Prestige Solo 110, Solo 80, Solo 250, Solo 299, Solo 399 Installation And Maintenance Manual
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prestige
Solo
80 250
110 299
155 399
175
Water Boiler
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* I N S T A L L A T I O N A N D M A I N T E N A N C E *
* I N S T A L L A T I O N A N D M A I N T E N A N C E *
M A N U A L
M A N U A L
NOTICE
WARNING
Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installation in order to gain warranty coverage.
When receiving the PRESTIGE Solo unit, any claims for damage or shortage in shipment must be filed
immediately against the transportation company by the consignee.
Leave all documentation received with appliance with owner for future reference.
If the information in this manual is not followed exactly, a fire or explosion may
result causing property damage, personal injury or death.
• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.
• WHAT TO DO IF YOU SMELL GAS
- Do not try to light any appliance
- Do not touch any electrical switch; do not use any phone in your building.
- Immediately call your gas supplier from a neighbor ’s phone. Follow the gas
- If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or the
Revised Date: 12/15/15
gas supplier.
FOR YOUR SAFETY
supplier ’s instructions.
2015-9 Prestige ACVMax Install Manual
Table of Contents
Product & Safety Information
Definitions .........................................................................................................1
Qualified Installer: .........................................................................................................2
Homeowner: .........................................................................................................2
Section I - Pre-Installation Items
1.1 Code Compliance..................................................................................................3
1.2 Determining Product Location..............................................................................3
1.3 Boiler Replacement...............................................................................................3
1.4 Recommended Clearances ....................................................................................4
1.5 Residential Garage Installations ...........................................................................4
1.6 Boiler Freeze Protection Feature ..........................................................................4
SECTION II - Combustion Air and Venting
2.1 Combustion Air Contamination ............................................................................5
2.2 Ventilation and Combustion Air Requirements - Direct Vent ..............................6
2.3 Ventilation and Combustion Air Requirements - Category IV.............................6
2.4 Methods of Accessing Combustion Air Into A Space - Category IV...................7
2.4.1 Indoor Combustion Air Opening Size and Location...................................7
2.4.2 Outdoor Combustion Air Opening Size and Location................................7
2.4.2.1 One Permanent Opening Method ...................................................7
2.4.2.2 Two Permanent Openings Method ................................................8
2.4.3 Combination of Indoor and Outdoor Combustion Air ..............................9
2.5 Combustion Air and Vent Piping ..........................................................................9
2.6 Removal of an Existing Boiler from a Common Vent System ............................10
2.7 Commonwealth of Massachusetts Installations Only...........................................11
SECTION III - Unit Preparations
3.1 Handling Instructions............................................................................................12
3.2 Wall Mounting Installation ...................................................................................12
3.3 Wall Mounting Guidelines ....................................................................................12
3.4 Stud Walls - Installation .......................................................................................13
3.4.1 PRESTIGE Solo 80/110/155/175/250.........................................................13
3.4.2 PRESTIGE Solo 299/399 ...........................................................................13
3.5 Wall Bracket Installation - Solid Walls.................................................................13
3.6 Boiler Mounting....................................................................................................13
SECTION IV - Boiler Piping
4.1 General Piping Requirements ...............................................................................14
4.2 Pressure Relief Valve ............................................................................................14
4.3 Boiler Air Vent ......................................................................................................14
4.4 Low Water Cutoff Device .....................................................................................15
4.5 Additional Limit Control ......................................................................................15
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Table of Contents
4.6 Backflow Preventer...............................................................................................16
4.7 Boiler System Piping Applications .......................................................................16
4.8 Expansion Tank and Makeup Water .....................................................................16
4.8.1 Diaphragm Expansion Tank ........................................................................16
4.8.2 Closed-Type Expansion Tank......................................................................16
4.9 Circulator .........................................................................................................19
4.10 Sizing Primary Piping ...........................................................................................19
4.11 Domestic Hot Water System Piping .....................................................................19
4.12 System Piping - Zone Circulators.........................................................................19
4.13 System Piping - Zone Valves ................................................................................19
4.14 System Piping - Through Boiler ...........................................................................19
4.15 System Piping - Radiant Heating..........................................................................19
4.16 System Piping - Special Application ....................................................................20
4.17 System Piping - Multiple Units Installation .........................................................20
SECTION V - Installing Vent / Combustion Air & Condensate Drain
5.1 Installing Vent and Combustion Air .....................................................................24
5.2 Installing Condensate Drain Assembly.................................................................24
SECTION VI - Gas Piping
6.1 Gas Supply Piping Connection .............................................................................26
6.2 Natural Gas .........................................................................................................27
6.2.1 Pipe Sizing...................................................................................................27
6.2.2 Supply Pressure Requirements ....................................................................27
6.3 Propane Gas 28
6.3.1 Pipe Sizing - Propane Gas...........................................................................28
6.3.2 Propane Gas Supply Pressure Requirements ..............................................28
SECTION VII - Internal Wiring
7.1 General Requirements...........................................................................................30
7.2 Fuse Locations ......................................................................................................30
SECTION VIII - External Wiring
8.1 Installation Compliance ........................................................................................32
8.2 Line Voltage Connections .....................................................................................32
8.3 Circulator Wiring ..................................................................................................32
8.4 Alarm Wiring ........................................................................................................33
8.5 Low Voltage Connections .....................................................................................33
8.6 Thermostat Wiring ................................................................................................33
8.7 Outdoor Sensor Wiring .........................................................................................34
8.8 Domestic Hot Water Wiring..................................................................................34
8.9 Additional Boiler Limits .......................................................................................34
8.10 External Modulation Control ................................................................................34
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Table of Contents
8.11 System Sensor Wiring...........................................................................................34
8.12 Cascade Wiring .....................................................................................................35
8.13 Modbus Wiring .....................................................................................................35
SECTION IX - ACVMax Operation
9.1 ACVMax Navigation ............................................................................................41
9.2 ACVMax Menu Structure.....................................................................................42
9.3 Home Screen .........................................................................................................43
9.4 Status Line Messages ............................................................................................44
9.5 Main Menu .........................................................................................................45
9.6 EZ Setup .........................................................................................................46
9.7 Heating EZ Setup .................................................................................................46
9.7.1 Select CH Demand ......................................................................................46
9.7.2 CH1 Setpoint ...............................................................................................46
9.7.3 CH2 Setpoint ...............................................................................................46
9.7.4 Select CH1 Reset Curve..............................................................................47
9.7.5 Select CH2 Reset Curve..............................................................................47
9.7.6 Set Warm Weather Shutdown Temperature.................................................47
9.7.7 CH EZ Setup Complete ...............................................................................47
9.8 Domestic Hot Water EZ Setup .............................................................................48
9.8.1 Select DHW Demand ..................................................................................48
9.8.2 Boiler DHW Setpoint ..................................................................................48
9.8.3 DHW Storage Setpoint ................................................................................48
9.8.4 DHW Priority Timeout................................................................................49
9.9 EZ Setup Reset......................................................................................................49
9.10 Display EZ Setup ..................................................................................................49
9.11 CH/DHW Operation .............................................................................................50
9.12 Boiler Information ...............................................................................................50
9.12.1 Boiler Information Logging ........................................................................50
9.12.2 Information Items ........................................................................................51
9.13 Lockout History ...................................................................................................52
9.13.1 Lockout Details ...........................................................................................52
9.13.2 Lockout Screen............................................................................................53
SECTION X - Start-Up Preparation
10.1 Boiler System Fluid Requirements .......................................................................56
10.1.1 Boiler Fluid pH Level 6.0 to 8.0 .................................................................56
10.1.2 Boiler Fluid Hardness Less Than 7 Grains .................................................56
10.1.3 Chlorinated Water........................................................................................56
10.1.4 Flush Boiler to Remove Sediment ..............................................................56
10.1.5 Cleaning of Old Boiler/System: .................................................................56
10.1.6 Cleaning of New Boiler/System: ..............................................................56
10.1.7 Check and Test Antifreeze...........................................................................57
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Table of Contents
10.1.8 Use of Antifreeze in the Boiler System.......................................................57
10.2 Filling the Boiler System ......................................................................................57
10.3 Check Low Water Cut-Off Device .......................................................................58
10.4 Check For Gas Leaks............................................................................................58
10.5 Check Thermostat Circuit .....................................................................................58
10.6 Inspection of Condensate Drain Assembly...........................................................58
SECTION XI - Start-Up Procedures
11.1 Final Checks Before Start-Up...............................................................................59
11.2 PRESTIGE Solo Start-Up.....................................................................................59
11.3 Check the PRESTIGE Solo and System...............................................................59
SECTION XII - Outdoor Reset Control
12.1 Mounting the Outdoor Sensor...............................................................................64
12.2 Wiring the Sensor..................................................................................................64
SECTION XIII - External Modulating Control
13.1 Wiring the Modulating Controller ........................................................................65
13.2 ACVMax Adjustment ...........................................................................................65
13.3 Programming of External Modulating Control.....................................................65
SECTION XV - Installation Record
SECTION XVI - Maintenance Schedule
16.1 Service Technician ................................................................................................69
16.2 Owner Maintenance ..............................................................................................69
SECTION XVII- Maintenance Procedures
17.1 Maintenance Procedures .......................................................................................70
17.2 Reported Problems................................................................................................70
17.3 Check Surrounding Area .....................................................................................70
17.4 Inspect Burner Area ..............................................................................................70
17.5 Check System Piping ............................................................................................70
17.6 Clean Condensate Drain Assembly.......................................................................71
17.7 Check Ventilation Air Openings ...........................................................................71
17.8 Inspect Vent and Combustion Air Piping..............................................................71
17.9 Check Boiler System.............................................................................................71
17.10 Check Expansion Tank..........................................................................................72
17.11 Check Boiler Relief Valve ....................................................................................72
17.12 Inspection of Ignitor..............................................................................................72
17.13 Check Ignition Wiring and Ground Wiring ..........................................................72
17.14 Check Control Wiring...........................................................................................73
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Table of Contents
17.15 Check Control Settings .........................................................................................73
17.16 Perform Start-up and Checkout Procedures .........................................................73
17.17 Check Burner Flame .............................................................................................73
17.18 Check Flame Signal ..............................................................................................74
17.19 Check Combustion Levels ....................................................................................74
17.20 Check Flue Gas Temperature................................................................................74
17.21 Clean Heat Exchanger...........................................................................................74
17.22 Review With Owner..............................................................................................75
17.23 Handling Previously Fired Combustion Chamber Insulation...............................75
17.24 Torque Specifications Table..................................................................................75
Section XVIII Replacement Parts
PRESTIGE Solo 80/110 Jacket Components..................................................................77
PRESTIGE Solo 175/250 Jacket Components................................................................78
PRESTIGE Solo 299/399 Jacket Components................................................................79
PRESTIGE Solo 80/110 Internal Components ...............................................................80
PRESTIGE Solo 155/175/250 Internal Components ......................................................81
PRESTIGE Solo 399 Internal Components ....................................................................82
PRESTIGE Solo 80/110 Burner Components.................................................................83
PRESTIGE Solo 155/175/250 Burner Components........................................................84
PRESTIGE Solo 299/399 Burner Components...............................................................85
PRESTIGE Solo Display Enclosure................................................................................86
PRESTIGE Solo Control Enclosure ................................................................................86
Section XIX Product Specifications
PRESTIGE Solo 80/110 Front View ...............................................................................88
PRESTIGE Solo 80/110 Right Side View.......................................................................89
PRESTIGE Solo 155/175/250 Front View......................................................................90
PRESTIGE Solo 155/175/250 Right Side View .............................................................91
PRESTIGE Solo 299/399 Front View.............................................................................92
PRESTIGE Solo 299/399 Right Side View.....................................................................93
Section XX Notes
General Notes .........................................................................................................97
v
Product & Safety Information
PRODUCT & SAFETY INFORMATION
Definitions
The following terms are used throughout this manual to bring attention to the presence of
potential hazards or important information concerning the product.
DANGER
Indicates the presence of a hazardous
situation which, if ignored, will result in
death, serious injury or substantial
property damage.
WARNING
Indicates a potentially hazardous situation which, if ignored, can result in
death, serious injury or substantial
property damage.
CAUTION
Indicates a potentially hazardous situation which, if ignored, may result in
minor injury or property damage.
NOTICE
Indicates special instructions on installation, operation or maintenance, which
are important to equipment but not
related to personal injury hazards.
BEST PRACTICE
Indicates recommendations made by
ACV-Triangle Tube for the installers
which will help to ensure optimum operation and longevity of the equipment
NOTICE
ACV-Triangle Tube reserves the right to modify the technical specifications and components of its products without prior notice.
1
Product & Safety Information
DANGER
Do not use this appliance if any part has
been under water. Immediately call a
qualified service technician to inspect
the appliance and to replace any part of
the control system which has been
under water.
WARNING
WHAT TO DO IF YOU SMELL GAS
- Do not try to light any appliance
- Do not touch any electrical switch; do
not use any phone in your building.
- Immediately call your gas supplier
from a neighbor’s phone. Follow the
gas supplier’s instructions.
- If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service
agency or the gas supplier.
WARNING
Qualified Installer:
Prior to installing this product read all instructions included in this manual and all accompanying manuals/documents with this appliance.
Perform all installation steps required in these
manuals in the proper order given. Failure to
adhere to the guidelines within these manuals
can result in severe personal injury, death or
substantial property damage.
Homeowner:
- This product should be maintained /
serviced and inspected annually by a
qualified service technician.
- This manual is intended for use by a
qualified Installer/Service Technician.
NOTICE
Please reference the unit’s model number
and the serial number from the rating label
when inquiring about service or troubleshooting.
WARNING
Should overheating occur or the gas
supply fails to shut off, turn OFF the
manual gas control valve external to the
appliance.
WARNING
DO NOT add cold make up water when
the appliance is hot. Thermal shock can
potentially cause cracks in the heat
exchanger.
CAUTION
When servicing the appliance:
- Avoid electrical shock by disconnecting the electrical supply prior to
performing maintenance.
WARNING
ACV-Triangle Tube accepts no liability for
any damage, injury or loss of life resulting
from incorrect installation, from alteration of any factory supplied parts or from
the use of parts or fittings not specified by
ACV-Triangle Tube. If there is a conflict
or doubt about the proper installation of
the unit or any factory supplied or
replacement parts please contact ACVTriangle Tube Technical Support.
WARNING
A byproduct of any gas fired appliance
is carbon monoxide. In the absence of
any state or local codes requiring the
installation of carbon monoxide detector and alarms, ACV-Triangle Tube’s
recommendation is to follow the
requirements of the Commonwealth of
Massachusetts, see page 11.
2
1.0 Pre-Installation Items
SECTION I - PRE-INSTALLATION ITEMS
1.1 Code Compliance
This product must be installed in accordance to
the following:
- All applicable local, state, national and
provincial codes, ordinances, regulations and laws.
- For installations in Massachusetts, code
requires the boiler to be installed by a
licensed plumber or gas fitter, and if
antifreeze is utilized, the installation of
a reduced pressure backflow preventer
device is required in the boiler’s cold
water fill or make up water supply line.
- For installation in Massachusetts all direct
vented appliances must comply with the
guidelines as outlined on page 11.
- The National Fuel Gas Code NFPA54/
ANSI Z 223.1 - Latest edition.
- National Electric Code ANSI/NFPA 70.
Before locating the PRESTIGE SOLO check
for convenient locations to:
- Heating system piping
- Venting
- Gas supply piping
- Electrical service
Ensure the boiler location allows the combustion air/vent piping to be routed directly through
the building and terminate properly outside with
a minimum amount of length and bends.
Ensure the area chosen for the installation of the
PRESTIGE Solo is free of any combustible
materials, gasoline and other flammable liquids.
WARNING
Failure to remove or maintain the area
free of combustible materials, gasoline
and other flammable liquids or vapors
can result in severe personal injury,
death or substantial property damage.
- For installations in Canada -“Installation
Code for Gas Burning Equipment”
CGA/B149.1 or B149.2 Canadian
Electrical Code Part 1 CSA C22.1.
- Standards for Controls and Safety
Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1, when required.
NOTICE
The PRESTIGE Solo boiler gas manifold
and gas controls meet the safe lighting and
other performance requirements as specified in ANSI Z21.13 latest edition.
1.2 Determining Product Location
NOTICE
The PRESTIGE boiler is certified for
indoor, conditioned space installations
ONLY.
Ensure the PRESTIGE Solo and its controls
are protected from dripping or spraying water
during normal operation or service.
The PRESTIGE Solo should be installed in a
location so that any water leaking from the
boiler or piping connections or relief valve will
not cause damage to the area surrounding the
unit or any lower floors in the structure.
1.3 Boiler Replacement
If the PRESTIGE Solo is replacing an existing
boiler, the following items should be checked
and corrected prior to installation:
- Boiler piping leaks and corrosion.
- Improper location and sizing of the
expansion tank on the boiler heating
loop.
- If applicable, level and quality of
antifreeze within the boiler system.
3
1.0 Pre-Installation Items
1.4 Recommended Clearances
The PRESTIGE Solo is approved for zero
clearance to combustibles, excluding vent and
boiler piping.
- Boiler Piping - 1/4 inch from combustible materials.
- Reference the appropriate vent supplement for clearance requirements.
BEST PRACTICE
To provide serviceability to the unit it is
recommended that the following clearances be maintained:
Top boiler jacket - 24 inches [610 mm].
Front - 24 inches [610 mm].
Bottom boiler piping - 24 inches [610 mm].
Rear - 0 inches
Sides - 6 inches [153 mm]
1.5 Residential Garage Installations
When installing the PRESTIGE Solo in a residential garage, the following special precautions
per NFPA 54/ANSI Z223.1 must be taken:
- Mount the unit a minimum 18 inches
[458 mm] above the floor level of the
garage. Ensure the burner and ignition
devices / controls are no less than 18
inches [458 mm] above the floor level.
- Locate or protect the unit in a manner so it
cannot be damaged by a moving vehicle.
1.6 Boiler Freeze Protection Feature
The ACVMax 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.
WARNING
If the clearances listed above cannot be
maintained or the enclosure in which the
boiler is installed is less than 85 cubic feet,
the space must be ventilated. See page 6
for ventilation requirements.
NOTICE
When maintaining less than recommended serviceability clearances, some
product labeling, including the rating
label, may become hidden and unreadable.
WARNING
When installing the PRESTIGE Solo in
a confined space, sufficient air must be
provided for proper combustion and
venting and to allow, under normal operating conditions, proper air flow around
the product to maintain ambient temperatures within safe limits to comply with
the National Fuel Gas Code NFPA 54 latest edition.
- 42ºF [6ºC] Pump outputs configured to
respond to a CH1 or CH2 Call are
enabled, Burner operates at low fire.
- 60ºF [15ºC] Freeze protection ends.
Burner & all pumps turn off after completing CH Post Pump Time.
CAUTION
The boiler freeze protection feature is
disabled during a hard lockout, however
the circulators will operate.
CAUTION
The boiler freeze protection feature is
designed to protect the boiler. The boiler
should be installed in a primary/secondary piping arrangement if it is
installed in an unheated space or
exposed to water temperatures of 46ºF or
less. See Section IV for primary/secondary piping examples. See Section X
for antifreeze guides.
4
2.0 Combustion Air & Venting
SECTION II - COMBUSTION AIR AND VENTING
2.1 Combustion Air Contamination
WARNING
If the PRESTIGE Solo combustion air
inlet is located in any area likely to cause
or contain contamination, or if products,
which would contaminate the air cannot
be removed, the combustion air must be
repiped and terminated to another location. Contaminated combustion air will
damage the unit and its burner system,
resulting in possible severe personal
injury, death or substantial property
damage.
WARNING
Do not operate a PRESTIGE Solo if its
combustion air inlet is located near a
laundry room or pool facility. These
areas will always contain hazardous contaminants.
Potential contaminating products
- Spray cans containing chloro/fluorocarbons
- Permanent Wave Solutions
- Chlorinated wax
- Chlorine - based swimming pool chemicals / cleaners
- Calcium Chloride used for thawing ice
- Sodium Chloride used for water softening
- Refrigerant leaks
- Paint or varnish removers
- Hydrochloric acid / muriatic acid
- Cements and glues
- Antistatic fabric softeners used in
clothes dryers
- Chlorine-type bleaches, detergents, and
cleaning solvents found in household
laundry rooms
- Adhesives used to fasten building products and other similar products
Pool and laundry products and common
household and hobby products often
contain fluorine or chlorine compounds.
When these chemicals pass through the
burner and vent system, they can form
strong acids. These acids can create corrosion of the heat exchanger, burner
components and vent system, causing
serious damage and presenting a possible threat of flue gas spillage or water
leakage into the surrounding area.
Please read the information listed below.
If contaminating chemicals are located
near the area of the combustion air inlet,
the installer should pipe the combustion
air inlet to an outside area free of these
chemicals per SECTION V of this
installation manual.
Areas likely to contain these products
- Dry cleaning / laundry areas and establishments
- Beauty salons
- Metal fabrication shops
- Swimming pools and health spas
- Refrigeration Repair shops
- Photo processing plants
- Auto body shops
- Plastic manufacturing plants
- Furniture refinishing areas and establishments
- New building construction
- Remodeling areas
- Garages with workshops
5
2.0 Combustion Air Venting
2.2 Ventilation and Combustion Air Requirements - Direct Vent
A Direct Vent appliance utilizes uncontaminated outdoor air (piped directly to the appliance)
for combustion.
For Direct Vent installations, involving only
the PRESTIGE Solo, in which the minimum
service clearances are maintained as listed on
page 4, no ventilation openings are required.
For Direct Vent, zero clearance installations
involving only the PRESTIGE Solo, the space
/ enclosure must provide two openings for ventilation. The openings must be sized to provide
1 square inch of free area per 1,000 BTUH of
boiler input. The openings shall be placed 12
inches from the top of the space and 12 inches
from the floor of the space.
For installations in which the PRESTIGE Solo
shares the space with air movers (exhaust fan,
clothes dryers, fireplaces, etc.) and other combustion equipment (gas or oil) the space must
be provided with adequate air openings to provide ventilation and combustion air to the
equipment. To properly size the ventilation /
combustion air openings, the installer must
comply with the National Fuel Gas Code
NFPA 54, ANSI Z223.1 for installations in the
U.S or CSA B149.1 and B149.2 for installations in Canada.
WARNING
The space must be provided with ventilation / combustion air openings properly sized for all make-up air requirements
(exhaust fans, clothes dryers, fireplaces,
etc.) and the total input of all appliances
located in the same space as the PRESTIGE Solo, excluding the input of a
Direct Vent PRESTIGE Solo which uses
combustion air directly from the outside,
thus additional free area for the openings is not required. Failure to provide
or properly size the openings could
result in severe personal injury, death or
substantial property damage.
2.3 Ventilation and Combustion Air Requirements - Category IV
A Category IV appliance utilizes uncontaminated indoor or outdoor air (surrounding the
appliance) for combustion.
BEST PRACTICE
In order to reduce the potential risks
associated with indoor contaminates
(listed on page 5), flammable vapors and
tight housing construction (little or no
infiltration air), it is recommended to
pipe uncontaminated combustion air
directly from the outdoors to the appliance. This practice also promotes higher
system efficiency by reducing heated
indoor air from being exhausted from
the house and replaced by cold infiltration air into the house.
For installations in which the PRESTIGE Solo
shares the space with air movers (exhaust fan,
clothes dryers, fireplaces, etc.) and other combustion equipment (gas or oil) the space must be
provided with adequate air openings to provide
ventilation and combustion air to the equipment.
To properly size the ventilation / combustion air
openings, the installer must comply with the
National Fuel Gas Code NFPA 54, ANSI Z223.1
for installations in the U.S or CSA B149.1 and
B149.2 for installations in Canada, as referenced
in this section of the manual and titled Methods
of Accessing Combustion Air into a Space.
WARNING
The space must be provided with ventilation / combustion air openings properly sized for all make-up air requirements
(exhaust fans, clothes dryers, fireplaces,
etc.) and the total input of all appliances,
including the PRESTIGE Solo when
located in the same space. Failure to provide or properly size the openings could
result in severe personal injury, death or
substantial property damage.
6
2.0 Combustion Air Venting
2.4 Methods of Accessing Combustion Air Into A Space - Category IV
2.4.1 Indoor Combustion Air
NOTICE
The methods listed in this section for
accessing Indoor Combustion Air
assume that the infiltration rate is adequate and not less than .40 ACH. For
infiltration rates less than .40 ACH, reference the NFPA 54 National Fuel Gas
Code for additional guidance.
Opening Size and Location
Openings used to connect indoor spaces shall
be sized and located in accordance with the
following, see Fig. 1:
- Combining spaces on the same story.
Each opening shall have a minimum
free area of 1 sq. in./1000 Btu/hr of the
total input rating of all gas utilization
equipment in the space, but not less than
100 sq. inches. One opening shall commence within 12 inches of the top, and
one opening shall commence within 12
inches of the bottom of the enclosure.
The minimum dimension of air openings shall be not less than 3 inches.
- Combining spaces in different stories.
The volumes of spaces in different stories shall be considered as communicating spaces where such spaces are connected by one or more openings in
doors or floors having a total minimum
free area of 2 sq. in./1000 Btu/hr of
total input rating of all gas utilization
equipment.
2.4.2 Outdoor Combustion Air
BEST PRACTICE
Isolating the combustion appliance room
from the rest of the building and bringing in uncontaminated outside air for
combustion and ventilation is always
preferred.
Opening Size and Location
The minimum dimension of air openings shall
be not less than 3 inches
Openings used to supply combustion and ventilation air shall be sized and located in accordance with the following:
2.4.2.1 One Permanent Opening Method
One permanent opening, commencing within 12
in. of the top of the enclosure, shall be provided
as shown in Fig 2 on page 8. The equipment
shall have clearances of at least 1 inch from the
sides and 6 in. from the front of the appliance.
The opening shall directly communicate with the
outdoors or shall communicate through a vertical
or horizontal duct to the outdoors or spaces that
freely communicate with the outdoors and shall
have a minimum free area of the following:
Fig. 1:
- 1sq. in./3000 Btu/hr of the total input
rating of all equipment located in the
enclosures, and
- Not less than the sum of the areas of all
vent connectors in the space.
All Combustion Air from Adjacent
Indoor Spaces Through Indoor
Combustion Openings
7
2.0 Combustion Air Venting
Fig. 2:
All Combustion Air from Outdoors
Through One Permanent Air
Opening
2.4.2.2 Two Permanent Openings Method
Two permanent openings, one commencing
within 12 in. of the top and one commencing
within 12 in. of the bottom of the enclosure,
shall be provided. The openings shall communicate directly, or by ducts, with the outdoors
or spaces that freely communicate with the outdoors, as follows:
- Where directly communicating with the
outdoors or where communication to the
outdoors is through vertical ducts, each
opening shall have a minimum free area
of 1 sq. in./4000 Btu/hr of total input rating of all equipment in the enclosure.
See Fig.3.
- Where communicating with the outdoors is through horizontal ducts, each
opening shall have a minimum free
area of not less than 1 sq.in./2000
Btu/hr of total input rating of all equipment in the enclosure. See Fig. 4.
Fig. 3:
Fig. 4:
All Combustion Air from Outdoors
Through Ventilated Attic
All Combustion Air from Outdoors
Through Horizontal Ducts
8
2.0 Combustion Air Venting
2.4.3 Combination of Indoor and Outdoor Combustion Air
Indoor Openings: Where used, openings connecting the interior spaces shall comply with
the Indoor Combustion Air section on page 7.
Outdoor Opening(s) Location. Outdoor opening(s) shall be located in accordance with the
Outdoor Combustion Air section.
Outdoor Opening(s) Size. Outdoor opening(s) shall
be calculated in accordance with the following:
- The ratio of the interior spaces shall be
the available volume of all communicating spaces divided by the required
volume.
- The outdoor size reduction factor shall
be 1 minus the ratio of interior spaces.
- The minimum size of outdoor opening(s) calculated in accordance with the
above outdoor air section multiplied by
the reduction factor. The minimum
dimension of air openings shall not be
less than 3 in.
ed outdoor air (piped directly to the appliance)
for combustion.
BEST PRACTICE
In order to reduce the potential risks
associated with indoor contaminates
(listed on page 5), flammable vapors
and tight housing construction (little or
no infiltration air), it is recommended
to pipe uncontaminated combustion air
directly from the outdoors to the appliance. This practice also promotes higher
system efficiency by reducing heated
indoor air from being exhausted from
the house and replaced by cold infiltration air into the house.
NOTICE
Install combustion air and vent pipe as
detailed in the PRESTIGE Solo Vent
Supplement included in the boiler
installation envelope. Refer to optional
vent kit instructions for additional vent
installation instructions.
DANGER
DANGER
Do not install the PRESTIGE Solo into a
common vent with other gas or oil appliances. This may cause flue gas spillage or
appliance malfunction, resulting in possible severe personal injury, death or substantial property damage.
2.5 Combustion Air and Vent Piping
The PRESTIGE Solo requires a Category IV
venting system, which is designed for pressurized venting and condensate.
The PRESTIGE Solo is certified per ANSI
Z21.13 as a Category IV or Direct Vent (sealed
combustion) appliance. A Category IV appliance utilizes uncontaminated indoor or outdoor
air (surrounding the appliance) for combustion.
A Direct Vent appliance utilizes uncontaminat-
Verify installed combustion air and vent
piping are sealed gas tight and meet all
provided instructions and applicable
codes, failure to comply will result in
severe personal injury of death.
9
2.0 Combustion Air Venting
2.6 Removal of an Existing Boiler
from a Common Vent System
EST PRACTICE
B
When an existing boiler is removed from a
common venting system, the common venting
system is likely to be too large for proper
venting of the remaining appliances. At the
time of removal of an existing boiler, the following steps shall be followed with each
appliance remaining connected to the common venting system placed in operation,
while the other appliances remaining connected to the common venting system are not
in operation.
1. Seal any unused openings in the common
venting system.
2. Visually inspect the venting system for
proper size and horizontal pitch and determine there is no blockage or restriction,
leakage, corrosion and other deficiencies
which could cause an unsafe condition.
5. Test for spillage at the draft hood relief
opening after 5 minutes of main burner
operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.
6. After it has been determined that each
appliance remaining connected to the common venting system properly vents when
tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and
any other gas-burning appliance to their
previous condition of use.
7. Any improper operation of the common
venting system should be corrected so the
installation conforms with the National
Fuel Gas Code, ANSI Z223.1/NFPA 54
and/or CAN/CGA B149, Installation codes.
When resizing any portion of the common
venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part II of the National Fuel
Gas Code ANSI Z223.1/NFPA 54 and/or
CAN/CGA B149, Installation codes.
3. Insofar as is practical, close all building
doors and windows and all doors between
the space in which the appliances remaining connected to the common venting system are located and other spaces of the
building. Turn on clothes dryers and any
appliance not connected to the common
venting system. Turn on any exhaust fans,
such as range hoods and bathroom
exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust
fan. Close fireplace dampers.
4. Place in operation the appliance being
inspected. Follow the lighting instructions.
Adjust thermostat so appliance will operate
continuously.
DANGER
Do not install the PRESTIGE Solo into a
common vent with other gas or oil appliances. This may cause flue gas spillage or
appliance malfunction, resulting in possible severe personal injury, death or substantial property damage.
10
2.0 Combustion Air Venting
2.7 Commonwealth of Massachusetts Installations Only
For direct-vent appliances, mechanicalvent heating appliances or domestic hot
water equipment, where the bottom of the
vent terminal and the air intake is installed
below four feet above grade the following
requirements must be satisfied:
1. If there is not one already present, on
each floor level where there are bedroom(s), a carbon monoxide detector
and alarm shall be placed in the living
area outside the bedroom(s). The carbon monoxide detector shall comply
with NFPA 720 (2005 Edition).
2. A carbon monoxide detector shall also
be located in the room that houses the
appliance or equipment and shall:
a. Be powered by the same electrical cir-
cuit as the appliance or equipment such
that only one service switch services
both the appliance and the carbon
monoxide detector;
b. Have battery back-up power;
c. Meet ANSI/UL 2034 Standards and
comply with NFPA 720 (2005 Edition);
and
d. Have been approved and listed by the
Nationally Recognized Testing
Laboratory as recognized under 527
CMR.
3. A Product-approved vent terminal must
be used, and if applicable, a Productapproved air intake must be used.
Installation shall be in strict compliance
with the manufacturer’s instructions. A
copy of the installation instructions
shall remain with the appliance or
equipment at the completion of the
installation.
4. A metal or plastic identification plate
shall be mounted at the exterior of the
building, four feet directly above the
location of vent terminal. The plate
shall be of sufficient size to be easily
read from a distance of eight feet away,
and read “Gas Vent Directly Below”.
NOTICE
Installer must provide tag identification
plate and ensure the lettering meets code
requirements.
For direct-vent appliances, mechanicalvent heating appliances or domestic hot
water equipment, where the bottom of the
vent terminal and the air intake are installed
above four feet above grade the following
requirements must be satisfied:
1. If there is not one already present, on
each floor level where there are bedroom(s), a carbon monoxide detector
and alarm shall be placed in the living
area outside the bedroom(s). The carbon monoxide detector shall comply
with NFPA 720 (2005 Edition).
2. A carbon monoxide detector shall:
a. Be located in the room that houses the
appliances or equipment;
b. Be either hard wired or battery powered
or both; and
c. Shall comply with NFPA 720 (2005
Edition)
3. A Product-approved vent terminal must
be used, and if applicable, a Productapproved air intake must be used.
Installation shall be in strict compliance
with the manufacturer’s instructions. A
copy of the installation instructions
shall remain with the appliance or
equipment at the completion of the
installation.
11
3.0 Unit Preparations
SECTION III - UNIT
PREPARATIONS
3.1 Handling Instructions
The PRESTIGE Solo is generally easier to
handle and maneuver once removed from the
shipping carton.
To remove the shipping carton:
CAUTION
Use care not to 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 Wall Mounting Installation
The PRESTIGE Solo should be wall mounted
using the bracket provided with the boiler. The
PRESTIGE Solo is not designed for floor
installation. If floor installation is required an
optional floor stand is available through ACVTriangle Tube.
3.3 Wall Mounting Guidelines
1. The wall-mounting bracket is designed for
stud spacing of 12 inch or 16 inch on centers. For unconventional stud spacing, a
solid / secure mounting surface must be
provided for installation of the bracket.
2. For applications using wood studs, install
the bracket using the lag screws provided
with the boiler. Ensure both lag screws are
installed securely in the studs.
3. For applications using metal studs, install
the bracket to the studs using 3/16” toggle
bolts and washers.
4. DO NOT mount or attempt to mount the
wall bracket to hollow sheet rock or lath
walls using anchors. Only install boiler to
studs or equivalent wood structure.
5. For applications using solid walls (rock,
concrete, brick, cinder block, etc.), install
the wall bracket using anchors (double
expansion shields) and bolts with washers
provided with the boiler.
6. The boiler is too heavy and bulky for a single person to lift and attempt to mount; a
minimum of 2 people is required for
mounting the boiler.
NOTICE
NOTICE
The wall used for mounting the PRESTIGE Solo must be vertically plumbed
and capable of supporting a minimum
130 pounds [59 kg] for the PRESTIGE
Solo 80/110, 175 pounds [80 kg] for
PRESTIGE Solo 155/175/250 and 265
pounds [120 Kg] for PRESTIGE Solo
299/399. Failure to comply with these
requirements could result in personal
injury, death or substantial property
damage.
Use extreme care not to drop the boiler
or cause bodily injury while lifting or
mounting the boiler onto the bracket.
Once mounted verify that the boiler is
securely attached to the bracket and
wall. Failure to comply with the above
guidelines could result in property damage, personal injury or death.
12
3.0 Unit Preparations
3.4 Stud Walls - Installation
3.4.1 PRESTIGE Solo 80/110/155/175/250
1. Locate the studs in the general area of the
boiler placement.
2. Place the wall-mounting bracket on the
wall centering the mounting slots with the
stud centers and ensuring the upper edge of
the bracket is away from the wall.
3. Level the bracket, while maintaining it’s
centering with the studs and use a pencil to
mark the location of the mounting slots.
4. Remove the bracket from the wall and drill
1/4” diameter hole by 3” deep positioned in
the center of each mark. For applications
using metal studs and 3/16” toggle bolts,
drill the required clearance hole.
5. Reposition the bracket onto the wall and
align mounting slots/holes. Insert the two
lag screws provided (or toggle bolts for
metal studs) through the mounting
slots/holes and loosely tighten.
6. Level bracket and tighten screws (bolts for
metal studs) securely making sure not to
over-tighten to avoid damaging drywall or
plaster.
3.5 Wall Bracket Installation - Solid Walls
1. Locate the general area of the boiler placement.
2. Place the wall-mounting bracket on the
wall ensuring the upper edge of the bracket
is away from the wall.
3. Level the bracket and use a pencil to mark
the location of the mounting slots on the
wall.
4. Remove the bracket from the wall and drill
a 5/8” diameter hole by 1-3/8” deep positioned in the center of each mark.
5. Install the anchors (provided) flush or
slightly recessed in the drilled holes with
threaded side facing down.
6. Reposition the bracket on the wall and
align mounting slots/holes. Insert the two
bolts (provided) through the mounting
slots/holes and loosely tighten.
7. Level bracket and tighten bolts securely.
3.6 Boiler Mounting
1. Obtain assistance in lifting the boiler onto
the wall bracket.
3.4.2 PRESTIGE Solo 299/399
1. To distribute the weight of the boiler evenly when mounting onto a stud wall it is recommended to use the PRESTIGE Solo
Wall Frame kit.
2. When using the wall frame to mount the
boiler reference the kit installation instructions and ensure the frame is securely fastened to the wall.
3. If the structure of the wall is questionable
in supporting a minimum weight of 265
pounds [120 kg.], it is recommended to use
the optional floor stand.
2. Install the boiler making sure the boiler
mounting lip located along the upper edge
of the rear jacket panel engages the wallmounting bracket. Ensure the boiler is
seated properly and is secure.
13
4.0 Boiler Piping
SECTION IV - BOILER PIPING
4.1 General Piping Requirements
- All plumbing must meet or exceed all local,
state and national plumbing codes.
- Support all piping using hangers. DO NOT
support piping by the unit or its components.
- Use isolation valves to isolate system components.
- Install unions for easy removal of the
PRESTIGE Solo from the system piping.
WARNING
Use a two wrench method when tightening piping onto the boiler connections.
Use one wrench to prevent the boiler
piping from turning / twisting. Failure
to support the boiler piping and connections in this manner could cause damage
to the boiler and its components.
4.2 Pressure Relief Valve
1. The PRESTIGE Solo is supplied with a 30
psi pressure relief valve and must be piped
using the PRV connection as shown in Fig.
5 page 15.
2. To avoid potential water damage to the surrounding area or potential scalding hazard
due to the operation of the relief valve, the
discharge piping:
- Should terminate with a plain end, not
with a threaded end. The material of
the piping should have a serviceable
temperature rating of 250ºF or greater.
- Should not be subject to conditions
where freezing could occur.
- Should not contain any shut-off valves
or obstructions. No shut-off valve
should be piped between the boiler and
relief valve.
WARNING
Failure to comply with the guidelines on
installing the pressure relief valve and
discharge piping can result in personal
injury, death or substantial property
damage.
4.3 Boiler Air Vent
NOTICE
This boiler is supplied with a special
automatic air vent that will provide reliable operation in purging air from the
boiler. The hygroscopic cap supplied
with the automatic air vent MUST
remain tight at all times on the air vent
body. The hygroscopic cap has a membrane which expands upon contact with
water and seals the air vent until the
membrane dries up due to new air forming in the air vent.
- Must be connected to the discharge outlet of the relief valve and directed to a
safe place of disposal.
- Length should be as short and direct as
possible. The size of the discharge line
should not be reduced, maintain the
same size as the outlet of the relief valve.
- Should be directed downward towards
the floor at all times. The piping should
terminate at least 6 inches [153 mm]
above any drain connection to allow
clear visibility of the discharge.
1. Make sure to fully tighten the cap on the air
vent on initial installation.
2. Never loosen the hygroscopic cap to allow
air to escape the air vent. Air will exit with
the cap fully tightened in place.
3. If the hygroscopic cap is not fully tightened, water may leak from the cap. Simply
tighten the cap securely.
14
4.0 Boiler Piping
Fig. 5: Pressure Relief Valve and Boiler Drain Valve Installation
4.4 Low Water Cutoff Device
- The PRESTIGE Solo is equipped with a factory installed pressure sensor type Low Water
Cut Off device.
- The minimum operating system pressure
allowable with this device is 10 psig.
- Check local codes if a Low Water Cutoff
Device is required. If so, determine if this
device meets the requirements of the local
codes.
NOTICE
The PRESTIGE Solo control system also
senses the water temperatures entering
and exiting the heat exchanger to provide protection against low water conditions. Where local codes and jurisdiction do not accept a pressure device for
low water protection, the jurisdictions
may accept these PRESTIGE Solo integral control functions as a means of providing low water protection.
4.5 Additional Limit Control
If a separate LWCO device is required by the
local jurisdiction or when the boiler is installed
above the system piping, the following guidelines must be followed:
- The LWCO device must be designed
for water installations, electrode probetype is recommended.
- The LWCO device must be installed in
a tee connection on the boiler supply
piping above the boiler.
- Wiring of the LWCO device to the PRESTIGE Solo is done directly onto the low
voltage terminal strip, reference Fig. 19
page 31 for available terminals for an
external limit (manual or auto reset).
If the installation is to comply with ASME or
Canadian requirements, an additional high
temperature limit may be needed. Consult
local code requirements to determine compliance. The limit should be installed as follows:
- Install the limit in the boiler supply piping between the boiler and any isolation
valve.
15
4.0 Boiler Piping
- Consult heat exchanger for maximum
set point of limit.
- For wiring of the limit, reference Fig. 19,
page 31, using the external manual reset
terminals on the low voltage terminal
strip. This will provide a "hard" lockout
requiring a manual reset of the control.
4.6 Backflow Preventer
- Use a backflow preventer valve in the
make-up water supply to the unit as
required by local codes.
4.7 Boiler System Piping Applications
BEST PRACTICE
It is recommended on all piping applications to utilize a primary/secondary piping arrangement as a means to provide
freeze protection of the boiler, which is an
integral function of the boiler control.
Maintain the minimum boiler flow rate
shown in Graphs 1 through 6 on pages 94
through 96. For other piping arrangements, contact ACV-Triangle Tube
Technical Support or consult other
approved/recognized design arrangements.
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.
The expansion tank must be located as shown
in Fig. 7 and Fig. 8 on page 18 when using a
primary/secondary piping arrangement or as
per recognized design methods. Refer to the
expansion tank manufacturer instructions for
additional installation details.
Connect the expansion tank to an air separator
only if the air separator is located on the suction side (inlet) of the system circulator.
Always locate and install the system fill connection at the same location as the expansion
tank connection to the system.
4.8.1 Diaphragm Expansion Tank
Always install an automatic air vent on the top
of the air separator to remove residual air from
the system.
BEST PRACTICE
On piping applications utilizing a single
zone or other recognized piping design
arrangements, it is recommended that the
installer uses flow/check valves with
weighted seats at or near the appliance to
prevent gravity circulation.
4.8 Expansion Tank and Makeup Water
Ensure the expansion tank is properly sized for
the boiler volume (3 gallons [12 L] for the
PRESTIGE Solo 80/110, 5 gallons [19 L] for
the PRESTIGE Solo 155/175/250, 7 gallons
[26 L] for PRESTIGE Solo 299/399) and the
system volume and temperature.
4.8.2 Closed-Type Expansion Tank
It is recommended to pitch any horizontal piping
upwards toward the expansion tank 1 inch per 5
feet of piping. Use 3/4” piping for the expansion
tank to allow air within the system to rise.
CAUTION
DO NOT install automatic air vents on a
closed-type expansion tank system. Air
must remain in the system and be
returned to the expansion tank to provide an air cushion. An automatic air
vent would cause air to be vented from
the system resulting in a water-logged
expansion tank.
16
4.0 Boiler Piping
Fig. 6: Piping Component Legend
17
B
oiler
Supply
B
oiler
Return
S
ystem
Supply
Cold
Water
Fill
S
ystem
Return
12"
Max.
Boiler
Supply
Boiler
Return
System
Supply
Cold
Water
Fill
System
Return
12"
Max.
Minimum
¾” Piping
4.0 Boiler Piping
Fig. 7: Near Boiler Piping - Diaphragm Expansion Tank
Fig. 8 : Near Boiler Piping - Closed Type Expansion Tank
Note: Pitch horizontal piping
upwards (1” of pitch per 5 ft
of piping) towards expansion
tank.
18
4.0 Boiler Piping
4.9 Circulator
The PRESTIGE Solo requires an external circulator to provide circulation through the boiler. The
circulator, when wired directly to the PRESTIGE
Solo, will allow for domestic hot water priority
and provide circulation for the freeze protection
feature of the boiler control. See Graphs 1 through
6 on pages 94 through 96 for pressure drop and
minimum flow rate through the boiler.
4.10 Sizing Primary Piping
See Fig. 9 through 13, pages 21 - 23, for recommended piping arrangements based on various applications. Size the piping and system
components required in the space heating system using recognized design methods.
4.11 Domestic Hot Water System Piping
See Fig. 9 through 12 on pages 21-22 for recommended piping to a DHW system. This recommended piping configuration ensures priority is
given to the production and recovery of the DHW.
The piping for the DHW is separate from the
boiler system piping and does not require a primary / secondary piping configuration.
NOTICE
To ensure an adequate flow rate through
the PRESTIGE Solo, the boiler supply and
return piping size must be a minimum of 1
inch for the PRESTIGE Solo 80/110, 1-1/4
inch for the PRESTIGE Solo 155/175/250
and 1-1/2 inch for the PRESTIGE Solo299/
399.
4.13 System Piping - Zone Valves
Connect the PRESTIGE Solo to the system piping as shown in Fig. 10 on page 21 when zoning
with zone valves. The primary / secondary piping
ensures that the boiler loop has sufficient flow.
NOTICE
To ensure an adequate flow rate through
the PRESTIGE Solo, the boiler supply
and return piping size must be a minimum
of 1 inch for the PRESTIGE Solo 80/110,
1-1/4 inch for the PRESTIGE Solo
155/175/250 and 1-1/2 inch for the PRESTIGE Solo 299/399.
4.14 System Piping - Through Boiler
To wire the DHW circulator to the boiler control
module, reference Section VIII - External Wiring.
4.12 System Piping - Zone Circulators
Connect the PRESTIGE Solo to the system
piping as shown in Fig. 9 on page 21 when zoning with zone circulators.
The installer must provide a separate circulator
for each zone of space heating as well as the
boiler circulator.
In applications in which primary/secondary
arrangement is not utilized, the PRESTIGE Solo
allows this flexibility due to a lower boiler pressure drop, see Graphs 1 through 6 on pages 94
through 96.
Figure 11 on page 22 illustrates a multiple zone
valve system with a single system/boiler circulator. A by-pass loop with a pressure differential
valve must be installed on the system piping.
Figure 12 on page 22 illustrates a single zone utilizing the boiler circulator as the system circulator.
4.15 System Piping - Radiant Heating
The heat exchanger design of the PRESTIGE
allows operation in a condensing mode. This
feature requires no regulation of the return tem-
19
4.0 Boiler Piping
perature back to the boiler in radiant heating
applications.
The design and construction of the PRESTIGE
heat exchanger allows the installation of the boiler on systems with non - oxygen barrier tubing.
CAUTION
DO NOT install a SMART tank along
with the PRESTIGE in systems with
non-oxygen barrier tubing. Failure to
comply could result in premature failure
of the SMART tank.
The boiler water supply temperature can be
maintained by the PRESTIGE, eliminating
the need for a mix system to achieve the
desired temperature.
It is recommended for the installer to install a
high temperature limit to ensure that the primary supply temperature does not exceed the
maximum allowable temperature for the radiant tubing.
Size the system piping and circulator to provide the flow needed for the radiant system.
4.16 System Piping - Special Application
If the boiler is used in conjunction with a
chilled water/medium system, the boiler and
chiller must be piped in parallel. Install
flow/check valves to prevent the chilled medium from entering into the boiler.
If the boiler is used to supply hot water to the
heating coils of an air handler where they may
be exposed to chilled air circulation, install
flow/check valves or other automatic means
to prevent gravity circulation of the boiler
water during cooling cycles.
4.17 System Piping - Multiple Units Installation
Use a balanced manifold system as the primary / secondary connection to the space heating
piping as shown in Fig. 13 page 23.
Maintain a minimum of 6 inches [153 mm] of
clearance between units to allow for servicing.
For the space heating piping refer to the applications mentioned in this manual or use recognized design methods.
NOTICE
To ensure an adequate flow rate through
the PRESTIGE Solo, the boiler supply
and return piping size must be a minimum of 1 inch for the PRESTIGE Solo
80/110, 1-1/4 inch for the PRESTIGE Solo
155/175/250 and 1-1/2 inch for the PRESTIGE Solo 299/399.
NOTICE
The addition of the high temperature limit
is important if the PRESTIGE is connected to a domestic hot water system, which
requires a high primary supply water
temperature.
20
4.0 Boiler Piping
smart
P G
P3 P4
CH
D
HW
DHW
Hot
DHW
Cold
smart
P G
Z.V.
Z.V.
DHW
P3
CH
DHW
Hot
DHW
Cold
Note: Reference Fig. 25, page 38 for
Prestige Wiring.
Fig. 9: System Piping - Zoning with Zone Circulators
Note: Reference Fig. 26, page 38 for
Prestige Wiring.
Fig. 10: System Piping - Zoning with Zone Valves
NOTICE
The boiler system piping shown must be a “closed” system to avoid any
oxygen contamination and potential failure of the outer tank of the Smart.
21
4.0 Boiler Piping
smart
P G
Z.V.
Z.V.
DHW
CH
DHW
Hot
DHW
Cold
smart
P G
CH
DHW
DHW
Hot
DHW
Cold
Note: Reference Fig. 27, page 39 for
Prestige Wiring.
Note: Verify CH circulator is
properly sized to overcome the
system pressure drop and provide adequate flow through the
boiler system.
Fig. 11: System Piping - Multiple Zone Valve with Single System/Boiler Circulator
Note: Reference Fig. 28, page 39 for
Prestige Wiring.
Note: Verify CH circulator is properly sized to
overcome the system pressure drop and provide adequate flow through the
boiler system.
Fig. 12: System Piping - Single Zone System with Single System/Boiler Circulator
NOTICE
The boiler system piping shown must be a “closed” system to avoid any
oxygen contamination and potential failure of the outer tank of the Smart.
22
4.0 Boiler Piping
P G
System
Supply
System
Return
12"
Max.
ACVMax Control Supplement
Note: Consult the PRESTIGE
built-in Cascade function
for information on wiring and
configuring the boilers using the
23
Fig. 13: Multiple PRESTIGE Solo Boiler Piping - Primary / Secondary
5.0 Installing Vent/Combustion Air & Condensate Drain
SECTION V - INSTALLING VENT
/ COMBUSTION AIR &
CONDENSATE DRAIN
5.1 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
trap assembly dislocating from the boiler.
The PRESTIGE Solo must be vented and
supplied with combustion air as shown in
the PRESTIGE Solo Vent Supplement,
included in the boiler installation envelope. Refer to optional vent kit instructions for additional vent installation
instructions. Once installation is completed, inspect the vent and combustion air
system thoroughly to ensure systems are
airtight and comply with the instructions
given in the venting supplement and are
within all requirements of applicable
codes. Failure to comply with the installation requirements on the venting and
combustion air piping will cause severe
personal injury or death.
5.2 Installing Condensate Drain Assembly
1. Locate the condensate drain assembly and
ensure the metal washer is installed as
shown in Fig. 14 on page 25.
NOTICE
The installer may want to fill the condensate trap with water prior to assembling on the unit.
WARNING
Ensure the condensate drain assembly
contains the plastic seated ball. Do not
install the condensate drain assembly if
the ball is lost or missing, replace the
entire assembly.
4. Remove the compression nut and rubber
seal from the condensate drain assembly
drain outlet.
5. Using 3/4” x 2’ flexible PVC tube provid-
ed, slide the compression nut and rubber
seal over the pipe
NOTICE
The use of 3/4” PVC or CPVC pipe is
also acceptable. If 3/4” pipe is used
deburr and chamfer pipe to allow mating onto the drain assembly.
6. Thread the rubber seal into the compres-
sion nut to ease installation of the pipe to
the drain assembly.
7. Seat the pipe onto the drain assembly and
tighten the compression nut. Hand tight
only!
2. Install the condensate drain assembly on the
boiler condensate drain by pushing the condensate drain assembly up until it stops.
3. Tighten the condensate drain assembly
retaining nut with rubber seal.
NOTICE
The installer may opt to use 13/16" ID
tubing in lieu of rigid piping.
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