Prestige Solo 110, Solo 80, Solo 250, Solo 299, Solo 399 Installation And Maintenance Manual

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.

24

5.0 Installing Vent/Combustion Air & Condensate Drain

Flexible Tubing

(or 3/4 PVC/
CPVC Piping

to Drain)

Compression

Nut with Rubber Seal

Fill Plug

with Vaccum

Break Port

Condensate

Drain Assembly

Plastic Ball

(Not shown)

Retaining Nut

Metal Washer

erty damage from potential condensate

NOTICE

The drain line materials must be an
approved material by the authority hav­ing jurisdiction. In absence of such
authority, PVC and CPVC piping must
comply with ASTM D1785 or D2845.
The cement and primer used on the pip­ing must comply with ASME D2564 or
F493. For installations in Canada, use
CSA or ULC certified PVC or CPVC
pipe, fittings and cement/primer.

8. Continue the pipe from the drain assembly
to a floor drain or condensate pump.

NOTICE

When selecting and installing a conden­sate pump, ensure the pump is approved
for use with condensing boilers and fur­naces. The pump should be equipped
with an overflow switch to prevent prop-

spillage.

9. The PRESTIGE Solo will typically produce
a condensate that is considered slightly
acidic with a pH content below 3.0. Install
a neutralizing filter if required by authority
having jurisdiction.

CAUTION

The condensate drain must remain filled
and unobstructed and allow unrestricted
flow of condensate. The condensate
should not be subject to conditions
where freezing could occur. If the con­densate is subjected to freezing or
becomes obstructed , it can leak, result­ing in potential water damage to the boil­er and surrounding area.

Fig. 14: Condensate Drain Assembly

25

6.0 Gas Piping

SECTION VI - GAS PIPING

6.1 Gas Supply Piping Connection

NOTICE

The gas supply piping must be installed
in accordance to all applicable local,
state and national codes and utility
requirements.

1. Install a 1/2” NPT for PRESTIGE Solo
80/110, 3/4” NPT for PRESTIGE Solo
155/175/250 or 1” NPT for PRESTIGE
Solo 299/399 pipe union at the factory sup­plied gas nipple, for ease of service.

2. Install a manual shutoff valve in the gas
supply piping as shown in Fig. 15. For
installations in Canada the installer must
tag and identify the main shutoff valve.

3. Install a sediment trap (drip leg) on the gas
supply line prior to connecting to the PRES­TIGE Solo gas train as shown in Fig. 15.

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.

WARNING

Failure to apply pipe dope as detailed
above can result in severe personal
injury, death or substantial property
damage.

WARNING

Use a two-wrench method of tightening
gas piping near the unit and its gas pip­ing connection. Use one wrench to pre­vent the boiler gas line connection from
turning and the second to tighten adja­cent piping. Failure to support the boil­er gas piping connection could damage
the gas line components.

4. Support the gas piping using hangers. Do
not support the piping by the unit or its
components.

5. Purge all air from the gas supply piping.

6. Before placing the PRESTIGE Solo into
operation, check and test all connections
for leaks.

- Close the manual shutoff valve during

any pressure test with less than 13”w.c..

- Disconnect the PRESTIGE Solo and its

gas valve from the gas supply piping
during any pressure test greater than
13”w.c..

WARNING

Do not check for gas leaks with an open
flame. Use a gas detection device or bub­ble test. Failure to check for gas leaks
can cause severe personal injury, death
or substantial property damage.

Fig. 15: Recommended Gas Supply Piping

26

6.0 Gas Piping

6.2 Natural Gas

6.2.1 Pipe Sizing

Refer to Table 1 for schedule 40 metallic pipe
length and diameter requirements for natural
gas, based on rated PRESTIGE Solo input
(divide by 1,000 to obtain cubic feet per hour).

- Table 1 is based on Natural Gas with a spe­cific gravity of 0.60 and a pressure drop
through the gas piping of 0.30”w.c..

- For additional gas piping sizing informa­tion, refer to ANSI Z223.1. For Canadian
installations refer to B149.1 or B149.2.

6.2.2 Supply Pressure Requirements

1. Pressure required at the gas valve inlet
supply pressure port:

- Maximum 13”w.c. at flow or no flow

conditions to the burner.

- Minimum 5”w.c. during flow conditions

to the burner. Must be verified during
start up and with all other gas appliances
operating within the building.

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.

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.

NOTICE

The natural gas orifice requirements are:

PRESTIGE Solo 80: 0.185” (4.7 mm)

PRESTIGE Solo 110: 0.242” (6.15 mm)

PRESTIGE Solo 155: None Required

PRESTIGE Solo 175: None Required

PRESTIGE Solo 250: None Required

PRESTIGE Solo 299: 0.421” (10.7 mm)

PRESTIGE Solo 399: 0.421” (10.7 mm)

Table 1: Gas Piping Sizing - Natural Gas

Length of Pipe in

Feet

SCH 40 1/2" 3/4" 1" 1-1/4" 1-1/2"

10 132 278 520 1050 1600

20 92 190 350 730 1100

30 73 152 285 590 890

40 63 130 245 500 760

50 56 115 215 440 670

75 45 93 175 360 545

100 38 79 150 305 460

150 31 64 120 250 380

Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per

Hour (based on 0.60 specific gravity, 0.30" w.c. pressure drop)

27

6.0 Gas Piping

6.3 Propane Gas

6.3.1 Pipe Sizing - Propane Gas

WARNING

The unit was shipped with a propane
conversion kit which is located on the
top of the unit in the instructions packet.
This kit includes all the necessary parts
and instruction to perform the conver­sion from natural to propane gas. If this
conversion kit is missing, please contact
ACV-Triangle Tube Technical Support
before installing unit for missing kit.

WARNING

Prior to start up, ensure the unit is set to
fire propane. Check the rating label for
the type of fuel. Check the gas valve for
propane conversion label. If there is a
conflict or doubt on the burner set up,
remove the gas valve and check for the
propane orifice, see Fig. 16, 17 or 18 on
page 29. Failure to ensure proper burner
setup could result in severe personal
injury, death or substantial property
damage.

Contact the local propane gas supplier for rec­ommended sizing of piping, tanks and 100%
lockup gas regulator.

2. Pressure required at the gas valve inlet sup­ply pressure port:

- Maximum 13”w.c. at flow or no flow

conditions to the burner

- Minimum 5”w.c. during flow conditions

to the burner. Must be verified during
start up and with all other gas appliances
operating within the building.

WARNING

DO NOT adjust or attempt to measure
gas valve outlet pressure. The gas valve
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.

NOTICE

The propane orifice requirements are:

PRESTIGE Solo 80: 0.142” (3.6 mm)

PRESTIGE Solo 110: 0.185” (4.7 mm)

PRESTIGE Solo 155: 0.205” (5.2 mm)

PRESTIGE Solo 175: 0.236” (6.0 mm)

6.3.2 Propane Gas Supply Pressure Requirements

1. Adjust the propane supply regulator pro­vided by the gas supplier for 13”w.c. max­imum pressure

PRESTIGE Solo 250: 0.268” (6.8 mm)

PRESTIGE Solo 299: 0.339” (8.6 mm)

PRESTIGE Solo 399: 0.339” (8.6 mm)

28

6.0 Gas Piping

Blower Assembly

Gas Valve Collar O-Ring

Orifice

Orifice O-Ring

Gas Valve

Gas Valve Collar

M5x12 Torx Collar Screws (4)

Venturi

Offset Pressure

Cover Screw

Throttle Screw (Not Shown)
Red Plastic Sleeve

Inlet Gas Pressure
Port (Not Shown)

Venturi

O

rifice

(if required)

Throttle

Screw

G

as Valve

Gasket

G

as Valve

O

ffset Pressure

Cover Screw

Inlet Gas

Pressure Port

Venturi O-Ring

V

enturi

G

as Valve

Throttle Screw

O

ffset Pressure

Cover Screw

O-Ring

Orifice

Venturi Clip

Inlet Gas

P

ressure Port

Fig. 16: Gas Valve / Venturi Assembly -

PRESTIGE Solo 80/110

Note: Orifice, orifice o-ring and

gas valve collar o-ring
must be inserted into the
bottom of the Gas Valve
Collar before installing
the collar onto the gas
valve.

Fig. 17: Gas Valve / Venturi Assembly -

PRESTIGE Solo 155/175/250

Fig. 18: Gas Valve / Venturi Assembly - PRESTIGE Solo 299/399

29

7.0 Internal Wiring

Location

of Fuses

SECTION VII - INTERNAL
WIRING

WARNING

ELECTRICAL SHOCK HAZARD. For
your safety, disconnect electrical power
supply to the unit before servicing or
making any electrical connections to
avoid possible electric shock hazard.
Failure to do so can cause severe person­al injury or death.

CAUTION

Prior to servicing, label all wires before
disconnecting. Wiring errors can cause
improper and dangerous operation.
Verify proper wiring and operation after
servicing.

7.1 General Requirements

Fig. 19: ACVMax Control Module Fuse Location

- Wiring must be N.E.C Class 1.

- If original wiring as supplied with the unit
must be replaced, use only Type T 194ºF
[90ºC] wire or equivalent as a minimum.

- The PRESTIGE must be electrically
grounded as required by National
Electrical Code ANSI/NFPA 70 - latest edi­tion and / or the Canadian Electrical Code
Part 1, CSA C22.1, Electrical Code.

7.2 Fuse Locations

The ACVMax control module contains 3 inter­nal replaceable 5A fuses as shown in Figure

19.

The top two fuses protect the PRESTIGE as
well as the CH, DHW, and Flame outputs.

The bottom fuse protects the P3, P4, and Alarm
outputs.

Spare fuses are located on the back of the con­trol module enclosure.

30

7.0 Internal Wiring

6

5

4

3

2

1

X11X13

Y
Y
Y
Y
Y
Y

Y

7YY
8

8

3

7

2

6

1

4

7

14

9

2

8

1

13

2

1

3

9

Y

Y

9YY

10YY

Y

Y

Y

Y

Y

Cascade

Slave

Cascade

Master

A

CV MAX

D

isplay

ACV MAX

Control Board

Flame

P4 Pump

P

3 Pump

DHW Pump

CH Pump

Power Supply

Alarm

6

5

1

2

4

3

1

2

3

4

5

12

11

6

4

3

2

1

2

1

1

2

3

1

2

3

4

5

6

X15

X

10

X12

P14

P13

X16

X1

X3

X2

X5

X6

X4

X7

W
W
W
W
W
W

W

6

5

4

3

2

1

W

W

W

W

W

BK

W

BK

W

BK

W

W

B

K

W

BK

W

BK

R

BK

Prestige Solo Internal Wiring

Wire Legend

- Line Voltage

- Ingnition Cable

Wire Color Legend

BK – Black
W – White
GR – Green
BL – Blue
R – Red
O – Orange
V – Violet
Y – Yellow
BR – Brown
GY – Gray

123

1

21234123456

F00

G

ND

GND

Ignitor

O

n / Off

Switch

Blower

Gas Valve

(Solo 80/110)

CH2

Thermostat

System

Sensor

Modulation

Signal

CH1

Thermostat

Outdoor

Sensor

Modbus

R
W
V

BK

1
2
4
5

Blower

Signal Terminals

Water Pressure

Sensor

BK

V

W

R

- Low Voltage

Flue Temperature Sensor

Return Temperature Sensor

Supply Temperature Sensor

R

R

BL

BL

Y

Y

4

3

2

1

2

1

W

O

O

BR

BR

3

2

1

6

5

4

9

8

7

12

11

10

15

14

13

18

1

7

16

21

2

0

19

GND

GND

G

ND

BK

W

L

G

N

L

G

N

L

G

N

L

G

N

L

G

N

L

G

N

L

G

N

BK

BK

B

K

BK

BK

BK

W

W

W

W

W

W

W

BK

Auto Reset
Limit

Mix
Sensor

Manual Reset
Limit

BR

BR

O

O

BK

BK

BK

BK

1
2
3

6

5

4

3

2

1

7
8
9

10

5

6

X9

W

BK

W

5

Gas Valve

(Solo 155/175/250)

V1
V1

G

V

2

V2

GND

Gas Valve

(Solo 299/399)

1
3

GND

4
3
2
1

1
2

3
2
1

GND

Blower

Power Terminals

W

BK

BK

DHW Sensor

or Aquastat

5

4

2

Fig. 20: Prestige Solo Boiler Factory Wiring

31

8.0 External Wiring

SECTION VIII - EXTERNAL
WIRING

8.1 Installation Compliance

All field wiring made during installation must
comply with:

- 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.

WARNING

ELECTRICAL SHOCK HAZARD.
Before making any electrical connec­tions to the PRESTIGE, disconnect elec­trical power supply at the service panel.
Failure to comply can cause severe per­sonal injury or death.

NOTICE

The line voltage terminals are located on
the right set of terminals 23 through 40.
The low voltage terminals are located on
the left set of terminals 1 through 22.

2. Route the incoming 120 VAC power wire
through the provided openings in the bot­tom jacket panel.

3. The unit is provided with a service switch
located on the front panel, check local code
requirements for compliance.

NOTICE

If local electrical codes or conditions
require an additional service switch, the
installer must provide and install a fused
disconnect or 15 amp (minimum) service
switch.

8.3 Circulator Wiring

1. The circulator connections used will
depend on the systems piping layout.

NOTICE

All circulators are fused with a common 5A
fuse located on the main control board. The
total combined amp draw of the circulators,
alarm, and flame terminals must not exceed
5 amps at any time. Use an isolation relay to
lower the total combined amp draw if
exceeding this limits.

8.2 Line Voltage Connections

1. Connect a dedicated 120 VAC/15A service
to the line voltage terminal on the terminal
block, Fig. 20 on page 31, located internally
in the lower right corner, as shown in Fig.

21.

Figure 21: Terminal Strip Location

2. Connect the CH circulator to the line volt­age terminal on the terminal block, Fig. 20
on page 31, located internally in the lower
right corner, as shown in Fig. 21. This cir­culator is typically used as the
primary/boiler circulator to supply heat to
the central/space heating loop.

3. Connect the DHW circulator to the line
voltage terminal on the terminal block, Fig.
20 on page 31, located internally in the
lower right corner, as shown in Fig. 21. The
DHW circulator is enabled during a DHW
call. This circulator is typically used to
supply heat to an indirect hot water heater.

4. Connect the P3 circulator to the line voltage
terminal on the terminal block, Fig. 20 on
page 31, located internally in the lower right
corner, as shown in Fig. 21. This circulator
is typically used to circulate water in the

32

8.0 External Wiring

Reset Limit

Terminals

Low Voltage
Terminals

secondary CH loop when zoning with zone
valves or as a dedicated circulator to a
space heating zone.

5. Connect the P4 circulator to the line voltage
terminal on the terminal block, Fig. 20 on
page 31, located internally in the lower right
corner, as shown in Fig. 21 on page 32. This
circulator is typically used as a dedicated
circulator to a second space heating zone.

8.4 Alarm Wiring

The alarm contact closes whenever the
Prestige is in a soft or hard lockout. This
dry contact can be connected to an external
monitoring system or other indicator to alert
the operator that the Prestige is locked out.

1. Connect the external monitoring device to
the line voltage terminal on the terminal
block, Fig. 20 on page 31, located internally
in the lower right corner, as shown in Fig. 21
on page 32.

NOTICE

CH and DHW call connections to the
PRESTIGE require a dry contact with no
external voltage present. Ensure no exter­nal voltage is present on each set of wires
before connecting to the PRESTIGE. If
external voltage is present, the use of an
isolation relay is required to prevent dam­age to the ACVMax controller.

NOTICE

The alarm contact is fused with a common
5A fuse located on the main control board.
The total combined amp draw of the circu­lators, alarm, and flame terminals must not
exceed 5 amps at any time. Use an isolation
relay to lower the total combined amp draw
if exceeding this limits.

8.5 Low Voltage Connections

NOTICE

Line and Low Voltage wiring should be
separated to prevent possible electrical
noise on the low voltage circuits. Line
and Low Voltage wiring should use sepa­rate electrical knockouts on the PRES­TIGE cabinet and should remain sepa­rated inside the PRESTIGE.

Figure 22: Low Voltage Connections

8.6 Thermostat Wiring

The ACVMax control has two thermostat call
inputs for multiple zone / temperature systems.
This allows each call to have its own outdoor reset
curve and maximizes the efficiency of the system.

WARNING

Simultaneous CH1 and CH2 calls will
result in the PRESTIGE operating at the
highest target temperature. The use of a
mixing device on the lower temperature
zones such as the ACV-Triangle Tube
Optima Series SMV Control may be
required to protect the lower tempera­ture zones from damage.

1. Connect the room thermostat or dry contact
end switch to the low voltage terminal strip
located on the bottom of the main control
board as shown in Fig. 19 on page 31 & Fig

22.

33

8.0 External Wiring

2. Follow thermostat manufacturer’s instruc­tions for proper installation. Thermostat
should be located on an inside wall away
from any heat or cold influences such as
drafts, lights, fireplaces, etc.

3. Set the thermostat anticipator (If applica­ble) as follows:

- Set for 0.2 amps when wired directly to

the PRESTIGE.

- Set to match the electrical power

requirements of the connected device
when wired to zone relays or other
devices. Refer to the relay manufactur­er’s specifications and the thermostat
instructions for additional information
on anticipator setting.

NOTICE

The use of power stealing thermostats
which draw their power from the PRES­TIGE can lead to erratic or unpre­dictable operation.

8.7 Outdoor Sensor Wiring

8.9 Additional Boiler Limits

Additional boiler limits (High Limit, LWCO,
etc.) can be wired into either the Manual Reset
Limit or Auto Reset Limit terminals of the
PRESTIGE. These limit connections will pro­vide a “hard” lockout requiring a manual reset
of the PRESTIGE or a “soft” lockout in which
the PRESTIGE will automatically reset when
the limit resets.

NOTICE

Manual Reset Limit and Auto Reset
Limit connections to the PRESTIGE
require a dry contact with no external
voltage present. Ensure no external volt­age is present on each set of wires before
connecting to the PRESTIGE. If exter­nal voltage is present, the use of an isola­tion relay is required to prevent damage
to the ACVMax controller.

1. Remove the factory installed jumper wire
on the Manual Reset or Auto Reset termi­nals that will accept the additional boiler
limit.

The Outdoor Reset function and Warm
Weather Shutdown (WWSD) features require
the connection of the included outdoor temper­ature sensor. See page 64 for outdoor sensor
installation and setup.

8.8 Domestic Hot Water Wiring

The Domestic Hot Water terminals can accept
either a call from an aquastat (thermostat) or
temperature sensor. Use of the included indi­rect water heater sensor is recommended.

1. Connect the DHW aquastat or temperature
sensor to the low voltage terminal strip
located on the bottom of the main control
board as shown in Fig. 19 on page 31 &
Fig. 22 on page 33.

2. Connect the additional boiler limit to the
low voltage reset limit terminal strip locat­ed on the bottom right of the main control
board as shown in Fig. 19 on page 31.

8.10 External Modulation Control

The PRESTIGE firing rate can be controlled by
an external modulating boiler controller. See
page 65 for external modulation signal wiring
and setup.

8.11 System Sensor Wiring

An optional system temperature sensor can be
placed on the central heating loop to control the
temperature in the central heating loop instead
of the boiler loop. When connected, the PRES­TIGE will automatically modulate to maintain
the target temperature in the central heating

34

8.0 External Wiring

loop. The boiler supply temperature sensor
will continue to be used as a high temperature
limit.

CAUTION

Locate the system temperature sensor
where it can accurately measure the sup­ply temperature to the heating system.
Inaccurate system temperature readings
could lead to overheating or under heat­ing resulting in property damage.

1. Connect the system temperature sensor to
the low voltage terminal strip on the wiring
panel below the PRESTIGE control mod­ule, as shown in Fig. 19 on page 31 & Fig.
22 on page 33.

8.12 Cascade Wiring

The ACVMax control includes the ability to
operate up to six boilers together as one with­out the need for external controllers. Consult
the PRESTIGE ACVMax Control Supplement
for more information.

8.13 Modbus Wiring

The ACVMax control includes the ability to
communicate with building management sys­tems (BMS) through a Modbus interface.
Consult the PRESTIGE ACVMax Control
Supplement for more information.

35

Factory

Installed

Transformer

Factory

Installed

Transformer

DHW

Low Voltage Connections

CH

L G N L G N L G N L G N L G N L G N L G N

FLAME PUMP 4 PUMP 3

D

HW PUMP

C

H PUMP

POWER SUPPLY

ALARM

Zone 2

Thermostat

Zone 1

Thermostat

Outdoor Sensor

Line Voltage Connections

Reset Limit

Connections

68

Manual Auto

120V/15A

Service

FOUR ZONE ZONE VALVE CONTROL WITH OPTIONAL PRIORITY

1234

Z

ONE 1

1234

Z

ONE 2

1234

Z

ONE 3

1234

Z

ONE 4

ZONE 1

TT

ZONE 2

TT

ZONE 3

TT

ZONE 4

TT

POWER IN

1234

ZONE 4 RELAY

N/O N/CCOM

PUMP

E

NDSW

B

BOILER

E

NDSW

A

MODE

RESET NORMAL

SLAVE

MASTER

POWER

CONTROLS

FUSE 7 AMP MAX

EXPANSION

PLUG-IN

CARDS

ON

OFF

Z

ONE 4

PRIORITY

68

68

Zone 3

Thermostat

Motor

1
2
3
4

End Switch

Zone 1

Zone Valve

Motor

1
2
3
4

End Switch

Zone 2

Zone Valve

Motor

1
2
3
4

End Switch

Zone 3

Zone Valve

C

H2

T

hermostat

S

ystem

Sensor

M

odulation

Signal

CH2

Thermosta

t

C

H1

T

hermostat

O

utdoor

Sensor

DHW

Sensor or

A

quastat

Modbus

DHW Sensor

System

Circulator

8.0 External Wiring

Fig. 23: Multiple Zone Field Wiring Using Zone Valves & Zone Valve Panel

36

DHW

Low Voltage Connections

CH

L G N L G N L G N L G N L G N L G N L G N

FLAME PUMP 4 PUMP 3

D

HW PUMP

CH PUMP

POWER SUPPLY

ALARM

Zone 2

Thermostat

Zone 1

Thermostat

Outdoor Sensor

Line Voltage Connections

Reset Limit

Connections

68

Manual Auto

120V/15A

Service

FOUR ZONE SWITCHING RELAY

W

ITH OPTIONAL PRIORITY

MODE

RESET NORMAL

SLAVE

MASTER

FUSE 1 AMP

ON

OFF

ZONE 4

PRIORITY

68

68

Zone 3

Thermostat

CH2

Thermostat

S

ystem

Sensor

M

odulation

Signal

CH2

Thermosta

t

CH1

Thermostat

O

utdoor

Sensor

DHW

Sensor or

A

quastat

Modbus

DHW Sensor

ZONE4ZONE3ZONE2ZONE1

PLUG IN CARDS

1234

E

XPANSION

INPUT

POWER

120 VOLT CIRCULATORS

ZONE4ZONE3ZONE2ZONE1

ZRZC

X X

END

SWITCH

120 VAC

INPUT

(H & N)

8.0 External Wiring

Fig. 24: Multiple Zone Field Wiring using Zone Circulators & Zone Relay Panel

37

664A0100 - Rev. A

8.0 External Wiring

P4 P3 DHW

Low Voltage Connections

CH

L G N L G N L G N L G N L G N L G N L G N

FLAME PUMP 4 PUMP 3

DHW PUMP

CH PUMP

POWER SUPPLY

ALARM

C

H2

Thermostat

System
S

ensor

Modulation

S

ignal

CH2

T

hermosta

t

C

H1

Thermostat

Outdoor
S

ensor

DHW

S

ensor or

A

quastat

M

odbus

Z

one 2

Thermostat

Z

one 1

Thermostat

Outdoor Sensor

DHW Sensor

Line Voltage Connections

Reset Limit

C

onnections

6

8

6

8

Manual Auto

1

20V/15A
S

ervice

P3 DHW

Low Voltage Connections

CH

L G N L G N L G N L G N L G N L G N L G N

FLAME PUMP 4 PUMP 3

DHW PUMP

CH PUMP

P

OWER SUPPLY

ALARM

CH2

Thermostat

System

Sensor

Modulation

Signal

C

H2

Thermosta

t

CH1

Thermostat

Outdoor

Sensor

D

HW

Sensor or

Aquastat

Modbus

Outdoor Sensor

DHW Sensor

Line Voltage Connections

Reset Limit

Connections

Manual Auto

120V/15A

Service

Zone 1
Zone Valve
End Switch

Zone 2
Zone Valve
End Switch

Note: Reference Fig. 9, page 21 for
System Piping.

Fig. 25: Prestige Wiring - Zoning with Zone Circulators

Note: Reference Fig. 10, page 21 for
System Piping.

Fig. 26: Prestige Wiring - Zoning with Zone Valves

38

8.0 External Wiring

DHW

Low Voltage Connections

CH

L G N L G N L G N L G N L G N L G N L G N

FLAME PUMP 4 PUMP 3

DHW PUMP

CH PUMP

P

OWER SUPPLY

ALARM

CH2

T

hermostat

System

S

ensor

Modulation

S

ignal

CH2

Thermosta

t

CH1

T

hermostat

Outdoor

S

ensor

DHW

Sensor or

A

quastat

Modbus

Outdoor Sensor

DHW Sensor

Line Voltage Connections

Reset Limit

Connections

Manual Auto

120V/15A

Service

Zone 1

Z

one Valve

End Switch

Zone 2
Zone Valve
E

nd Switch

DHW

Low Voltage Connections

CH

L G N L G N L G N L G N L G N L G N L G N

FLAME PUMP 4 PUMP 3

D

HW PUMP

CH PUMP

P

OWER SUPPLY

ALARM

CH2

Thermostat

System

Sensor

Modulation

Signal

C

H2

Thermosta

t

CH1

Thermostat

Outdoor

Sensor

D

HW

Sensor or

Aquastat

Modbus

Outdoor Sensor

DHW Sensor

Line Voltage Connections

Reset Limit

Connections

Manual Auto

120V/15A

Service

Zone

Thermostat

68

Note: Reference Fig. 11, page 22 for
System Piping.

Fig. 27: Prestige Wiring - Multiple Zone Valve with Single System/Boiler Circulator

Note: Reference Fig. 12, page 22 for
System Piping.

Fig. 28: Prestige Wiring - Single Zone System with Single System/Boiler Circulator

39

9.0 ACVMax Operation

DHW Demand

Target = 186°F

SECTION IX - ACVMAX OPERATION

The ACVMax Boiler Management System is designed to be flexible yet easy to use. ACVMax
monitors and controls the Prestige to provide heat as efficiently as possible. ACVMax includes
many advanced features which previously were not available in the Prestige.

• Two central/space heating (CH) call inputs with separate outdoor reset curves.

• Domestic Hot Water (DHW) call input with optional priority.

• EZ Setup feature allows the installer to quickly customize ACVMax for each installation.

• Cascade function allows up to six Prestige boilers to operate together in a single heating system.

• Modbus interface for integrating with building management systems.

All ACVMax features are easy to use through a graphical display where information is presented
either graphically or in plain English, so code charts are not required. Figure 29 shows a
ACVMax display example of the Prestige fired for a domestic hot water demand.

Fig. 29: ACVMax User Interface

40

9.0 ACVMax Operation

9.1 ACVMax Navigation

Navigation is performed through four arrow buttons UP, DOWN, LEFT, RIGHT with a center
OK button for making selections and entering information. The INSTALLER button (the small

round button) provides the installing contractor with full access to all available features after
entering a password. Reference the ACVMax Control Supplement for Installer level functions.

Figure 30 – ACVMax Navigation Buttons

The Main Menu can be entered from the Home Screen by pressing the OK button. The menu
system utilizes icons to represent each selection. The current selected menu is displayed as a
reversed image with a text description shown at the top of the display. Menus can be entered by
highlighting the desired icon and pressing the OK button. The Home Screen icon at the bot­tom of each screen returns to the Home Screen when selected. The Previous Screen icon at
the bottom of each screen returns to the previous screen when selected.

41

9.0 ACVMax Operation

EZ Setup

Home Screen

EZ Setup Menu

CH/DHW Operation Menu Boiler Information Menu

Main Menu

Heating EZ Setup

Heating Enabled

Boiler Information

a

b

c

d

e

f

b

b

b

b

a

b

c

d

e

f

b

b

a

b

c

d

e

a

b

c

d

e

f

b

b

b

b

a

b

c

d

e

f

b

b

a

b

c

d

a

b

c

d

e

f

b

b

b

b

a

b

c

d

e

f

b

b

a

b

c

d

e

a

b

c

d

e

f

b

b

b

b

a

b

c

d

e

f

b

b

f

b

g

a

b

c

d

9.2 ACVMax Menu Structure

42

9.0 ACVMax Operation

CH

P3

P4

Boiler Protection

1

2

The faucet icon indicates that a
domestic hot water call has been
received.

Circulator icons indicate which
circulators are currently powered.

This line provides basic information.
The user can press the LEFT or RIGHT
arrow buttons to view Target, Supply,
Return, Domestic, Outdoor and System
Temperatures.

The radiator icon indicates that a

central heating call has been

received. A small number 1 or 2

indicates which CH calls are

active.

The Prestige is represented in the center of the Home Screen. Basic operating
information such as supply and return temperatures are displayed as well as
current burner status. A flame symbol is displayed when the unit is fired. The
flame size changes to indicate the current firing rate.

The status line displays the current operating state of the Prestige.
See page 44 for a list of all Status Line Messages.

9.3 Home Screen

The Home Screen presents status information in a very user friendly way so that the current
state of the boiler can be quickly accessed.

The screen backlight will illuminate when any button is pressed and remain illuminated for five
minutes. Press the UP or DOWN buttons to turn on the backlight while at the Home Screen
without making any changes.

The screen contrast can be adjusted at the Home Screen by pressing and holding the OK but­ton then pressing and holding the LEFT arrow along with the OK button. The contrast can
then be increased by pressing the UP button or decreased by pressing the DOWN button while
holding in the OK button and LEFT arrow. All buttons must be released and the procedure
performed again to switch between increasing and decreasing contrast.

43

9.0 ACVMax Operation

9.4 Status Line Messages

Status Line Message Description

Standby Indicates that the Prestige is ready to respond when a demand is received.

CH Demand A central heating call has been received.

DHW Demand A domestic hot water call has been received.

CH / DHW Demand

DHW Priority

Priority Timeout

External Demand An external modulation call has been received.

Central heating and domestic hot water calls are being received simultane­ously. Both calls are being satisfied simultaneously because domestic hot
water priority has been disabled.

Central heating and domestic hot water calls are being received simultane­ously. Domestic hot water call is being satisfied first because it has priority
over central heating calls.

Central heating and domestic hot water calls are being received simultane­ously. The domestic hot water priority time limit has been exceeded.
Priority will now switch back and forth between central heating and domes­tic hot water calls until one call is satisfied.

Slave Operation The Prestige is a slave in a cascade system.

Manual Operation The burner or circulators have manually been enabled in the Installer Menu.

CH Burner Delay The burner will not fire until the call blocking time has elapsed.

DHW Burner Delay The burner will not fire until the call blocking time has elapsed.

The burner is not fired because the supply/system water temperature

CH Setpoint Reached

DHW Setpoint Reached

CH Post Pump

DHW Post Pump

Freeze Protection

Boiler Protection

exceeds the setpoint. The central heating circulator continues to operate
and the burner will fire again once the supply/system water temperature
drops below the setpoint.

The burner is not fired because the supply/system water temperature
exceeds the setpoint. The domestic circulator continues to operate and the
burner will fire again once the supply/system water temperature drops
below the setpoint.

The central heating circulator is running to remove heat from the Prestige at
the completion of a call.

The domestic hot water circulator is running to remove heat from the
Prestige at the completion of a call.

The burner is fired because the freeze protection feature has been activated.
Freeze protection will end once the supply/system water temperature is
raised to 60ºF [16ºC].

The burner firing rate is being reduced because of an excessive difference
between the boiler supply and return temperatures. The firing rate will
begin increasing once the temperature difference is less than 45ºF [25ºC].

Lockout Description The lockout which currently has the Prestige shut down is displayed.

44

9.0 ACVMax Operation

Press OK Button

The EZ Setup menu can
be accessed by selecting
this icon.

The CH / DHW Operation
Menu can be accessed by
selecting this icon.

Currently selected menu

The Boiler Information
Menu can be accessed
by selecting this icon.

The Home Screen icon at
the bottom of each screen
returns to the Home Screen
when selected.

The Previous Screen icon at the
bottom of each screen returns to
the previous screen when selected.

9.5 Main Menu

The Main Menu can be entered from the Home Screen by pressing the OK button. The menu
system utilizes icons to represent each selection. The currently selected menu is displayed
as an inversed image with a text description shown at the top of the display. Menus can be
entered by highlighting the desired icon and pressing the OK button.

45

9.0 ACVMax Operation

Select CH Demand

Thermostat & Setpoint

Constant & Setpoint

0

-10V Modulation Signal

Select CH Demand

Thermostat & Outd. Curve

Constant & Outdoor Curve

C

onstant & Setpoint

0-10V Modulation Signal

OR

60ºF

188ºF

180ºF

CH1 Setpoint

9.6 EZ Setup

Navigation: Home Screen>Main Menu>EZ Setup

The EZ Setup menus provide a simple way to quickly customize the
TriMax for each installation. EZ Setup prompts the user to make selections
which allows the Prestige to be setup very quickly without searching
through long lists of settings and manually making adjustments.

9.7 Heating EZ Setup

Navigation: Home Screen>Main Menu>EZ Setup>Heating EZ Setup

Heating EZ Setup allows the installer to quickly customize the central heat­ing settings for the application.

9.7.1 Select CH Demand Default: Switch & Outdoor Reset

Select CH Demand prompts the installer to select how a CH Demand is gen­erated. Press the UP or DOWN buttons to select the CH Demand type then
press the OK button to store the setting. The Select CH Demand options are:

• Thermostat & Outd. Curve – This option is only displayed when the

outdoor temperature sensor is connected. A central heating call from a
thermostat or zone panel will enable the Prestige and the setpoint will
vary with the outdoor temperature for central heating calls.

• Thermostat & Setpoint - This option is only displayed when the out-

door temperature sensor is not connected. A central heating call from
a thermostat or zone panel will enable the Prestige and the setpoint will
be fixed for central heating calls

• Constant & Outdoor Curve - This option is only displayed when the

outdoor temperature sensor is connected. The Prestige will maintain set­point without an external call from a thermostat or zone panel. The set­point will vary with the outdoor temperature for central heating calls.

• Constant & Setpoint - The Prestige will maintain setpoint without an

external call from a thermostat or zone panel. The setpoint will be fixed
for central heating calls.

• 0-10V Modulation Signal – This option allows the Prestige firing rate

to be controlled by an external control system.

9.7.2 CH1 Setpoint Default: 180°F [82°C]

CH1 Setpoint prompts the installer to enter the fixed setpoint for a CH1
heating call when a Setpoint option is chosen in Select CH Demand. Press
the LEFT or RIGHT buttons to adjust the CH1 Setpoint then press the

OK button to store the setting.

9.7.3 CH2 Setpoint Default: 140°F [60°C]

CH2 Setpoint prompts the installer to enter the fixed setpoint for a CH2
heating call when a Setpoint option is chosen in Select CH Demand. Press
the LEFT or RIGHT buttons to adjust the CH2 Setpoint then press the
OK button to store the setting.

46

9.0 ACVMax Operation

180ºF

120ºF

64ºF

0ºF

Current Settings

Select CH1 Outd. Curve

O 78ºF

O

Warm Weather Shutdown

EZ Setup Complete

Heating EZ setup is complete.

Additional changes can be made in

the Installer Menu if required.

Press OK to return to EZ Setup Menu

9.7.4 Select CH1 Reset Curve Default: Finned Tube Baseboard

Select CH1 Reset Curve prompts the installer to select an outdoor reset curve
for a CH1 heating call when an Outdoor Reset option is chosen in Select CH
Demand. Outdoor reset curve presets are available to cover most applica­tions. The outdoor reset curve can also be adjusted to any desired settings in
the Installer Menu. Press the UP or DOWN buttons to select the outdoor
reset curve appropriate for the type of heating system then press the OK but­ton to store the setting.

9.7.5 Select CH2 Reset Curve Default: Low Mass Radiant

Select CH2 Reset Curve prompts the installer to select an outdoor reset curve
for a CH2 heating call when an Outdoor Reset option is chosen in Select CH
Demand. Outdoor reset curve presets are available to cover most applica­tions. The outdoor reset curve can also be adjusted to any desired settings in
the Installer Menu. Press the UP or DOWN buttons to select the outdoor
reset curve appropriate for the type of heating system then press the OK but­ton to store the setting.

Table 3: Outdoor Reset Preset Selections

Preset Minimum Setpoint Maximum Setpoint

Low Mass Radiant 80ºF [27ºC] 140ºF [60ºC]

High Mass Radiant 80ºF [27ºC] 120ºF [49ºC]

Cast Iron Baseboard 100ºF [38ºC] 170ºF [77ºC]

Finned Tube Baseboard 120ºF [49ºC] 180ºF [82ºC]

Radiators 120ºF [49ºC] 170ºF [77ºC]

Fan Coil 140ºF [60ºC] 180ºF [82ºC]

9.7.6 Set Warm Weather Shutdown Temperature Default: OFF

Warm Weather Shutdown prompts the installer to enter an optional outdoor
temperature at which to disable the central heating function and any circu­lators placed into constant circulation with the Pump Constant Circulation
setting. The Prestige will continue to respond to a domestic hot water call
or a 0-10V Modulation Signal when the outdoor temperature exceeds the
Warm Weather Shutdown Temperature setting. Press the LEFT or
RIGHT buttons to adjust the Warm Weather Shutdown Temperature then
press the OK button to store the setting. The Warm Weather Shutdown
icon is displayed on the home screen when the outdoor temperature
reaches the Warm Weather Shutdown Temperature.

9.7.7 CH EZ Setup Complete

EZ Setup Complete informs the installer upon completion of all necessary
steps that the EZ setup is complete. Press the OK button to return to the
EZ Setup Menu.

47

9.0 ACVMax Operation

S

elect DHW Demand

Thermostat

S

ensor

96ºF

188ºF

186ºF

Boiler

DHW Setpoint

68ºF

150ºF

140ºF

DHW

Storage Setpoint

9.8 Domestic Hot Water EZ Setup

Navigation: Home Screen>Main Menu>EZ Setup>DHW EZ Setup

Domestic Hot Water EZ Setup allows the installer to quickly customize the
domestic hot water settings for the application.

9.8.1 Select DHW Demand Default: Switch

Select DHW Demand prompts the installer to select the type of device which
will generate a DHW call. Press the UP or DOWN buttons to select the
DHW Demand type then press the OK button to store the setting. The Select
DHW Demand options are:

• Thermostat – A domestic hot water call from an aquastat or dry con-

tact switch will enable the Prestige with a fixed setpoint for a domestic
hot water call.

• Sensor – This option requires the use of Indirect Water Heater Sensor

PSRKIT22. The Prestige will monitor the DHW storage temperature
and generate a domestic hot water call when the temperature drops
below the DHW Storage Setpoint by 6ºF [3ºC].

9.8.2 Boiler DHW Setpoint Default: 186°F [86°C]

Boiler DHW Setpoint prompts the installer to enter the fixed boiler setpoint
temperature during a Domestic hot water call when the Switch option is cho­sen in Select DHW Demand. Press the LEFT or RIGHT buttons to adjust
the Boiler DHW Setpoint then press the OK button to store the setting.

9.8.3 DHW Storage Setpoint Default: 140°F [60°C]

DHW Storage Setpoint prompts the installer to enter the domestic hot water
storage setpoint temperature when the Sensor option is chosen in Select
DHW Demand. Press the LEFT or RIGHT buttons to adjust the DHW
Storage Setpoint then press the OK button to store the setting.

NOTICE

The Boiler DHW Setpoint will automatically be set 46°F [25°C]
higher than the DHW Storage Setpoint setting.

48

9.0 ACVMax Operation

O

120 min.

O

DHW Priority Timeout

EZ Setup Reset

Press OK

to restore factory settings,

any other button

to keep current settings.

Select Language

English

Français

Nederlands

EZ Setup Complete

Heating EZ setup is complete.

Additional changes can be made in

the Installer Menu if required.

Press OK to return to EZ Setup Menu

Select Unit

Fahrenheit

Celsius

9.8.4 DHW Priority Timeout Default: Off

DHW Priority Timeout prompts the installer to enter an optional time limit
that a domestic hot water call has priority over a central heating call. Press
the LEFT or RIGHT buttons to adjust the DHW Priority Timeout then press
the OK button to store the setting.

9.7.7 CH EZ Setup Complete

EZ Setup Complete informs the installer upon completion of all necessary
steps that the EZ setup is complete. Press the OK button to return to the
EZ Setup Menu.

9.9 EZ Setup Reset

Navigation: Home Screen>Main Menu>EZ Setup>EZ Setup Reset

EZ Setup Reset allows the installer to reset all EZ Setup settings back to
the original factory defaults. Follow the onscreen instructions to reset all
EZ Setup settings back to the original factory defaults.

9.10 Display EZ Setup

Navigation: Home Screen>Main Menu>EZ Setup>Display EZ Setup

Display EZ Setup allows the installer to select the language used for all
text as well as the type of temperature units displayed. Press the UP or
DOWN buttons to select then press the OK button to store the setting.

49

9.0 ACVMax Operation

H

eating Enabled

Boiler Information

Boiler Status

H

eating Call

DHW Call

B

oiler Firing Rate

Ionization Current

Boiler Setpoint

Standby

No

No

__

µA

__

194

68

-24.00

-16.00 -8.00

0.00

Boiler Setpoint

9.11 CH/DHW Operation

Navigation: Home Screen>Main Menu>CH / DHW Operation

CH / DHW Operation provides a simple way to disable either the central
heating or domestic hot water functions of the Prestige. Operation can be
enabled and disabled by selecting the central heating or domestic hot water
icon then pressing the OK button to toggle between enabled and disabled.
An icon with an X through it indicates that function has been disabled. The
disabled icon is also displayed on the home screen when a function has
been disabled.

9.12 Boiler Information

Navigation: Home Screen>Main Menu>Boiler Information>Boiler
Information

Boiler Information provides real time operating information of the
Prestige. Each line contains an information item followed by its current
value. Six information items are displayed on the screen at one time. Press
the UP or DOWN buttons to scroll through additional information items.
See page 51 for a list of all information items.

9.12.1 Boiler Information Logging

Some information items include a logging function which records one sam­ple every 12 minutes to produce a graph of the last 24 hours. Select the infor­mation item in Boiler Information then press the OK button to view its
graph. The following items have a logging function:

• Boiler Firing Rate

• Ionization Current

• Boiler Setpoint

• Boiler Supply Temperature

• Boiler Return Temperature

• Boiler Flue Temperature

• Outdoor Temperature

• DHW Storage Temperature

• External Modulation Signal

• Pressure

50

9.0 ACVMax Operation

9.12.2 Information Items

Information Item Description

Boiler Status

Heating Call

DHW Call

Boiler Firing Rate

Ionization Current

Boiler Setpoint

Supply Temp.

Return Temp.

Boiler Flue Temp.

Outdoor Temp.

DHW Storage Temp.

External Modulation Signal

Displays the current operating state of the Prestige. This is the same as
the status line on the home screen.

Displays if a central heating call is present.

Displays if a domestic hot water call is present.

Displays the current firing rate of the Prestige.

Displays the current flame ionization current from the ignitor.

Displays the current setpoint of the Prestige.

Displays the current supply temperature of the Prestige.

Displays the current return temperature to the Prestige.

Displays the current flue temperature of the Prestige.

Displays the current outdoor temperature.

Displays the current DHW storage temperature when Indirect Water
Heater Sensor PSRKIT22 is installed.

Displays the current external modulation signal being received from an
external controller.

Pressure

CH Ignitions

CH Runtime

DHW Ignitions

DHW Runtime

Mix Zone Temperature

Displays the current system pressure.

Displays the number of central heating ignitions since the unit was
installed. This counter increases in increments of twenty.

Displays the number of hours the Prestige has run for a central heating
call since the unit was installed.

Displays the number of domestic hot water ignitions since the unit was
installed. This counter increases in increments of twenty.

Displays the number of hours the Prestige has run for a domestic hot
water call since the unit was installed.

Displays the temperature of the low temperature mixed circuit.

51

9.0 ACVMax Operation

Lockout History

1: Low water

2

: No error

3: No error

4: No error

5: No error

6: No error

5h ago

25h ago

25h ago

2

5h ago

25h ago

25h ago

Lockout Details

Low Water

Boiler Status

Heating Call

Domestic Call

Boiler Firing Rate

Ionization Current

Standby

No

No

-

-%

-µA

a

b

c

d

e

f

b

b

b

b

a

b

c

d

e

f

b

b

a

b

c

d

e

a

b

c

d

e

f

b

b

b

b

a

b

c

d

e

f

b

b

a

b

c

d

a

b

c

d

e

f

b

b

b

b

a

b

c

d

e

f

b

b

a

b

c

d

e

a

b

c

d

e

f

b

b

b

b

a

b

c

d

e

f

b

b

f

b

g

a

b

c

d

9.13 Lockout History

Navigation: Home Screen>Main Menu>Boiler Information>Lockout
History

Lockout History records the last eight lockouts. Each line contains a lock­out description followed by how long ago the lockout occurred. Six lock­outs are displayed on the screen at one time. Press the UP or DOWN but­tons to scroll through additional lockouts. See pages 54 & 55 for a list of
lockouts and descriptions.

9.13.1 Lockout Details

Some information items are recorded at the time of a lockout to aid in diag­nosing the cause of the lockout. Select the lockout description in Lockout
History then press the OK button to view the recorded information. Press the
UP or DOWN buttons to scroll through the recorded information. The fol­lowing information items are recorded at the time of a lockout:

• Boiler Status

• Heating Call

• Domestic Call

• Boiler Firing Rate

• Flame Ionization Current

• Boiler Setpoint

• Boiler Supply Temperature

• Boiler Return Temperature

• Boiler Flue Temperature

• Outdoor Temperature

• System Temperature

52

9.0 ACVMax Operation

Press any ARROW Button

The status line now displays the lockout

The lockout message is displayed at the top of the screen

The lower right corner displays
the lockout reference code.

The first sentence describes the
lockout, the second sentence
gives a possible cure and the
third sentence tells how to reset
the lockout.

Press any ARROW button
to return to the Home Screen while
locked out.The main menu can then
be entered from the Home Screen to
help diagnose the problem. Select
the Home Screen icon at the bottom
of any menu screen to return to the
Lockout Screen.

Water level has fallen below

0.5bar. Increase pressure
to normal range.

Low Water

If problem persists, call for service

E37

--

9.13.2 Lockout Screen

The Lockout Screen replaces the Home Screen if a lockout occurs. The screen backlight will
also illuminate constantly while the Prestige is locked out. Pressing any arrow button will
return to the Home Screen so that additional troubleshooting can be performed. See pages 54
and 55 for a list of lockouts and descriptions.

53

9.0 ACVMax Operation

Manual Reset Hard Lockouts

Code Lockout Message Description

E1 Failed Ignition The burner failed to light after 5 ignition attempts.

E2 False Flame A flame is being detected prior to ignition.

E3 High Boiler Temperature Boiler temperature has reached 210°F [99ºC]

E5 Blower Speed

E8 Flame Circuit Error Flame circuit test failed.

E9 Gas Valve Circuit Error Gas valve circuit test failed.

E13 Reset Limit Reached Resets are limited to 5 every 15 minutes.

E15 Sensor Drift Supply or return sensor reading has drifted.

E16 Supply Sensor Stuck Supply sensor reading is not changing.

E17 Return Sensor Stuck Return sensor reading is not changing.

E18 Sensor Failure Supply or return sensor reading changed very rapidly.

E21 Internal Control Fault A / D conversion error.

E30 Supply Sensor Shorted

Blower is not at correct speed or speed signal is not being received
by control module.

A short circuit has been detected in the boiler supply temperature
sensor circuit.

E31 Supply Sensor Open

E43 Return Sensor Shorted

E44 Return Sensor Open

E47 Water Pressure Sensor Error Water pressure sensor is disconnected or broken.

E80 Return > Supply Return temperature is higher than supply temperature.

E87 External Limit Open An external manual reset limit has opened

An open circuit has been detected in the boiler supply temperature
sensor circuit.

A short circuit has been detected in the boiler return temperature
sensor circuit.

An open circuit has been detected in the boiler return temperature
sensor circuit.

54

9.0 ACVMax Operation

Automatic Reset Soft Lockouts

Code Lockout Message Description

E7 High Flue Temperature Flue temperature exceeds high limit.

E12 Internal Control Fault EEPROM misconfiguration

E25 Internal Control Fault CRC check error.

E32 DHW Sensor Shorted A short circuit has been detected in the DHW temperature sensor circuit.

E33 DHW Sensor Open An open circuit has been detected in the DHW temperature sensor circuit.

E34 Low Voltage Line voltage has fallen below an acceptable operating level.

E37 Low Water Water level has fallen below an acceptable operating level.

E45 Flue Sensor Shorted

E46 Flue Sensor Open

E76 External Limit Open An external automatic reset boiler limit has opened.

E81 Sensor Drift Supply and return temperatures are not equal.

E89 Incorrect Setting A parameter setting is in conflict with another setting.

E90 Firmware Mismatch Control module and display firmware versions are incompatible.

E91 System Sensor Shorted A short circuit has been detected in the system temperature sensor circuit.

E92 System Sensor Open An open circuit has been detected in the system temperature sensor circuit.

E93 Outdoor Sensor Shorted A short circuit has been detected in the outdoor temperature sensor circuit.

E94 Internal Display Fault Display memory error.

E95 Supply Sensor Error Supply sensor reading is invalid.

E96 Outdoor Sensor Open

A short circuit has been detected in the boiler flue temperature sensor
circuit.

An open circuit has been detected in the boiler flue temperature sensor
circuit.

An open circuit has been detected in the outdoor temperature sensor
circuit.

E97 Cascade Mismatch Cascade configuration has changed.

E98 Cascade Bus Error Communication with other boilers has been lost.

E99 Controller Bus Error

Communication between boiler display and control module has been
lost.

55

10.0 Start-Up Preparation

SECTION X - START-UP
PREPARATION

NOTICE

Requirements below must be met for
warranty coverage of Prestige heat
exchangers. A thorough cleaning of any
existing system, using approved heating
system cleaning agents is required prior
to installation of the Prestige boiler.
System should be treated with an
approved inhibitor after filling for long
term protection.

10.1 Boiler System Fluid Requirements

WARNING

Do not use petroleum-based cleaning or
sealing compounds in the boiler system.
Damage to seals and gaskets in the sys­tem components could occur, resulting in
substantial property damage.

NOTICE

10.1.3 Chlorinated Water

Do not use the PRESTIGE Solo to heat a
swimming pool or spa directly.

Maintain the chlorine level of the water at lev­els considered safe for drinking.

10.1.4 Flush Boiler to Remove Sediment

The installer must flush the boiler system to
remove any sediment to allow proper operation
of the PRESTIGE Solo .

Flush the systems until the water runs clean
and is free of sediment.

For zoned systems, each zone should be
flushed through a purge valve. Purge valves
and isolation valves should be installed on each
zone to allow proper flushing of the system.

10.1.5 Cleaning of Old Boiler/System:

• Drain the existing system.

• Fill system with fresh water and cleaner,
place existing boiler in operation and run
all zones.

System fluid including additives must be
practically non-toxic, having a toxicity
rating or Class of 1, as listed in Clinical
Toxicology of Commercial Products.

10.1.1 Boiler Fluid pH Level 6.0 to 8.0

Maintain the boiler fluid pH between 6.0 and

8.0. Check using litmus paper or contact a water
treatment company for a chemical analysis.

If the pH does not meet this requirement, do
not operate the PRESTIGE Solo or leave the
unit filled until the condition is corrected.

10.1.2 Boiler Fluid Hardness Less Than 7 Grains

For areas with unusually hard water (hardness
above 7 grains) consult a water treatment
company.

• Follow manufacturer’s instructions for
proper cleaner concentration and proper
cleaning time.

• Thoroughly drain and flush system with
fresh water after cleaning.

• Install new boiler, fill system with fresh
water and proper amount of inhibitor.

• Verify pH and inhibitor level per inhibitor
manufacturer’s specs; add inhibitor if
necessary.

10.1.6 Cleaning of New Boiler/System:

• Install new boiler and flush system with
cleaner water to remove any debris.

• Fill system with fresh water and proper
amount of inhibitor.

• Verify pH and inhibitor level per inhibitor
manufacturer’s specs; add inhibitor if
necessary.

56

10.0 Start-Up Preparation

10.1.7 Check and Test Antifreeze

For boiler systems containing antifreeze solu­tions, follow the antifreeze manufacturer’s
instructions in verifying the inhibitor level and
to ensure the fluid characteristics are within
specification requirements.

Due to the degradation of inhibitors over time,
antifreeze fluids must be periodically replaced.
Refer to the manufacturer of the antifreeze for
additional instructions.

10.1.8 Use of Antifreeze in the Boiler System

WARNING

NEVER use automotive or ethylene glycol
antifreeze or undiluted antifreeze in the
primary system as freeze protection. This
can cause severe personal injury, death or
substantial property damage if ignored.

Determine the antifreeze fluid quantity using
the system water content volume and following
the antifreeze manufacturer instructions.

The water volume of the PRESTIGE Solo is
approximately 3 gallons [12 L] for PRESTIGE
Solo 80/110 or 5 gallons [19 L] for PRESTIGE
Solo 155/175/250 or 7 gallons [26 L] for PRES­TIGE Solo 299/399 . Remember to include the
volume of the expansion tank.

Check with local codes requirements for the
installation of backflow preventers or actual
disconnection from the boiler’s cold water fill
or make up water supply line.

NOTICE

Massachusetts Code requires the instal­lation of a backflow preventer if
antifreeze is used.

NOTICE

System fluid including additives, must be
practically non-toxic, having a toxicity
rating or Class of 1, as listed in Clinical
Toxicology of Commercial Products.

10.2 Filling the Boiler System

1. Close the boiler drain valve located on the
bottom of the unit and any manual or auto­matic air vent in the system.

2. Open all system isolation valves.

3. Fill the boiler system to correct system
pressure. Correct pressure will vary with
each application.

NOTICE

Typical residential system fill pressure is
12 psi. System pressure will increase
when system temperature increases.
Operating pressure of the system should
never exceed 25 psi.

4. Purge air and sediment in each zone of the
boiler system through the purge valve.
Open air vents to allow air to be purged in
the zones.

5. Once the system is completely filled and
purged of all air and sediment, check the
system pressure and check/repair any leaks.

WARNING

Unrepaired system leaks will cause con­tinual makeup water to be added to the
boiler. Continual makeup water will
cause mineral buildup within the heat
exchanger, reducing the heat transfer,
causing possible heat buildup and even­tual heat exchanger failure.

Ensure the concentration of antifreeze to water
does not exceed a 50/50 ratio.

57

10.0 Start-Up Preparation

10.3 Check Low Water Cut-Off Device

- The PRESTIGE Solo is provided with a
factory installed LWCO device that moni­tors system pressure.

- Access the Boiler Information Menu by fol­lowing instructions in Section 9.12 on page

50. Scroll down to see the current system
pressure displayed and verify it is within the
recommended numbers given in Section 10.2
on page 57.

10.4 Check For Gas Leaks

WARNING

Prior to start-up and during initial opera­tion, smell near the floor and around the
unit for gas odorant or any unusual odor.
Do not proceed with the start-up if there
is any indication of a gas leak. Any leaks
found must be repaired immediately.

- If voltage is measured at the panel under any
condition, check and correct the external wiring.

NOTICE

In systems using 3-wire zone valves, back­feed of voltage to the unit is a common
problem. Use an isolation relay to prevent
voltage from the external circuit entering
the PRESTIGE Solo control panel.

- Reconnect the external thermostat wires to
the low voltage terminal strip.

10.6 Inspection of Condensate Drain

Assembly

1. Inspect and ensure the Condensate Drain
Assembly is properly installed as described
on page 24 and shown in Fig. 14 on page 25.

2. Remove the plug from the Condensate
Drain Assembly and fill with fresh water.

WARNING

Propane installations only - The propane
supplier mixes an odorant with the
propane to make its presence detectable.
In some cases the odorant can fade and
the gas may no longer have an odor.

Prior to start-up of the unit and periodi­cally after start-up have the propane sup­plier check and verify the odorant level.

10.5 Check Thermostat Circuit

- Disconnect the external thermostat wires
from the low voltage terminal strip.

- Connect a voltmeter across the wire ends of
the external thermostat wiring.

- Close each thermostat, zone valve and
relay in the external circuit one zone at a
time and check the voltage reading across
the wire ends.

- There should NEVER be voltage measured
at the wire ends.

NOTICE

The condensate drain assembly must be
filled with water when the PRESTIGE
Solo is in operation. The condensate
drain assembly prevents flue gas emis­sions from entering the condensate line.
Failure to ensure trap is filled with water
could result in severe personal injury or
death.

3. Re-Install plug in condensate drain assem­bly.

58

11.0 Start-Up Procedures

SECTION XI - START-UP
PROCEDURES

11.1 Final Checks Before Start-Up

c Read page 40 through 55 regarding the

operation of the ACVMax Boiler
Management System.

c Verify the PRESTIGE Solo and the boiler

system are full of water and all system
components are correctly set for operation,
including the minimum flow rate through
the boiler, see pages 93 through 95.

c Verify Start-up Preparation items outlined on

pages 56 thru 58 have been completed.

c Verify all electrical connections are correct

and securely fastened.

c Inspect vent and combustion air piping for

signs of deterioration from corrosion, physical
damage or sagging. Verify combustion air
and vent piping are intact and correctly
installed and supported. Reference the PRES­TIGE Solo vent supplement.

c Verify burner configuration - Propane only.

- Check for proper labeling on the gas
valve and the rating label for propane
configuration.

- If there is doubt on the burner configura­tion, remove the gas valve and check for
proper propane gas orifice size. Refer to
Section 6.2.3 on page 28 for orifice sizes.
Refer to Figs. 16, 17, & 18 on page 29 for
location of the propane gas orifice.

11.2 PRESTIGE Solo Start-Up

1. Press the ON-OFF button located on the
front control panel to the OFF position. Turn
ON the electrical supply/service to the unit.

2. Read and follow the Operating Instructions
outlined on page 63.

If PRESTIGE Solo Does Not Start Correctly

1. Check for loose electrical connections,
blown fuses, (on control module and in ter­minals) or an open service switch.

2. Verify CH and DHW operation is enabled.
A radiator or faucet icon with an X through
it indicates that function is disabled.

3. Check the system pressure in the Boiler
Information Menu by following the
instructions in Section 9.12 on page 50.

4. Is an external limit control (if applicable)
open? Ensure the external limit is reset to
the closed position.

5. Are the gas supply valves open at the unit
and meter?

6. Is incoming gas supply pressure at the unit
more than 5”w.c. and less than 13” w.c. for
natural or propane with all gas appliances
ON or OFF.

7. Are the heating thermostats set above room
temperature?

If none of these conditions correct the problem,
refer to the PRESTIGE Solo Trouble-Shooting
Guide or contact ACV-Triangle Tube Technical
Support.

NOTICE

For natural gas applications the Prestige
80 requires an orifice: 0.185” (4.7mm), the
Prestige 110 requires an orifice: 0.424”
(6.15mm), and the Prestige 299 & 399
require an orifice: 0.421” (10.7 mm)

c Ensure the vent Condensate Drain

Assembly is filled with water.

11.3 Check the PRESTIGE Solo and

System

c Check Boiler Piping.

Check Boiler system piping and com­ponents for leaks. If found, shut down
the unit and repair immediately.

Purge any remaining air from the system
piping. Air in the system piping will
interfere with circulation creating heat
distribution problems and system noise.

59

11.0 Start-Up Procedures

Manual Operation

Released

O

O

O

CH1

FAN

DHW

CH2

c Check Vent Piping and Combustion Air

Piping.

Check for gas-tight seal at every con­nection and seam of the venting and
combustion air piping.

WARNING

Venting system must be sealed gas-tight
to prevent flue gas spillage and potential
carbon monoxide emissions, which will
result in severe personal injury or death.

c Check Gas Piping

Check around the unit for gas odor fol­lowing the procedure outlined in this
manual on Page 63.

WARNING

If any gas leaks are found or suspected,
shut the unit down immediately. Use a
gas detection device or bubble test to
locate the source of the gas leak and
repair at once. Do not operate the unit
until the leak is corrected. Failure to
comply with this procedure could result
in severe personal injury, death or sub­stantial property damage.

ings should be within the range listed in
Table 4 on page 61. The CO level

should not exceed 100 ppm when
combustion is correct. Perform the

following procedure to manually place
the burner into high fire.

a. Press the round INSTALLER button.

Reference Fig. 30, page 41.

b. Enter the installer access code “054” by

using the LEFT and RIGHT buttons to
select a digit and the UP and DOWN
buttons to change the digit. Press the
OK button to enter the access code.

c. Press the RIGHT button to highlight

the Manual Operation icon then
press the OK button.

d. Press the OK button while the FAN

icon is highlighted to manually fire the
burner and power the CH circulator.

c Verify Flame Pattern and Combustion

1. Check the flame pattern through the
inspection port of the heat exchanger.
The flame should be blue and stable.
The flame should be the length of the
burner head openings.

WARNING

The combustion testing and adjustments
must be performed by a qualified
installer, service agency or the gas suppli­er. All combustion measurements must
be performed with calibrated equipment
to ensure proper reading and accuracy.

2. Test for CO2 or O2 and for CO during
high firing rate. The combustion read-

NOTICE

An adequate CH load must be present to
dissipate the heat generated during the
combustion test. If an adequate CH load
is not available, an indirect water heater
can be used to dissipate the heat by cre­ating a DHW call which will enable the
DHW circulator.

60

11.0 Start-Up Procedures

e. Press the LEFT and RIGHT buttons to

adjust the firing rate from 1% to 100%.
Hold down the LEFT or RIGHT but­ton to rapidly increase or decrease the
firing rate.

Table 4: Recommended Combustion Levels

Natural Gas

All Models

O2 Min. 2.30% 2.70% 3.70%

O2 Max. 5.30% 4.70% 5.20%

CO2 Min. 8.80% 10.70% 10.00%

CO2 Max. 10.50% 12.00% 11.00%

CO Max. 100 ppm 100 ppm 100 ppm

Propane

Solo 80/110/

155/175/250

Propane

Solo 299/399

f. Press the OK button while the FAN icon

is highlighted to shutdown the burner.

g. Cycle power to the Prestige once com-

bustion testing is complete to return to
normal operation.

4. If the CO2 combustion level during low
fire (1%) is not within +/- 0.2 of the com­bustion level measured at high fire, adjust
the plastic OFFSET SCREW under the
cover screw on the top of the gas valve (see
Figs. 16, 17, & 18 on page 29) according to
Table 6.

Direction 80/110

Clockwise

Counter-Clockwise

Table 5: Throttle Screw - High Fire

Direction All Units

Clockwise

Counter-Clockwise

Table 6: Offset Screw - Low Fire

Increase CO

Decrease O

Decrease CO

Increase O

155/175/250

299/399

Decrease CO

2

Increase O

2

Increase CO

2

Decrease O

2

Increase CO

Decrease O

Decrease CO

Increase O

2

2

2

2

2

2

2

2

WARNING

The combustion levels should be mea­sured at high firing rate. If the combus­tion levels are not within the range given
in Table 4 for the firing rate, shut the
boiler down and contact ACV-Triangle
Tube Technical Support. Failure to com­ply with this requirement could result in
severe personal injury, death or substan­tial property damage.

If the combustion levels during HIGH
FIRE (100%) is outside the recommended
combustion settings adjust the THROT­TLE SCREW (see Figs. 16, 17, & 18 on
page 29) according to Table 5.

3. Once the combustion level is set at high fire
(100%), manually place the boiler into low
fire (1%) mode by pressing the LEFT but-
ton to adjust firing rate down.

c Measure Input - Natural Gas Only

1. Ensure the boiler is firing at maximum firing
rate. To manually place the boiler into high
fire mode, reference page 60.

2. Operate the unit for approximately 10
minutes.

3. Turn off all gas appliances within the build­ing, except the PRESTIGE Solo.

4. At the gas meter, record the time required
to use one cubic foot of gas.

5. Calculate Natural gas input using the fol­lowing equation:

3600 x 1000 / number of second recorded
for one cubic foot of gas = BTU/H.

6. The BTU/H calculated should approximate
the input rating listed on the unit.

61

11.0 Start-Up Procedures

c Test High Temperature Limit

The high temperature limit can be temporarily
lowered from 210ºF [99ºC] to 102ºF [39ºC] for
testing.

1. Press the round INSTALLER button.

Reference Fig. 30, page 41.

2. Enter the installer access code “054” by

using LEFT and RIGHT buttons to select
a digit and the UP and DOWN buttons to
change the digit. Press the OK button to
enter the access code.

3. Press the OK button while CH & DHW

Settings icon is highlighted.

4. Press the DOWN button to highlight the
Boiler Settings icon then press the OK
button.

5. Press the DOWN button to highlight
Lockout Temperature then press the OK
button.

8. Initiate a CH or DHW call and confirm that
a High Boiler Temperature lockout occurs
once the supply temperature reaches 102ºF
[39ºC].

9. Press any ARROW button to return to the
Home Screen.

10. Press the round INSTALLER button.

11. Press the OK button while the CH & DHW

Settings icon is highlighted.

12. Press the DOWN button to highlight the
Boiler Settings icon then press the OK
button.

13. Press the DOWN button to highlight
Lockout Temperature, then press the OK
button.

14. Press the DOWN button to highlight 210ºF
[99ºC] then press the OK button.

15. Press the DOWN button twice to highlight
the Home Screen icon then press the
OK button.

6. Press the UP button to highlight 102ºF
[39ºC] then press the OK button.

7. Press the DOWN button twice to highlight
the Home Screen icon then press the
OK button.

16. Press the OK button to reset the lockout

and return the unit to service.

62

11.0 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 life.

A. This appliance does not have a pilot. It is

equipped with an ignition device which automat­ically lights the burner. DO NOT try to light the
burner by hand.

B. BEFORE OPERATING, smell all around the

appliance area for gas. Be sure to smell next to
the floor because some gas is heavier than air and
will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use
any phone in your building

•Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above. This

appliance is equipped with an ignition device
which automatically lights the burner. DO NOT
try to light the burner by hand.

2. Set room thermostat(s) to lowest setting. Turn the
external manual gas valve handle clockwise

“CLOSE” (valve handle shall be per-

pendicular to gas piping).

3. Turn the service switch on the PRESTIGE con­trol panel OFF.

4. Remove the front jacket panel on the unit.

5. Turn the external manual gas valve handle
counter clockwise to “OPEN” gas sup­ply (valve handle shall be parallel to gas piping).

6. Wait five (5) minutes to clear out any gas. If you
then smell gas in the jacket enclosure or around
the unit, STOP! Follow “B” in the safety infor­mation above. If you don’t smell gas, go to the
next step.

• If you cannot reach your gas supplier, call the
fire department.

C. Use only your hand to turn the external manual gas

valve. Never use tools. If the valve will not turn by
hand, don’t try to repair it; call a qualified service
technician. Force or attempted repair may result in
a fire or explosion.

D. Do not use this appliance if any part has been

under water. Immediately call a qualified service
technician to inspect the appliance and to replace
any part of the control system and any gas control
which has been under water.

7. Turn the service switch on the PRESTIGE con­trol panel “ON”.

8. Set room thermostat(s) to desired setting(s).

9. The PRESTIGE control panel display will show
the current operating status on the Status Line at
the bottom of the screen. “Standby” means there is
no call for heat (all thermostats are satisfied). “CH
Demand” indicates a space heating call has been
received. “DHW Demand” indicates a domestic
hot water call has been received. A flame icon will
be displayed when the unit is fired.

10. If the unit will not operate with a call for heat and the
system piping is not hot, follow the instructions “To
Turn Off Gas to Appliance”, below and call your
service technician or gas supplier.

11. Replace the front jacket panel. Make sure the panel is
seated firmly in place and all mounting screws are
tightened.

TO TURN OFF GAS TO APPLIANCE

1. Set the room thermostat to lowest setting.

2. Turn the service switch on the PRESTIGE con­trol panel to “OFF”

3. Turn the external manual gas valve handle clock­wise to “CLOSE”.

63

12.0 Outdoor Reset Control

SECTION XII - OUTDOOR RESET
CONTROL

The use of the outdoor reset function is
required to optimize boiler efficiency, see
notice below. If the outdoor sensor is not
installed before turning on the boiler, an
Outdoor Sensor Open error (E96) will be dis­played. The error will not prevent the boiler
from operating. The error will automatically
reset once the outdoor sensor is installed or if
the outdoor reset function is disabled.
Reference ACVMax Operation - EZ Setup sec­tion for information on disabling the outdoor
reset function. The outdoor reset function can
only be disabled if the boiler installation meets
one of the exceptions listed in the notice.

12.1 Mounting the Outdoor Sensor

1. The exterior wall selected for mounting the
outdoor sensor should represent the heat
load of the building. Typically a northern
or northeastern wall will suit most build­ings. A southern facing wall for those
buildings, which may have large glass
walls or windows on the southern face.

2. Ensure the outdoor sensor is shielded from
direct sunlight or the effects of heat or cold
from other sources (exhaust fans, appliance
vents...) to prevent false temperature sensing.

3. Mount the outdoor sensor at an elevation
on the exterior wall to prevent accidental
damage or tampering.

4. Avoid mounting the outdoor sensor in areas
subjected to excessive moisture.

5. Once an area on the exterior wall has been
determined, follow the mounting instruc­tions included with the outdoor sensor.

12.2 Wiring the Sensor

1. Connect 18 AWG 2-wire cable or similar
cable to the outdoor sensor.

2. Route the cable back to the PRESTIGE
Solo boiler, ensuring the wires are not run
parallel to telephone or power cables.

NOTICE

If the sensor wires are located in an area
with sources of potential electromagnetic
interference (EMI) the sensor wires
should be shielded or the wires should be
routed in a grounded metal conduit. If
using shielded cable, the shielding should
be connected to the common ground of
the unit.

3. Connect the outdoor sensor wires to the out­door sensor terminals on the low voltage ter­minal strip located on the boiler control
module inside the enclosure (see Fig. 20 on
page 31 and Fig. 22 on page 33). The out­door sensor wires do not have polarity.

IMPORTANT

In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boil­er is equipped with a feature that saves energy by reducing the boiler water temperature as the
heating load decreases. This feature is equipped with an override which is provided primari­ly to permit the use of an external energy management system that serves the same function.

THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOL­LOWING CONDITIONS IS TRUE.

• An external energy management system is installed that reduces the boiler water tem­perature as the heating load decreases.

• This boiler is not used for any space heating

• This boiler is part of a modular or multiple boiler system having a total input of
300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

64

13.0 External Modulating Control

SECTION XIII - EXTERNAL
MODULATING CONTROL

The boiler can directly accept an analog 0-10
VDC signal to control the firing rate from an
external modulating boiler controller.

13.1 Wiring the Modulating Controller

Run two 18 gauge wires from the external
modulating boiler controller’s 0-10 VDC boil­er output to the modulation signal terminals on
the low voltage terminal strip located on the
boiler control module inside the enclosure (see
Fig. 20 on page 31 and Fig. 22 on page 33).
This signal will both enable and modulate the
boiler. No wiring is required at the thermostat
terminals.

NOTICE

Ensure that the polarity of the connec­tions from the external modulating boil­er controller to the boiler are correct.
Reversed polarity will lead to no
response from the boiler.

13.2 ACVMax Adjustment

The ACVMax control must be programmed to
accept the 0-10 VDC signal from the external
modulating boiler control.

1. Use the Heating EZ Setup function to set
the CH Demand to 0-10V Modulation
Signal. Reference page 46 for the Heating
EZ Setup function.

13.3 Programming of External

Modulating Control

The external modulating control must be pro­grammed to send 2 VDC to enable the boiler
and run it at low fire, and 10 VDC to run the
boiler at high fire. Once the control enables the
boiler, it must wait 30 seconds to allow the burn­er to stabilize before modulating the boiler.

65

13.0 External Modulating Control

Factory ACVMax Setting

HEATING SETTING FACTORY DEFAULT EZ SETUP RESET INSTALLER RESET

Heating Operation

Enabled

3

Demand Type

Absolute Max CH Setpoint

CH1 Maximum Setpoint

CH1 Minimum Setpoint

Outdoor Curve Coldest Day

Outdoor Curve Warmest Day

CH2 Circuit

CH2 Maximum Setpoint

CH2 Minimum Setpoint

Warm Weather Shutdown

Circulation Pump Permanent

CH Post Pump Time

Freeze Protection

Frost Protection Setpoint

Parallel Shift Value

CH Call Blocking

DOMESTIC SETTING FACTORY DEFAULT EZ SETUP RESET INSTALLER RESET

DHW Operation

Demand Type

Boiler DHW Setpoint

DHW Setpoint

DHW On Differential

DHW Storage Adder

DHW Post Pump Time

DHW Priority Timeout

DHW Priority

DHW Call Blocking

DHW to CH Call Blocking

Antilegionella Function

Thermostat &

Outd. Curve

188°F [87°C]

180°F [82°C]

120°F [49°C]

0°F [-18°C]

64°F [18°C]

Enabled

140°F [60°C]

80°F [27°C]

OFF

Disabled

5 Minute

Enabled

-22°F [-30°C]

0°F [0°C]

1 Minute

Enabled

Thermostat (Solo)

Sensor (Excellence)

167°F [75°C]

140°F [60°C]

6°F [3°C]

28°F [15°C]

1 Minute

Off

Enabled

0 Minute

1 Minute

Disabled

33

33
33

3
3

3
33
33
33

3

3

3

3

3

3

3

33

33

3

3

3

33

3

3

3

3

BOILER SETTING FACTORY DEFAULT EZ SETUP RESET INSTALLER RESET

Prestige Model

Lockout Temp.

Modbus Address 0=BCST

Pump Settings Solo/Excellence 2

Ignition Level NAT

Solo (2 pumps)

Solo/Excel. (3 way valve)

210°F [99°C]

66

3

3

3

3

14.0 Check-Out Procedures

SECTION XIV- 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 68.

c Boiler system fluid chemistry checked and

verified as outlined on page 56.

c Boiler system was completely flushed to

remove any debris/sediment.

c Any automatic air vents placed within the

system are open one full turn.

c Air is purged from the heating zones and

boiler system piping.

c If applicable, confirm that the burner has

been properly configured for Propane as
outlined on page 28.

c Test high temperature limit as outlined on

page 62.

c Checked the incoming gas pressure to the

PRESTIGE Solo to ensure a minimum
pressure of 5”w.c during flow conditions to
all gas appliances and a maximum pressure
of 13”w.c during non-flow conditions for
Natural and Propane.

c Adjusted balancing valves and system limit

controls to provide design temperatures to
the primary space heating system.

c In multiple zone applications, adjusted for

correct flow of boiler water to each zone.

c Checked and verified room thermostat(s)

function properly and the thermostat(s)
heat anticipator (if used) was properly set.

c Observed several operating cycles for

proper operation of the PRESTIGE Solo
and the system.

c Set the room thermostat(s) to the desired

room temperature.

c Thermostat circuit wiring checked and ver-

ified that no voltage is present to the low
voltage terminals as outlined on page 58.

c Operating Instructions on page 63 were fol-

lowed during start-up.

c Combustion levels and flame pattern veri-

fied as outlined on page 60.

c Measured the rate of input on Natural Gas

as outlined on page 61.

c Reviewed all instructions shipped with the

PRESTIGE Solo with the homeowner or
maintenance personnel.

c Completed the Installation Record on page

68.

c Ensure all manuals and other documents

are returned to the Installation envelope
and given to the owner for safekeeping.

67

15.0 Installation Record

PRESTIGE Model Number:

Serial Number:

Date of Installation:

Fuel: Natural Gas Propane

Measured Rate of Input:

Combustion Readings:

CO

2

O2

CO

The following items were completed during installation:

 Installation instructions have been followed and completed

 Check-out procedures have been followed and completed

 Information regarding the unit and installation received and left with owner /
 maintenance personnel.

Installer Information

(Company)

(Address)

(Address)

(Phone Number)

Btu/hr

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

_________________________________________________________________

%

%

ppm

SECTION XV - INSTALLATION RECORD

68

16.0 Maintenance Schedules

SECTION XVI - MAINTENANCE
SCHEDULE

16.1 Service Technician

At least on an annual basis the following main­tenance should be performed by a qualified ser­vice technician:

General

- Attend to any reported problems.

- Inspect the interior of the boiler jacket area;
clean and vacuum if necessary.

- Clean the condensate drain assembly and
fill with fresh water.

- Check boiler fluid pH on systems.

- Check for leaks: water, gas, flue and con­densate.

- Verify flue vent piping/gaskets and air inlet
piping are in good condition, sealed tight
and properly supported.

- Check boiler water pressure, piping and
expansion tank.

16.2 Owner Maintenance

Periodically:

- Check the area around the unit.

- Check and remove any blockage from the
combustion air inlet and ventilation open­ings.

- Check the temperature and pressure
gauges.

Monthly:

- Check vent piping.

- Check combustion air inlet piping.

- Check the pressure relief valve.

- Check the condensate drain system.

Every 6 months:

- Check boiler piping and gas supply piping
for corrosion or potential signs of leakage.

- Operate the pressure relief valve.

- Check control settings.

- Check ignition electrode (sand off any
white oxide; clean and reposition).

- Check ignition wiring and ground wiring.

- Check all control wiring and connections.

- Check burner flame pattern (stable and uni­form).

Additional items if combustion or performance
is poor:

- Clean heat exchanger and flue ways.

- Remove burner assembly and clean burner
head using compressed air only.

Once the maintenance items are completed,
review the service with the owner.

WARNING

Follow the maintenance procedures
given throughout this manual. Failure
to perform the service and maintenance
or follow the directions in this manual
could result in damage to the PRES­TIGE Solo or in system components,
resulting in severe personal injury, death
or substantial property damage.

69

17.0 Maintenance Procedures

SECTION XVII- MAINTENANCE
PROCEDURES

17.1 Maintenance Procedures

WARNING

The PRESTIGE Solo should be inspect­ed and serviced annually, preferably at
the start of the heating season, by a qual­ified service technician. In addition, the
maintenance and care of the unit as out­lined on page 69 and further explained
on pages 70 through 75 should be per­formed to assure maximum efficiency
and reliability of the unit. Failure to ser­vice and maintain the PRESTIGE Solo
and the system components could result
in equipment failure, causing possible
severe personal injury, death or substan­tial property damage.

Verify that combustion air inlet area is free of
any contaminates. Refer to the materials listed
on page 5 of this manual. If any of these prod­ucts are in the area from which the unit takes its
combustion air, they must be removed immedi­ately or the combustion air intake must be relo­cated to another area.

17.4 Inspect Burner Area

Remove the boiler front jacket panel and ven­turi inlet elbow.

Vacuum any dirt or debris from the
burner/blower components.

Check the burner plate mounting nuts for tightness,
see Section 17.24 on page 75 for torque specification.

Check burner plate gasket for discoloration or
damage.

Re-install venturi inlet elbow and front jacket
panel when completed.

NOTICE

The following information provides
detailed instruction for completing the
maintenance items outline in the mainte­nance schedule on page 69. In addition
to this maintenance, the PRESTIGE
Solo should be serviced at the beginning
of the heating season by a qualified ser­vice technician.

17.2 Reported Problems

Any problems reported by the owner should be
checked, verified and corrected before pro­ceeding with any maintenance procedures.

17.3 Check Surrounding Area

Verify that the area surrounding the PRES­TIGE Solo is free of combustible / flammable
materials or flammable vapors or liquids.
Remove immediately if found.

WARNING

Do not use solvents to clean any of the
burner components. The components
could be damaged, resulting in unreli­able or unsafe operation.

17.5 Check System Piping

Inspect all piping (water and gas) on the boiler
system for leaks and verify that the piping is
leak free and properly supported.

Inspect the fittings and components on the unit
and verify they are leak free.

WARNING

Eliminate all boiler water system leaks.
Continual fresh make-up water will
reduce the heat exchanger life causing
boiler failure. Leaking water may also
cause severe property damage to the sur­rounding area. Inspect the gas supply
piping using the procedure outlined on
Page 60.

70

17.0 Maintenance Procedures

17.6 Clean Condensate Drain

Assembly

Loosen the retaining nut from the condensate
drain assembly and disconnect the assembly
from the boiler.

Empty any water from the trap and drain
assembly. Flush with fresh water as necessary
to clean.

Check the drain piping from the condensate
drain assembly to the drain. Flush to clean as
necessary.

Reassemble the condensate drain assembly
onto the boiler by tightening the retaining nut
with rubber seal onto the boiler. Hand tight
only.

Remove the fill plug on the condensate drain
assembly and fill with water. See Fig. 14 on
page 25.

Replace the fill plug on drain assembly.

17.7 Check Ventilation Air Openings

Verify that all ventilation openings to the
mechanical room or building are open and
unobstructed. Check the operation and wiring
of any automatic ventilation dampers.

Check and verify the vent discharge and the
combustion air intake are free of debris and
obstructions.

17.8 Inspect Vent and Combustion Air

Piping

WARNING

Failure to inspect the vent system and
combustion air inlet piping and to have
any conditions repaired, can result in
severe personal injury or death.

17.9 Check Boiler System

Verify all system components are correctly
installed and operating properly.

Check the cold fill pressure for the system, typ­ical cold water fill pressure is 12 psig.

Verify the system pressure, as the unit operates at
high temperature, to ensure the pressure does not
exceed 25 psig. Excessive pressure reading indi­cates expansion tank sizing is incorrect or system
performance problems.

Inspect air vent and air separators in the sys­tem. Remove the caps on automatic air vents
and briefly depress the valve stem to flush
vent. Replace the cap when completed. Ensure
vents do not leak, replace any leaking vents.

Verify boiler fluid pH level is between 6.0 and

8.0.

Check and verify inhibitor /antifreeze concen­tration within the boiler water meets
inhibitor/antifreeze manufacturer’s specifica­tions.

If necessary contact a boiler water treatment
company for a chemical analysis.

Visually inspect the venting system and com­bustion air piping for blockage, deterioration
of gaskets or leakage. Repair any deficiencies.

Verify that the combustion air inlet piping is
connected, sealed and properly supported.

71

17.0 Maintenance Procedures

17.10 Check Expansion Tank

Refer to Section IV - Boiler Piping for rec­ommended location of the expansion tank
and air eliminators.

Closed -Type Tank:

- Ensure tank is partially filled with

water leaving an air gap as a cushion.
Refer to the manufacturer’s instruction
for proper fill level.

- Ensure the tank is fitted with a device

that reduces gravity circulation of air­saturated tank water back into the sys­tem. This device prevents air from
bubbling up through the water as it
returns from the system.

- Ensure no automatic air vents are used

in the system. This will allow air to
escape from the system instead of
returning to the tank.

Diaphragm Tank:

- Ensure the system contains a minimum of

one automatic air vent. Recommended
location of the air vent should be atop an
air eliminator.

- Remove the tank from the system and

check the charge pressure. For residen­tial applications the charge pressure is
typically 12 psig. If tank does not hold
a charge pressure, then the membrane is
damaged and the tank should be
replaced.

17.11 Check Boiler Relief Valve

WARNING

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.

If after closing the valve, the valve fails to seat
properly or continually weeps, replace the
relief valve. Ensure the cause of the relief
valve to weep is the valve itself, not due to sys­tem over-pressurization caused by an expan­sion tank that is waterlogged or undersized.

17.12 Inspection of Ignitor

Remove the ignitor from the burner mounting
plate.

Remove any white oxides accumulated on the
ignitor using fine grit sandpaper or steel wool. If
the ignitor does not clean to a satisfactory con­dition, replace the ignitor .

When replacing the ignitor, ensure the gasket is
in good condition and correctly positioned.
Replace the gasket if necessary. Torque screws
to specification in Section 17.24 on page 75.

17.13 Check Ignition Wiring and Ground Wiring

Inspect the ignition cable from the ignitor to
the ACVMax control module.

Inspect the relief valve and lift the lever to ver­ify flow at least annually or as recommended
on the warning tag of the valve.

Inspect the ground wire from the ignitor to the
boiler jacket ground terminals.

Ensure wiring is in good condition and secure­ly connected.

Check ground continuity of the wiring to the
boiler jacket or piping using a continuity meter.

Replace and correct ground wire if ground con­tinuity is not completed and satisfactory.

72

17.0 Maintenance Procedures

17.14 Check Control Wiring

Inspect all control wiring. Ensure wiring is in
good condition and properly connected.

17.15 Check Control Settings

Review all boiler settings in the Heating &
DHW EZ Setup menus. Adjust settings as nec­essary, see page 46-49

Check any external limit control settings (if
used). Adjust settings as necessary.

17.16 Perform Start-up and Checkout

Procedures

Start the unit and perform the start-up proce­dure as listed in this manual.

Verify the cold water fill pressure is correct and
the operating pressure of the boiler is within
normal operating range.

Carefully remove the burner plate assembly
from the heat exchanger. Ensure that the com­bustion chamber 2-in-1 insulation is not dam­aged during removal of burner mounting plate
assembly. See WARNING on page 75.

Remove the burner head mounting screws and
remove the burner head. Inspect the burner
head for deterioration. Use compressed air or
a vacuum to clean the burner head.

Remove the venturi and gas valve assembly
from the blower.

Use a vacuum cleaner or compressed air to
clean the interior of the blower assembly.
Inspect the blower blades to ensure they are
clean and not damaged.

Re-assemble the venturi and gas valve onto the
blower. Ensure the venturi gasket or o-ring is
in good condition, positioned correctly and
replace gasket or o-ring if necessary.

Complete the checkout procedures as refer­enced in this manual.

17.17 Check Burner Flame

Inspect the burner flame through the observa­tion port on the heat exchanger.

If flame pattern is not fully blue and covers the
entire burner surface during high fire, shut the
unit down and allow it to cool thoroughly before
disassembly.

Close the external manual gas valve on the gas
supply line and disconnect the gas piping and
gas valve wire harness connector.

Disconnect the wiring harness connectors from
the blower and remove the blower clamp.
Remove the blower from the unit.

Remove the mounting nuts securing the burner
plate to the heat exchanger and set aside.

Re-assemble the burner head onto the burner
mounting plate. Ensure the burner head gasket
is in good condition, positioned correctly and
replace gasket if necessary.

Re-assemble the burner plate assembly onto
the heat exchanger. Ensure the combustion
chamber 2-in-1 insulation is in place, posi­tioned correctly, and not damaged, replace if
necessary. See WARNING on page 75.

Re-assemble the blower onto the burner plate
and reconnect the wiring harness connectors.

Re-assemble the gas supply connection and
wire harness to gas valve. Open the external
manual gas valve. Check gas piping for any
leaks as outlined on page 58 and repair if nec­essary.

Torque all screws, bolts, and nuts in accor­dance with specifications in Section 17.24 on
page 75.

Place the unit back into service.

73

17.0 Maintenance Procedures

17.18 Check Flame Signal

The flame signal can be read from the Boiler
Information screen. It should be a min. 1μ Α −DC.

Check the ignitor for fouling or damaged
insulation if a low flame signal is read.

Check ground wiring and continuity as a cause
for low flame signal. Replace ignitor if condi­tions are satisfactory.

17.19 Check Combustion Levels

Refer to page 60 of this manual for measuring
combustion levels and burner adjustments.

17.20 Check Flue Gas Temperature

Manually place the boiler into high fire. See
page 60 for procedure.

Navigate to the Boiler Information Menu to
observe the flue gas temperature. See page 50
for procedure.

Disconnect the wiring harness connectors from
the blower and remove the blower clamp.
Remove the blower from the unit.

Remove the mounting nuts securing the burner
plate to the heat exchanger and set aside.

Carefully remove the burner plate assembly
from the heat exchanger. Ensure that the com­bustion chamber 2-in-1 insulation is not dam­aged during removal of burner mounting plate
assembly. See WARNING on page 75.

Use compressed air or water to remove any
accumulation from the heat exchanger flue
ways.

Re-assemble the burner plate assembly onto
the heat exchanger. Ensure the combustion
chamber 2-in-1 insulation is in place, posi­tioned correctly, and not damaged, replace if
necessary. See WARNING on page 75.

Re-assemble the blower onto the burner plate
and reconnect the wiring harness connectors.

If the flue gas temperature is more than 54°F
[30°C] above the supply water temperature, shut
the boiler down and follow the heat exchanger
cleaning procedure below.

17.21 Clean Heat Exchanger

Shut down the boiler:

- Follow the instructions on Page 63 "To
Turn Off Gas to Appliance"

- Do not drain the boiler unless the boil­er will be subject to freezing condi­tions.

- Do not drain the boiler if freeze protec­tion fluid is used in the system.

Allow the boiler to cool down to room temper­ature before servicing.

Disconnect the gas piping and gas valve wire
harness connector.

Reconnect the gas piping and wire harness to
gas valve. Check for leaks, repair if necessary.

Torque all screws, bolts, and nuts in accor­dance with specifications in Section 17.24 on
page 75.

Close isolation valves on the boiler water pip­ing to isolate the boiler from the heating sys­tem.

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.

Once the boiler has been completely flushed,
return the boiler and system piping back to
operation.

Perform the required startup and checkout pro­cedures as outlined on pages 56 to 67.

74

17.0 Maintenance Procedures

17.22 Review With Owner

Ensure the owner understands the importance
to perform the maintenance schedule specified
in this manual.

WARNING

The combustion chamber insulation con­tains ceramic fibers, which are classified
as a possible human carcinogen. When
exposed to extremely high temperatures,

Remind the owner of the importance to call a
licensed contractor should the unit or system
exhibit any unusual behavior.

the ceramic fibers, which contain crys­talline silica, can be converted into
cristobalite.

17.23 Handling Previously Fired Combustion Chamber Insulation

Avoid Breathing and Contact with Skin
and Eyes

When removing or repairing the combustion
chamber insulation follow these precaution
measures:

1. Use a NIOSH approved respirator which
meets OSHA requirements for cristobalite
dust, similar to N95. Contact NIOSH at
1-800-356-4676 or on the web at
www.cdc.gov/niosh for latest recommen­dations.

6. Discard used insulation in an air tight
plastic bag.

NIOSH Stated First Aid:

Eye/Skin: Immediately irrigate
Breathing: Clean fresh air

2. Wear long sleeved, loose fitting clothing,
gloves and eyes protection.

3. Assure adequate ventilation.

4. Wash with soap and water after contact.

5. Wash potentially contaminated clothes
separately from other laundry and rinse
washing machine thoroughly.

17.24 Torque Specifications Table

Item

Burner Plate Nuts
Burner Head Bolts
Fan Clamp Screw
Gas Valve Screws

Venturi Screws

Ignitor Screws

Torque Req'd (in-lbs)

Min. Max.

44 53
27 31
62 71
31 35
31 35
27 31

75

18.0 Replacement Parts

SECTION XVIII REPLACEMENT PARTS

WARNING

Replacement parts must be purchased through a local ACV-Triangle Tube distributor.
When ordering part please provide the model number and description and/or part num­ber of replacement part. Use only genuine ACV-Triangle Tube replacement parts to
ensure warranty coverage and to avoid damage to appliance and improper operation of
appliance. Contact ACV-Triangle Tube at 856-228-8881 or www.triangletube.com for list
of distributors nearest you.

76

18.0 Replacement Parts

1

3

2

4

5

Fig. 31: PRESTIGE Solo 80/110 Jacket Components

Item Part # Description

1 PAJKT01 Front Jacket Panel (with insulation)

2 PAJKT03 Left Side Jacket Panel (with insulation)

3 PAJKT21 Right Side Jacket Panel (with insulation)

4 PAJKT04 Top Panel

5 PSRKIT21 Wall Mounting Bracket with Hardware

77

18.0 Replacement Parts

2

3

4

5

1

Fig. 32: PRESTIGE Solo 175/250 Jacket Components

Item Part # Description

1 PAJKT01 Front Jacket Panel (with insulation)

2 PAJKT03 Left Side Jacket Panel (with insulation)

3 PAJKT21 Right Side Jacket Panel (with insulation)

4 PAJKT12 Top Panel

5 PSRKIT21 Wall Mounting Bracket with Hardware

78

18.0 Replacement Parts

1

2

6

5

3

4

Fig. 33: PRESTIGE Solo 299/399 Jacket Components

Item Part # Description

1 PAJKT15 Front Jacket Panel (with insulation)

2 PAJKT16 Left Side Jacket Panel (with insulation)

3 PAJKT22 Right Side Jacket Panel (with insulation)

4 PAJKT17 Top Panel - Front

5 PAJKT18 Top Panel - Rear

6 PSRKIT21 Wall Mounting Bracket with Hardware

79

18.0 Replacement Parts

1

4

5

2

2

3

6

10

8

9

7

Fig. 34: PRESTIGE Solo 80/110 Internal Components

Item Part # Description

1 PARKIT90 Heat Exchanger Body

2 PTADPT07 Vent Outlet/Combustion Air Inlet Adapter

3 PARKIT02 Polypropylene Vent Pipe

4 PTRKIT123 Supply/Return Temperature Sensor

5 PARKIT01 Flue Temperature Sensor

6 PARKIT04 LWCO Pressure Sensor

7 PARKIT05 Condensate Drain Assembly

8 PARKIT06 Boiler Piping - Return Assembly

9 PARKIT07 Boiler Piping - Supply Assembly

10 PARKIT13 Polypropylene Condensate Pan

80

18.0 Replacement Parts

1

3

2

2

4

4

5

6

7

9

8

10

Fig. 35: PRESTIGE Solo 155/175/250 Internal Components

Item Part # Description

1

PARKIT91 Heat Exchanger Body Solo 155
PARKIT92 Heat Exchanger Body Solo 175

PARKIT93 Heat Exchanger Body Solo 250
2 PTADPT07 Vent Outlet/Combustion Air Inlet Adapter
3 PARKIT08 Polypropylene Vent Pipe
4 PTRKIT122 Supply/Return Temperature Sensor
5 PARKIT01 Flue Temperature Sensor
6 PARKIT04 LWCO Pressure Sensor
7 PSRKIT44 Condensate Drain Assembly
8 PARKIT46 Boiler Piping - Return Assembly
9 PARKIT47 Boiler Piping - Supply Assembly

10

PARKIT43 Polypropylene Condensate Pan Solo 155

PARKIT53 Polypropylene Condensate Pan Solo 175 & 250

81

18.0 Replacement Parts

1

2

2

3

4

4

5

6

7

9

8

10

Fig. 36: PRESTIGE Solo 399 Internal Components

Item Part # Description

PARKIT94 Heat Exchanger Body Solo 299
1

PARKIT95 Heat Exchanger Body Solo 399

2 PTADPT08 Vent Outlet/Combustion Air Inlet Adapter

3 PARKIT09 Polypropylene Vent Pipe

4 PARKIT78 Supply/Return Temperature Sensor

5 PARKIT01 Flue Temperature Sensor

6 PARKIT04 LWCO Pressure Sensor

7 PSRKIT44 Condensate Drain Assembly

8 PARKIT76 Boiler Piping - Return Assembly

9 PARKIT77 Boiler Piping - Supply Assembly

10 PARKIT73 Polypropylene Condensate Pan Solo 155

82

1

3

6

4

2

5

8

7

9

18.0 Replacement Parts

Fig. 37: PRESTIGE Solo 80/110 Burner Components

Item Part # Description

1 PARKIT12 Combustion Chamber 2-in-1 Insulation

2 PARKIT14 Burner Head Assembly (with Gasket)

3 PARKIT11 Blower Assembly (with Gasket)

4 PARKIT18 Blower Clamp

5 PARKIT19 Blower Gasket

6 PARKIT15 Burner Plate Assembly

7 PARKIT17 Gas Valve

PARKIT10 Venturi - Solo 80

8

PARKIT20 Venturi - Solo 110

9 PARKIT16 Igniter Assembly

83

18.0 Replacement Parts

3

9

6

2

1

7

8

4

5

Fig. 38: PRESTIGE Solo 155/175/250 Burner Components

Item Part # Description

PARKIT42 Combustion Chamber 2-in-1 Insulation - Solo 155

1

PARKIT52 Combustion Chamber 2-in-1 Insulation - Solo 175 & 250

2 PARKIT54 Burner Head Assembly (with Gasket)

3

PARKIT61 Blower Assembly (with Gasket) - Solo 250

PARKIT51 Blower Assembly (with Gasket) - Solo 155 & 175

4 PARKIT18 Blower Clamp

5 PARKIT19 Blower Gasket

PARKIT45 Burner Plate Assembly - Solo 155

6

PARKIT55 Burner Plate Assembly - Solo 175 & 250

7 PARKIT59 Gas Valve

PARKIT30 Venturi - Solo 155

8

PARKIT40 Venturi - Solo 175

PARKIT50 Venturi - Solo 250

9 PARKIT56 Igniter Assembly

84

18.0 Replacement Parts

8

6

2

1

3

7

4

5

Fig. 39: PRESTIGE Solo 299/399 Burner Components

Item Part # Description

1 PARKIT72 Combustion Chamber 2-in-1 Insulation

2 PARKIT74 Burner Head Assembly (with Gasket)

3 PARKIT71 Blower Assembly (with Gasket)

4 PARKIT18 Blower Clamp

5 PARKIT19 Blower Gasket

6 PARKIT75 Burner Plate Assembly

7 PARKIT79 Gas Valve

8 PARKIT16 Igniter Assembly

85

18.0 Replacement Parts

4

2

3

1

6

5

Fig. 40: PRESTIGE Solo Control & Display Enclosures

Item Part # Description

1 PTRKIT109 Pressure Gauge

2 PTSWI01 Power Switch

3 PTSWI02 Power Switch Cover

4 PADIS02 Display Module

5 PACON01 Control Module

6 PAHNG01 Control Box Hinges

86

19.0 Product Specifications

SECTION XIX PRODUCT SPECIFICATIONS

Boiler
Model

Solo 80

Solo 110

Solo 155

Solo 175

Solo 250

Solo 299

Boiler

Model

uel

F

Natural

Propane

Natural

Propane

Natural

Propane

Natural

Propane

Natural

Propane

Natural

Propane

Fuel Input Output

nput

I

80,000 72,000 63,000 95% 103 / 47

110,000 99,000 86,000 95% 103 / 47

153,000 138,000 120,000 95% 118 / 53.5

170,000 154,000 134,000 95% 128 / 58

240,000 218,000 190,000 95% 140 / 63.5

299,000 272,000 237,000 95% 210 / 95

Heating Capacity

DOE

Net AHRI

Rating

Net AHRI

Rating

DOE Seasonal

Efficiency AFUE

Combustion

Efficiency

Thermal

Efficiency

Shipping

eight

W

Lbs / Kg

Shipping

Weight

Lbs / Kg

Solo 399

Note 1: The heating capacity of the PRESTIGE Solo

Note 2: The AHRI rating is based on a piping and

Note 3: Based on the given AFUE the PRESTIGE

Natural

Propane

80/110/155/175/250 is based on the test
requirements of the U.S. Department of
Energy.

pick up allowance of 1.15. This allowance
should be sufficient for the standard radiation
requirements for a building load.

Solo 80/110/155/175/250 meets the energy
efficiency guidelines established by Energy
Star.

399,000 379,000 330,000 94.1% 95.1% 216 / 98

DOE

Note 4: Input and output ratings are shown for sea

level applications. The PRESTIGE Solo
automatically derates the input at approxi­mately 2% for every 1,000 Ft. of altitude. No
alterations to the boiler or burner system is
required.

Note 5: PRESTIGE Solo 399 output rating is based

off of the thermal efficiency.

87

19.0 Product Specifications

C

B

A

D

E

F

G

H

Fig. 41: Front View PRESTIGE Solo 80/110

ABCDEFGH

Connection

Dimension

in [mm]

3/4" NPSC

Pressure Relief

Valve

16-5/8"

[423]

3"

Combustion

Air Inlet

15-13/16"

[402]

3" Vent

Outlet

8-13/16"

[224]

1" NPT

Boiler
Return

2-7/8"

[73]

88

1/2" NPT Gas

Connection

5-7/8"

[150]

1" NPT

Boiler

Supply

16-7/16"

[418]

Boiler
Width

19-3/4"

[502]

Boiler

Height

36-9/16"

[928]

19.0 Product Specifications

J

I

M

K

L

Fig. 42: Right Side View PRESTIGE Solo 80/110

I J K LM

3" Combustion Air Inlet

&

3" Vent Outlet

5-9/16"

[141]

Connection

Dimension

in [mm]

3/4" NPSC

Pressure Relief Valve

11-1/4"

[286]

89

1/2" NPT Gas

Connection

4"

[102]

1" NPT Boiler

Return &

Supply

13-7/16"

[341]

Boiler Depth

17-5/16"

[440]

19.0 Product Specifications

C

B

A

D

E

F

G

H

Fig. 43: Front View PRESTIGE Solo 155/175/250

ABCDEFGH

Connection

Dimension

in [mm]

3/4" NPSC

Pressure

Relief Valve

17"

[432]

3" Combustion

Air Inlet

16-5/16"

[415]

3" Vent

Outlet

4-5/16"

[110]

1-1/4" NPT

Boiler

Return

2-9/16"

[65]

90

3/4" NPT

Gas

Connection

7-5/16"

[186]

1-1/4" NPT

Boiler Supply

17"

[432]

Boiler
Width

19-3/4"

[502]

Boiler

Height

36-9/16"

[928]

19.0 Product Specifications

J

I

M

K

L

Fig. 44: Right Side View PRESTIGE Solo 155/175/250

I J K LM

3" Combustion Air Inlet

&

3" Vent Outlet

6-15/16"

[175]

Connection

Dimension

in [mm]

3/4" NPSC

Pressure Relief Valve

11-5/16"

[288]

91

3/4" NPT Gas

Connection

1-7/8"

[48]

1-1/4" NPT Boiler

Return & Supply

11-5/16"

[288]

Boiler Depth

17-5/16"

[440]

19.0 Product Specifications

D

E

F

G

B

A

C

H

Fig. 45: Front View PRESTIGE Solo 299/399

ABCDEFGH

Connection

Dimension

in [mm]

3/4" NPSC

Pressure

Relief Valve

18-5/8"

[473]

4" Combustion

Air Inlet

13-1/4"

[336]

4" Vent

Outlet

20-1/4"

[514]

1-1/2" NPT

Boiler

Return

3-1/4"

[82]

92

1" NPT Gas

Connection

9-1/4"

[236]

1-1/2" NPT

Boiler

Supply

17-7/8"

[454]

Boiler
Width

24-7/8"

[632]

Boiler

Height

39-3/8"

[1000]

19.0 Product Specifications

J

I

M

K

L

Fig. 46: Right Side View PRESTIGE Solo 299/399

I J K LM

4" Combustion Air

Inlet &

4" Vent Outlet

15-1/4"

[388]

93

Connection

Dimension

in [mm]

3/4" NPSC

Pressure Relief Valve

5-3/8"

[136]

1" NPT Gas

Connection

16-1/4"

[412]

1-1/2" NPT Boiler

Return & Supply

14-5/8"

[372]

Boiler Depth

23-5/8"

[600]

19.0 Product Specifications

0

2

4

6

8

10

12

14

16

4 5 6 7 8 9101112

Pressure Drop (Ft. W.C.)

Flow Rate (GPM)

Pressure Drop Comparison - Taco

Solo 80 Solo 110 Taco 005 Taco 007 Taco 0010 Taco 0012

0

2

4

6

8

10

12

14

16

4 5 6 7 8 9101112

Pressure Drop (Ft. W.C.)

Flow Rate (GPM)

Pressure Drop Comparison - Grundfos

Solo 80 Solo 110
Grundfos UPS15-58F/FC - Spd 1 Grundfos UPS15-58F/FC - Spd 2
Grundfos UPS15-58F/FC - Spd 3

Graph 1: Pressure Loss Through Boiler - Taco Circulators

Graph 2: Pressure Loss Through Boiler - Grundfos Circulators

Note: Minimum allowable flow rate at full input:

- 3 gpm SOLO 80

- 4 gpm SOLO 110

94