prestige Excellence Water Boiler Part 1 of 2 * I N S TALLAT I O N AN D MAI N T E NAN C E * NOTICE Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installation in order to gain warranty coverage. When receiving the PRESTIGE 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.
WARNING WARNING This manual outlines the requirements for installation of the PRESTIGE Excellence. Those requirements include Boiler Piping, Venting/Combustion Air, Start-Up and Maintenance. - For detailed instructions regarding the installation of the vent/combustion air system reference the PRESTIGE Vent Supplement and/or the various optional vent kit instructions.
Table of Contents PRODUCT AND SAFETY INFORMATION Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Product and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SECTION I - PRE-INSTALLATION ITEMS Code Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Determining Product Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Backflow Preventer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Boiler System Piping Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Expansion Tank and Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17 Diaphragm Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Closed-Type Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents System Circulator - Zone Valve Application . . . . . . . . . . . . . . . . . . . . . . . . 31 External Modulating Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Outdoor Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Additional 24V Limit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 External Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents SECTION XI - OUTDOOR RESET CONTROL Mounting the Outdoor Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Wiring the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Summer/Winter Switch at Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Adjusting Outdoor Reset Curve CH Maximum Boiler Operating Setpoint (Parameter 4) . . . . . . . . .
Table of Contents Check Ventilation Air Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Inspect Vent and Combustion Air Piping . . . . . . . . . . . . . . . . . . . . . 57 Check Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Check Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Check Boiler Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Inspection of Ignition Electrode . . .
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.
Product & Safety Information DANGER WARNING Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system which has been under water. Should overheating occur or the gas supply fails to shut off, turn OFF the manual gas control valve external to the appliance. WARNING WARNING DO NOT add cold make up water when the boiler is hot.
Pre-Installation Items SECTION I - Pre-Installation Items Code Compliance - - Gas supply piping - Electrical service Ensure the boiler location allows the combustion air/vent piping to be routed directly through the building and terminate properly outside with a minimum amount of length and bends. This product must be installed in accordance to the following: - - All applicable local, state, national and provincial codes, ordinances, regulations and laws.
Pre-Installation Items Recommended Clearances Residential Garage Installations The PRESTIGE Excellence is approved for zero clearance to combustibles, excluding vent and boiler piping. When installing the PRESTIGE Excellence in a residential garage, the following special precautions per NFPA 54/ANSI Z223.1 must be taken: - Vent & Boiler Piping - 1/4 inch from combustible materials. - Mount the unit with a minimum 18 inches above the floor level of the garage.
Combustion Air and Venting SECTION II - Combustion Air and Venting Potential contaminating products Combustion Air Contamination WARNING If the PRESTIGE Excellence combustion air inlet is located in any area likely to cause or contain contamination, or if products, which would contaminate the air cannot be removed, the combustion air must be repiped and terminated to another location.
Combustion Air and Venting Ventilation and Combustion Air Requirements - Direct Vent Ventilation and Combustion Air Requirements - Category IV A Direct Vent appliance utilizes uncontaminated outdoor air (piped directly to the appliance) for combustion) A Category IV appliance utilizes uncontaminated indoor or outdoor air (surrounding the appliance) for combustion.
Combustion Air and Venting Methods of Accessing Combustion Air Into A Space - Category IV inches of the bottom of the enclosure. The minimum dimension of air openings shall be not less than 3 inches. 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.
Combustion Air and Venting - Not less than the sum of the areas of all vent connectors in the space. Fig. 3: Fig. 2: All Combustion Air from Outdoors Through Ventilated Attic All Combustion Air from Outdoors Through One Permanent Air Opening 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.
Combustion Air and Venting Outdoor Opening(s) Location. Outdoor opening(s) shall be located in accordance with the Outdoor Combustion Air section. 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.
Combustion Air and Venting Removal of an Existing Boiler from a Common Vent System BEST PRACTICE When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the remaining appliances.
Combustion Air and Venting Commonwealth of Massachusetts Installations Only For direct-vent appliances, mechanicalvent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied: 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.
Unit Preparations SECTION III - Unit Preparations secure mounting surface must be provided for installation of the bracket. Handling Instructions 2. DO NOT mount or attempt to mount the wall bracket to hollow sheet rock or lathe walls using anchors. Only install boiler to studs or equivalent wood structure. The PRESTIGE Excellence is generally easier to handle and maneuver once removed from the shipping carton and pallet. 3. For applications using solid walls (rock, concrete, brick, cinder block, etc.
Unit Preparations Wall Bracket Installation - Solid Walls 6. Reposition the bracket on the wall and align mounting slots/holes. Insert the two bolts (provided) through the mounting slots/holes and loosely tighten. 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. 7. Level bracket and tighten bolts securely. 3.
Boiler Piping SECTION IV - Boiler Piping - Should be directed downward towards the floor at all times. The piping should terminate at least 6 inches 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 the piping should have a serviceable temperature rating of 250ºF or greater. - Should not be subject to conditions where freezing could occur. - Should not contain any shut-off valves or obstructions.
Boiler Piping Pressure Relief Valve (Supplied with Boiler) 3/4" Street Elbow Air Vent Drain Piping Directed to a Suitable Place of Drainage CH Supply Connection Fig.
Boiler Piping Additional Limit Control Boiler System Piping Applications If a separate LWCO device is required by certain local jurisdictions or when the boiler is installed above the system piping, the following guidelines must be followed: - The LWCO device must be designed for water installations, electrode probetype is recommended. - The LWCO device must be installed in a tee connection on the boiler supply piping above the boiler.
Boiler Piping The expansion tank must be located as shown in the piping diagrams on pages 19 through 21 or as per recognized design methods. Refer to the expansion tank manufacturer instructions for additional installation details. Sizing Primary Piping See Fig. 9 through 13, pages 19 - 21, for recommended piping arrangements based on various applications. Connect the expansion tank to an air separator only if the air separator is located on the suction side (inlet) of the system circulator.
Boiler Piping System Piping - Through Boiler Size the system piping and circulator to provide the flow needed for the radiant system. In applications in which primary/secondary piping is not utilized and the system is zoned with zone valves a circulator could pump through the boiler and system directly. When pumping through with more than one zone, a pressure differential bypass valve is required to avoid dead heading the pump through the post pump feature of the control. Consult Fig.
Boiler Piping 4 3 5 4 3 Additional Zone Load 3 5 4 3 4 Zone Load 9 4 12" Max. 4 6 7 8 1 2 6 Fig. 9: CH System Piping - Zoning with Zone Circulators 1. 2. 3. 4 PRESTIGE Excellence boiler CH circulator (provided) Flow/check valve Isolation valve 5. 6. 7. 8. 4 Zone circulator Drain/purge valve Pressure relief valve Air separator 4 5 4 5 10 11 9. Automatic air vent 10. Diaphragm expansion tank 11. Automatic fill valve 4 Additional Zone Load 4 Zone Load 9 4 12 12" Max.
Boiler Piping 12 P 4 4 5 4 Additional Zone Load 5 7 4 Zone Load 7 1 Note: Verify CH circulator is properly sized to overcome the system pressure drop and provide adequate flow through the boiler system. 2 9 4 8 10 11 6 4 Fig. 11: CH System Piping - Multiple Zone Valve with Single System/Boiler Circulator 1. 2. 4 5. PRESTIGE Excellence boiler CH circulator Isolation valve Zone valve 6. 7. 8. 9. Drain/purge valve Pressure relief valve Air separator Automatic air vent 10.
Boiler Piping 5 4 Additional Radiant Zone 4 5 4 Radiant Zone 4 9 4 12 12" Max. 4 6 7 8 1 2 6 Note: Manifold mounted valve actuators may be used in lieu of zone valves. 4 11 10 Fig. 13: CH System Piping - Radiant/Low Temp. Heating 1. 2. 3. 4 5. 6. 7. PRESTIGE Excellence boiler CH circulator (provided) Flow/check valve Isolation valve Zone valve Drain/purge valve Pressure relief valve 8. Air separator 9. Automatic air vent 10. Diaphragm expansion tank 11. Automatic fill valve 12.
Installation Vent/Combustion Air & Condensate SECTION V - Installing Vent / Combustion Air & Condensate Drain 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. Installing Vent and Combustion Air DANGER The PRESTIGE Excellence must be vented and supplied with combustion air as shown in the PRESTIGE Vent Supplement, included in the boiler installation envelope.
Installation Vent/Combustion Air & Condensate 7. Continue the pipe from the drain assembly to a floor drain or condensate pump. 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 exit from the heat exchanger, resulting in potential water damage to the boiler and surrounding area.
Gas Piping SECTION VI - Gas Piping 7. Use pipe dope compatible with natural and propane gases. Apply sparingly only to the male threads of pipe joints so that pipe dope does not block gas flow. Gas Supply Piping Connection The gas supply piping must be installed in accordance to all applicable local, state and national codes and utility requirements. WARNING Failure to apply pipe dope as detailed above can result in severe personal injury, death or substantial property damage. 1.
Gas Piping NATURAL GAS - Pipe Sizing - Natural Gas Refer to Table 1 for Schedule 40 metallic pipe length and diameter requirements for natural gas, based on rated PRESTIGE Excellence input (divide by 1,000 to obtain cubic feet per hour). - - 2. Install 100% lockup gas pressure regulator in the gas supply line if inlet pressure can exceed 13”w.c at any time. Adjust the lockup pressure regulator for 13”w.c maximum. Table 1 is based on Natural Gas with a specific gravity of 0.
Gas Piping PROPANE GAS WARNING DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane and requires no field adjustment. Attempts by the installer to adjust or measure the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death or substantial property damage. Pipe Sizing - Propane Gas 1.
Gas Piping Inlet Supply Pressure Port Venturi Gas Valve Propane Orifice Gas Valve Gasket Fig.
Internal Wiring SECTION VII - Internal Wiring Control Module Circulator AMP Ratings - WARNING ELECTRICAL SHOCK HAZARD. For your safety, disconnect electrical power supply to the unit before servicing or making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring Tool Instructions 1. Locate the wiring tool on the PRESTIGE Excellence just below the MCBA control in a plastic bag. 2.
Fig. 20: PRESTIGE Excellence Boiler Factory Wiring 29 Note: To properly connect wires to terminal block, use wiring tool included with PRESTIGE. See wiring tool instructions, page 28.
External Wiring SECTION VIII- External Wiring Thermostat Wiring Installation Compliance NOTICE All field wiring made during installation must comply with: Isolate 120V wiring from 24V wiring to prevent any potential electrical “noise”. - National Electrical Code NFPA 70 and any other national, state, provincial or local codes or requirements. - In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any other local codes. 1.
External Wiring System Circulator - Zone Valve Application To energize the system circulator shown as item 12 in Fig. 10 page 19 reference Fig. 21. Installer to provide a Transformer / Relay such as Honeywell R8285 or equivalent and Zone Valves with isolated end switch such as Honewell V8043 or equivalent. NOTICE If the installer opts for a fixed operating temperature for the boiler system, the outdoor sensor is not required and should not be installed.
External Wiring H 120 N V.A.C. High Voltage 4 Wire Zone Valve Transformer (Power) 24 V.A.C. Room Thermostat Zone Valve Zone 1 Room Thermostat Zone 2 Zone Valve Additional zones Additional zones may be added as shown above 8 7 To Prestige 24V Terminal Strip 3 Wire Zone Valve Transformer (Power) H 120 N V.A.C. High Voltage Room Thermostat 24 V.A.C. Zone Valve Zone 1 Zone 2 NOTICE *Use isolation relay on 3-wire zone valve with non-isolated end switch.
External Wiring Fig. 23: Field Wiring with Zone Circulators. Thermostat zone 1 Honeywell R845A Relay T T T 2 1 120 VAC H N 4 3 5 6 Circulator Zone 1 Thermostat zone 2 T T 2 1 4 3 5 6 Circulator Zone 2 Additional zones may be added as shown above 7 8 To Prestige 24V Terminal Strip Thermostat Zone 1 Fig.
Start-Up Preparation SECTION IX - Start-Up Preparation Flush System to Remove Sediment Check Boiler System Water Chemistry The installer must flush the boiler system to remove any sediment to allow proper operation of the PRESTIGE Excellence . WARNING Flush the systems until the water runs clean and is free of sediment. Do not use petroleum-base cleaning or sealing compounds in the boiler system.
Star-Up Preparation Use of Antifreeze in the Boiler System CAUTION Ensure the domestic inner tank of the PRESTIGE Excellence water heater is properly filled and pressurized prior to filling the boiler system. Reference the PRESTIGE Excellence water heater for proper guidelines on filling the inner tank. Failure to comply could result in damage of the inner tank. WARNING NEVER use automotive or ethylene glycol antifreeze or undiluted antifreeze in the primary system as freeze protection.
Start-Up Preparation Check Low Water Cut-Off Device - - The PRESTIGE Excellence is provided with a factory installed LWCO device that measures system pressure of more than 10 psi. Remove the front jacket panel and check for continuity across the low water cut-off device wire terminals. The contacts should be closed when system pressure is greater than 10 psi. See item 5, on Fig. 27 page 63. 1. Inspect and ensure the condensate drain assembly is properly installed as described on page 22 and shown in Fig.
Start-Up Procedures SECTION X - Start-Up Procedures If PRESTIGE Excellence Correctly Final Checks Before Start-Up 1. Verify DHW (parameter 2) and CH (parameter 3) Systems are turned ON or set to “01”. Read the Boiler Display Standby and Parameter Section of the manual starting on page 42 for more information. c Read page 42 through 45 regarding the operation of the PRESTIGE Excellence control.
Start-Up Procedures WARNING WARNING The combustion levels should be measured at high firing rate, refer to page 42 of the PRESTIGE Excellence control section on how to set the firing rate. If the combustion levels are not within the range given in Table 2 for the firing rate, shut the boiler down and contact Triangle Tube Engineering Department. Failure to comply with this requirement could result in severe personal injury, death or substantial property damage.
Start-Up Procedures FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of A. This appliance does not have a pilot. It is • If you cannot reach your gas supplier, call the fire department. equipped with an ignition device which automatically lights the burner. DO NOT try to light the burner by hand. C. Use only your hand to turn the external manual gas valve. Never use tools.
Start-Up Procedures Set Boiler CH Target Temperature 4. The following displays should occur: 1. Press the MODE button until the display shows PARA. This is the parameter mode of the control. [U1.22] Software version 2. Press the STEP button until the first digit on the display shows "4". The last three digits on the display shows the outlet water temperature setting (high limit). [0140] No call for heat 3. Press the "+" or "-" button to change the setting of the outlet temperature (high limit).
Start-Up Preparation 3. Press the “+” or “-” button to change the setting of the DHW storage temperature. [3140] This is the normal CH operation cycle. After the flame is proven and stabilized the burner will fire at low input for approximately 1 minute. After this time period, the control module will begin to modulate the burner firing rate based on actual boiler outlet temperature and the set point temperature. NOTICE The DHW outlet temperature is controlled by the factory supplied mixing valve.
Start-Up Procedures 3. Lower the DHW storage temperature as outlined in Set DHW Storage Temperature to satisfy the call for heat. Boiler Control Display Standby Mode [1180] The post purge cycle begins. The control module closes the gas valve and the blower continues for a 30 second post purge. StbY This is the standard mode for the PRESTIGE Excellence. The control automatically returns to this mode after 20 minutes if no keys have been pressed on the display.
Start-Up Procedures Standby Mode Display TO TEMPORARILY PLACE THE BURNER INTO LOW FIRE TEST MODE: press the MODE button until “StbY” is displayed. Then press and hold both the MODE and “-” button simultaneously until the first digit flashes “L”. Display 0 180 1 180 2 180 3 180 4 180 5180 6 180 7180 8 180 9 180 b 18 TO DEACTIVATE THE HIGH OR LOW FIRE TEST MODE: Press and hold the “+” and “-” button simultaneously to deactivate the high or low fire test mode.
Start-Up Procedures Setting The Boiler Parameters Parameter mode Note 1: This parameter is factory set to 140ºF. It is important to note the control adds 46ºF to this setting, therefore the actual domestic hot water setting is 140ºF + 46ºF = 186ºF. P ARA To access PARAMETER mode when the system is in STANDBY mode, press the MODE button once. Key: Display MODE P ARA Note 2: This parameter should not be changed from the factory setting of “01”.
Start-Up Procedures Accessing Boiler Information Information mode NOTICE I NFO The ignition counters and burner hours are split into three two digit numbers. For example: To switch from STANDBY mode to INFORMATION mode, press MODE twice. Key: MODE MODE Display P ARA I NFO J 12 .34 .56 Pressing MODE once Pressing MODE twice Write the numbers down from left to right to arrive at 123,456 CH ignitions. Press STEP until the system displays the information you need.
Start-Up Procedures Error (Hard Lockout) Mode Display E 00 E 02 E 03 E 04 E 05 E 06 E 07 E 08 E 09 E 11 E 12 E 13 E 14 E 15 E 16 E 17 E 18 E 19 E 24 E 25 E 28 E 29 E 31 E 32 E 35 E 36 E 37 E 40 E 44 E 52 E 60 E 61 E 65 E 113 E 115 E 122 E 1 23 E 1 24 If a system fault occurs while the boiler is running, the system goes into lockout and the display starts to flash with the first digit as an E and the next two digits give the code for this fault.
Outdoor Reset Control SECTION XI - Outdoor Reset Control 4. Mount the sensor enclosure at an elevation on the exterior wall to prevent accidental damage or tampering. The boiler setpoint for a heating call can be fixed or vary with the outdoor temperature. If the application requires a constant supply temperature from the boiler, the outdoor temperature sensor should not be connected to the boiler.
Outdoor Reset Control Summer / Winter Switch at Boiler CH Maximum Boiler Operating Setpoint (Parameter 4) If required the CH (Central Heating) system can be turned off at the boiler, similar to manual summer / winter switch by press/hold the “+” button while in the “StbY” mode, the display will show “cOFF”. Press/hold the “+” button to turn the CH system back on, the display will show “c” followed by CH set point temperature (Parameter 4) or CH target temperature.
Outdoor Reset Control CH Reset Curve Warmest Day (Parameter 12) Press STEP once- 1140 Press STEP x2 - 2_01 Press STEP x3 - 3_01 Press STEP x4 - 4186 Press STEP x5 - P_10 Press STEP x6 - P_11 This parameter is not applicable if an outdoor sensor is not connected to the boiler. When an outdoor temperature sensor is connected, the CH Reset Curve Warmest Day is the warmest design temperature of the heating system. Etc...... After Parameter 4, the display will show P followed by the parameter number.
Outdoor Reset Control Parameter 4 Set Point 140 86 Parameter 10 Set Point Parameter 11 Setting 100 Parameter 12 Setting Boiler Temperature ( F) 180 60 20 90 70 64 50 30 10 0 -10 Outdoor Air Temperature ( F) Graph 1: Outdoor Air Temperature Reset Curve (Example) Table 3: Outdoor Air Temperature Reset (Example) Graph 1 illustrates Parameter 4 adjusted to 140ºF target temperature at 0ºF outdoor air temperature. Note: Factory setting of Parameter 4 is 186ºF.
External Modulating Control SECTION XII - External Modulating Control NOTICE The boiler can directly accept an analog 0-10 VDC signal to control the firing rate from an external modulating boiler controller. Ensure that Parameter 4 is set above the highest setpoint of the external modulating control. Parameter 4 is a boiler high temperature limit when using an external modulating controller.
External Modulating Control Factory Setting Parameters 52
Check-Out Procedures SECTION XIII- Check-Out Procedures NOTICE Perform the following check-out procedures as outlined and check off items as completed. When procedures are completed, the installer should complete the installation record on page 53. Check-out Procedures c c Boiler system water chemistry checked and verified as outlined on page 34. The boiler air vent and any automatic air vents placed within the system are open one full turn.
Installation Record SECTION XIV - Installation Record PRESTIGE Excellence Model Number: Serial Number: Date of Installation: Fuel: Natural Gas Propane Measured Rate of Input: Btu/hr Combustion Readings: CO2 % O2 % 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.
Maintenance Schedule SECTION XV - Maintenance Schedule Owner Maintenance Service Technician Periodically: At least on an annual basis the following maintenance should be performed by a qualified service technician: - Check the area around the unit. - Check and remove any blockage from the combustion air inlet and ventilation openings. Check the temperature/pressure gauge. General - Attend to any reported problems.
Maintenance Schedule SECTION XVI - Maintenance Procedures Verify that combustion air inlet area is free of any contaminates. Refer to the list of potential 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.
Maintenance Procedures Clean Condensate Drain Assembly Inspect Vent and Combustion Air Piping 1. Loosen the slip ring nut from the condensate drain assembly disconnecting the assembly from the boiler. Visually inspect the venting system and combustion air piping for blockage, deterioration or leakage. Repair any deficiencies. 2. Empty any water from the trap and drain assembly. Flush with fresh water as necessary to clean.
Maintenance Procedures Check Expansion Tank WARNING Refer to Section IV - Boiler Piping for recommended location of the expansion tank and air eliminators. Before manually operating the pressure relief valve, ensure the discharge piping is directed to a suitable place of disposal to avoid a potential scald hazard. The discharge piping must be full size without restriction and installed to permit complete drainage of both the valve and line.
Maintenance Procedures Check Control Wiring Carefully remove the burner mounting plate assembly from the heat exchanger. Ensure combustion chamber insulation is not damaged during removal of burner mounting plate assembly. See WARNING on page 61. Inspect all control wiring. Ensure wiring is in good condition and properly connected. Check Control Settings 1. Set the control display to PARAMETER mode and check all boiler settings. Adjust setting as necessary see page 44.
Maintenance Procedures Check Flame Signal 2. Allow the boiler to cool down to room temperature before servicing. The flame signal should be a min. 3μ Α −DC. 3. Disconnect the gas piping and rectifier plug to the gas valve. Check the ignitor for fouling or damaged insulation if a low flame signal is read. 4. Disconnect the wiring harness connectors from the blower and remove the blower retaining screws. Remove the blower from the unit. Check ground wiring and continuity as a cause for low flame signal.
Maintenance Procedures 14. Attach a hose to the boiler drain valve and flush the boiler thoroughly with fresh water by using the purge valves to allow water to enter through the make-up water line to the boiler. 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. 15.
Replacement Parts 7 8 6 5 10 3 1A 2 1 1B Fig.
Replacement Parts 2 3 11 9 14 12 10 15 1 5 8 13 Fig.
Replacement Parts Fig.
Replacement Parts Fig.
Product Specifications 24.7" 628 mm 20.4" 516 mm 3” Vent Outlet 14.8" 377 mm 12" 306 mm 7.2" 183 mm 12" 305 mm 16" 405 mm 18.
Product Specifications 20.8" 529 mm 15" 381 mm 11.4" 289 mm 3/4” NPSC Pressure Relief Valve Connection 3” Vent Outlet 3” Combustion Air Inlet 37.2” 945 mm 2.4" - 61 mm 1/2” NPT Gas Connection 8.
Product Specifications 3/4” NPT DHW Outlet 11.3" 286 mm 7.3" 186 mm 3.4” 87 mm 3/4” NPSC Aux. Connection (Rear) 1/2” NPSC Air Vent Connection 3/4” NPT DHW Inlet 4.
Product Specifications Boiler Model Fuel DOE Heating Capacity Note 1 & 4 Input Note 4 Net IBR Rating Note 2 Excellence Natural 99,000 110,000 86,000 95% 190 / 86 Excellence Propane 87,000 97,000 76,000 95% 190 / 86 DOE Seasonal Efficiency AFUE Note 3 Shipping Weight Lbs / Kg Note 1: The heating capacity of the PRESTIGE Excellence is based on the test requirements of the U.S. Department of Energy.
Product Specifications Graph 2: Pressure Drop Comparison Excellence 110 vs Grundfos UPS 15-58F-FC Note: Minimum allowable flow rate at full input: 5.
Additional Quality Water Heating Equipment Available from Triangle Tube Maxi-Flo and Spa Heat Exchangers - Construction 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 5 sizes that can accommodate any size pool or spa Smart Indirect Fired Water Heaters - Exclusive Tank-in-Tank design Stainless steel construction Available in 8 sizes and 2 models Limited LIFETIME r
prestige Excellence Indirect Water Heater Part 2 of 2 * I N S TALLAT I O N AN D MAI N T E NAN C E * M A N U A L 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.
Tables of Contents Product & Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Installation - Domestic Piping Temperature & Pressure (T&P) Relief Valve . . . . . . . . . . . . . . . . . .5 Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Automatic Air Vent . . . . . . . . . . . . . . . . . . . . . . . .
Tables of Contents Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Water Heater Specifications Excellence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Performance Excellence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
Product & Safety Information CAUTION WARNING Protection must be taken against excessive temperature and pressure! Bacteria can develop in the domestic water system if certain minimum water temperatures are not maintained. TO PROTECT AGAINST EXCESSIVE TEMPERATURE AND PRESSURE DANGER • Check if the Temperature & Pressure (T&P) relief valve is installed in the location provided (DHW Side).
Pre-Installation 2. The pressure of the heat transfer medium is maintained less than the normal minimum operating pressure of the potable water system Codes Compliance Installation of the Excellence Water Heater must conform with the instructions in this manual and where applicable: • • Exception: Steam complying with section #1 above. local, state, provincial, and national codes, laws, regulations and ordinances. 3.
Pre-Installation 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.
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
Installation - Domestic Piping Drain Valve CAUTION 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 T&P relief valve is not intended for constant duty, such as relief of pressure due to repeated normal system expansion.
Installation - Domestic Piping Domestic Piping • DANGER Union on domestic hot water outlet should be piped at a higher elevation than domestic water drain valve. This will make draining the water heater easier. • 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.
Installation - Domestic Piping DHW Hot Water Outlet T&P Valve (Drain Piping Not Shown) DHW Aux. Connection DHW Cold Water Inlet Air Vent Connection Fig. 2: Standard Installation of the T&P Relief Valve T&P Valve (Drain Piping Not Shown) Drain Dip Tube 3/4” Brass Tee 3/4” Brass Close Nipple DHW Hot Water Outlet DHW Aux. Connection Air Vent Connection DHW Cold Water Inlet Fig.
Installation - Piping Diagrams 12" Min. Heat Trap Loop (Optional) 12" min. Heat Trap Loop (Optional) C 3 4 H 8 5 M 6 1 Cold Water Inlet 9 Fig. 4: Standard Installation Domestic Piping Excellence Series Fig. 5: Standard Installation Domestic Piping with Optional Recirculation Excellence Series 1. 2. 3. 4. 5. 6. 7. 8 9.
Installation - Piping Diagrams Optional recirculation 2 7 M C H 3 Optional 12" Heat trap 1 9 8 4 3 Cold water inlet 6 3 7 2 Fig. 6: Domestic Piping with Optional Storage Tank 1. 2. 3. 4. 6. 7. 8 9. Mixing valve with check valve Flow check valve Shut-off valve Backflow preventer or pressure reducing valve(*) Thermal expansion tank Circulator (controlled by aquastat) Domestic drain valve Vacuum Breaker * (*) Optional devices may be required by local codes.
Water Heater Start-Up Filling the Inner (Domestic Water) Tank WARNING 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. 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.
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 or less. Setting thermostat higher than 130ºF will increase risk of scald injury and cause severe personal injury or death.
Water Heater Start-Up Important Information - Read Before Proceeding Activating the Access Code To enter the parameter listing of the MCBA control, the installer must enter the service code as follows: WARNING This document is intended to be used by a factory trained and qualified heating contractor or service technician only. Read all instructions within this document and within the PRESTIGE Excellence Boiler Installation and Maintenance Manual, before proceeding.
Water Heater Start-Up P_10 Press STEP x6 - P_11 Press STEP x5 - WARNING Etc...... After Parameter 4 the display will show P followed by a two-digit number that increases with each press of the STEP button. NOTICE The actual parameter values displayed on the unit may vary depending on the application. The parameter sequence will always occur in the order shown. Once a particular parameter is reached, release the STEP button.
Water Heater Start-Up DHW Storage Temperature Setting The parameter setting for the DHW storage temperature is Parameter 1 and is accessible without having to enter the service code. To revise the parameter setting within the Prestige Control Module for the set point of the Domestic Storage temperature, the installer can access the parameter setting by entering the Parameter Mode PARA during normal operation, the service code is not required.
Water Heater Start-Up DHW OFF Differential DANGER The DHW ON Differential setting of Parameter 38 greatly affects the production of domestic hot water. A minimum setting of Parameter 38 could result in a rapid response to a DHW request for heat resulting in a potential scald hazard. It is strongly recommended that the installer utilize the factory supplied thermostatic mixing valve on the DHW outlet of the Excellence.
Water Heater Start-Up Troubleshooting Error Codes b_38 alternating with a status code of 9 4. Press the + or - button until the desired setting is achieved. Press STORE to save the setting. The display will flash when the revised setting is accepted. 5. Once the desired parameter setting has been revised and stored within the Prestige Control module, press RESET to exit the CODE mode.
Water Heater Start-Up FACTORy SETTING FOR PARAmETERS 18
Water Heater Maintenance Check function of field-installed controls and valves. See component manufacturer’s instructions. Maintenance Schedule Annual service by qualified service technician should include the following: Review homeowner’s maintenance responsibilities and their frequencies, including any not listed in the following section. Any procedure required by local codes. Check air vent operation. Verify system pressure.
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.
Replacement Parts 3 1 2 Fig.
Water Heater Specifications 20.8" 529 mm 24.7" 628 mm 20.4" 516 mm 3” Vent Outlet 14.8" 377 mm 12" 306 mm 15" 381 mm 3” Combustion Air Inlet 11.4" 289 mm 3/4” NPSC Pressure Relief Valve Connection 3/4” NPSC Pressure Relief Valve Connection 3” Vent Outlet 3” Combustion Air Inlet 37.2” 945 mm 7.2" 183 mm 15.9" 405 mm 15.9" 405 mm 18.9" - 479 mm 1/2” NPSC Boiler Drain 2.4" - 61 mm 1/2” NPT Gas Connection 1” NPT Boiler Return 8.
Water Heater Specifications 3/4” NPT DHW Outlet 11.3" 286 mm 7.3" 186 mm 3.4” 87 mm 3/4” NPSC Aux. Connection (Rear) 1/2” NPSC Air Vent Connection 3/4” NPT DHW Inlet 4.
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