Installation & Maintenance Manual Part 1 of 2 EXC EL L E NC E 110 WATER BOILER NOTICE • • • Customer must register unit within thirty (30) days of installation in order to gain warranty coverage. See Warranty Card for details. 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 the owner for future reference.
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TABLE OF CONTENTS PRODUCT AND SAFETY INFORMATION........................................................................... IX CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS......................................................... 1 1.1. Code Compliance............................................................................................................................. 1 1.2. Determining Product Location....................................................................................................
TABLE OF CONTENTS CHAPTER 4 - BOILER PIPING............................................................................................ 13 4.1. General Piping Requirements....................................................................................................... 13 4.2. Pressure Relief Valve..................................................................................................................... 13 4.3. Boiler Air Vent..............................................................
TABLE OF CONTENTS CHAPTER 8 - EXTERNAL WIRING..................................................................................... 31 8.1. General Requirements................................................................................................................... 31 8.2. Line Voltage Connections.............................................................................................................. 31 8.3. Internal Circulator & Diverter Valve.............................................
TABLE OF CONTENTS CHAPTER 10 - START-UP PREPARATION......................................................................... 51 10.1. Boiler System Fluid Requirements............................................................................................... 51 10.1.1 Boiler Fluid pH Level 6.6 to 8.5............................................................................................ 51 10.1.2 Boiler Fluid Hardness Less Than 7 Grains...............................................................
TABLE OF CONTENTS CHAPTER 14 - CHECK-OUT PROCEDURES......................................................................63 CHAPTER 15 - INSTALLATION RECORD...........................................................................65 CHAPTER 16 - MAINTENANCE SCHEDULES.................................................................... 67 16.1. Service Technician.........................................................................................................................67 16.2.
INDEX OF ILLUSTRATIONS AND TABLES Fig. 1 - All Combustion Air from adjacent Indoor Spaces through Indoor Combustion Openings.......5 Fig. 2 - All Combustion Air from Outdoors Through One Permanent Air Opening................................5 Fig. 3 - All Combustion Air from Outdoors Through Ventilated Attic......................................................6 Fig. 4 - All Combustion Air from Outdoors Through Horizontal Ducts....................................................6 Fig.
SAFETY PRODUCT AND SAFETY INFORMATION IMPORTANT SAFETY INFORMATION FOR THE HOMEOWNER AND THE INSTALLER This manual contains important information with respect to the installation, starting up and maintenance of the appliance. This manual must be provided to the Homeowner, who will keep it in a safe place for future reference.
SAFETY PRODUCT AND SAFETY INFORMATION NOTICE WARNING • Should overheating occur or if the gas supply fails to shut off, turn OFF the manual gas control valve external to the appliance. • Do not add cold make up water when the appliance is hot. Thermal shock can potentially cause cracks in the heat exchanger. • Failure to comply with these instructions can result in substantial property damage, serious injury, or death.
Chapter 1 - PRE-INSTALLATION REQUIREMENTS Code Compliance The PRESTIGE Excellence must be installed by a qualified installer in accordance with the following: • All applicable local, state, national and provincial codes, ordinances, regulations and laws. 1.2. Determining Product Location NOTICE The PRESTIGE Excellence is certified for indoor, conditioned space installations ONLY.
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS 1.3. Boiler Freeze Protection Feature • CHAPTER 1 The ControlMax (CTRLMax) boiler management system has a 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.
Chapter 2 - COMBUSTION AIR & VENTING Combustion Air Contamination WARNING If the PRESTIGE Excellence combustion air inlet is located in an area likely to cause or contain contamination, or if products which could contaminate the air cannot be removed, the combustion air must be repiped and terminated at another location. Contaminated combustion air will damage the unit and its burner system, and can result in substantial property damage, serious injury, or death.
CHAPTER 2 - 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. CHAPTER 2 For Direct Vent installations involving only the PRESTIGE Excellence, in which the minimum service clearances are maintained as listed in Section 1.5 on page 2, no ventilation openings are required, but may be necessary to equalize the air pressure with the outside.
CHAPTER 2 - COMBUSTION AIR & VENTING Methods of Accessing Combustion Air Into A Space - Category IV 2.4.1. Indoor Combustion Air NOTICE • The methods listed in this chapter 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 National Fuel Gas Code (NFPA 54 / ANSI Z223.1) for additional guidance.
CHAPTER 2 - COMBUSTION AIR & VENTING • CHAPTER 2 Two Permanent Opening 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.
CHAPTER 2 - COMBUSTION AIR & VENTING In order to reduce the potential risks associated with indoor contaminates (see list in Section 2.1 on page 3), flammable vapors and tight housing construction with 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.
CHAPTER 2 - COMBUSTION AIR & VENTING 2.7. Carbon Monoxide Detector Installation CHAPTER 2 Triangle Tube follows the recommended advice of CPSC and requires the installation of a minimum of two (2) carbon monoxide detectors with an alarm and battery back-up if hard wired; one in the mechanical room where the Prestige Excellence is located and another installed in the area outside each sleeping area for all installations.
2.8.5 Manufacturer Requirements - Gas Equipment Venting System Provided. 2.8.6 Manufacturer Requirements - Gas Equipment Venting System Not Provided.
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Chapter 3 - UNIT PREPARATIONS Handling Instructions The PRESTIGE Excellence is generally easier to handle and maneuver once removed from the shipping carton. To remove the shipping carton: NOTICE Use care not to drop, bump or rotate the boiler upside down, as damage to the boiler will result. 1. Remove any shipping straps and open the side of the shipping carton. 2. Slide the unit with the foam inserts out of the carton. 3. Discard all packing materials. 3.2.
CHAPTER 3 - UNIT PREPARATIONS 3.4. Stud Walls - Installation 1. To distribute the weight of the boiler evenly when mounting onto a stud wall it is recommended to use the PRESTIGE Wall Frame kit. 2. When using the wall frame to mount the boiler reference the kit installation instructions and ensure the frame is securely fastened to the wall. 3. If the structure of the wall is questionable in supporting a minimum weight of 250 pounds [115 kg.], it is recommended to use the optional floor stand.
Chapter 4 - BOILER PIPING • • • • • General Piping Requirements All plumbing must meet or exceed all local, state and national plumbing codes. Support all piping using hangers. DO NOT support piping by the unit or its components. Use isolation valves to isolate system components. Install unions for easy removal of the PRESTIGE Excellence from the system piping. If nonmetallic pipe is used in the system, it must have a maximum oxygen diffusion rate of 0.1 mg/ liter per day.
CHAPTER 4 - BOILER PIPING 4.3. 4.4. 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 membrane dries up due to new air forming in the air vent. CHAPTER 4 1.
CHAPTER 4 - BOILER PIPING 4.6. Additional Limit Control If a separate Low Water Cut Off (LWCO) is required by the local jurisdiction or when the boiler is installed above the system piping, the following guidelines must be followed: • The LWCO must be designed for water installations, electrode probe-type is recommended. • The LWCO must be installed in a tee connection on the boiler supply piping above the boiler.
CHAPTER 4 - BOILER PIPING 4.8. Expansion Tank and Makeup Water Ensure the expansion tank is properly sized for the boiler volume, (5 gallons [19 L] for the PRESTIGE Excellence), the system water volume, and the system water temperature. CAUTION Undersized expansion tanks will cause system water to be lost through the pressure relief valve and cause additional makeup water to be added to the system. Eventual boiler heat exchanger failure can result due to this excessive makeup water addition.
CHAPTER 4 - BOILER PIPING The heat exchanger design of the PRESTIGE Excellence allows operation in a condensing mode. This feature requires no regulation of the return water temperature back to the boiler in radiant heating applications. CAUTION Do not install the PRESTIGE Excellence in a system which is considered an open system or contains non-oxygen barrier tubing.
CHAPTER 4 - BOILER PIPING PRESTIGE EXCELLENCE PRESET PUMP CONFIGURATION 1 Heat Call CH1 CH2 DHW Pump 4 OFF ON OFF Pump 3 ON OFF OFF DHW Pump OFF OFF OFF CH Pump ON ON ON NOTICE Consult the CTRLMax Control Supplement for information on setting the required Preset Pump Configuration.
CHAPTER 4 - BOILER PIPING PRESTIGE EXCELLENCE PRESET PUMP CONFIGURATION 2 Heat Call CH1 CH2 DHW Pump 4 OFF ON OFF Pump 3 ON OFF OFF DHW Pump ON ON OFF CH Pump ON ON ON NOTICE Consult the CTRLMax Control Supplement for information on setting the required Preset Pump Configuration.
CHAPTER 4 - BOILER PIPING PRESTIGE EXCELLENCE PRESET PUMP CONFIGURATION 1 Heat Call CH1 CH2 DHW Pump 4 OFF ON OFF Pump 3 ON OFF OFF DHW Pump OFF OFF OFF CH Pump ON ON ON NOTICE Consult the CTRLMax Control Supplement for information on setting the required Preset Pump Configuration.
CHAPTER 4 - BOILER PIPING PRESTIGE EXCELLENCE PRESET PUMP CONFIGURATION 1 Heat Call CH1 CH2 DHW Pump 4 OFF ON OFF Pump 3 ON OFF OFF DHW Pump OFF OFF OFF CH Pump ON ON ON NOTICE Consult the CTRLMax Control Supplement for information on setting the required Preset Pump Configuration.
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Chapter 5 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN Installing Vent and Combustion Air DANGER WARNING • Ensure installation of the condensate drain assembly included the metal washer. Failure to comply could result in the assembly dislocating from the boiler. Dislocation of the condensate drain assembly can result in property damage, serious injury, or death.
CHAPTER 5 - INSTALLING VENT/COMBUSTION AIR & CONDENSATE DRAIN 8. Route the tube from the condensate drain assembly to a floor drain or condensate pump. NOTICE When selecting and installing a condensate pump, ensure the pump is approved for use with condensing appliances. The pump should be equipped with an overflow switch to prevent property damage from potential condensate spillage. 9. The PRESTIGE Excellence will typically produce a condensate that is considered slightly acidic with a pH content below 4.
Chapter 6 - GAS PIPING Gas Supply Piping Connection NOTICE The gas supply piping must be installed in accordance to all applicable local, state, national codes, and utility requirements. 1. Install a 1/2” NPT pipe union at the gas nipple, for ease of service. 2. Install a manual shutoff valve in the gas supply piping as shown in Fig. 13 on the right. For installations in Canada, the installer must tag and identify the main shutoff valve. 3.
CHAPTER 6 - GAS PIPING 6.2. Natural Gas WARNING 6.2.1 Pipe Sizing Refer to Table 1 below for schedule 40 metallic pipe 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 below 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 pipe sizing information, refer to National Fuel Gas Code (NFPA 54 / ANSI Z223.
CHAPTER 6 - GAS PIPING 6.3. Propane Gas WARNING 6.3.1 Pipe Sizing WARNING • • • The unit was shipped with a propane conversion kit which is located on the top of the unit in the instructions packet. 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 Triangle Tube Technical Support for missing kit before installing unit. Prior to start up, ensure the unit is set to fire propane.
CHAPTER 6 - GAS PIPING Venturi O-Ring Venturi Clip Venturi Gas Valve Orifice O-Ring Offset Pressure Cover Screw Throttle Screw Inlet Gas Pressure Port Fig.
Chapter 7 - INTERNAL WIRING WARNING ELECTRICAL SHOCK HAZARD. For your safety, disconnect electrical power supply to the unit before servicing or making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause serious injury, or death. 7.2. • • • • CAUTION Fuse Locations The CTRLMax control module contains 3 internal replaceable 5A fuses as shown in Fig. 15 below. The top two fuses protect the PRESTIGE Excellence as well as the CH, DHW, and Flame outputs.
CHAPTER 7 - INTERNAL WIRING CTRLMax Control Board CTRLMax Display X13 4 5 Cascade Slave Flame P4 Pump P3 Pump DHW Pump 1 2 3 4 5 6 7 8 9 10 X11 1 2 3 4 5 6 W W W W W W 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 6 5 4 3 2 1 P14 BK W 3 2 1 P13 BK L 1 G 2 N 3 W L 4 BK G 5 N 6 W L 7 BK G 8 N 9 W BK L 10 G 11 N 12 13 14 N 15 L 16 G 17 N 18 L 19 G 20 N 21 CH Pump On / Off Switch W BK GND 1 2 6 5 4 3 2
Chapter 8 - EXTERNAL WIRING General Requirements All field wiring must comply with: • National Electrical Code (ANSI/NFPA 70) for installations in the U.S., and any other national, state, provincial or local codes or requirements. • Canadian Electrical Code Part 1 (CSA C22.1) for installations in Canada. 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.
CHAPTER 8 - EXTERNAL WIRING 8.5. Flame Status & Alarm Wiring NOTICE The Flame and Alarm outputs both supply 110VAC when activated. Use an isolation relay to provide dry contacts if required by the external monitoring system. The Flame output is typically used to provide on/off status to an external monitoring system. The Flame output will provide 0VAC when the PRESTIGE Excellence is not fired and 110VAC when the PRESTIGE Excellence is fired.
CHAPTER 8 - EXTERNAL WIRING The use of power stealing thermostats which draw their power from the PRESTIGE Excellence can lead to erratic or unpredictable operation. 8.8. Outdoor Sensor Wiring The Outdoor Reset function and Warm Weather Shutdown (WWSD) features require the connection of the included outdoor temperature sensor. See Chapter 12 on page 59 for outdoor sensor installation and setup. 8.9.
CHAPTER 8 - EXTERNAL WIRING 8.13. Cascade Wiring Modbus communication will only occur if the external device is properly wired to the PRESTIGE Excellence as follows: X7-1 = RS-485 – X7-2 = RS-485 Ground X7-3 = RS-485 + The CTRLMax control includes the ability to operate up to six Prestige Solo boilers together as one without the need for external controllers. Consult the CTRLMax Control Supplement for more information. 8.14.
CHAPTER 8 - EXTERNAL WIRING PRESET PUMP CONFIGURATION 1 Pump 4 Pump 3 DHW Pump CH Pump CH1 CH2 OFF ON OFF ON ON OFF OFF ON DHW OFF OFF OFF ON External Limit Terminals Low Voltage Terminals 5 System Sensor 4 3 X5 Modulation Signal + 2 1 CH1 CH2 Thermostat Thermosta 4 t 3 Outdoor Sensor 2 1 X6 DHW Sensor or Aquastat 2 1 X4 Modbus + 3 G 2 Line Voltage Terminals Auto 1 X7 L G N FLAME L G N PUMP 4 L G N PUMP 3 L G N L G N L G N DHW PUMP CH PUMP POWER SUPPLY DHW Sensor
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Chapter 9 - CTRLMAX OPERATION The ControlMax (CTRLMax) Boiler Management System is designed to be flexible yet easy to use. CTRLMax monitors and controls the PRESTIGE Excellence to provide heat as efficiently as possible. CTRLMax includes many advanced features: • 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 CTRLMax for each installation.
CHAPTER 9 - CTRLMAX OPERATION 9.2.
CHAPTER 9 - CTRLMAX OPERATION 9.3. Home Screen Main Icons of CTRLMax display The Home Screen presents status information in a very user friendly way so that the current state of the boiler can be quickly accessed. • Screen backlight - it will illuminate when any button is depressed, and remain illuminated for five minutes. • Screen contrast - it can be adjusted at the Home screen by pressing and holding the OK button, then pressing and holding the LEFT button along with the OK button.
CHAPTER 9 - CTRLMAX OPERATION 9.4. Status Line Messages Standby - Indicates that the Prestige is ready to respond when a demand is received. CH Demand - A central heating call has been received. DHW Demand - A domestic hot water call has been received. Freeze Protection - 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 60°F [16°C].
CHAPTER 9 - CTRLMAX OPERATION Main Menu 9.6. 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 entered by highlighting the desired icon and pressing the OK button. EZ Setup The EZ Setup menus provide a simple way to quickly customize CTRLMax for each installation.
CHAPTER 9 - CTRLMAX OPERATION 9.7. Heating EZ Setup Heating EZ Setup allows the installer to quickly customize the central heating settings for the application. 9.7.1 Select CH Demand (No outdoor sensor connected) EZ Setup Select CH Demand prompts the installer to select how a CH Demand is generated. Thermostat & Setpoint - A central heating call from a thermostat or zone panel will enable the Prestige and the setpoint will be fixed for central heating calls.
CHAPTER 9 - CTRLMAX OPERATION 9.7.2 Select CH Demand (Outdoor sensor connected) EZ Setup Select CH Demand prompts the installer to select how a CH Demand is generated. Heating EZ Setup Select CH Demand Thermostat & Outd. Curve – A central heating call from a thermostat or zone panel will enable the Prestige and the setpoint will vary with the outdoor temperature for central heating calls. After Thermostat & Outd. Curve is selected, the Select CH1 Reset Curve screen appears (see below).
CHAPTER 9 - CTRLMAX OPERATION 9.8. Domestic Hot Water EZ Setup Domestic Hot Water EZ Setup allows the installer to quickly customize the Domestic Hot Water settings for the application EZ Setup Select DHW Demand prompts the installer to select how a DHW Demand is generated. When Thermostat is selected in Select DHW Demand, 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.
CHAPTER 9 - CTRLMAX OPERATION 9.9. EZ Setup Reset EZ Setup EZ Setup Reset allows reset of all EZ Setup settings back to the original factory defaults. See Chapter 13 on page 61 for the list of settings reset by this function. EZ Setup Reset Follow the on-screen instructions to reset all EZ Setup settings. EZ Setup Reset Press OK to restore factory settings, any other button to keep current settings. 9.10.
CHAPTER 9 - CTRLMAX OPERATION 9.11. CH/DHW Operation CH / DHW Operation CH/DHW Operation provides a simple way to enable/disable either the CH or the DHW function of the Prestige. Press the LEFT or RIGHT buttons to select the CH or DHW icon, then press OK to toggle between the enabled/disabled status. The status is displayed at the top of the screen.
CHAPTER 9 - CTRLMAX OPERATION Information Item Description Boiler Status Displays the current operating state of the Prestige. This is the same as the status line on the home screen. Heating Call Displays if a central heating call is present. DHW Call Displays if a domestic hot water call is present. Boiler Firing Rate Displays the current firing rate of the Prestige. Ionization Current Displays the current flame ionization current from the ignitor.
CHAPTER 9 - CTRLMAX OPERATION Boiler Information Lockout History records the last eight lockouts. Six lines are displayed on the Lockout History screen at one time. Each line contains a lockout description followed by how long ago the lockout occurred. Lockout History abc de fb abc d bb b efb b abc d efb bb b bbb b de f abc e f bb b cd ab e f bbb cd ab Press the UP or DOWN buttons to scroll through the items then press OK to select and get more details through the Lockout Details screen.
CHAPTER 9 - CTRLMAX OPERATION 9.12.3 Manual Reset Lockouts Code Lockout Message Description E1 Failed Ignition The burner failed to light after 5 ignition attempts. E2 False Flame Flame detected prior to ignition. E3 High Boiler Temperature Boiler temperature has reached 210°F [99ºC] or 102°F [39°C]. E5 Blower Speed Blower is not at correct speed or speed signal is not being received by control module. E8 Flame Circuit Error Flame circuit test failed.
CHAPTER 9 - CTRLMAX OPERATION 9.12.4 Automatic Reset Blocking Lockouts CHAPTER 9 50 Code Lockout Message Description E7 High Flue Temperature Flue temperature exceeds high limit. E12 Internal Control Fault EEPROM misconfiguration. E25 Internal Control Fault CRC check error. E32 DHW Sensor Shorted A short circuit has been detected in the DHW temperature sensor circuit. E33 DHW Sensor Open An open circuit has been detected in the DHW temperature sensor circuit.
Chapter 10 Chapter 10 - START-UP PREPARATION NOTICE Requirements below must be met for warranty coverage of Prestige Excellence heat exchangers. A thorough cleaning of any existing system, using approved heating system cleaning agents is required prior to installation of the Prestige Excellence boiler. System should be treated with an approved inhibitor after filling for long term protection. 10.1.
Chapter 10 CHAPTER 10 - START-UP PREPARATION 10.1.9 Cleaning of Old Boiler/System: • • • • • • Drain the existing system. Fill system with fresh water and cleaner, place existing boiler in operation and run 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 and fill system with fresh water and proper amount of inhibitor.
Chapter 10 CHAPTER 10 - START-UP PREPARATION 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 heat buildup and eventual heat exchanger failure. This can result in substantial property damage, serious injury, or death. 10.
FOR YOUR SAFETY, READ BEFORE OPERATING WARNING If you do not follow these instructions exactly, a fire or explosion may result, causing substantial property damage, serious injury, or death. 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.
Chapter 11 - START-UP PROCEDURES Ø Read Chapter 9 on page 37 regarding the operation of the CTRLMax Boiler Management System. Ø Verify the PRESTIGE Excellence and the boiler system are full of water and all system components are correctly set for operation, including the minimum flow rate through the boiler, see specifications in Chapter 19 on page 77. Ø Verify Start-up Preparation items outlined in Chapter 10 on page 51 have been completed.
CHAPTER 11 - START-UP PROCEDURES 11.3.4 Check Gas Piping CHAPTER 11 Check around the unit for gas odor following the procedure outlined in this manual on page 54. Manual Operation FAN DANGER 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.
CHAPTER 11 - START-UP PROCEDURES 3. Press the OK button while CH & DHW Settings icon Table 3 - Throttle Screw Adjustment Prestige Excellence 110 Clockwise Increase CO2 Decrease O2 Counter-Clockwise Decrease CO2 Increase O2 is highlighted. CHAPTER 11 Direction b bbb f bbb b bb f ed cebd cba de f b b ed cba a abcc de f ab d e abc b bbb f ed bbb b bb f ed cb cba de f a abc de f bb d cba gb f abc d abc 4. Press the DOWN button to highlight the Boiler Setthen press the OK button. tings icon 5.
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Chapter 12 - OUTDOOR RESET CONTROL 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 wall will suit most buildings. 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 readings. 3.
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Chapter 13 - EXTERNAL MODULATING CONTROL 13.1. Wiring the Modulating Controller Run two 18 gauge wires from the external modulating boiler controller’s 0-10 VDC boiler output to low voltage terminals X5-1&2 located at the bottom of the CTRLMax control module, as shown in Fig. 18 on page 32.. This signal will both enable and modulate the boiler. No wiring is required at the thermostat terminals.
CHAPTER 13 - EXTERNAL MODULATING CONTROL Factory CTRLMax Settings (cont’d) DHW SETTING FACTORY DEFAULT DHW Operation Enabled Demand Type Sensor MAXIMUM SETTING CHAPTER 13 168°F [75°C] 96°F [35°C] 188°F [87°C] DHW Setpoint 140°F [60°C] 68°F [20°C] 168°F [75°C] DHW On Differential 6°F [3°C] 4°F [2°C] 18°F [10°C] DHW Storage Adder 28°F [15°C] 10°F [5°C] 54°F [30°C] DHW Post pump time 2 Minutes Off 30 minutes DHW Priority Timeout Off Off 120 Minutes DHW Priority Enabled DHW Call
Chapter 14 - CHECK-OUT PROCEDURES 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 in Chapter 15 on page 65. q Domestic inner tank is filled with water. q Central/space heating outer tank is filled with water. q Boiler system fluid chemistry checked and verified as outlined in Section 10.1 on page 51.. q Boiler system was completely flushed to remove any debris/sediment.
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Chapter 15 - INSTALLATION RECORD Ensure all manuals and other documents are returned to the Installation envelope and given to the owner for safekeeping.
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Chapter 16 - MAINTENANCE SCHEDULES 16.1. Service Technician General • Attend to any reported problems. • Inspect the interior of the boiler jacket area; clean and vacuum if necessary. • Clean the condensate drain assembly and fill with fresh water. • Check boiler fluid pH on systems. • Check for leaks, both inside and outside the unit: water, gas, flue and condensate. • Verify vent piping and air inlet piping are in good condition, sealed tight and properly supported.
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Chapter 17 - MAINTENANCE PROCEDURES WARNING The PRESTIGE Excellence must be inspected and serviced annually, preferably at the start of the heating season, by a qualified service technician. In addition, the owner maintenance and care of the unit as outlined in Chapter 16 on page 67 and further explained in the Prestige User’s Information manual should be performed to assure maximum efficiency and reliability of the unit.
CHAPTER 17 - MAINTENANCE PROCEDURES 17.7. Check Ventilation Air Openings • • Verify that all ventilation openings to the mechanical room or building are open and unobstructed. Check the operation and wiring of any automatic ventilation dampers. Check and verify the vent termination and the combustion air intake are free of debris and obstructions. 17.8.
CHAPTER 17 - MAINTENANCE PROCEDURES Check ground continuity using a continuity meter. Replace ground wire if ground continuity is not satisfactory. 17.14. Check Control Wiring Inspect all control wiring. Ensure wiring is in good condition and properly connected. 17.15. Check Control Settings • • Review all boiler settings in the Heating & DHW EZ Setup menus. Adjust settings as necessary, see Section 9.7 on page 42 and Section 9.8 on page 44 Check any external limit control settings (if used).
CHAPTER 17 - MAINTENANCE PROCEDURES 17.21. Clean Heat Exchanger Shut down the boiler: • Follow the instructions on Page 54 “To Turn Off Gas to Appliance” • Do not drain the boiler unless the boiler will be subject to freezing conditions. • Do not drain the boiler if antifreeze is used in the system. • • • • • • • • CHAPTER 17 • • • • • 72 Allow the boiler to cool down to room temperature before servicing.
Chapter 18 - REPLACEMENT PARTS WARNING • Replacement parts must be purchased through a local Triangle Tube distributor. When ordering a part, please provide the model number and description and/or part number of replacement part. • Use only genuine Triangle Tube replacement parts to ensure warranty coverage and to avoid improper operation or damage to appliance. • Contact Triangle Tube at 856-228-8881 or www.triangletube.com for a list of distributors near you. Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig.
CHAPTER 18 - REPLACEMENT PARTS Fig. 24 - PRESTIGE Excellence Control & Display Enclosures 5a 5b 6 4 22 1 Item Part # Description 1 PTRKIT109 Pressure Gauge 2 PTSWI01 Power Switch 3 PTSWI02 Power Switch Cover 4 PARKIT101 Display Module 5a PARKIT102 Control Module (Requires Display Software 4.
CHAPTER 18 - REPLACEMENT PARTS Fig.
Chapter 19 - PRODUCT SPECIFICATIONS Boiler Model Fuel Input DOE Heating Capacity Net AHRI Rating AFUE Shipping Weight Lbs / Kg Excellence 110 Natural Propane 20,000 110,000 102,000 89,000 95% 190 / 86 • The heating capacity of the PRESTIGE Excellence is based on the test requirements of the U.S. Department of Energy. • The AHRI rating is based on a piping and pick up allowance of 1.15. This allowance should be sufficient for standard radiation requirements.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig.
CHAPTER 19 - PRODUCT SPECIFICATIONS I J K L Connection 3” Combustion Air Inlet & 3” Vent Outlet Boiler Drain 1” NPT Boiler Return & Supply Boiler Depth Dimension in [mm] 4-3/4 ” [120] 9” [226] 16-7/8” [428] 23-5/8 ” [600] CHAPTER 19 Fig.
CHAPTER 19 - PRODUCT SPECIFICATIONS Fig. 29 - Top View PRESTIGE Excellence 110 A CHAPTER 19 80 Connection 3/4” NPSC Aux. Connection (rear) Dimension in [mm] 6” [151] B C 3/4” NPT DHW Inlet and 3/4” NPT DHW Inlet & 3/4” Outlet NPSC Aux.
CHAPTER 19 - PRODUCT SPECIFICATIONS Pressure Drop (Ft. W.C.
Additional quality water heating equipment available from Triangle Tube Maxi-Flo Pool and Spa Heat Exchangers • • • • Constructed of high quality corrosion resistant stainless steel (AISI 316) or titanium Specially designed built-in flow restrictor to assure maximum heat exchange Compact and light weight Available in 8 sizes to accommodate any size pool or spa SMART316 Indirect Fired Water Heaters • • • • • • Exclusive Tank-in-Tank design Stainless steel construction Available in 7 sizes Limited LIFETI
Installation & Maintenance Manual Part 2 of 2 EXC EL L E NC E 110 INDIRECT WATER HEATER NOTICE • • • Customer must register unit within thirty (30) days of installation in order to gain warranty coverage. See Warranty Card for details. 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 the owner for future reference.
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TABLE OF CONTENTS PRODUCT AND SAFETY INFORMATION.......................................................................... VII CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS......................................................... 1 1.1. Code Compliance............................................................................................................................. 1 1.2. Code Restrictions..............................................................................................................
TABLE OF CONTENTS CHAPTER 4 - WATER HEATER MAINTENANCE............................................................... 13 4.1. Maintenance Schedule.................................................................................................................. 13 4.1.1 Annual service by qualified service technician ................................................................. 13 4.1.2 Homeowner monthly maintenance....................................................................................
INDEX OF ILLUSTRATIONS Fig. 1 - Standard Installation of the T&P Relief Valve................................................................................3 Fig. 2 - Commonwealth of Massachusetts Installation............................................................................4 Fig. 3 - Mixing Valve Assembly....................................................................................................................6 Fig. 4 - Standard Installation Domestic Piping Excellence Series............
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SAFETY PRODUCT AND SAFETY INFORMATION IMPORTANT SAFETY INFORMATION FOR THE HOMEOWNER AND THE INSTALLER This manual contains important information with respect to the installation, starting up and maintenance of the appliance. This manual must be provided to the Homeowner, who will keep it in a safe place for future reference. DANGER HOT WATER CAN SCALD! Water temperature over 125ºF can cause severe burns instantly or death from scalds.
SAFETY PRODUCT AND SAFETY INFORMATION CAUTION WARNING Protection must be taken against excessive temperature and pressure! TO PROTECT AGAINST EXCESSIVE TEMPERATURE AND PRESSURE: • Verify the Temperature & Pressure (T&P) relief valve is installed in the location provided (DHW Side). • Verify the 30 psi relief valve supplied is installed in the location provided (CH Side). • To avoid injury, install the relief valves in compliance with local code requirements.
Chapter 1 - PRE-INSTALLATION REQUIREMENTS Code Compliance The PRESTIGE Excellence must be installed by a qualified installer in accordance with the following: • All applicable local, state, national and provincial codes, ordinances, regulations and laws. The PRESTIGE Excellence water heater is exempt from ASME Section VIII, Division 1 Code construction per Interpretation VIII-86-136. Check with local codes for applicability.
CHAPTER 1 - PRE-INSTALLATION REQUIREMENTS 1.4. Locating Water Heater CHAPTER 1 NOTICE WARNING • If the recommended clearances listed above cannot be maintained or the enclosure in which the boiler is installed is less than 85 cubic feet, the space must be ventilated. See Section 2.2 on page 4 of the Excellence Boiler Manual (part 1 of 2).
Chapter 2 - 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 Shutof
CHAPTER 2 - DOMESTIC PIPING Drain Dip Tube 3/4” Brass Close Nipple CHAPTER 2 D T&P Relief Valve w/ 3/4” Tee C DHW Aux. Connection C Air Vent Connection DHW Cold Water Inlet DHW Hot Water Outlet Fig. 2 - Commonwealth of Massachusetts Installation 2.3. Commonwealth of Massachusetts Installation Follow this procedure for jurisdictions requiring a vacuum breaker to be installed on the domestic cold water inlet.
CHAPTER 2 - DOMESTIC PIPING 2.5.2 Commonwealth of Massachusetts Installation • • 2.6. • • 2.7. Thread a 3/4” close nipple onto the Auxiliary connection and insert an open-end dip tube into the Auxiliary connection on top of water heater. As shown in Fig. 2 on page 4. Install a 3/4” NPT elbow on the Auxiliary connection.
CHAPTER 2 - DOMESTIC PIPING • When the water supply pressure is higher than 70 psig, it is recommended to install a pressure reducing valve on cold water supply line to prevent water loss through T&P relief valve. 2.13. Recirculation Piping • • Recirculation piping must be installed in the cold water inlet as shown in Fig. 5 on page 7. A stainless steel or bronze circulator is recommended. CHAPTER 2 2.12.
CHAPTER 2 CHAPTER 2 - INSTALLATION - PIPING Fig. 4 - Standard Installation Domestic Piping Excellence Series Fig. 5 - Domestic Piping with Optional Recirculation Excellence Series 1. 2. 3. 4. 5. Shut-off valve Flow check valve Mixing valve with check valve Vacuum Breaker * Unions 6. 7. 8. 9. Backflow preventer or pressure reducing valve (*) Circulator (controlled by aquastat) Domestic drain valve Thermal expansion tank (potable) (*) Optional devices may be required by local codes.
CHAPTER 2 - INSTALLATION - PIPING CHAPTER 2 Fig. 6 - Standard Installation Domestic Piping with Optional Storage Tank 1. 2. 3. 4. 5. 8 Shut-off valve Flow check valve Mixing valve with check valve Vacuum Breaker * Unions 6. 7. 8. 9. Backflow preventer or pressure reducing valve (*) Circulator (controlled by aquastat) Domestic drain valve Thermal expansion tank (potable) (*) Optional devices may be required by local codes.
Chapter 3 - WATER HEATER START-UP Filling the Inner (Domestic Water) Tank CAUTION • Never use the PRESTIGE Excellence unless inner and outer tanks of the water heater are completely filled with water. • Inner tank of the PRESTIGE Excellence water heater must be completely filled and pressurized before pressurizing outer tank. • 1. 2. 3. 4. 5. Failure to comply with these instructions can result in minor property damage, or injury. Close domestic water drain valve.
CHAPTER 3 - WATER HEATER START-UP DANGER HOT WATER CAN SCALD! CHAPTER 3 • 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 or less. Setting thermostat higher than 130ºF will increase risk of scald injury and cause severe personal injury or death.
CHAPTER 3 - WATER HEATER START-UP 3.4. Domestic Hot Water EZ Setup Domestic Hot Water EZ Setup allows the installer to quickly customize the Domestic Hot Water settings for the application EZ Setup Select DHW Demand prompts the installer to select how a DHW Demand is generated. When Thermostat is selected in Select DHW Demand, 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.
CHAPTER 3 - WATER HEATER START-UP 3.5. DHW Frost Protection CHAPTER 3 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 designed to protect the Excellence water heater from a potential freeze up. Frost Protection will generate a DHW call once the IDWH temperature falls below 42º F [6ºC].
Chapter 4 - WATER HEATER MAINTENANCE 4.1. Maintenance Schedule 4.1.1 Annual service by qualified service technician should include the following: ¨ Any procedure required by local codes. ¨ Verify system pressure. 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. 4.1.2 Homeowner monthly maintenance to include: ¨ Check for air.
CHAPTER 4 - WATER HEATER MAINTENANCE 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. A maximum 50/50 mixture of inhibited propylene glycol is recommended. Follow antifreeze manufacturer’s instruction. WARNING • • Do not use automotive, ethylene glycol or petroleum-based antifreeze. Do not use any undiluted antifreeze.
Chapter 5 - REPLACEMENT PARTS WARNING Replacement parts must be purchased through a local Triangle Tube distributor. When ordering a part, please provide the model number and description and/or part number of replacement part. • Use only genuine Triangle Tube replacement parts to ensure warranty coverage and to avoid improper operation or damage to appliance. • Contact Triangle Tube at 856-228-8881 or www.triangletube.com for a list of distributors near you. CHAPTER 5 • 3 2* 1 Fig.
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Chapter 6 - WATER HEATER SPECIFICATIONS Fig.
CHAPTER 6 - WATER HEATER SPECIFICATIONS Fig.
CHAPTER 6 - WATER HEATER SPECIFICATIONS Fig. 10 - Top View PRESTIGE Excellence 110 A B C CHAPTER 6 D E A Connection Dimension in [mm] B C 3/4” NPSC Aux. Connection 3/4” DHW Inlet & 3/4” NPSC 3/4” DHW inlet and outlet (rear) Aux.
CHAPTER 6 - WATER HEATER SPECIFICATIONS 6.1.
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