank of the Excellence water heater to oxygen contamination will lead to premature tank failure and denial of the warranty.
Locating Water Heater
• The Excellence is not intended for outdoor installations.
• Locate Excellence so that any leakage from the tank or water connections will not cause damage to the area adjoining the water heater or to lower floors in the structure.
- When such a loation is unavoidable, a suitable drain pan with adequate drainage should be placed under the water heater.
Recommended Clearances
The Excellence is approved for zero clearance to combustibles, excluding vent and boiler piping.
- Vent & Boiler Piping - 1/4 inch from combustible materials.
NOTICE
When maintaining zero clearance or less than recommended clearances, some product labeling may become hidden and unreadable
WARNING
When installing the Excellence 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. Reference the
Excellence Boiler Manual for additional guidelines.
Residential Garage Installations
When installing the Excellence in a residential garage, the following special precautions per NFPA
54/ANSI Z223.1 must be taken:
- Mount the unit with a minimum 18 inches above the floor level of the garage. Ensure the burner and ignition devices / controls are no less than 18 inches above the floor level.
- Locate or protect the unit in a matter so it cannot be damaged by a moving vehicle.
664A0300 - Rev. B
4
Installation - Domestic Piping
Temperature & Pressure (T&P) Relief Valve
CAUTION
To reduce risk of excessive pressures and temperatures in the water heater, install temperature and pressure protective equipment required by local codes, but no less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials, as meeting the requirements for Relief Valves and
Automatic Gas Shutoff Devices for Hot Water
Supply Systems, ANSI Z21.22. This valve must be marked with a maximum working pressure of the water heater.
• The Excellence water heater must be protected with a T&P relief valve.
• Size the Excellence T&P relief valve by the following specifications, unless they conflict with local codes: 3/4” NPT with an AGA
Rating of 100,000 BTU/hr (Watts 100XL-8 or equivalent).
NOTICE
For proper operation of the T&P and to prevent the T&P from activating due to boiler water temperature, use a T&P relief valve with extended element. A 8” minimum length is recommended.
Standard Installation
• Install T&P relief valve in the Auxiliary connection located near the air vent on the top of the water heater as shown Fig. 2 page 8.
Commonwealth
Installation of Massachusetts
Follow this procedure for jurisdictions requiring a vacuum breaker to be installed on the domestic cold water inlet.
5
• Install the T&P in the run (straight through leg) of a tee located at the domestic hot water outlet. Use a long element T&P relief valve, as shown in Fig. 3 page 8.
T&P Relief Valve Discharge Piping
T&P relief valve discharge piping must be:
- directed so that hot water flows away from all persons.
- directed to a suitable place for disposal.
- installed so as to allow complete draining of the T&P relief valve and discharge line.
T&P relief valve discharge piping must not be:
- excessively long. Using more than 2 elbows or 15 feet of piping can reduce discharge capacity.
- directly connected to a drain. Terminate discharge piping within 6” from drain.
Refer to local codes.
- plugged, reduced or restricted.
- subject to freezing.
WARNING
Do not install any valve between T&P relief valve and tank connection or on T&P relief valve discharge piping. Do not plug T&P relief valve or discharge piping. Improper placement and piping of T&P relief valve can cause severe personal injury, death or substantial property damage.
664A0300 - Rev. B
Installation - Domestic Piping
Drain Valve
Drain valve and fittings are supplied by others.
Standard Installation
• Install a tee connection at the domestic cold water inlet, as shown in Fig. 4, pages 9.
• Pipe the drain piping with drain valve from the tee connection to:
- a suitable place for disposal or
- terminate within 12” of the floor
Thermal Expansion
If a backflow preventer, check valve or pressure reducing valve is piped on cold water supply piping of water heater, install an expansion tank on cold water supply line to prevent normal thermal expansion from repeatedly forcing open T&P relief valve.
Commonwealth of Massachusetts Installation
• Thread a 3/4” brass close nipple onto the
Auxiliary connection and insert an openend dip tube into the Auxiliary connection page 8.
• Install a 3/4” NPT elbow to the Auxiliary connection.
• Pipe the drain piping with drain valve from the elbow connection to:
- a suitable place for disposal or
- terminate within 12” of the floor
Manual Air Vent
1. Open manual air vent at the top of the unit.
Once air has stopped escaping, close the manual air vent.
2. Once the system is completely filled and purged of all air and sediment, check the system pressure and check/repair any leaks.
CAUTION
T&P relief valve is not intended for constant duty, such as relief of pressure due to repeated normal system expansion. Correct this condition by installing a properly sized expansion tank in domestic water system.
Refer to expansion tank manufacturer’s installation instructions for proper sizing.
Water Hammer
Dishwashers, clothes washers and fast-closing positive shut-off valves incorporated in the system all contribute to creating water shock. Install a water hammer arrester to prevent damage to pipes and appliances. See device manufacturer’s instructions for application and installation.
NOTICE
Water hammering within the domestic piping system can cause premature failure of the inner tank of the water heater. This type of failure is NOT covered under warranty.
Vacuum Breaker
Installing a vacuum breaker on the domestic cold water outlet will prevent damage to the inner tank if a negative pressure is developed in the domestic supply line. See manufacturer’s instructions for application and installation of the vacuum breaker.
664A0300 - Rev. B
6
Installation - Domestic Piping
General Piping
• For domestic water piping diagrams, see pages
9 and 10.
• All plumbing must meet or exceed all local, state and national plumbing codes.
• Use isolation valves to isolate system components.
Domestic Piping
• Union on domestic hot water outlet should be piped at a higher elevation than domestic water
For applications with a domestic recirculation loop, the recirculation pump should be controlled by an aquastat. The maximum recommended setting of the aquastat is 10ºF lower than the thermostatic mixing valve setting.
DANGER
For proper operation of the thermostatic mixing valve and to prevent potential scalding hazards, the recirculation loop should be controlled by an aquastat. DO NOT use continuous recirculation.
Recirculation Piping
• Use dielectric unions or couplings to protect hot and cold water fittings from corrosion when connecting dissimilar materials such as copper and galvanized iron pipe.
• If copper pipe is used for domestic water connections, first solder pipe to a threaded adapter and then screw adapter into cold water inlet on top of Excellence. Cold Water Inlet contains an internal plastic dip tube which can be damaged by heat from soldering.
Adapter
Check Valve
Cold
Hot
NOTICE
Do not apply heat to the cold water inlet when making sweat connections to water heater.
Sweat tubing to adapter before fitting adapter to cold water inlet of heater. It is imperative that no heat be applied to the cold water inlet, as it contains a non metallic dip tube.
• When the water supply pressure is higher than
70 psig, it is recommended to install a pressure
Thermostatic Mixing Valve
The Excellence is factory supplied with a thermostatic mixing valve with built-in check valve. The mixing valve must be installed as shown in Fig. 1.
The operating range of the thermostatic mixing is
85ºF [30ºC] to 150ºF [65ºC].
7
Mixed
Fig. 1: Mixing Valve Assembly
• Recirculation piping must be installed in the cold water inlet as shown Fig. 5, page 9.
Storage Tank Application
For applications requiring large volumes of domestic hot water in a short time period, the installer may include a storage type tank (see Fig. 6 page 10) in the domestic piping.
The installer must:
1. Relocate the thermostatic mixing valve from the Excellence to the outlet of the storage tank.
back to the Excellence using a bronze type circulator. Maximum recommended recirculation flow rate is 1 gpm.
664A0300 - Rev. B
Installation - Domestic Piping
DHW Aux. Connection
(T&P Relief Valve)
DHW Hot
Water Outlet
Fig. 2: Standard Installation of the T&P Relief Valve
T&P Relief
Valve w/ 3/4”
Tee
C
Drain
Dip Tube
3/4” Brass Close
Nipple
D
DHW Aux. Connection
Air Vent Connection
DHW Cold Water
Inlet
DHW Hot
Water Outlet
Manual Air Vent
DHW Cold Water
Inlet
Fig. 3: Commonwealth of Massachusetts Installation
664A0300 - Rev. B
8
Installation - Piping Diagrams
Fig. 4: Standard Installation Domestic Piping Excellence Series
Fig. 5: Standard Installation Domestic Piping with Optional Recirculation Excellence Series
1. Shut-off valve
2. Flow check valve
3. Mixing valve with check valve
4. Vacuum Breaker *
5. Unions
9
6. Backflow preventer or pressure reducing valve(*)
7. Circulator (controlled by aquastat)
8 Domestic drain valve
9. Thermal expansion tank (potable)
(*) Optional devices may be required by local codes.
664A0300 - Rev. B
Installation - Piping Diagrams
Fig. 6: Domestic Piping with Optional Storage Tank
1. Mixing valve with check valve
2. Flow check valve
3. Shut-off valve
4. Backflow preventer or pressure reducing valve(*)
6. Thermal expansion tank
7. Circulator (controlled by aquastat)
8 Domestic drain valve
9. Vacuum Breaker *
(*) Optional devices may be required by local codes.
664A0300 - Rev. B
10
Water Heater Start-Up
Filling the Inner (Domestic Water) Tank
CAUTION
• Never use the Excellence unless inner and outer tank of the water heater is completely filled with water.
• Inner tank of the Excellence water heater must be completely filled and pressurized before pressurizing outer tank.
1. Close domestic water drain valve.
2. Open domestic water isolation valves on the water heater piping.
3. Vent air from inner (domestic water) tank by opening nearest hot water faucet. Fill domestic water tank completely by allowing water to run until there is a constant flow of water.
4. Close hot water faucet.
Filling the Outer (Boiler Water) Tank
CAUTION outer tank of the water heater is completely filled with water.
• Inner tank of the Excellence water heater before pressurizing outer tank.
WARNING
Do not use automotive, ethylene glycol or petroleum-based antifreeze. Do not use any undiluted antifreeze. This can cause severe personal injury, death or substantial property damage.
Setting the Thermostatic Mixing Valve
NOTICE
The thermostatic mixing valve controls the outlet hot water temperature delivered to the faucets.
WARNING
POTENTIAL SCALD HAZARD. The mixing valve must be installed on the Excellence.
Removal or adjustment of the mixing valve will create a potential scald hazard resulting in severe personal injury or death.
If any adjustment needs to be made to the valve’s temperature setpoint refer to the manufacturer’s instructions included with the valve.
NOTICE
Reference the PRESTIGE Excellence boiler manual for boiler start-up and guidelines for filling the boiler.
If antifreeze is used in boiler water, check concentration. Boiler water (including additives) must be practically non-toxic, having toxicity rating or class of 1, as listed in Clinical Toxicology of Commercial
Products.
11
664A0300 - Rev. B
Water Heater Start-Up
DANGER
HOT WATER CAN SCALD!
• Water temperatures over 125ºF can cause severe burns instantly, or death from scalds.
• Feel water before bathing or showering.
• Consumer Product Safety Commission and some states recommend temperatures settings of
130ºF will increase risk of scald injury and cause severe personal injury or death.
clothes washing, dish washing and other sanitizing needs will scald and cause permanent injury.
handicapped persons are more likely to be injured by hot water. Never leave them unattended in or near a bathtub. If anyone using hot water in the building fits this description, or if state laws or local codes require certain water temperatures at hot water faucets, take special precautions.
- Install the factory supplied automatic mixing valve at water heater and/or install a point of use mixing valve at each hot water faucet, bath and shower outlet. Selection and installation of point of use mixing valves must comply with valve manufacturer’s recommendation and instructions.
- Use the lowest practical temperature setting.
- Check water temperature after any adjustment of the mixing valve.
General Notes
• Household water usage patterns will affect water temperature at any faucet or shower.
Occasionally check temperature at each point of use, then adjust the mixing valve setting accordingly. Always recheck temperature after adjusting the mixing valve.
ed in these instructions will reduce water temperature levels. Consult your installer or service technician.
664A0300 - Rev. B
12
Water Heater Start-Up
Domestic Hot Water EZ Setup
Navigation: Home Screen>Main Menu>EZ Setup>DHW EZ Setup
Domestic Hot Water EZ Setup allows the installer to quickly customize the domestic hot water settings for the application.
Select DHW Demand Default: Sensor
Select DHW Demand prompts the installer to select the type of device which will generate a DHW call. Press the UP or DOWN buttons to select the DHW Demand options are:
• Thermostat – A domestic hot water call from an aquastat or dry contact call.
• Sensor – The Prestige Excellence utilizes an Indirect Water Heater Sensor.
domestic hot water call when the temperature drops below the DHW Storage
Setpoint by 6ºF [3ºC].
Select DHW Demand
Thermostat
DHW Storage Setpoint Default: 140°F [60°C]
DHW Storage Setpoint prompts the installer to enter the domestic hot water storage setpoint temperature when the Sensor option is chosen in Select DHW Demand.
Press the LEFT or RIGHT buttons to adjust the DHW Storage Setpoint then press the OK button to store the setting.
68ºF
DHW
Storage Setpoint
140ºF
150ºF
NOTICE
The Boiler DHW Setpoint will automatically be set 46°F [25°C] higher
DHW Priority Timeout Default: Off
DHW Priority Timeout prompts the installer to enter an optional time limit that a domestic hot water call has priority over a central heating call. Press the LEFT or store the setting.
Off
DHW Priority Timeout
Off
120 min.
13
664A0300 - Rev. B
Additional DHW Feature
DHW Frost Protection
The Indirect Water Heater (IDWH) Sensor used in the Prestige Excellence provides a Frost Protection feature to the water heater. The Frost Protection feature is
Protection will generate a DHW call once the IDWH temperature falls below 42º F
[6ºC]. Once Frost Protection is activated, the internal circulator and diverter valve will direct water flow to the water heater and the burner will fire. Frost Protection will end once the IDWH temperature is raised to 60ºF [16ºC]. This feature is always active and cannot be disabled. Frost Protection is still active even if DHW operation has been disabled.
664A0300 - Rev. B
14
Additional DHW Feature
HEATING SETTING
Heating Operation
Demand Type
Absolute Max CH Setpoint
CH1 Maximum Setpoint
CH1 Minimum Setpoint
Outdoor Curve Coldest Day
Outdoor Curve Warmest Day
CH2 Circuit
CH2 Maximum Setpoint
CH2 Minimum Setpoint
Warm Weather Shutdown
Circulation Pump Permanent
CH Post Pump Time
Freeze Protection
Frost Protection Setpoint
Parallel Shift Value
CH Call Blocking
DOMESTIC SETTING
DHW Operation
Demand Type
Boiler DHW Setpoint
DHW Setpoint
DHW On Differential
DHW Storage Adder
DHW Post Pump Time
DHW Priority Timeout
DHW Priority
DHW Call Blocking
DHW to CH Call Blocking
Antilegionella Function
BOILER SETTING
Prestige Model
Lockout Temperature
Modbus Address
Pump Settings
Ignition Level NAT
Factory ACVMax Setting
FACTORY DEFAULT EZ SETUP RESET INSTALLER RESET
Enabled
Thermostat & Outdoor
Reset
188°F [87°C]
180°F [82°C]
120°F [49°C]
0°F [-18°C]
64°F [18°C]
Enabled
140°F 60°C]
80°F [27°C]
OFF
Disabled
5 Minutes
Enabled
-22°F [-30°C]
0°F [0°C]
1 Minute
FACTORY DEFAULT EZ SETUP RESET INSTALLER RESET
Enabled
Thermostat (Solo)
Sensor (Excellence)
167°F [75°C]
140°F [60°C]
6°F [3°C]
28°F [15°C]
1 minute
OFF
Enabled
0 minute
1 minute
Disabled
FACTORY DEFAULT EZ SETUP RESET INSTALLER RESET
Solo (2 pumps)
Solo/Excel. (3-way valve
210°F [99°C]
0=BCST
Solo/Excellence 2
15
664A0300 - Rev. B
Water Heater Maintenance
Maintenance Schedule
Annual service by qualified service technician should include the following:
Any procedure required by local codes.
Check air vent operation.
Verify system pressure. Manual air venting procedure may require adding water to bring system up to pressure, typically 12 psig.
Manually operate T&P relief valve at least once a year. This will release some hot water.
WARNING
Check function of field-installed controls and valves. See component manufacturer’s instructions.
Review homeowner’s maintenance responsibilities and their frequencies, including any not listed in the following section.
Homeowner monthly maintenance to include:
Check for air.
• Manual air vent-open and close briefly to realease any air.
Before operating T&P relief valve, make sure no one is in front of or around T&P relief valve discharge piping. Hot discharge water can cause severe personal injury or substantial property damage.
Move operating lever to open position for a few seconds and then move it back, allowing it to snap closed. After T&P relief valve is operated, if it continues to release water, close cold water inlet to water heater immediately. Follow draining instructions, and replace T&P relief valve. If T&P relief valve weeps periodically, it may be due to thermal expansion see Thermal Expansion, page 6.
Do not plug T&P relief valve or discharge piping.
leaks. Call qualified service technician to repair leaks.
Filling Water Heater
See “Filling the Outer (Boiler Water) Tank” and
“Filling the Inner (Domestic Water) Tank on page
11.
Draining Water Heater
Drain water heater if it will be shut off and exposed to freezing temperatures. Freezing water will expand and damage water heater.
• If boiler water contains sufficient antifreeze, then only the domestic water needs to be drained.
DANGER
WARNING
Close boiler water isolation valves and relieve system pressure to below 15 psig in outer tank before draining inner tank to prevent damage to inner tank.
Plugging T&P relief valve or discharge piping can cause excessive pressure in water heater, resulting in severe personal injury, death, or substantial property damage.
Follow instructions on circulator to oil it, if required.
Check mixing valve, valves, pipes and fittings for leaks.
antifreeze, then the boiler water and domestic water must be drained.
664A0300 - Rev. B
16
Water Heater Maintenance
tration. Boiler water (including additives) must be practically non-toxic, having toxicity rating or class of 1, as listed in Clinical Toxicology of
Commercial Products. A maximum 50/50 mixture of inhibited propylene glycol is recommended.
Follow antifreeze manufacturer’s instruction.
Draining Inner (Domestic Water) Tank
(See Domestic Piping Fig. 4 page 9)
1. Disconnect power supply to water heater.
- If outer (boiler water) tank pressure is greater than 15 psig, relieve boiler pres-
WARNING
Do not use automotive, ethylene glycol or petroleum-based antifreeze. Do not use any undiluted antifreeze. This can cause severe personal injury, death or substantial property damage.
2. Close system supply isolation valve.
3. Connect a hose to domestic water drain valve at cold water inlet. Hose should extend to drain at floor level to allow siphoning of domestic water tank.
4. Open hot water faucet at highest point above heater.
5. Open domestic water drain valve to start siphoning.
6. When draining is complete, close hot water faucet and domestic water drain valve.
WARNING
Water from opened drain valves, unions and other connections may be extremely hot. To avoid severe personal injury, death or substantial property damage:
- Tighten all drain hose connections.
- Direct hot water away from all persons.
Draining Outer (Boiler Water) Tank
1. Disconnect power supply to water heater.
2. Close boiler water isolation valves.
3. Connect hose to boiler water drain valve at water heater. Open and drain water to a safe place.
4. To speed draining procedure, loosen air vent on top of tank.
5. When draining is complete, close drain valve and retighten air vent.
17 664A0300 - Rev. B
Replacement Parts
WARNING ordering part please provide the model number and description and/or part number of replacement part. Use only genuine ACV-Triangle Tube replacement parts to ensure warranty coverage and to avoid damage to appliance and improper operation of appliance. Contact ACV-
Triangle Tube at 856-228-8881 or www.triangletube.com for list of distributors nearest you.
2*
1
Fig. 7: Excellence Domestic Components
Part
1
2*
3
Description
Drywell
DHW Temp. Sensor
(located in drywell)
Dip Tube
Part Number
P3DW05
PSRKIT63
P3WKITDT01
3
664A0300 - Rev. B
18
Water Heater Specifications
2-1/8” [52 mm]
3/4” NPSC Pressure
Relief Valve
24-7/8” [632 mm]
17” [432 mm]
10-1/4” [258 mm]
3” Vent Outlet
3” Combustion Air
Inlet
Front View PRESTIGE Excellence 110
19
7-5/8”
15-7/8” [403 mm]
[191 mm]
20-7/8” [528 mm]
1” NPT Boiler Return
1/2” NPT Gas
Connection
1” NPT Boiler Supply
664A0300 - Rev. B
Water Heater Specifications
23-5/8” [600 mm]
4-3/4”
[120 mm]
3”Vent Outlet
3” Combustion Air Inlet
Side View PRESTIGE Excellence 110
9” [226 mm]
16-7/8” [428 mm]
Boiler Drain
1” NPT Boiler Supply
1” NPT Boiler Return
664A0300 - Rev. B
20
Water Heater Specifications
10-3/8” [262 mm]
3/4” NPT DHW Outlet
7-5/8” [191 mm]
Manual Air Vent
4-3/4”
[121 mm]
3/4” NPSC Aux. Connection (Rear)
3/4” NPT DHW Inlet
Top View PRESTIGE Excellence 110
21 664A0300 - Rev. B
Water Heater Specifications
Performance
664A0300 - Rev. B
22
Notes
664A0300 - Rev. B
Notes
664A0300 - Rev. B
Notes
664A0300 - Rev. B
Additional quality water heating equipment available from: ACVTriangle Tube
Smart Indirect Fired Water Heaters
- Exclusive Tank-in-Tank design
- Stainless steel construction
- Available in 7 sizes
- Limited LIFETIME residential warranty
- 6 year limited commercial warranty
- Self cleaning/self descaling design
TTP Brazed Plate Heat Exchangers
Maxi-flo Pool and Spa Heat Exchangers
- For domestic water, snow melting, radiant floor, refrigeration
- Plates made of stainless steel, with a 99.9 % copper and brazed, ensuring a high resistance to corrosion
- Self cleaning and self descaling
- Computerized sizing available from ACV- Triangle
Tube
- Available in capacities from 25,000 BTU/hr to
5,000,000 BTU/hr
- UL Listed
- Construction of high quality corrosion resistant stainless steel (AISI 316)
- Specially designed built-in flow restrictor to assure maximum heat exchange
- Compact and light weight
- Available in 8 sizes that can accommodate any size pool or spa
664A0300 - Rev. B
Triangle Tube - 1 Triangle Lane - Blackwood, NJ 08012 (856) 228 8881 Fax (856) 228 3584 www.triangletube.com / [email protected].
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