Instructions

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PRESTIGE Solo 175 & 250

Service Parts Instructions

Kit Part Number: PSRKIT91

Recommended tools:

• Pipe wrenches

• Phillips and flat head screwdrivers

• 10 mm socket and/or 10 mm wrench

• Adjustable wrench

• Needle nose pliers

• Calibrated combustion analyzer

• Diagonal cutting pliers

• T 20 Torx long screwdriver

• T 25 Torx wrench

• Phillips head long screwdriver

Indicates a potentially hazardous situation

which, if ignored, can result in serious injury or

substantial property damage.

For your safety, turn off electrical power supply

at service panel and allow unit to cool before

proceeding to avoid possible electrical shock and

scald hazard. Failure to do so can cause severe

personal injury or death.

Use a two wrench method when tightening pip-

ing onto the boiler piping connections. Use one

wrench to prevent the boiler piping from turning

/ twisting. Failure to support the boiler piping

and connections in this manner could cause

damage to the boiler and its components.

Failure to follow instructions below can result in

severe personal injury or damage if ignored.

• Instructions are for a qualified installer/

service technician only.

• Read all instructions before proceeding.

• Follow instructions in proper order.

WARNING

Kit Includes:

• Qty 1 - 175/250 INSULATION/GASKET

• Qty 1 - SIGHT GLASS ASSEMBLY

• Qty 1 - PS175-250 IGNITER

• Qty 1 - PT175-250 IGNITER

• Qty 1 - GASKET: VENTURI

• Qty 1 - GASKET: HX/FLUE PIPE

• Qty 1 - GASKET: VENT ADAPTER

• Qty 1 - GASKET: BURNER HEAD

• Qty 2 - GASKET: IGNITER

• Qty 4 - GASKET: PIPING

• Qty 1 - WASHER: CONDENSATE TRAP

• Qty 1 - WIRE TIE

• Qty 1 - CONNECTOR: IGNITER GROUND WIRE

• Qty 1 - AIR VENT

• Qty 4 - IGNITER SCREW

• Qty 1 - T-25 TORX KEY

Summary of content (13 pages)

PAGE 1
PRESTIGE Solo 175 & 250 Service Parts Instructions Kit Part Number: PSRKIT91 Kit Includes: Recommended tools: • • • • • • • • • • • Pipe wrenches Phillips and flat head screwdrivers 10 mm socket and/or 10 mm wrench Adjustable wrench Needle nose pliers Calibrated combustion analyzer Diagonal cutting pliers T 20 Torx long screwdriver T 25 Torx wrench Phillips head long screwdriver • • • • • • • • • • • • • • • Qty 1 - 175/250 INSULATION/GASKET Qty 1 - SIGHT GLASS ASSEMBLY Qty 1 - PS175-250 IGNITER Qty 1
PAGE 2
PRESTIGE Solo 175 & 250 Service Parts Instructions Maintenance Procedures WARNING Every PRESTIGE Boiler should be inspected and serviced annually, preferably at the start of the heating season, by a qualified service technician. Failure to service and maintain the PRESTIGE Boiler and the system components could result in equipment failure, causing possible severe personal injury, death or substantial property damage.
PAGE 3
PRESTIGE Solo 175 & 250 Service Parts Instructions retaining nut and screw onto the condensate drain assembly without rubber gaskets. Use the condensate drain assembly as a tool to press the retaining nut with split metal washer onto the polypropylene condensate pan. Unscrew the condensate drain assembly and proceed to the next step. WARNING Do not use solvents to clean any of the burner components. The components could be damaged, resulting in unreliable or unsafe operation. Check System Piping 1.
PAGE 4
PRESTIGE Solo 175 & 250 Service Parts Instructions Check Ventilation Air Openings Vent Outlet Adapter 1. 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. 2. Check and verify the vent discharge and the combustion air intake are free of debris and obstructions. Inspect Vent and Combustion Air Piping Vent/Heat Exchanger Gasket 1.
PAGE 5
PRESTIGE Solo 175 & 250 Service Parts Instructions Check Expansion Tank Inspection of Sight Glass Closed -Type Tank: 1. Visually inspect sight glass and gasket for signs of deterioration. 1. Ensure tank is partially filled with water leaving an air gap as a cushion. Refer to the manufacturer’s instruction for proper fill level. 2. Replace sight glass if necessary. 2. Ensure the tank is fitted with a device that reduces gravity circulation of air-saturated tank water back into the system.
PAGE 6
PRESTIGE Solo 175 & 250 Service Parts Instructions 2. 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 dis-assembly. Check Ignition Cable and Ground Wire 1. Inspect the ignition cable from the igniter to the control module. Replace if necessary. 2. Inspect the igniter ground wire for signs of deterioration. Replace if necessary. 3.
PAGE 7
PRESTIGE Solo 175 & 250 Service Parts Instructions 13. Remove the combustion chamber insulation from the heat exchanger and inspect for any signs of damage or deterioration. Replace combustion chamber insulation if necessary. See WARNING on page 13. 16. Check combustion chamber insulation alignment with the burner mounting plate. The combustion chamber insulation igniter cutout should align with the opening in the burner mounting plate.
PAGE 8
PRESTIGE Solo 175 & 250 Service Parts Instructions 2. Check the igniter for fouling or damaged insulation if a low flame signal is read. NOTICE 3. Check ground wiring and continuity as a cause for low flame signal. Replace igniter if conditions are unsatisfactory. The control panel will display a H followed by the current boiler temperature when placed into high fire test mode. Check Combustion Levels 2.
PAGE 9
PRESTIGE Solo 175 & 250 Service Parts Instructions Offset Pressure Cover Screw NOTICE Throttle Screw An adequate CH load must be present to 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. 5. Press the RIGHT button to adjust the firing rate to high fire (100%). Hold down the RIGHT button to rapidly increase the firing rate. Fig.
PAGE 10
PRESTIGE Solo 175 & 250 Service Parts Instructions 10. Press the DOWN button to highlight the home screen icon to exit the service mode. screw driver provided in the kit. Remove the blower with venturi and gas valve from the unit. 5. Remove the mounting nuts securing the burner mounting plate to the heat exchanger and set aside. Check Flue Gas Temperature (MCBA) 1.
PAGE 11
PRESTIGE Solo 175 & 250 Service Parts Instructions 12. Hand tighten the burner mounting plate nuts to hold the burner plate in place. Once all mounting nuts are in place, use a wrench to tighten using an alternating pattern until the gasket is slightly compressed. See Table 1, page 14 for torque specifications. Clean Heat Exchanger (Water side) 13. Re-assemble the blower onto the burner mounting plate and reconnect the wiring harness connectors. Tighten screws evenly.
PAGE 12
PRESTIGE Solo 175 & 250 Service Parts Instructions Maintenance Check List Description Inspect boiler jacket area: clean and vacuum as needed Clean condensate drain and fill with fresh water Check for leaks: water, gas, flue and condensate Verify vent piping is in good condition, sealed tight, well supported and unobstructed Verify combustion air piping is in good condition, sealed tight, well supported and unobstructed Verify area surrounding unit is free from contaminating products and flamable vapors or
PAGE 13
PRESTIGE Solo 175 & 250 Service Parts Instructions Handling Previously Fired Combustion Chamber Insulation 2. Wear long sleeved, loose fitting clothing, gloves and eyes protection. WARNING The combustion chamber insulation contains ceramic fibers, which are classified as a possible human carcinogen. When exposed to extremely high temperatures, the ceramic fibers, which contain crystalline silica, can be converted into cristobalite.