TriangleTube 399 Solo User Manual

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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 *

prestige

Solo 60 Solo 175 Solo 250 Solo 399

Water Boiler

* 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

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.

Series III

• 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.

FOR YOUR SAFETY

2010-7 Manual Prestige Solo 60/175/250/399 - Revised 02/17/10

Page 2

Table of Contents

PRODUCT AND SAFETY INFORMATION

Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Product and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION I - PRE-INSTALLATION ITEMS

Code Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Determining Product Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Boiler Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Recommended Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Residential Garage Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Boiler Freeze Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION II - COMBUSTION AIR AND VENTING

Combustion Air Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Ventilation and Combustion Air Requirements - Direct Vent . . . . . . . . . . . 6

Ventilation and Combustion Air Requirements - Category IV . . . . . . . . . . 6

Methods of Accessing Combustion Air into a Space - Category IV . . . . . . 7

- Indoor Combustion Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

- Outdoor Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

- Combination of Indoor and Outdoor Combustion Air. . . . . . . . . . 8-9

Combustion Air and Vent Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Removal of an Existing Boiler from a Common Vent System . . . . . . . . . . 10

Commonwealth of Massachusetts Installation . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION III - UNIT PREPARATIONS

Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Wall Mounting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Wall Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Wall Bracket Installation - Stud Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Wall Bracket Installation - Solid Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Boiler Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION IV - BOILER PIPING

General Piping Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Low Water Cut Off Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Additional Limit Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Backflow Preventer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Table of Contents

Boiler System Piping Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Expansion Tank and Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17

Diaphragm Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Closed-Type Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Sizing Primary Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Domestic Hot Water System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

System Piping - Zone Circulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Near Boiler Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

System Piping - Zone Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

System Piping - Through Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

System Piping - Radiant Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

System Piping - Special Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

System Piping - Multiple Units Installation . . . . . . . . . . . . . . . . . . . . . . . . . 19

DHW Boiler Piping with PRESTIGE Solo and SMART . . . . . . . . . . . . . . 20

Central Heating System Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24

SECTION V - INSTALLING VENT / COMBUSTION AIR & CONDENSATE DRAIN

Installing Vent and Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Installing Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-26

SECTION VI - GAS PIPING

Gas Supply Piping Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Natural Gas

Pipe Sizing -Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Natural Gas Supply Pressure Requirements. . . . . . . . . . . . . . . . . . . 28

Propane Gas

Pipe Sizing - Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Propane Gas Supply Pressure Requirements . . . . . . . . . . . . . . . . . . 29

Gas Valve/Venturi Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SECTION VII - INTERNAL WIRING

General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Control Module Circulator AMP Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Wiring Tool Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Internal Factory Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

SECTION VIII - EXTERNAL WIRING

Installation Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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Table of Contents

Domestic Hot Water Aquastat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Thermostat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-34

CH and DHW Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

System Circulator - Zone Valve Application . . . . . . . . . . . . . . . . . . . . . . . . 34

External Modulating Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Outdoor Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Additional 24V Limit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

External Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-36

SECTION IX - START-UP PREPARATION

Check Boiler System Water Chemistry

Water pH Level 6.0 to 8.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Water Hardness Less Than 7 Grains. . . . . . . . . . . . . . . . . . . . . . . . . 37

Chlorinated Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Flush Boiler and Domestic System to Remove Sediment . . . . . . . . . . . . . . 37

Check and Test Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Use of Antifreeze in the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Filling the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Check Low Water Cut-Off Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Check for Gas Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Check Thermostat Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Inspection of Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 39

SECTION - START-UP PROCEDURES

Final Checks Before Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

PRESTIGE Solo Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

If PRESTIGE Solo Does Not Start Correctly . . . . . . . . . . . . . . . . . . . . . . . 40

Check the PRESTIGE Solo and System . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41

Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Set Boiler CH Target Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Operation Verification - Space Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-44

Operation Verification - Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . 44

Boiler Control Display

Standby Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-46

Setting the Boiler Parameters

Parameter Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Accessing Boiler Information

Information Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Error (Hard Lockout) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

iii

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Table of Contents

SECTION XI - OUTDOOR RESET CONTROL

Mounting the Outdoor Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Wiring the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Summer/Winter Switch at Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Adjusting Outdoor Reset Curve

CH Maximum Boiler Operating Setpoint (Parameter 4) . . . . . . . . . 51

CH Minimum Boiler Operating Setpoint (Parameter 10) . . . . . . . . 51

CH Reset Curve Coldest Day (Parameter 11) . . . . . . . . . . . . . . . . . 51

CH Reset Curve Warmest Day (Parameter 12) . . . . . . . . . . . . . . . . 52

Entering MCBA Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Changing a Parameter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Outdoor Reset Curve Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

SECTION XII - EXTERNAL MODULATING CONTROL

Wiring the Modulating Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Parameter Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Programming of External Modulating Control . . . . . . . . . . . . . . . . . . . . . . 54

Factory Setting for Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

SECTION XIII - CHECK-OUT PROCEDURES

Check-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

SECTION XIV - INSTALLATION RECORD

Installation Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

SECTIONS XV - MAINTENANCE SCHEDULE

Service Technician - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Owner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

SECTION XVI - MAINTENANCE PROCEDURES

Maintenance Procedures

Reported Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Check Surrounding Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Inspect Burner Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Check System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Clean Condensate Drain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 60

Check Ventilation Air Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Page 6

Table of Contents

Inspect Vent and Combustion Air Piping . . . . . . . . . . . . . . . . . . . . . 60

Check Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Check Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Check Boiler Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Inspection of Ignition Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Check Ignition Wiring and Ground Wiring . . . . . . . . . . . . . . . . . . . 61

Check Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Check Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Perform Start-Up and Checkout Procedure . . . . . . . . . . . . . . . . . . . 62

Check Burner Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Check Flame Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Check Combustion Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Check Flue Gas Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Clean Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-64

Review with Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Handling Previously Fired Combustion Chamber Insulation . . . . . 64

REPLACEMENT PARTS

Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-71

PRODUCT SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-81

Page 7

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 Triangle Tube for the installers which will help to ensure optimum operation and longevity of the equipment

NOTICE

Triangle Tube reserves the right to modify the technical specifications and components of its products without prior notice.

Page 8

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

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 boiler is hot. Thermal shock can cause potential cracks in the heat exchanger.

CAUTION

When servicing the boiler:

- Avoid electrical shock by disconnecting the electrical supply prior to performing maintenance.

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, on the backside of the control panel when inquiring about service or troubleshooting.

NOTICE

Triangle Tube accepts no liability for any damage resulting from incorrect installation or from the use of components or fittings not specified by Triangle Tube.

Page 9

Pre-Installation Items

SECTION I - Pre-Installation Items

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.

- 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.

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.

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.

Boiler Replacement

If the PRESTIGE Solo is replacing an existing boiler, the following items should be checked and corrected prior to installation:

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.

Determining Product Location

Before locating the PRESTIGE SOLO check for convenient locations to:

- Heating system piping

- Venting

- Gas supply piping

- Electrical service

- Boiler piping leaks and corrosion.

- Improper location and sizing of the expansion tank on the boiler heating loop.

- If applicable, level and quality of freeze protection within the boiler system.

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.

Page 10

Pre-Installation Items

- 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]

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.

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.

Boiler Freeze Protection Feature

The boiler control has a freeze protection feature built in. This feature monitors the boiler temperature and responds as follows when no call for heat is present:

- 46ºF Boiler circulator is ON

- 38ºF Boiler circulator is ON and burner operates at low fire

- 50ºF Burner OFF and boiler circulator operates for approximately 10 minutes

NOTICE

When maintaining zero clearance or less than recommended clearances, some product labeling 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.

CAUTION

The boiler freeze protection feature is disabled during a hard lockout, however the CH circulator 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 IX for antifreeze guides.

Page 11

Combustion Air Venting

SECTION II - Combustion Air and Venting

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

Page 12

Combustion Air Venting

Ventilation and Combustion Air Requirements - Direct Vent

A Direct Vent appliance utilizes uncontamined 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.

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.

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.

Page 13

Combustion Air Venting

Methods of Accessing Combustion Air Into A Space - Category IV

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:

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.

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.

Fig. 1:

All Combustion Air from Adjacent Indoor Spaces Through Indoor Combustion Openings

- 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.

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:

One Permanent Opening Method. See Fig. 2

One permanent opening, commencing within 12 in. of the top of the enclosure, shall be provided. 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:

- 1sq. in./3000 Btu/hr of the total input rating of all equipment located in the enclosures, and

Page 14

Combustion Air Venting

Fig. 2:

All Combustion Air from Outdoors Through One Permanent Air Opening

- Not less than the sum of the areas of all vent connectors in the space.

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.

Fig. 3:

Fig. 4:

All Combustion Air from Outdoors Through Ventilated Attic

All Combustion Air from Outdoors Through Horizontal Ducts

- 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.

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.

Page 15

Combustion Air Venting

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.

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.

Combustion Air and Vent Piping

The PRESTIGE Solo requires a Category IV venting system, which is designed for pressurized venting and condensate.

BEST PRACTICE

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 addition vent installation instructions.

DANGER

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.

The PRESTIGE Solo is certified per ANSI Z21.13 as a Category IV or Direct Vent (sealed combustion) appliance. A Category IV appliance utilizes uncontamined indoor or outdoor air (surrounding the appliance) for combustion. A Direct Vent appliance utilizes uncontaminated outdoor air (piped directly to the appliance) for combustion.

Page 16

Combustion Air Venting

Removal of an Existing Boiler from a Common Vent System

BEST PRACTICE

When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the remaining appliances. 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

Page 17

Combustion Air Venting

Commonwealth of Massachusetts Installations Only

For direct-vent appliances, mechanicalvent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied:

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

circuit 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.

Page 18

Unit Preparations

SECTION III - Unit Preparations

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 lift the unit from, or place the unit on the front plastic control panel, damage can occur. 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.

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.

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 Triangle Tube.

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 60, 175 pounds [80 kg] for PRESTIGE Solo 175/250 and 250 pounds [115 Kg] for PRESTIGE Solo 399. Failure to comply with these requirements could result in personal injury, death or substantial property damage.

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

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.

Page 19

Unit Preparations

PRESTIGE Solo 60/175/250 Stud Walls Installation

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.

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.

6. Level bracket and tighten screws (bolts for metal studs) securely making sure not to over-tighten to avoid damaging drywall or plaster.

PRESTIGE Solo 399 Stud Walls Installation

1. To distribute the weight of the boiler evenly when mounting onto a stud wall it is recommended to use the PRESTIGE 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 wall is questionable, in supporting a minimum weight of 250 pounds [115 kg.], it is recommended to use the optional floor stand.

Boiler Mounting

1. Obtain assistance in lifting the boiler onto the wall bracket.

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.

Page 20

Boiler Piping

SECTION IV - Boiler Piping

General Piping Requirements

- All plumbing must meet or exceed all local, state and national plumbing codes.

- Support all piping using hangers. DO NOT support piping by the unit or its components.

- Use isolation valves to isolate system components.

- Install unions for easy removal of the PRESTIGE 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.

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:

- Must be connected to the discharge out-

let 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.

- 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.

Low Water Cutoff Device

- The PRESTIGE Solo is equipped with a factory installed pressure switch 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 system 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.

Page 21

Boiler Piping

Boiler Return Connection

with Tee Fitting and

Boiler Drain Valve

Boiler Supply

Connection

Pressure Relief Valve

(

Supplied with Boiler)

3/4" Street Elbow

Air Vent

Drain Piping Directed

to a Suitable

Place of Drainage

Fig. 5: Pressure Relief Valve and Boiler Drain Valve Installation

Page 22

Boiler Piping

Additional Limit Control

If a separate LWCO device is required by certain local jurisdictions or when the boiler is installed above the system piping, the following guidelines must be followed:

- The LWCO device must be designed for water installations, electrode probetype is recommended.

- The LWCO device must be installed in a tee connection on the boiler supply piping above the boiler.

- Wiring of the LWCO device to the PRESTIGE Solo is done directly onto the 24V terminal strip, reference Fig. 20 page 32 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.

- Maximum set point for the limit is 194ºF.

- For wiring of the limit reference Fig. 20, page 32, using the external limit/manual reset terminals on the 24V terminal strip. This will provide a "hard" lockout requiring a manual reset of the control.

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, see Graphs 2 through 5 on pages 72 & 73. For other piping arrangements, consult the Engineering Department at Triangle Tube or consult other approved/recognized design arrangements.

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.

Expansion Tank and Makeup Water

Ensure the expansion tank is properly sized for the boiler volume (3 gallons [12 L] for the PRESTIGE Solo 60, 5 gallons [19 L] for the PRESTIGE Solo 175/250, 7 gallons [26 L] for PRESTIGE Solo 399) and the system volume and temperature.

CAUTION

Backflow Preventer

- Use a backflow preventer valve in the make-up water supply to the unit as required by local codes.

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.

Page 23

Boiler Piping

The expansion tank must be located as shown in Fig. 6 and Fig. 7 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.

Diaphragm Expansion Tank

Always install an automatic air vent on the top of the air separator to remove residual air from the system.

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.

Sizing Primary Piping

See Fig. 8 through 14, pages 20 - 24, for recommended piping arrangements based on various applications. Size the piping and system components required in the space heating system, using recognized design methods.

Domestic Hot Water System Piping

See Fig. 8 , page 20 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.

To wire the DHW circulator to the boiler control module, reference Section VIII - External Wiring.

System Piping - Zone Circulators

Connect the PRESTIGE Solo to the system piping as shown in Fig. 9 page 21 when zoning with zone circulators.

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.

Circulator

The PRESTIGE Solo must be supplied with a Central Heating (CH) circulator. The circulator when wired directly to the PRESTIGE Solo will allow for domestic hot water priority and to provide circulation for the freeze protection feature of the boiler control. See Graphs 2 through 5 on pages 72 & 73 for pressure drop and minimum flow rate through the boiler.

The installer must provide a separate circulator for each zone of space heating as well as the boiler circulator.

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 60, 1-1/4 inch for the PRESTIGE Solo 175/250 and 1-1/2 inch for the PRESTIGE Solo 399.

Page 24

Boiler Piping

Max.

12"

Boiler

Supply

System

Return

System

Cold

Water Fill

Boiler

Supply

Return

Cold

Water Fill

Boiler

Supply

Minimum

3/4" Piping

Boiler

Return

System

Supply

System

Max.

12"

Fig. 6: Near Boiler Piping - Diaphragm Expansion Tank

Fig. 7 : Near Boiler Piping - Closed Type Expansion Tank

1. System circulator

2. Automatic air vent

3. Air separator

4. Automatic fill valve

5. Diaphragm expansion tank

6. Isolation valve

Note: Pitch horizontal piping upwards (1” of pitch per 5 ft of piping) towards expansion tank.

7. Drain/purge valve

8. Tank fitting

9. Closed type expansion tank

10. Primary/secondary connection

11. Boiler circulator

12. Flow/check valve

Page 25

Boiler Piping

System Piping - Zone Valves

Connect the PRESTIGE Solo to the system piping as shown in Fig. 10 page 21 when zoning with zone valves. The primary / secondary piping ensures that the boiler loop has sufficient flow.

NOTICE

System Piping - Through Boiler

In new or retrofit applications in which primary/secondary arrangement is not utilized, the PRESTIGE Solo allows this flexibility due to a lower boiler pressure drop, see Graphs 2 through 7 on pages 75 through 77.

Figure 11, 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, page 22 illustrates a single zone utilizing the boiler circulator as the system circulator.

System Piping - Radiant Heating

The heat exchanger design of the PRESTIGE Solo allows operation in a condensing mode. This feature requires no regulation of the return water temperature back to the boiler in radiant heating applications.

The boiler water supply temperature can be maintained by the PRESTIGE Solo, eliminating the need for a mix system to achieve the desired temperature.

It is recommended for the installer to add a high temperature limit as shown in Fig.13 page

23. This will ensure that the primary supply temperature does not exceed the maximum allowable temperature for the radiant tubing.

EST PRACTICE

The addition of the high temperature limit is important if the PRESTIGE Solo is connected to a domestic hot water system, which requires a high primary supply water temperature.

Size the system piping and circulator to provide the flow needed for the radiant system.

NOTICE

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.

System Piping - Multiple Units Installation

Use a balanced manifold system as the primary / secondary connection to the space heating piping as shown in Fig. 14 page 24.

Maintain a minimum of 6 inches [153 mm] of clearance between units to allow for servicing.

Refer to Figs. 6 and 7 page 18 to install air separator and expansion tank.

For the space heating piping refer to the applications mentioned in this manual or use recognized design methods.

Page 26

Boiler Piping

Supply

System

Hot

Cold

Domestic

Return

Fig. 8: DHW Boiler Piping with a PRESTIGE Solo and SMART

1. PRESTIGE Solo boiler

2. SMART water heater

3. Isolation valve

4. DHW circulator

5. CH circulator

6. Flow/check valve

7. Pressure relief valve

8. Drain/purge valve

NOTICE

The boiler system piping shown in Fig. 8 must be a “closed” system to avoid any oxygen contamination and potential failure of the outer tank of the Smart.

Page 27

Boiler Piping

one Load

Additional

Max.

12"

one Load

Zone Load

Additional

Max.

12"

Zone Load

Fig. 9: CH System Piping - Zoning with Zone Circulators

1. PRESTIGE Solo boiler

2. CH circulator

3. Flow/check valve 4 Isolation valve

5. Zone circulator

7. Pressure relief valve

8. Air separator

9. Automatic air vent

10. Diaphragm expansion tank

11. Automatic fill valve

6. Drain/purge valve

Fig. 10: CH System Piping - Zoning with Zone Valves

1. PRESTIGE Solo boiler

2. CH circulator

3. Flow/check valve 4 Isolation valve

5. Zone valve

6. Drain/purge valve

7. Pressure relief valve

8. Air separator

9. Automatic air vent

10. Diaphragm expansion tank

11. Automatic fill valve

12. System circulator

Page 28

Boiler Piping

Additional

Zone Load

Single

Zone load

Note: Verify CH circulator is properly sized to overcome the system pressure drop and provide adequate flow through the boiler system.

Fig. 11: CH System Piping - Multiple Zone Valve with Single System/Boiler Circulator

1. PRESTIGE Solo boiler

2. CH circulator 4 Isolation valve

5. Zone valve

6. Drain/purge valve

8. Air separator

9. Automatic air vent

10. Diaphragm expansion tank

11. Automatic fill valve

12. Pressure Differential Valve

7. Pressure relief valve

Note: Verify CH circulator is properly sized to overcome the system pressure drop and provide adequate flow through the boiler system.

Fig. 12: CH System Piping - Single Zone System with Single System/Boiler Circulator

1. PRESTIGE Solo boiler

2. CH circulator

3. Flow/check valve 4 Isolation valve

5. Zone valve

6. Drain/purge valve

7. Pressure relief valve

8. Air separator

9. Automatic air vent

10. Diaphragm expansion tank

11. Automatic fill valve

Page 29

Boiler Piping

Radiant Zone

Additional

Radiant Zone

Max.

12"

Note: Manifold mounted valve actuators may be used in lieu of zone valves.

Fig. 13: CH System Piping - Radiant/Low Temp. Heating

1. PRESTIGE Solo boiler

2. CH circulator

3. Flow check valve 4 Isolation valve

5. Zone valve

6. Drain/purge valve

7. Pressure relief valve

8. Air separator

9. Automatic air vent

10. Diaphragm expansion tank

11. Automatic fill valve

12. System circulator

13. High temperature limit control

Page 30

Boiler Piping

To the

System

From the System

12"

Max.

5 5

1. Boiler circulator

2. Isolation valve

3. Flow/check valve

4. System circulator

5. Drain/purge valve

6. Automatic air vent

7. Air separator

8. Diaphragm expansion tank

9. Automatic fill valve

Fig. 14: Multiple PRESTIGE Solo Boiler Piping - Primary / Secondary / Piping using Balanced Manifold System

Page 31

Installating Vent/Combustion Air & Condensate Drain

SECTION V - Installing Vent / Combustion Air & Condensate Drain

Installing Vent and Combustion Air

DANGER

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.

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.

3. Remove the compression nut and rubber seal from the drain outlet.

4. Using 3/4” x 2’ flexible PVC tube provided, 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.

5. Thread the rubber seal into the compression nut to ease installation of the pipe to the drain assembly.

Installing Condensate Drain Assembly

1. Locate the condensate drain assembly and install as shown in Fig. 15 page 26.

NOTICE

The installer may want to fill the condensate trap with water prior to assembling on the unit.

2. Remove the retaining nut and rubber seal from the condensate drain assembly and slide over the heat exchanger condensate drain nipple. Connect the condensate drain assembly to the retaining nut and tighten.

Hand tight only!

6. Seat the pipe onto the drain assembly and

tighten the compression nut. Hand tight

only!

NOTICE

The installer may opt to using 13/16" ID tubing in lieu of rigid piping.

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.

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

Page 32

Installating Vent/Combustion Air & Condensate Drain

Flexible Tubing

(or 3/4 PVC/ CPVC Piping

to Drain)

Compression

Nut with Rubber Seal

Fill Plug

with Vac cum

Break Port

Condensate

Drain Assembly

Plastic Ball

Retaining Nut with Rubber Seal (Hand Tight Only)

Heat Exchanger Condensate Drain Nipple

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 property damage from potential condensate spillage.

8. 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. 15: Condensate Drain Assembly

Page 33

Gas Piping

Sediment Trap Min. Length of 3"

Union Fitting

Cap

Te e Fitting

External Manual Gas Shut Off Valve (Must Be Within 6' of the Boiler)

Gas Flow

SECTION VI - Gas Piping

Gas Supply Piping Connection

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.

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 60, 3/4” NPT for PRESTIGE Solo 175/250 or 1” NPT for PRESTIGE Solo 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. 16. 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. 16.

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

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.

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. 16: Recommended Gas Supply Piping

Page 34

Gas Piping

NATURAL GAS

Pipe Sizing - Natural Gas

Refer to Table 1 for schedule 40 metallic pipe length and diameter requirements for natural gas, based on rated PRESTIGE 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.

Natural Gas 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 60: 0.204” (5.2 mm)

PRESTIGE Solo 175: None Required

PRESTIGE Solo 250: None Required

PRESTIGE Solo 399: 0.339” (8.6 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)

Page 35

Gas Piping

PROPANE GAS

Pipe Sizing - Propane Gas

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

Propane Gas Supply Pressure Requirements

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

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

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. 17 or 18, page

30. Failure to ensure proper burner setup could result in severe personal injury, death or substantial property damage.

NOTICE

The propane orifice requirements are:

PRESTIGE Solo 60: 0.120” (3.1 mm)

PRESTIGE Solo 175: 0.221” (5.6 mm)

PRESTIGE Solo 250: 0.250” (6.3 mm)

PRESTIGE Solo 399: 0.264” (6.7 mm)

WARNING

Page 36

Gas Piping

Gas Valve

Orifice

Gaskets

Venturi

enturi

nlet Supply

Pressure Port

ropane

rifice

as Valve

Gasket

Gas Valve

Pipe Fitting

Gas Valve

Fig. 17: Gas Valve / Venturi Assembly - PRESTIGE Solo 60/175/250

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

Page 37

Internal Wiring

Terminal Block

Wiring Tool

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.

General Requirements

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

- If original wiring as supplied with the unit

must be replaced, use only Type T 90ºC wire or equivalent as a minimum.

- The PRESTIGE Solo 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.

Control Module Circulator AMP Ratings

- AMP draw of the CH circulator not to exceed 2 amps.

- AMP draw of the DHW circulator not to exceed 2 amps.

Wiring Tool Instructions

1. Locate the wiring tools on the PRESTIGE Solo just below the MCBA control in a plastic bag and below the extra fuses.

2. Locate the terminal blocks on the PRESTIGE Solo below the MCBA control.

NOTICE

The 120V Terminals are located on the left set of Terminal Blocks. The 24V Terminals are located on the right set of terminal blocks.

3. Carefully pull down on the lower half of the terminal block to remove.

4. Hook the wiring tool into the desired slot of the terminal block as shown in Fig.19.

5. Push wiring tool in towards the terminal block and insert wire in slot at bottom of terminal block.

6. Repeat steps 4 & 5 until all wiring is complete.

Fig. 19:

7. Re-connect the lower half of the terminal block to the upper half.

8. Place the wiring tool back into the plastic bag or leave tool hooked to a slot on the 24V terminal block.

BEST PRACTICE

When wiring the PRESTIGE Solo allow additional length of wire for the access panel to swing open during servicing.

Using the Wiring Tool on the Terminal Blocks

Page 38

Internal Wiring

O-10v External Inputs (+)

DHW Sensor or Thermostat

O-10v External Inputs (-)

Gas Valve

PRESTIGE

Solo 399 Only

Heating circulator (supplied on the PRESTIGE Solo 110 only)

Fig. 20: Prestige Solo Boiler Factory Wiring

To properly connect wires to terminal block, use wiring tool included with PRESTIGE Solo. See wiring tool instructions, page 31.

Page 39

External Wiring

SECTION VIII- External Wiring

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 Solo, disconnect electrical power supply at the service panel. Failure to comply can cause severe personal injury or death.

Line Voltage Connections

1. Connect a 120 VAC/15A service to the 120V terminal strip on the wiring panel below the PRESTIGE Solo control module, as shown in Fig. 20, page 32.

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.

Domestic Hot Water Aquastat Wiring

1. Connect the DHW thermostat (aquastat) to the 24V terminal strip on the wiring panel located below the PRESTIGE Solo control module as shown in Fig. 20, page 32.

2. Route all wiring through the provided openings, in the bottom jacket panel. Allow enough wire for access panel to swing open during servicing.

Thermostat Wiring

NOTICE

Isolate 120V wiring from 24V wiring to prevent any potential electrical “noise”.

1. Connect room thermostat or the end switch (isolated contact only) of a relay control panel to the 24V terminal strip on the wiring panel below the PRESTIGE Solo control module, as shown in Fig. 20, page

32.

2. For proper operation install the room thermostat on an inside wall away from influences of heat and cold, i.e. water pipes, areas of draft, lighting fixtures and fireplaces.

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

- Set for 0.2 amps when wired directly to

the PRESTIGE Solo.

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.

- Set to match the total electrical power

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

Page 40

External Wiring

24 V

Transf ormer

by Others

Honeywell V8043

Zone Valves

or Equivalent

Honeywell R8285D Transformer / Relay or Equivalent

24V Terminal Strip

System Circulator

24V Low Voltage Wiring

120V High Voltage Wiring

Room Therm ostats

120V

To Prestige

NOTICE

When making low voltage connections to the Prestige, ensure no external voltage is present in the thermostat circuits. If external voltage is present, provide an isolated contact to prevent damage to the boiler control.

CH and DHW Circulator

1. Connect the CH primary circulator to the PRESTIGE Solo 120 V terminals 1,2 and 3 as shown in Fig. 20, page 32.

2. Connect the DHW circulator to the PRESTIGE Solo 120 V terminals 4, 5 and 6 as shown in Fig. 20, page 32.

3. Maximum circulator continuous current draw is 2A for each circulator.

System Circulator - Zone Valve Application

To energize the system circulator shown as item 12 in Fig. 10 page 21 reference Fig. 21. Installer to provide a Transformer / Relay such as Honeywell R8285 or equivalent and Zone Valves with isolated end switch such as Honeywell V8043 or equivalent.

External Modulating Control

The PRESTIGE Solo firing rate can be controlled by an external modulating boiler controller. See page 32 for wiring and Page 54 for control module setup.

Outdoor Reset Control

The PRESTIGE Solo may operate with a variable boiler operating temperature using the Triangle Tube outdoor sensor, see pages 50 through 53 for installation and set-up.

NOTICE

If the installer opts for a fixed operating temperature for the boiler system, the outdoor sensor is not required and should not be installed.

Additional 24V Limit Wiring

The PRESTIGE Solo provides 24V terminal connections for additional limit controls as shown in Fig. 20 page 32. These limit terminal connections will provide a "hard" lockout requiring a manual reset of the PRESTIGE Solo control, or a “soft” lockout in which the PRESTIGE Solo will automatically reset.

Fig. 21: Secondary System Circulator Wiring

Page 41

External Wiring

High Voltage

120

V. A . C .

Room

Thermostat

Room

Thermostat

Zone 1

Zone 2

Additional zones

Additional zones may

be added as shown above

To Prestige

24V Terminal Strip

Transformer

(Power)

Zone

Va l ve

Zone Valve

To Prestige

24V Terminal Strip

High Voltage

120

V.A.C.

Room

Thermostat

Room

Thermostat

Zone 1

Zone 2

Additional zones

Additional zones may

be added as shown above

Transformer

(Power)

Zone

Valve

Zone Valve

* Isolation relay

*Use isolation relay on 3-wire zone valve with non-isolated end switch. Transformer and the Prestige MCBA control can burn out if isolation relay is not used.

NOTICE:

4 Wire Zone Valve

3 Wire Zone Valve

Fig. 22: Multiple Zone Field Wiring Using Zone Valves

Page 42

External Wiring

To Prestige

24V Terminal Strip

irculator Zone 1

Thermostat

zone 1

oneywell R

845A

Relay

120

VA C

irculator Zone 2

Thermostat

zone 2

Additional zones may be

added as shown above

Thermostat

Zone 1

Zone 1 Circulator

120 VAC

To Prestige

24V Terminal Strip

Zone 2 Circulator

Zone 3 Circulator

Thermostat

Zone 2

Thermostat

Zone 3

T1 T1 T2T2T3T3

C2C2C1C1PRPR

X2X1L1L2ZC

Fig. 23: Field Wiring with Zone Circulators

Fig. 24: Typical Zone Relay Panel Wiring

Page 43

Start-Up Preparation

SECTION IX - Start-Up Preparation

Check Boiler System Water Chemistry

WARNING

Do not use petroleum-base 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

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

Water pH Level 6.0 to 8.0

Flush Boiler and Domestic System 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.

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.

Maintain the boiler water 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.

Water Hardness Less Than 7 Grains

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

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.

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

NOTICE

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

Page 44

Start-Up Preparation

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 60 or 5 gallons [19 L] for PRESTIGE Solo 175/250 or 7 gallons [26 L] for PRESTIGE Solo 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.

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 could 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.

NOTICE

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

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.

Check Low Water Cut-Off Device

- The PRESTIGE Solo is provided with a factory installed LWCO device that measures system pressure of more than 10 psi.

- Remove the front jacket panel and check for continuity across the low water cut-off device wire terminals. The contacts should be closed when system pressure is greater than 10 psi. See item 6, on Fig. 27 page 66 (PRESTIGE Solo 60) or on Fig. 27A page 67 (PRESTIGE Solo 175/250) or Fig. 27B page 68 (PRESTIGE Solo 399) for location of the LWCO.

Page 45

Start-Up Preparation

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.

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.

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 24V terminal strip on the wiring panel.

Inspection of Condensate Drain Assembly

1. Inspect and ensure the Condensate Drain Assembly is properly installed as described on page 25 and shown in Fig. 15 on page

26.

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

Check Thermostat Circuit

- Disconnect the external thermostat wires from the 24V terminal strip on the wiring panel.

- 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.

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

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.

Page 46

Start-Up Procedures

SECTION - Start-Up Procedures

Final Checks Before Start-Up

c Read page 45 through 48 regarding the

operation of the PRESTIGE Solo control.

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 79 through 81.

c Verify Start-up Preparation items outlined on

pages 37 thru 39 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: 0.120” or

3.1 mm for PRESTIGE Solo 60, 0.221” or

5.6mm for PRESTIGE Solo 175, 0.250” or

6.3 mm for PRESTIGE Solo 250 or 0.264” or 6.7 mm for PRESTIGE Solo 399. Refer to Figs. 17 & 18, page 30 for location of the propane gas orifice.

NOTICE

PRESTIGE Solo Start-Up

1. Turn the ON-OFF switch 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 42.

If PRESTIGE Solo Does Not Start Correctly

1. Verify DHW (parameter 2) and CH (parameter 3) systems are turned ON or set to “01”. Read the Boiler Display Standby and Parameter Section of the manual starting on page 47 for more information.

2. Check for loose electrical connections, blown fuse (external or internal to the MCBA Control) or open service switch.

3. Check continuity across the L.W.C.O device for a closed circuit. See item 5 on Fig. 27, page 66 and item 6 Fig. 27A, page 67 and Fig. 27B, page 68.

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

5. Is the gas supply valve(s) 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 Triangle Tube Tech Service.

For natural gas applications the Prestige 60 requires an orifice: 0.204” (52mm), and the Prestige 399 requires and orifice:

0.330” (8.6 mm)

c Ensure the vent Condensate Drain

Assembly is filled with water.

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.

Page 47

Start-Up Procedures

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 39.

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.

Test for CO2 or O2 and for CO during high firing rate. To manually place the boiler into high fire mode, reference page 45. The combustion reading should be within the range listed in Table 2. The CO level should not

exceed 100 ppm when combustion is correct.

WARNING

The combustion levels should be measured at high firing rate, refer to page 45 of the PRESTIGE Solo control section on how to set the firing rate. If the combustion levels are not within the range given in Table 2 for the firing rate, shut the boiler down and contact Triangle Tube Engineering Department. Failure to comply with this requirement could result in severe personal injury, death or substantial property damage.

Table 2: Recommended Combustion Levels

Natural Gas

All Models

O2 Min. 2.30% 2.70% 3.70%

O2 Max. 5.30% 4.70% 5.20%

Propane

Solo 60/175/250

Propane

Solo 399

c Verify Flame Pattern and Combustion

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.

CO2 Min. 8.80% 10.70% 10.00%

CO2 Min. 10.50% 12.00% 11.00%

CO Max. 100 ppm 100 ppm 100 ppm

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 45.

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.

Page 48

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 a sequence of numbers (0,1,2,3,4,etc.) as the left digit. Sequence digit 3 or 4 indicates the boiler is firing. Sequence digit 0 means there is no call for heat (all external thermostats are satisfied).

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”.

Page 49

Start-Up Procedures

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.

Set Boiler CH Set Point

1. Press the MODE button until the display shows PARA. This is the parameter mode of the control.

2. Press the STEP button until the first digit on the display shows "4". The last three digits on the display shows the CH Maximum Boiler Operating Setpoint.

3. Press the "+" or "-" button to change the setting.

NOTICE

When an outdoor sensor is used, the setting of Parameter 4 is the CH setpoint when the outdoor temperature is at or below 0ºF. When the outdoor temperature is above 0ºF, the PRESTIGE Solo control will calculate the boiler setpoint between the minimum and maximum temperature settings.

4. Press the "STORE" button to save the setting.

TIGE Solo or turn down DHW tank aquastat (if used) to ensure the boiler does not receive a DHW call for heat.

2. Set the room thermostat to the lowest setting.

3. Turn off power to the boiler, wait a few seconds and turn on power to the boiler.

4. The following displays should occur:

U1.22] Software version

[

A140] Self check on power up 0140] No call for heat

[

5. Initiate a call for heat by raising the set point of the room thermostat to the highest setting. The following display should occur.

5140] This is a fan / air flow check. The

[ burner blower will be energized momentarily prior to the prepurge cycle.

1140] This is the prepurge cycle. The

[ burner blower and the CH (Central Heating) circulator become energized. The blower has a 10 second prepurge cycle.

2140] This is the ignition cycle. The con-

[ trol module will energize and open the gas valve and begin the spark for ignition.

- If the burner flame proves, the burner

will continue to fire at the ignition fan speed for approximately 10 seconds to stabilize the flame.

Operation Verification - Space Heating

NOTICE

Digits and characters shown as [ in the following outline, represent the control panel display. The last three digits on the display represent the measured boiler water temperature and may differ from what is shown in the manual.

1. Disconnect the DHW (Domestic Hot Water) thermostat wiring from the PRES-

0000

- If the burner flame is not proven the control module will repeat the ignition sequence. If the flame is not proven after five attempts the control will lockout and the display will show [

- To verify flame failure lockout, close the manual shut off valve on the gas supply piping to the boiler and repeat ignition sequence. When verification is completed, ensure the manual shut off valve is returned to the open position.

3140] This is the normal CH operation

[ cycle. After the flame is proven and stabilized the burner will fire at low input for

E-02]

Page 50

Start-Up Procedures

approximately 1 minute. After this time period, the control module will begin to modulate the burner firing rate based on actual boiler outlet temperature and the set point temperature.

6. Allow the boiler to operate and allow the boiler outlet temperature to reach the set point temperature.

6180] This begins the burner shutdown

[ and post purge cycle. The CH circulator will continue to run until the room thermostat is satisfied.

7. Lower the room thermostat set point below the room temperature to end the call for heat.

1180] This begins a post purge cycle.

[ When the room thermostat is satisfied, the boiler will shutdown. The control module will close the gas valve and the blower will continue for 30 seconds for a post purge cycle before shutting down. If another call for heat is initiated, the boiler will remain off for an additional 30 seconds before starting a new ignition sequence.

7180] The CH circulator will continue to

[ run for a 1 minute post pump cycle.

0180]The boiler is in standby MODE

[ waiting for a call for heat.

8. Verify the operation of the boiler by repeating the operational sequence several times.

9. Return the room thermostat to a desired setting. Reconnect the DHW wiring or return the DHW aquastat to desired setting, placing the DHW system into operation.

Operation Verification - Domestic Hot Water (if applicable)

5140] This is a fan / air flow check. The

[ burner blower will be energized momentary prior to the prepurge cycle.

1180] This is prepurge cycle. The burner

[ blower and DHW circulator become energized and the 10 second prepurge cycle begins.

2180] The boiler will begin the ignition

[ sequence. The same sequence of establishing flame, trail for ignition and attempts for ignition as described in the space heating applies for domestic water heater.

4180] This indicates normal operation

[ for DHW. The burner will begin modulating its input to maintain the DHW set point. The burner will not go into the low input rate for the 1 minute flame stabilization period that occurs in CH mode.

3. Lower the DHW aquastat to satisfy the call for heat.

1180] The post purge cycle begins. The

[ control module closes the gas valve and the blower continues for a 30 second post purge.

8180] The DHW circulator will continue

[ for a 30 second post pump cycle. If another DHW call for heat is initiated the boiler ignition sequence will begin immediately.

0180] Boiler is in standby MODE wait-

[ ing for a CH or DHW call for heat.

4. Verify the DHW operation of the boiler by repeating the outlined operation sequence several times.

5. Return the DHW aquastat and room thermostat to the desired setting.

1. As outlined in the verification for space heating, repeat STEPS 2 through 4.

2. Raise the DHW aquastat setting to initiate a call for heat. As in the space heating operation the display should show:

Page 51

Start-Up Procedures

est function: Burner on, high fire mode

Test function: Burner on, low fire mode

H L

Display

Boiler function

Boiler Control Display

Standby Mode

This is the standard mode for the PRESTIGE Solo. The control automatically returns to this mode after 20 minutes if no keys have been pressed on the display. Any parameters that were modified are then stored.

The first character shows (on left side of display) the current status of the boiler depending on the condition of both the boiler and the burner. The last 3 characters indicate the boiler supply temperature.

If the burner is blocked due to a “soft” lockout, the display alternates between a 9 followed by the boiler supply temperature and a “b” with a two digit error code.

TO TEMPORARILY PLACE THE BURNER INTO HIGH FIRE TEST MODE: press

the MODE button until “ Then press and hold both the MODE and “+” buttons simultaneously until the first digit flashes “H”.

While in the test mode:

- high limit will function

- boiler CH circulator will function

StbY” is displayed.

TO DEACTIVATE THE HIGH OR LOW FIRE TEST MODE: press the MODE button

until “ hold both the “+” and “-” buttons simultaneously to deactivate the high or low fire test mode.

StbY” is displayed. Then press and

NOTICE

If the “+” button is held in, the CH system (parameter 3) will be turned OFF and the display will show “ hold the “+” button to turn the CH system back ON, the display will show “c” followed by CH set point. If the “-” button is held in while in the “ domestic system (parameter 2) will be turned OFF and the display will show

dOFF”. Press and hold “-” button to

“

turn the domestic system back ON, the display will show “d” followed by domestic set point temperature.

cOFF”. Press and

StbY” mode,

- domestic circulator will not function

- the test mode will time out in approxi-

mately 10 minutes

TO TEMPORARILY PLACE THE BURNER INTO LOW FIRE TEST MODE: press

the MODE button until “ Then press and hold both MODE and “-” buttons simultaneously until the first digit flashes “L”.

StbY” is displayed.

Page 52

STANDBY, no demand for heat

Fan prepurge or post purge cycle

Ignition sequence

Burner ON for space heating (CH)

Burner ON for domestic hot water (DHW)

Pre-check for air flow prior to prepurge cycle

Burner OFF due to reaching temperature setpoint

Domestic hot water (DHW) post pump cycle

Space Heating (CH) post pump cycle

Burner blocked:

Supply temperature too high (202 F) . Burner will remain OFF until temperature drops below 200 F

Return temperature too high (202 F). Burner will remain OFF until temperature drops below 200 F

Return temperature is higher than supply temperature. Burner will remain OFF until corrected.

Supply temperature increased too quickly. Burner will remain OFF for a 10 minute period. Burner will recycle, increasing waiting period 1 minute for a max. 15 minutes

Factory supplied LWCO device or external limit (terminals 15 & 16) is OPEN. Burner off for 150 seconds, auto reset.

3 4 5 6 7 8

isplay

oiler function

No blower signal

Blower signal present with no demand, Burner will remain OFF until condition terminates

Temperature difference between the supply and return is more than 72 F. Burner will remain OFF for 150 seconds. Burner will recycle increasing wating period 1 minute for a max. 20 cycle.

Flue temperature sensor is short-circuited. Burner OFF until corrected

Flue temperature senor is “open” Burner OFF until corrected.

Flue temperature greater than 240 F but less than 250 F. Burner off for 150 seconds

Wait for the blower to start

Indirect water heater temperature sensor is short-circuited. Burner OFF until corrected.

Indirect water heater temperature sensor is “open” or disconnected. Burner OFF until corrected.

Power frequency deviation

Flame current signal lost

Start-Up Procedures

Standby Mode Display

Page 53

Start-Up Procedures

omestic Hot Water Setting (See Note 1)

DHW Application Selection (See Note 2)

CH Application Selection (See Note 3)

CH Maximum Boiler Operating Setpoint

1. 2

3 4

STEP

ey:

Display

escription of parameters

MODE

Key:

Display

Pressing MODE once

Setting The Boiler Parameters

Parameter mode

To access PARAMETER mode when the system is in STANDBY mode, press the MODE button once.

To scroll through the list of parameters, simply press the “STEP” button. The first digit is the parameter number followed by the parameter value. To modify a parameter value, use the + or - keys. Then press “STORE” to save the value you just changed. The display flashes once to confirm the data has been stored.

To activate the parameters you changed, press “RESET”. However, if you do not press a key, the system returns to STANDBY mode after 20 minutes and automatically stores the changes.

Note 1: This parameter is factory set to 140ºF. It is important to note the control adds 46ºF to this setting, therefore the actual domestic hot water boiler setpoint is 140ºF + 46ºF = 186ºF.

Note 2: This parameter should not be changed from the factory setting of 01. The performance of the DHW will be affected and can become unreliable.

Note 3: This parameter should not be changed from the factory setting of 01. The performance of the CH (Central/Space Heating) will be affected and can become unreliable.

Page 54

Start-Up Procedures

MODE

Key:

Display

Pressing MODE once

Pressing MODE twice

Accessing Boiler Information

Information mode

To switch from STANDBY mode to INFORMATION mode, press MODE twice.

Press STEP until the system displays the information you need. The first digit is the information item number followed by the items value. The decimal point located behind the first position flashes to indicate that the boiler is in INFO mode.

NOTICE

The ignition counters and burner hours are split into three two digit numbers. For example:

Write the numbers down from left to right to arrive at 123,456 CH ignitions.

NOTICE

In the INFO Mode a temperature reading of -22 typically indicates an “open” circuit. A temperature reading of 240 typically indicates a short-circuit.

Display Digit

Segments

Page 55

as valve harness not properly connected

Failed ignition after 5 attempts

ower supply lost after lockout occured

Internal control failure

E E

2 03 0

8 0

E E

Display

ard Lockout

Internal control failure

Flame detected prior to burner startup

nternal control failure

External limit (terminals 13 & 14) is OPEN

Blower signal does not reset to zero

No blower signal present

Supply Temperature sensor is short circuited

1 1

5 1

E E

Flue Temperature exceeds 250 F

Internal control error - failure to read parameters

Return Temperature sensor is short circuited

Supply Temperature sensor is OPEN

Return Temperature sensor is OPEN

Internal control failure

Inadequate power supply to the fan

E E

6 3

E E

Flue Temperature sensor is short circuit

Return Temperature exceeds 212 F

Supply Temperature increased too rapidly

Internal control failure

nternal control failure

Internal control failure

9 2

E E

Supply Temperature exceeds 212 F

Flue Temperature sensor is OPEN

Internal control failure

Supply or Return Temperature sensor drift

Invalid power frequency

Supply or Return Temperature failure

Supply or Return Temperature not changing

31 1 1 1 1

E E

Start-Up Procedures

Error (Hard Lockout) Mode

If a serious fault occurs, the system enters a hard lockout condition which requires a manual reset by pressing the RESET button. A hard lock is indicated by displaying an E for the first digit, followed by the error code.

For a detailed description of the error codes, reference the PRESTIGE Solo Troubleshooting Guide.

CAUTION

The boiler freeze protection feature is disabled during a Hard Lockout, however the CH circulator will operate.

CAUTION

During a hard lockout or low water condition the boiler will not re-start without service. If the heating system is left unattended in cold weather appropriate safeguards or alarms should be installed to prevent property damage.

Page 56

Outdoor Reset Control

SECTION XI - Outdoor Reset Control

The boiler setpoint for a heating call can be fixed or vary with the outdoor temperature. If the application requires a constant supply temperature from the boiler, the outdoor temperature sensor should not be connected to the boiler. If an outdoor temperature sensor is connected to the boiler, the outdoor reset function is automatically enabled and will vary the CH setpoint with the change in outdoor temperature. The outdoor reset function has no affect on the DHW setpoint during a domestic call.

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

5. Avoid mounting the enclosure in areas subjected to excessive moisture.

6. Once an area on the exterior wall has been determined, to affix the enclosure use the enclosure as a template to mark the location of the mounting screws.

7. Using a 3/16” drill bit, drill 2 pilot holes on the marked locations.

8. Tap the enclosed plastic anchors into the pilot holes. Use care not to damage the anchors.

9. Mount the sensor enclosure using the screws provided.

Wiring the Sensor

1. Remove the sealing nut and sealing gasket from the sensor enclosure.

Fig. 25: Sensor Enclosure and Components

Mounting the Outdoor Sensor

1. Remove the front cover and mounting screws / anchors from the sensor enclosure.

2. When mounting the enclosure the exterior wall selected should represent the heat load of the building. Typically a northern or northeastern wall will suit most buildings. A southern facing wall may suit buildings that have large glass walls or windows on the southern face.

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

2. Route two 18 gauge wires through the sealing nut and gasket. Connect the wires to the sensor terminals 1 and 2.

3. Re-insert the sealing gasket and tighten the sealing nut to the sensor enclosure.

4. Route the sensor wire 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.

5. Connect the sensor wires to the outdoor sensor terminals on the 24V terminal strip located inside the boiler enclosure (see boiler wiring diagram, Fig. 20 page 32).

Page 57

Outdoor Reset Control

Summer / Winter Switch at Boiler

If required the CH (Central Heating) system can be turned off at the boiler, similar to a manual summer / winter switch by pressing and holding

the “+” button while in

the “StbY” mode. The

display will show “cOFF”. Pressing and holding the “+” button turns the CH system back on. The display will show “c” followed by the CH set point temperature.

WARNING

If a parameter setting is changed but the STORE button is not pressed to save the setting, the MCBA will automatically store the setting after 20 minutes. Ensure all parameters are at their factory settings or appropriately revised for the application prior to commissioning the boiler. Failure to comply could result in erratic or unreliable operation of the Prestige boiler.

CH Maximum Boiler Operating Setpoint (Parameter 4)

inimum

Factory Setting

186ºF 86ºF 194ºF

Setting

aximum

Setting

If an outdoor temperature sensor is not connected to the boiler, the boiler setpoint for a heating call will be set to the CH Maximum Boiler Operating Setpoint. If an outdoor temperature sensor is connected, the CH Maximum Boiler Operating Setpoint becomes the boiler setpoint on the CH Reset Curve Coldest Day. The outdoor temperature can be monitored on the boiler display via item 4 of the INFO menu.

CH Minimum Boiler Operating Setpoint (Parameter 10)

Factory Setting

86ºF 60ºF 140ºF

Minimum

Setting

Maximum

Setting

NOTICE

Once a parameter setting has been revised and stored pressing the STEP button will display the setting of the next parameter without showing P_XX. To avoid confusion, it is advisable to continue pressing the STEP button until Parameter 46 is reached. The next press of the STEP button will cause the display to roll over to Parameter 1. Continue pressing the STEP button until the next parameter to be adjusted is reached and revise the setting.

Adjusting Outdoor Reset Curve

Parameters 4, 10, 11, & 12 define the settings of the outdoor reset curve. See Graph 1 and Table 3, page 53 for an example of modifying the outdoor reset curve.

This parameter is not applicable if an outdoor sensor is not connected to the boiler. When an outdoor temperature sensor is connected, the CH Minimum Boiler Operating Setpoint becomes the boiler setpoint on the CH Reset Curve Warmest Day.

CH Reset Curve Coldest Day (Parameter 11)

Factory Setting

00ºF (-)22ºF 50ºF

Minimum

Setting

Maximum

Setting

This parameter is not applicable if an outdoor sensor is not connected to the boiler. When an outdoor temperature sensor is connected, the CH Reset Curve Coldest Day is the coldest design temperature of the heating system.

Page 58

Outdoor Reset Control

CH Reset Curve Warmest Day (Parameter 12)

Factory Setting

64ºF 60ºF 78ºF

This parameter is not applicable if an outdoor sensor is not connected to the boiler. When an outdoor temperature sensor is connected, the CH Reset Curve Warmest Day is the warmest design temperature of the heating system.

Entering MCBA Access Code

The installer must enter the MCBA Access Code to adjust the advanced parameter settings of the MCBA. The Access Code can be entered as follows:

1. Press the MODE button until the display shows

2. Press and hold the MODE and STEP buttons together for 2 to 3 seconds until the display shows

STbY.

Minimum

Setting

CODE.

Maximum

Setting

Press STEP x2 - 2_01 Press STEP x3 - 3_01 Press STEP x4 - 4186 Press STEP x5 - P_10

Press STEP x6 - P_11 Etc......

After Parameter 4, the display will show P followed by the parameter number. Once a particular parameter is reached, the display will change to show the current setting of that parameter.

NOTICE

The actual parameter values displayed on the display may vary depending on the application, but the sequence will always occur in the order shown.

Changing a Parameter Setting

1. Use the “+” or “–“ button to change the parameter setting.

3. Press the STEP button once and the display

will show random number.

4. Press the “+” or “–“ buttons to change the number displayed to read hold the “+” or “–“ button to rapidly change the number.

5. When the display reads STORE button to save the Access Code. The display should flash to indicate that the Access Code was saved.

After the Access Code has been entered, the advanced parameters can be accessed by pressing the MODE button until the display shows

where

represents a

C_54.. Press and

C_54, press the

PARA. Once the display shows PARA, press

the STEP button to reach the appropriate parameter. The display should follow the following sequence:

Press STEP once-

1140

2. Press the STORE button to save the change. The display should flash to indicate that the change was saved.

3. Press the RESET button to leave the Access Code mode.

Page 59

Outdoor Reset Control

100

140

180

10 0

-10

Boiler Temperature ( F)

Outdoor Air Temperature ( F)

Parameter 4 Set Point

Parameter 10

Set Point

Parameter 12 Setting

Parameter 11 Setting

Graph 1: Outdoor Air Temperature Reset Curve (Example)

Table 3: Outdoor Air Temperature Reset (Example)

Outdoor

Temperature

0ºF or Lower 140ºF

23ºF 122ºF

40ºF 108ºF

64ºF or Higher 86ºF

Boiler target Temp.

Based on Outdoor Temp.

Graph 1 illustrates Parameter 4 adjusted to 140ºF target temperature at 0ºF outdoor air temperature

Note: Factory setting of Parameter 4 is 186ºF.

Page 60

External Modulating Control

SECTION XII - 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.

Wiring the Modulating Controller

Run two 18 gauge wires from the external modulating boiler controllers 0-10 VDC boiler output to the external input terminals on the low voltage terminal strip inside the boiler. (see boiler wiring diagram, Fig. 20 page 32). This signal will both enable and modulate the boiler. No wiring is required at the thermostat (TT) terminals 7 and 8 of the boiler.

NOTICE

Ensure that the polarity of the connections from the external modulating boiler controller to the boiler is correct. Reversed polarity could lead to erratic and/or no response from the boiler controller.

NOTICE

Ensure that Parameter 4 is set above the highest setpoint of the external modulating control. Paramater 4 is a boiler high temperature limit when using an external modulating controller.

Programming of External Modulating Control

The external modulating control must be programmed to send 1.8 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 2 minutes to allow the burner to stabilize before modulating the boiler.

Parameter Adjustment

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

CH Operating Signal Section (Parameter 45)

Factory Setting

00 02

Revised

Setting

Follow the procedure for entering the MCBA Access Code on page 52, and then change the setting of Paramater 45 from the factory setting of 00 to 02.

Page 61

External Modulating Control

Factory Setting Parameters

1 1

2 01 DHW Application Selection

3 01 CH Application Selection

4 186ºF CH Maximum Boiler Operating Setpoint

10 86ºF CH Minimum Boiler Operating Setpoint

11 00ºF CH Reset Curve Coldest Day

12 64ºF CH Reset Curve Warmest Day

13 -22ºF Frost Protection Setpoint

18 32ºF CH Block Temperature Setting

19 00 Minutes Boost Feature Setting

20 00ºF Parallel Shift Value

21 46ºF Setpoint Value Addition for DHW

40ºF

HW Setting

32 01 Minutes CH Circulator Post Pump Time Period

33 03 x 10.2 Sec. DHW Circulator Post Pump Time Period

38 02ºF DHW On Differential

39 06ºF DHW Off Differential

40 03 x 10.2 Sec. CH Call Blocking Time

41 00 x 10.2 Sec. DHW Call Blocking Time

42 00 x 10.2 Sec. DHW to CH Call Blocking Time

43 00 Minutes DHW Priority Timeout

45 00 CH Operating Signal Selection

46 02 DHW Operating Signal Selection

Page 62

Check-Out Procedures

SECTION XIII- Check-Out Procedures

NOTICE

Perform the following check-out procedures as outlined and check off items as completed. When procedures are completed, the installer should complete the installation record on page 57.

Check-Out Procedures

c Boiler system water chemistry checked and

verified as outlined on page 37.

c The boiler air vent and 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 29.

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 Reviewed all instructions shipped with the

PRESTIGE Solo with the homeowner or maintenance personnel.

c Completed the Installation Record on page

57.

c Ensure all manuals and other documents

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

c Thermostat circuit wiring checked and ver-

ified that no voltage is present to the low voltage terminals as outlined on page 39.

c Operating Instructions on page 42 were fol-

lowed during start-up.

c Combustion levels and flame pattern veri-

fied as outlined on page 41.

c Measured the rate of input on Natural Gas

as outlined on page 41.

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.

Page 63

Installation Record

PRESTIGE Model Number:

Serial Number:

Date of Installation:

Fuel: Natural Gas Propane

Measured Rate of Input:

Combustion Readings:

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)

(Phone Number)

Btu/hr

____________________________________________________________________

_________________________________________________________________

ppm

SECTION XIV - Installation Record

Page 64

Maintenance Schedule

SECTION XV - Maintenance Schedule

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 for leaks: water, gas, flue and condensate.

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

- Check boiler water pressure, piping and expansion tank.

- Check control settings.

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 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.

Page 65

Maintenance Procedures

SECTION XVI - Maintenance Procedures

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 58 and further explained on pages 59 through 64 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.

NOTICE

The following information provides detailed instruction for completing the maintenance items outline in the maintenance schedule on page 58. In addition to this maintenance, the PRESTIGE Solo should be serviced at the beginning of the heating season by a qualified service technician.

Reported Problems

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.

Inspect Burner Area

Remove the boiler front jacket panel and venturi inlet elbow.

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

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

WARNING

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

Check System Piping

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.

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

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

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 41.

Page 66

Maintenance Procedures

Clean Condensate Drain Assembly

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

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

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

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

5. Remove the fill plug on the condensate drain assembly and fill with water. See Fig. 15 on page 26.

6. Replace the fill plug on drain assembly.

Check Ventilation Air Openings

Inspect Vent and Combustion Air Piping

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

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

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.

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 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.

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.

Page 67

Maintenance Procedures

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.

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.

Inspection of Ignition Electrode

Remove the ignition electrode from the burner mounting plate.

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

When replacing the ignition electrode, ensure the gasket is in good condition and correctly positioned, replace gasket if necessary.

Check Ignition Wiring and Ground Wiring

Inspect the burner wiring from the burner control module to the ground terminal behind the control panel.

Check Boiler Relief Valve

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

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.

Page 68

Maintenance Procedures

Check Control Wiring

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

Check Control Settings

1. Set the control display to PARAMETER mode and check all boiler settings. Adjust setting as necessary see page 47.

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

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.

Complete the checkout procedures as referenced in this manual.

Check Burner Flame

Carefully remove the burner mounting plate assembly from the heat exchanger. Ensure combustion chamber insulation is not damaged during removal of burner mounting plate assembly. See WARNING on page 64.

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 is in good condition, positioned correctly and replace gasket if necessary.

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.

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 rectifier plug.

Disconnect the wiring harness connectors from the blower and remove the blower retaining screws or nuts. Remove the blower from the unit.

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

Re-assemble the burner mounting plate assembly onto the heat exchanger. Ensure the burner plate gasket and combustion chamber insulation is in place and not damaged, replace gasket and insulation if necessary. See WARNING on page 64.

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

Re-assemble the gas supply connection and rectifier to gas valve. Open the external manual gas valve. Check gas piping for any leaks as outlined on page 41 and repair if necessary. Place the unit back into service.

Page 69

Maintenance Procedures

Check Flame Signal

The flame signal can be read from item E of the information mode. It should be a min. 3μ 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.

Check Combustion Levels

Refer to page 41 of this manual for measuring combustion levels and burner adjustments.

Check Flue Gas Temperature

1. Adjust the boiler to fire at HIGH fire, see page 45. Place the control display to INFORMATION mode, see page 47 for procedures.

2. The flue gas temperature is indicated on the display when the first digit is 5. The measured temperature (shown as the last 3 digits) should not be more than 54ºF higher than the measured supply water temperature.

3. The measured supply water temperature is indicated on the information display when the first digit is 1 and the temperature shown as the last 3 digits.

4. If the measured flue gas temperature is higher than 54ºF over the supply water temperature, shut the boiler down and follow the procedures listed below to clean the heat exchanger.

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

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

3. Disconnect the gas piping and rectifier plug to the gas valve.

4. Disconnect the wiring harness connectors from the blower and remove the blower retaining screws or nuts. Remove the blower from the unit.

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

6. Carefully remove the burner mounting plate assembly from the heat exchanger. Ensure combustion chamber insulation is not damaged during removal of burner mounting plate assembly. See WARNING on page 64.

7. Carefully remove the combustion chamber insulation from the heat exchanger and set aside. See WARNING on page 64.

8. Use a vacuum cleaner, compressed air or water to remove any accumulation from the heat exchanger flue ways. Do not use any solvent.

9. Re-install the combustion chamber insulation onto the heat exchanger.

10. Re-assemble the burner mounting plate assembly onto the heat exchanger. Ensure the burner plate gasket and combustion chamber insulation is in place and not damaged, replace gasket and insulation if necessary. See WARNING on page 64.

Clean Heat Exchanger

1. Shut down the boiler:

- Follow the instructions on Page 42 "To Turn Off Gas to Appliance"

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

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

12. Reconnect the gas piping and rectifier to gas valve. Check for leaks, repair if necessary.

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

Page 70

Maintenance Procedures

14. Attach a hose to the boiler drain valve and flush the boiler thoroughly with fresh water by using the purge valves to allow water to enter through the make-up water line to the boiler.

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

16. Perform the required startup and checkout procedures as outlined on pages 37 to 57.

Handling Previously Fired Combustion Chamber Insulation

WARNING

The combustion chamber insulation contains ceramic fibers, which are classified as a possible human carcinogen. When exposed to extremely high temperatures, the ceramic fibers, which contain crystalline silica, can be converted into cristobalite.

Avoid Breathing and Contact with Skin and Eyes

Review With Owner

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

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

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.

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

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.

NIOSH Stated First Aid:

Eye/Skin: Immediately irrigate Breathing: Clean fresh air

Page 71

Replacement Parts

Fig. 26: PRESTIGE Solo Jacket Components

Part #

Item

PRESTIGE

Solo 60

1 PSCS01 Disply Control Panel

1A -- --

2 PSJKT01B PSJKT03B PSJKT04B Base Panel

3 PSJKT01F PSJKT02F Front Jacket Panel

5 PSJKT02S PSJKT03S Side Jacket Panel (Left and Right)

Part #

PRESTIGE

Solo 175-250

Part #

PRESTIGE

Solo 399

PSCS02 (Left)

PSCS03 (Right)

Description

Display Control Panel Extensions (Not Shown)

6 PSJKT01T PSJKT03T PSJKT05T Top Jacket Panel

7 PSJKT02T PSJKT04T PSJKT06T Top Jacket Access Panel

8 PSJKT03 PSJKT04 Control Cover Panel

9 PSRKIT21 Wall Mounting Braket with 1 Hardware

Page 72

Replacement Parts

Fig. 27: PRESTIGE Solo 60 Internal Components

Item Part # Description

1 PSRKIT01 Heat Exchanger Body

2 PSRKIT02 Vent Outlet Adapter

3 PSRKIT03 Combustion Air Inlet Adapter

4 PSRKIT04 NTC Sensor (NTC1, NTC2 and NTC5)

5 PGRKIT20 LWCO Pressure Device

6 PSRKIT05 Condensate Drain Assembly

7 PSRKIT06 Boiler Piping - Return Assembly

8 PSRKIT52 Boiler Piping - Supply Assembly

9 PSRKIT17 Pressure Gauge and Fitting

Page 73

Replacement Parts

Fig. 27A: PRESTIGE Solo 175/250 Internal Components

Part #

Item

2 PSRKIT27 Vent Outlet Adapter

3 PSRKIT03 Combustion Air Inlet Adapter

4 PSRKIT04 Supply & Return NTC Sensor (NTC1, NTC2)

5 PSRKIT34 Flue NTC Sensor (NTC5)

6 PGRKIT20 LWCO Pressure Device

7 PSRKIT05 Condensate Drain Assembly

8 PSRKIT28 Boiler Piping - Return Assembly

9 PSRKIT29 Boiler Piping - Supply

PRESTIGE

Solo 175/250

PSRKIT25 Heat Exchanger Body Solo 175

PSRKIT26 Heat Exchanger Body Solo 250

Description

10 PSRKIT17 Pressure Gauge and Fitting

Page 74

Replacement Parts

Fig. 27B: PRESTIGE Solo 399 Internal Components

Part #

Item

1 PSRKIT44 Heat Exchanger Body

2 PSRKIT45 Vent Outlet Adapter

3 PSRKIT46 Combustion Air Inlet Adapter

4 PSRKIT47 Supply & Return NTC Sensor (NTC1, NTC2)

5 PSRKIT34 Flue NTC Sensor (NTC5)

6 PGRKIT20 LWCO Pressure Device

7 PSRKIT05 Condensate Drain Assembly

PRESTIGE

Solo 399

Description

8 PSRKIT48 Boiler Piping - Return Assembly

9 PSRKIT49 Boiler Piping - Supply Assembly

10 PSRKIT17 Pressure Gauge and Fitting

Page 75

Replacement Parts

Fig. 28: PRESTIGE Solo 60/175/250 Burner Components

Item

1 PSRKIT09 PSRKIT30 Combustion Chamber Insulation

2 PSRKIT11 PSRKIT31 Burner Head with Gasket

3 PSRKIT12 PSRKIT32 Burner Plate

4 PSRKIT55 PSRKIT13 Blower with Gasket

5 PGRKIT01 Gas Valve

6 -- Venturi - 055 (Solo 60) - 052 (Solo 175) - 051 (Solo 250)

7 PSRKIT14 Ignition Cable

8 PSRKIT15 Igniter with Gasket

9 PSRKIT16 Sight Glass Assembly (Glass, Gasket and Bracket)

10 -- Propane Orifice - Not Shown

11 -- Burner Plate Gasket - Not Shown

Part #

PRESTIGE

Solo 60

Part #

PRESTIGE

Solo 175-250

Description

12 PGRKIT15 Gas Valve Rectifiier Plug - Not Shown

Page 76

Replacement Parts

Fig. 28A: PRESTIGE Solo 399 Burner Components

Item

1 PSRKIT37 Combustion Chamber Insulation

PRESTIGE Solo 399

2 PSRKIT38 Burner Head with Gasket

3 PSRKIT39 Burner Plate

4 PSRKIT40 Blower with Gasket

5 PSRKIT41 Gas Valve

6 -- Venturi

7 PSRKIT14 Ignition Cable

8 PSRKIT15 Igniter with Gasket

9 PSRKIT16 Sight Glass Assembly (Glass, Gasket and Bracket)

10 -- Propane Orifice - Not Shown

11 -- Burner Plate Gasket - Not Shown

12 PSRKIT42 Gas Valve Piping

13 PSRKIT43 Gas Supply Piping

Part #

Description

Page 77

Replacement Parts

Fig. 29: PRESTIGE Solo Electronic Components

Item Part # Description

1 PSRKIT50 Prestige Control Module

2 PSRKIT19 Transformer with Surge Protection

3 PSRKIT20 Prestige Control Module Display

Page 78

Product Specifications

35.50” [902 mm]

15.43” [392 mm]

9.87” [251 mm]

2.2” [56 mm]

3”

[76 mm]

1 ” NPT Boiler Supply

1/2” NPT Gas Connection

3/4” NPSC Pressure Relief Valve

3” Combustion AIr Inlet

3” Vent Outlet

19.75” [502 mm]

7.31” [186 mm]

1” NPT Boiler Return

Front View PRESTIGE Solo 60

Page 79

Product Specifications

Front View PRESTIGE Solo 175/250

Page 80

Product Specifications

37.20” [945 mm]

24.70” [628 mm]

20.40” [516 mm]

8.60” [473 mm]

13.40” [340 mm]

9.25” [235 mm]

3.27” [83 mm]

1 1/2” NPT Boiler Supply

1” Gas Connection

1 1/2” NPT Boiler Return

4” Combustion Air Inlet

3/4” NPSC Pressure Relief Valve

4” Vent Outlet

17.87” [454 mm]

Front View PRESTIGE Solo 399

Page 81

Product Specifications

Side View PRESTIGE Solo 60

Page 82

Product Specifications

Side View PRESTIGE Solo 175/250

Page 83

Product Specifications

20.80” [529 mm]

15.40” [490 mm]

14.72” [374 mm]

16.10” [409 mm]

5.90” [150 mm]

1 1/2” NPT Boiler Supply

1 1/2” NPT Boiler Return

1” Gas Connection

4” Combustion Air Inlet

4” Vent Outlet

3/4” NPSC Pressure Relief Valve

Side View PRESTIGE Solo 399

Page 84

Product Specifications

94.1%

95.1%

Fuel

Combustion

Efficiency

Input

Note 4

Output Note 4 Note 5

Thermal

Efficiency

Net IBR

Rating Note 2

Shipping

Weight

Lbs / Kg

Boiler

Model

379,000

399,000

330,000

Natural

SOLO 399

102,500

110 ,000

102,500

Propane

87,000

Fuel

DOE

eating Capacity

Note 1 & 4

Input

ote 4

DOE Seasonal

Efficiency AFUE

Note 3

Net IBR

ating

Note 2

0,000

95%

Shipping

Weight

Lbs / Kg

95 / 43

atural

Boiler Model

OLO 60

47,000

110 ,000

02,500

95%

95 / 43

ropane

87,000

154,000

4,000

70,000

95%

131 / 60

Natural

OLO 175

34,000

02,500

102,500

95%

131 / 60

ropane

Propane

7,000

23,000

45,000

42 / 65

Natural

SOLO 250

94,000

102,500

10,000

02,500

95%

42 / 65

7,000

Note 1: The heating capacity of the PRESTIGE Solo

60/175/250 is based on the test requirements of the U.S. Department of Energy.

Note 2: The IBR rating is based on a piping and pick

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

Note 3: Based on the given AFUE the PRESTIGE

Solo 60/175/250 meets the energy efficiency guidelines established by Energy Star.

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.

Page 85

Product Specifications

Pressure Drop Comparison -Grundfos

Graph 2: Pressure Loss Through Boiler-Grundfos Circulator

Pressure Drop Comparison -Taco

Graph 3: Pressure Loss Through Boiler-Taco Circulators

Note: Minimum allowable flow rate at full input:

- 3 gpm SOLO 60

Page 86

Product Specifications

Graph 4: Pressure Loss Through Boiler - Grundfos Circulators

Graph 5: Pressure Loss Through Boiler - Taco Circulators

Note: Minimum allowable flow rate at full input:

- 8 gpm SOLO 175

- 12 gpm SOLO 250

Page 87

Product Specifications

Graph 6: Pressure Loss Through Boiler - Grundfos Circulators

Graph 7: Pressure Loss Through Boiler - Taco Circulators

Note: Minimum allowable flow rate at full input:

- 19 gpm SOLO 399

Page 88

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- Available in capacities from 25,000 BTU/hr to 5,000,000 BTU/hr

Freeway Center - 1 Triangle Lane - Blackwood, NJ 08012 Tel: (856) 228 8881 - Fax: (856) 228 3584 http://www.triangle tube.com E-mail: Info@triangle tube.com

Member of

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TriangleTube 399 Solo User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual