Triangle Tube PEA110 User Manual

prestige

Excellence
Water Boiler

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Part 1 of 2

* I N S T A L L A T I O N A N D M A I N T E N A N C E *

* I N S T A L L A T I O N A N D M A I N T E N A N C E *

M A N U A L

M A N U A L

NOTICE

WARNING

If the information in this manual is not followed exactly, a fire or explosion may
result causing property damage, personal injury or death.

Installation and service must be performed by a qualified installer, service agency or the

Revised Date: 12/15/15

gas supplier.

Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installa­tion in order to gain warranty coverage.

When receiving the PRESTIGE Excellence unit, any claims for damage or shortage in shipment must be
filed immediately against the transportation company by the consignee.

Leave all documentation received with appliance with owner for future reference.

FOR YOUR SAFETY

• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.

• WHAT TO DO IF YOU SMELL GAS

- Do not try to light any appliance

- Do not touch any electrical switch; do not use any phone in your building.

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

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

2015-9 Prestige ACVMax Install Manual

Table of Contents

Product & Safety Information

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

Qualified Installer: .........................................................................................................2

Homeowner: .........................................................................................................2

Section I - Pre-Installation Items

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

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

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

1.4 Recommended Clearances ....................................................................................4

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

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

SECTION II - Combustion Air and Venting

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

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

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

2.4 Methods of Accessing Combustion Air Into A Space - Category IV...................7

2.4.1 Indoor Combustion Air Opening Size and Location...................................7

2.4.2 Outdoor Combustion Air Opening Size and Location ................................7

2.4.2.1 One Permanent Opening Method ...................................................7

2.4.2.2 Two Permanent Openings Method ................................................8

2.4.3 Combination of Indoor and Outdoor Combustion Air ..............................9

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

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

2.7 Commonwealth of Massachusetts Installations Only...........................................11

SECTION III - Unit Preparations

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

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

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

3.4 Wall Bracket Installation - Stud Wall Installation ...............................................13

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

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

SECTION IV - Boiler Piping

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

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

4.3 Boiler Air Vent ......................................................................................................14

4.4 Low Water Cutoff Device .....................................................................................15

4.5 Additional Limit Control ......................................................................................15

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

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

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Table of Contents

4.8 Expansion Tank and Makeup Water .....................................................................16

4.8.1 Diaphragm Expansion Tank ........................................................................16

4.8.2 Closed-Type Expansion Tank......................................................................16

4.9 Circulator .........................................................................................................16

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

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

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

4.13 System Piping - Zone Valves ................................................................................17

4.14 System Piping - Through Boiler ...........................................................................17

4.15 System Piping - Radiant Heating..........................................................................17

4.16 System Piping - Special Application ....................................................................18

SECTION V - Installing Vent / Combustion Air & Condensate Drain

5.1 Installing Vent and Combustion Air .....................................................................22

5.2 Installing Condensate Drain Assembly.................................................................22

SECTION VI - Gas Piping

6.1 Gas Supply Piping Connection .............................................................................24

6.2 Natural Gas .........................................................................................................25

6.2.1 Pipe Sizing...................................................................................................25

6.2.2 Supply Pressure Requirements....................................................................25

6.3 Propane Gas .........................................................................................................26

6.3.1 Pipe Sizing - Propane Gas...........................................................................26

6.3.2 Propane Gas Supply Pressure Requirements ..............................................26

SECTION VII - Internal Wiring

7.1 General Requirements...........................................................................................28

7.2 Fuse Locations ......................................................................................................28

SECTION VIII - External Wiring

8.1 Installation Compliance ........................................................................................30

8.2 Line Voltage Connections .....................................................................................30

8.3 Circulator Wiring ..................................................................................................30

8.4 Alarm Wiring ........................................................................................................31

8.5 Low Voltage Connections .....................................................................................31

8.6 Thermostat Wiring ................................................................................................31

8.7 Outdoor Sensor Wiring .........................................................................................32

8.8 Domestic Hot Water Wiring..................................................................................32

8.9 Additional Boiler Limits.......................................................................................32

8.10 External Modulation Control ................................................................................32

8.11 System Sensor Wiring...........................................................................................32

8.12 Cascade Wiring .....................................................................................................32

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Table of Contents

SECTION IX - ACVMax Operation

9.1 ACVMax Navigation............................................................................................39

9.2 ACVMax Menu Structure.....................................................................................40

9.3 Home Screen.........................................................................................................41

9.4 Status Line Messages............................................................................................42

9.5 Main Menu .........................................................................................................45

9.6 EZ Setup .........................................................................................................44

9.7 Heating EZ Setup .................................................................................................44

9.7.1 Select CH Demand ......................................................................................44

9.7.2 CH1 Setpoint ...............................................................................................44

9.7.3 CH2 Setpoint ...............................................................................................44

9.7.4 Select CH1 Reset Curve..............................................................................45

9.7.5 Select CH2 Reset Curve..............................................................................45

9.7.6 Set Warm Weather Shutdown Temperature.................................................45

9.7.7 CH EZ Setup Complete...............................................................................45

9.8 Domestic Hot Water EZ Setup .............................................................................46

9.8.1 Select DHW Demand ..................................................................................46

9.8.2 Boiler DHW Setpoint ..................................................................................46

9.8.3 DHW Storage Setpoint................................................................................46

9.8.4 DHW Priority Timeout................................................................................47

9.9 EZ Setup Reset......................................................................................................47

9.10 Display EZ Setup ..................................................................................................47

9.11 CH/DHW Operation .............................................................................................48

9.12 Boiler Information ...............................................................................................48

9.12.1 Boiler Information Logging ........................................................................48

9.12.2 Information Items ........................................................................................49

9.13 Lockout History ...................................................................................................50

9.13.1 Lockout Details ...........................................................................................50

9.13.2 Lockout Screen ............................................................................................51

SECTION X - Start-Up Preparation

10.1 Boiler System Fluid Requirements .......................................................................54

10.1.1 Boiler Fluid pH Level 6.0 to 8.0 .................................................................54

10.1.2 Boiler Fluid Hardness Less Than 7 Grains .................................................54

10.1.3 Chlorinated Water........................................................................................54

10.1.4 Flush Boiler to Remove Sediment ..............................................................54

10.1.5 Cleaning of Old Boiler/System: .................................................................54

10.1.6 Cleaning of New Boiler/System: ..............................................................54

10.1.7 Check and Test Antifreeze...........................................................................55

10.1.8 Use of Antifreeze in the Boiler System.......................................................55

10.2 Filling the Boiler System ......................................................................................55

10.3 Check Low Water Cut-Off Device .......................................................................56

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Table of Contents

10.4 Check For Gas Leaks............................................................................................56

10.5 Check Thermostat Circuit.....................................................................................56

10.6 Inspection of Condensate Drain Assembly...........................................................56

SECTION XI - Start-Up Procedures

11.1 Final Checks Before Start-Up...............................................................................57

11.2 PRESTIGE Solo Start-Up.....................................................................................57

11.3 Check the PRESTIGE Solo and System...............................................................57

SECTION XII - Outdoor Reset Control

12.1 Mounting the Outdoor Sensor...............................................................................62

12.2 Wiring the Sensor..................................................................................................62

SECTION XIII - External Modulating Control

13.1 Wiring the Modulating Controller ........................................................................63

13.2 ACVMax Adjustment ...........................................................................................63

13.3 Programming of External Modulating Control.....................................................63

SECTION XV - Installation Record

SECTION XV - Check-Out Procedures

SECTION XVI - Maintenance Schedule

16.1 Service Technician ................................................................................................67

16.2 Owner Maintenance ..............................................................................................67

SECTION XVII- Maintenance Procedures

17.1 Maintenance Procedures .......................................................................................68

17.2 Reported Problems................................................................................................68

17.3 Check Surrounding Area .....................................................................................68

17.4 Inspect Burner Area ..............................................................................................68

17.5 Check System Piping ............................................................................................68

17.6 Clean Condensate Drain Assembly.......................................................................69

17.7 Check Ventilation Air Openings ...........................................................................69

17.8 Inspect Vent and Combustion Air Piping .............................................................69

17.9 Check Boiler System.............................................................................................69

17.10 Check Expansion Tank..........................................................................................70

17.11 Check Boiler Relief Valve ....................................................................................70

17.12 Inspection of Ignitor..............................................................................................70

17.13 Check Ignition Wiring and Ground Wiring..........................................................70

17.14 Check Control Wiring ...........................................................................................71

17.15 Check Control Settings .........................................................................................71

17.16 Perform Start-up and Checkout Procedures .........................................................71

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Table of Contents

17.17 Check Burner Flame .............................................................................................71

17.18 Check Flame Signal ..............................................................................................72

17.19 Check Combustion Levels ....................................................................................72

17.20 Check Flue Gas Temperature................................................................................72

17.21 Clean Heat Exchanger...........................................................................................72

17.22 Review With Owner..............................................................................................73

17.23 Handling Previously Fired Combustion Chamber Insulation...............................73

17.24 Torque Specifications Table..................................................................................73

Section XVIII Product Specifications

PRESTIGE Excellence Front View .................................................................................74

PRESTIGE Excellence Right Side View.........................................................................75

PRESTIGE Excellence Top View....................................................................................76

Section XIX Notes

General Notes .........................................................................................................79

v

Product & Safety Information

PRODUCT & SAFETY INFORMATION

Definitions

The following terms are used throughout this manual to bring attention to the presence of
potential hazards or important information concerning the product.

DANGER

Indicates the presence of a hazardous
situation which, if ignored, will result in
death, serious injury or substantial
property damage.

WARNING

Indicates a potentially hazardous situa­tion which, if ignored, can result in
death, serious injury or substantial
property damage.

CAUTION

Indicates a potentially hazardous situa­tion which, if ignored, may result in
minor injury or property damage.

NOTICE

Indicates special instructions on installa­tion, operation or maintenance, which
are important to equipment but not
related to personal injury hazards.

BEST PRACTICE

Indicates recommendations made by
ACV-Triangle Tube for the installers
which will help to ensure optimum oper­ation and longevity of the equipment

NOTICE

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

1

Product & Safety Information

DANGER

Do not use this appliance if any part has

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

WARNING

WHAT TO DO IF YOU SMELL GAS

- Do not try to light any appliance

- Do not touch any electrical switch; do
not use any phone in your building.

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

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

Installation and service must be per­formed by a qualified installer, service
agency or the gas supplier.

WARNING

Qualified Installer:

Prior to installing this product read all instruc­tions included in this manual and all accompa­nying manuals/documents with this appliance.
Perform all installation steps required in these
manuals in the proper order given. Failure to
adhere to the guidelines within these manuals
can result in severe personal injury, death or
substantial property damage.

Homeowner:

- This product should be maintained /
serviced and inspected annually by a
qualified service technician.

- This manual is intended for use by a
qualified Installer/Service Technician.

NOTICE

Please reference the unit’s model number

and the serial number from the rating label
when inquiring about service or trou­bleshooting.

WARNING

Should overheating occur or the gas
supply fails to shut off, turn OFF the
manual gas control valve external to the
appliance.

WARNING

DO NOT add cold make up water when

the appliance is hot. Thermal shock can
potentially cause cracks in the heat
exchanger.

CAUTION

When servicing the appliance:

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

WARNING

ACV-Triangle Tube accepts no liability for

any damage, injury or loss of life resulting
from incorrect installation, from alter­ation of any factory supplied parts or from
the use of parts or fittings not specified by
ACV-Triangle Tube. If there is a conflict
or doubt about the proper installation of
the unit or any factory supplied or
replacement parts please contact ACV­Triangle Tube Technical Support.

WARNING

A byproduct of any gas fired appliance

is carbon monoxide. In the absence of
any state or local codes requiring the
installation of carbon monoxide detec­tor and alarms, ACV-Triangle Tube’s
recommendation is to follow the
requirements of the Commonwealth of
Massachusetts, see page 11.

2

1.0 Pre-Installation Items

SECTION I - PRE-INSTALLATION ITEMS

1.1 Code Compliance

This product must be installed in accordance to
the following:

- All applicable local, state, national and
provincial codes, ordinances, regula­tions and laws.

- For installations in Massachusetts, code
requires the boiler to be installed by a
licensed plumber or gas fitter, and if
antifreeze is utilized, the installation of
a reduced pressure backflow preventer
device is required in the boiler’s cold
water fill or make up water supply line.

- For installation in Massachusetts all direct
vented appliances must comply with the
guidelines as outlined on page 11.

- The National Fuel Gas Code NFPA54/
ANSI Z 223.1 - Latest edition.

- National Electric Code ANSI/NFPA 70.

- For installations in Canada -“Installation
Code for Gas Burning Equipment”
CGA/B149.1 or B149.2 Canadian
Electrical Code Part 1 CSA C22.1.

- Standards for Controls and Safety
Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1, when required.

NOTICE

Before locating the PRESTIGE Excellence
check for convenient locations to:

- Heating system piping

- Venting

- Gas supply piping

- Electrical service

Ensure the boiler location allows the combus­tion air/vent piping to be routed directly through
the building and terminate properly outside with
a minimum amount of length and bends.

Ensure the area chosen for the installation of the
PRESTIGE Solo is free of any combustible
materials, gasoline and other flammable liquids.

WARNING

Failure to remove or maintain the area
free of combustible materials, gasoline
and other flammable liquids or vapors
can result in severe personal injury,
death or substantial property damage.

Ensure the PRESTIGE Excellence and its con­trols are protected from dripping or spraying
water during normal operation or service.

The PRESTIGE Excellence 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.

The PRESTIGE Solo boiler gas manifold

and gas controls meet the safe lighting and
other performance requirements as speci­fied in ANSI Z21.13 latest edition.

1.2 Determining Product Location

NOTICE

The PRESTIGE boiler is certified for

indoor, conditioned space installations
ONLY.

1.3 Boiler Replacement

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

- Boiler piping leaks and corrosion.

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

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

3

1.0 Pre-Installation Items

1.4 Recommended Clearances

The PRESTIGE Excelence is approved for
zero clearance to combustibles, excluding
vent and boiler piping.

- Boiler Piping - 1/4 inch from com­bustible materials.

- Reference the appropriate vent supple­ment for clearance requirements.

BEST PRACTICE

To provide serviceability to the unit it is
recommended that the following clear­ances be maintained:

Top boiler jacket - 24 inches [610 mm].

Front - 24 inches [610 mm].

Bottom boiler piping - 24 inches [610 mm].

Rear - 0 inches

Sides - 6 inches [153 mm]

1.5 Residential Garage Installations

When installing the PRESTIGE Solo in a resi­dential garage, the following special precautions
per NFPA 54/ANSI Z223.1 must be taken:

- Mount the unit a minimum 18 inches
[458 mm] above the floor level of the
garage. Ensure the burner and ignition
devices / controls are no less than 18
inches [458 mm] above the floor level.

- Locate or protect the unit in a manner so it
cannot be damaged by a moving vehicle.

1.6 Boiler Freeze Protection Feature

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

- 46ºF [8ºC] Pump outputs configured to
respond to a CH1 Call are enabled.

WARNING

If the clearances listed above cannot be
maintained or the enclosure in which the
boiler is installed is less than 85 cubic feet,
the space must be ventilated. See page 6
for ventilation requirements.

NOTICE

When maintaining less than recom­mended serviceability clearances, some
product labeling, including the rating
label, may become hidden and unread­able.

WARNING

When installing the PRESTIGE
Excellence in a confined space, sufficient
air must be provided for proper combus­tion and venting and to allow, under
normal operating conditions, proper air
flow around the product to maintain
ambient temperatures within safe limits
to comply with the National Fuel Gas
Code NFPA 54 - latest edition.

- 42ºF [6ºC] Pump outputs configured to
respond to a CH1 or CH2 Call are
enabled, Burner operates at low fire.

- 60ºF [15ºC] Freeze protection ends.
Burner & all pumps turn off after com­pleting CH Post Pump Time.

CAUTION

The boiler freeze protection feature is
disabled during a hard lockout, however
the circulators will operate.

CAUTION

The boiler freeze protection feature is
designed to protect the boiler. The boiler
should be installed in a primary/sec­ondary piping arrangement if it is
installed in an unheated space or
exposed to water temperatures of 46ºF or
less. See Section IV for primary/sec­ondary piping examples. See Section X
for antifreeze guides.

4

2.0 Combustion Air & Venting

SECTION II - COMBUSTION AIR AND VENTING

2.1 Combustion Air Contamination

WARNING

If the PRESTIGE Excellence combus­tion air inlet is located in any area likely
to cause or contain contamination, or if
products, which would contaminate the
air cannot be removed, the combustion
air must be repiped and terminated to
another location. 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 Excellence
if its combustion air inlet is located near
a laundry room or pool facility. These
areas will always contain hazardous con­taminants.

Potential contaminating products

- Spray cans containing chloro/fluorocar­bons

- Permanent Wave Solutions

- Chlorinated wax

- Chlorine - based swimming pool chem­icals / cleaners

- Calcium Chloride used for thawing ice

- Sodium Chloride used for water soft­ening

- Refrigerant leaks

- Paint or varnish removers

- Hydrochloric acid / muriatic acid

- Cements and glues

- Antistatic fabric softeners used in
clothes dryers

- Chlorine-type bleaches, detergents, and
cleaning solvents found in household
laundry rooms

- Adhesives used to fasten building prod­ucts and other similar products

Pool and laundry products and common
household and hobby products often
contain fluorine or chlorine compounds.
When these chemicals pass through the
burner and vent system, they can form
strong acids. These acids can create cor­rosion of the heat exchanger, burner
components and vent system, causing
serious damage and presenting a possi­ble threat of flue gas spillage or water
leakage into the surrounding area.

Please read the information listed below.
If contaminating chemicals are located
near the area of the combustion air inlet,
the installer should pipe the combustion
air inlet to an outside area free of these
chemicals per SECTION V of this
installation manual.

Areas likely to contain these products

- Dry cleaning / laundry areas and estab­lishments

- Beauty salons

- Metal fabrication shops

- Swimming pools and health spas

- Refrigeration Repair shops

- Photo processing plants

- Auto body shops

- Plastic manufacturing plants

- Furniture refinishing areas and estab­lishments

- New building construction

- Remodeling areas

- Garages with workshops

5

2.0 Combustion Air Venting

2.2 Ventilation and Combustion Air Requirements - Direct Vent

A Direct Vent appliance utilizes uncontaminat­ed outdoor air (piped directly to the appliance)
for combustion.

For Direct Vent installations, involving only
the PRESTIGE Excellence, 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 Excellence, 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
Excellence 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 Excellence
which uses combustion air directly from
the outside, thus additional free area for
the openings is not required. Failure to
provide or properly size the openings
could result in severe personal injury,
death or substantial property damage.

2.3 Ventilation and Combustion Air Requirements - Category IV

A Category IV appliance utilizes uncontami­nated indoor or outdoor air (surrounding the
appliance) for combustion.

BEST PRACTICE

In order to reduce the potential risks
associated with indoor contaminates
(listed on page 5), flammable vapors and
tight housing construction (little or no
infiltration air), it is recommended to
pipe uncontaminated combustion air
directly from the outdoors to the appli­ance. This practice also promotes higher
system efficiency by reducing heated
indoor air from being exhausted from
the house and replaced by cold infiltra­tion air into the house.

For installations in which the PRESTIGE
Excellence shares the space with air movers
(exhaust fan, clothes dryers, fireplaces, etc.) and
other combustion equipment (gas or oil) the
space must be provided with adequate air open­ings to provide ventilation and combustion air to
the equipment. To properly size the ventilation
/ combustion air openings, the installer must
comply with the National Fuel Gas Code NFPA
54, ANSI Z223.1 for installations in the U.S or
CSA B149.1 and B149.2 for installations in
Canada, as referenced in this section of the man­ual and titled Methods of Accessing
Combustion Air into a Space.

WARNING

The space must be provided with ventila­tion / combustion air openings properly
sized for all make-up air requirements
(exhaust fans, clothes dryers, fireplaces,
etc.) and the total input of all appliances,
including the PRESTIGE Excellence
when located in the same space. Failure
to provide or properly size the openings
could result in severe personal injury,
death or substantial property damage.

6

2.0 Combustion Air Venting

2.4 Methods of Accessing Combustion Air Into A Space - Category IV

2.4.1 Indoor Combustion Air

NOTICE

The methods listed in this section for
accessing Indoor Combustion Air
assume that the infiltration rate is ade­quate and not less than .40 ACH. For
infiltration rates less than .40 ACH, ref­erence the NFPA 54 National Fuel Gas
Code for additional guidance.

Opening Size and Location

Openings used to connect indoor spaces shall
be sized and located in accordance with the
following, see Fig. 1:

- Combining spaces on the same story.
Each opening shall have a minimum
free area of 1 sq. in./1000 Btu/hr of the
total input rating of all gas utilization
equipment in the space, but not less than
100 sq. inches. One opening shall com­mence within 12 inches of the top, and
one opening shall commence within 12
inches of the bottom of the enclosure.

The minimum dimension of air open­ings shall be not less than 3 inches.

- Combining spaces in different stories.
The volumes of spaces in different sto­ries shall be considered as communicat­ing spaces where such spaces are con­nected by one or more openings in
doors or floors having a total minimum
free area of 2 sq. in./1000 Btu/hr of
total input rating of all gas utilization
equipment.

2.4.2 Outdoor Combustion Air

BEST PRACTICE

Isolating the combustion appliance room
from the rest of the building and bring­ing in uncontaminated outside air for
combustion and ventilation is always
preferred.

Opening Size and Location

The minimum dimension of air openings shall
be not less than 3 inches

Openings used to supply combustion and ven­tilation air shall be sized and located in accor­dance with the following:

Fig. 1:

All Combustion Air from Adjacent

Indoor Spaces Through Indoor
Combustion Openings

2.4.2.1 One Permanent Opening Method

One permanent opening, commencing within 12
in. of the top of the enclosure, shall be provided
as shown in Fig 2 on page 8. The equipment
shall have clearances of at least 1 inch from the
sides and 6 in. from the front of the appliance.
The opening shall directly communicate with the
outdoors or shall communicate through a vertical
or horizontal duct to the outdoors or spaces that
freely communicate with the outdoors and shall
have a minimum free area of the following:

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

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

7

2.0 Combustion Air Venting

Fig. 2:

All Combustion Air from Outdoors

Through One Permanent Air
Opening

2.4.2.2 Two Permanent Openings Method

Two permanent openings, one commencing
within 12 in. of the top and one commencing
within 12 in. of the bottom of the enclosure,
shall be provided. The openings shall commu­nicate directly, or by ducts, with the outdoors
or spaces that freely communicate with the out­doors, as follows:

- Where directly communicating with the
outdoors or where communication to the
outdoors is through vertical ducts, each
opening shall have a minimum free area
of 1 sq. in./4000 Btu/hr of total input rat­ing of all equipment in the enclosure.
See Fig.3.

- Where communicating with the out­doors is through horizontal ducts, each
opening shall have a minimum free
area of not less than 1 sq.in./2000
Btu/hr of total input rating of all equip­ment in the enclosure. See Fig. 4.

Fig. 3:

Fig. 4:

All Combustion Air from Outdoors

Through Ventilated Attic

All Combustion Air from Outdoors

Through Horizontal Ducts

8

2.0 Combustion Air Venting

2.4.3 Combination of Indoor and Outdoor Combustion Air

Indoor Openings: Where used, openings con­necting the interior spaces shall comply with
the Indoor Combustion Air section on page 7.

Outdoor Opening(s) Location. Outdoor open­ing(s) shall be located in accordance with the
Outdoor Combustion Air section.

Outdoor Opening(s) Size. Outdoor opening(s) shall
be calculated in accordance with the following:

- The ratio of the interior spaces shall be
the available volume of all communi­cating spaces divided by the required
volume.

- The outdoor size reduction factor shall
be 1 minus the ratio of interior spaces.

- The minimum size of outdoor open­ing(s) calculated in accordance with the
above outdoor air section multiplied by
the reduction factor. The minimum
dimension of air openings shall not be
less than 3 in.

DANGER

Do not install the PRESTIGE Excellence
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.

uncontaminated outdoor air (piped directly to
the appliance) for combustion.

BEST PRACTICE

In order to reduce the potential risks
associated with indoor contaminates
(listed on page 5), flammable vapors
and tight housing construction (little or
no infiltration air), it is recommended
to pipe uncontaminated combustion air
directly from the outdoors to the appli­ance. This practice also promotes higher
system efficiency by reducing heated
indoor air from being exhausted from
the house and replaced by cold infiltra­tion air into the house.

NOTICE

Install combustion air and vent pipe as
detailed in the PRESTIGE Excellence
Vent Supplement included in the boiler
installation envelope. Refer to optional
vent kit instructions for additional 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.

2.5 Combustion Air and Vent Piping

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

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

9

2.0 Combustion Air Venting

2.6 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

Do not install the PRESTIGE Excellence
into a common vent with other gas or oil
appliances. This may cause flue gas
spillage or appliance malfunction, result­ing in possible severe personal injury,
death or substantial property damage.

10

2.0 Combustion Air Venting

2.7 Commonwealth of Massachusetts Installations Only

For direct-vent appliances, mechanical-

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

1. If there is not one already present, on

each floor level where there are bed­room(s), a carbon monoxide detector
and alarm shall be placed in the living
area outside the bedroom(s). The car­bon monoxide detector shall comply
with NFPA 720 (2005 Edition).

2. A carbon monoxide detector shall also

be located in the room that houses the
appliance or equipment and shall:

a. Be powered by the same electrical cir-

cuit as the appliance or equipment such
that only one service switch services
both the appliance and the carbon
monoxide detector;

b. Have battery back-up power;

c. Meet ANSI/UL 2034 Standards and

comply with NFPA 720 (2005 Edition);
and

d. Have been approved and listed by the

Nationally Recognized Testing
Laboratory as recognized under 527
CMR.

3. A Product-approved vent terminal must

be used, and if applicable, a Product­approved air intake must be used.
Installation shall be in strict compliance
with the manufacturer’s instructions. A
copy of the installation instructions
shall remain with the appliance or
equipment at the completion of the
installation.

4. A metal or plastic identification plate
shall be mounted at the exterior of the
building, four feet directly above the
location of vent terminal. The plate
shall be of sufficient size to be easily
read from a distance of eight feet away,
and read “Gas Vent Directly Below”.

NOTICE

Installer must provide tag identification
plate and ensure the lettering meets code
requirements.

For direct-vent appliances, mechanical-

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

1. If there is not one already present, on
each floor level where there are bed­room(s), a carbon monoxide detector
and alarm shall be placed in the living
area outside the bedroom(s). The car­bon monoxide detector shall comply
with NFPA 720 (2005 Edition).

2. A carbon monoxide detector shall:

a. Be located in the room that houses the

appliances or equipment;

b. Be either hard wired or battery powered

or both; and

c. Shall comply with NFPA 720 (2005

Edition)

3. A Product-approved vent terminal must
be used, and if applicable, a Product­approved air intake must be used.
Installation shall be in strict compliance
with the manufacturer’s instructions. A
copy of the installation instructions
shall remain with the appliance or
equipment at the completion of the
installation.

11

3.0 Unit Preparations

SECTION III - UNIT
PREPARATIONS

3.1 Handling Instructions

The PRESTIGE Solo is generally easier to
handle and maneuver once removed from the
shipping carton.

To remove the shipping carton:

CAUTION

Use care not to drop, bump or rotate the
boiler upside down, as damage to the
boiler will result.

1. Remove any shipping straps and open the
side of the shipping carton.

2. Slide the unit with the foam inserts out of
the carton.

3. Discard all packing materials.

3.2 Wall Mounting Installation

The PRESTIGE Excellence should be wall
mounted using the bracket provided with the
boiler. The PRESTIGE Excellence is not
designed for floor installation. If floor installa­tion is required an optional floor stand is avail­able through ACV-Triangle Tube.

NOTICE

The wall used for mounting the PRES­TIGE Excellence must be vertically
plumbed and capable of supporting a
minimum 250 pounds [115 kg] for the
PRESTIGE Excellence. Failure to com­ply with these requirements could result
in personal injury, death or substantial
property damage.

3.3 Wall Mounting Guidelines

1. The wall-mounting bracket is designed for
stud spacing of 12 inch or 16 inch on cen­ters. For unconventional stud spacing, a
solid / secure mounting surface must be
provided for installation of the bracket.

2. For applications using wood studs, install
the bracket using the lag screws provided
with the boiler. Ensure both lag screws are
installed securely in the studs.

3. For applications using metal studs, install
the bracket to the studs using 3/16” toggle
bolts and washers.

4. DO NOT mount or attempt to mount the
wall bracket to hollow sheet rock or lath
walls using anchors. Only install boiler to
studs or equivalent wood structure.

5. For applications using solid walls (rock,
concrete, brick, cinder block, etc.), install
the wall bracket using anchors (double
expansion shields) and bolts with washers
provided with the boiler.

6. The boiler is too heavy and bulky for a sin­gle person to lift and attempt to mount; a
minimum of 2 people is required for
mounting the boiler.

NOTICE

Use extreme care not to drop the boiler
or cause bodily injury while lifting or
mounting the boiler onto the bracket.
Once mounted verify that the boiler is
securely attached to the bracket and
wall. Failure to comply with the above
guidelines could result in property dam­age, personal injury or death.

12

3.0 Unit Preparations

3.4 Wall Bracket Installation - Stud
Walls

1. To distribute the weight of the boiler evenly
when mounting onto a stud wall it is rec­ommended to use the PRESTIGE Solo
Wall Frame kit.

2. When using the wall frame to mount the
boiler reference the kit installation instruc­tions and ensure the frame is securely fas­tened to the wall.

3. If the structure of the wall is questionable
in supporting a minimum weight of 265
pounds [120 kg.], it is recommended to use
the optional floor stand.

3.5 Wall Bracket Installation - Solid

Walls

1. Locate the general area of the boiler place­ment.

2. Place the wall-mounting bracket on the
wall ensuring the upper edge of the bracket
is away from the wall.

3.6 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.

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.

13

4.0 Boiler Piping

SECTION IV - BOILER PIPING

4.1 General Piping Requirements

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

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

- Use isolation valves to isolate system com­ponents.

- Install unions for easy removal of the
PRESTIGE Excellence from the system
piping.

WARNING

Use a two wrench method when tighten­ing piping onto the boiler connections.
Use one wrench to prevent the boiler
piping from turning / twisting. Failure
to support the boiler piping and connec­tions in this manner could cause damage
to the boiler and its components.

4.2 Pressure Relief Valve

1. The PRESTIGE Excellence 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.

4.3 Boiler Air Vent

NOTICE

This boiler is supplied with a special
automatic air vent that will provide reli­able operation in purging air from the
boiler. The hygroscopic cap supplied
with the automatic air vent MUST
remain tight at all times on the air vent
body. The hygroscopic cap has a mem­brane which expands upon contact with
water and seals the air vent until the
membrane dries up due to new air form­ing in the air vent.

1. Make sure to fully tighten the cap on the air
vent on initial installation.

2. Never loosen the hygroscopic cap to allow
air to escape the air vent. Air will exit with
the cap fully tightened in place.

3. If the hygroscopic cap is not fully tight­ened, water may leak from the cap. Simply
tighten the cap securely.

14

4.0 Boiler Piping

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

4.4 Low Water Cutoff Device

- The PRESTIGE Excellence is equipped with
a factory installed pressure sensor type Low
Water Cut Off device.

- The minimum operating system pressure
allowable with this device is 10 psig.

- Check local codes if a Low Water Cutoff
Device is required. If so, determine if this
device meets the requirements of the local
codes.

NOTICE

The PRESTIGE Excellence control sys­tem also senses the water temperatures
entering and exiting the heat exchanger
to provide protection against low water
conditions. Where local codes and juris­diction do not accept a pressure device
for low water protection, the jurisdic­tions may accept these PRESTIGE
Excellence integral control functions as a
means of providing low water protection.

4.5 Additional Limit Control

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

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

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

- Wiring of the LWCO device to the PRES­TIGE Excellence is done directly onto the
low voltage terminal strip, reference Fig.
15 page 29 for available terminals for an
external limit (manual or auto reset).

If the installation is to comply with ASME or
Canadian requirements, an additional high
temperature limit may be needed. Consult
local code requirements to determine compli­ance. The limit should be installed as follows:

- Install the limit in the boiler supply pip­ing between the boiler and any isolation
valve.

15

4.0 Boiler Piping

- Consult heat exchanger for maximum
set point of limit.

- For wiring of the limit, reference Fig. 15,
page 29, using the external manual reset
terminals on the low voltage terminal
strip. This will provide a "hard" lockout
requiring a manual reset of the control.

4.6 Backflow Preventer

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

4.7 Boiler System Piping Applications

BEST PRACTICE

It is recommended on all piping applica­tions to utilize a primary/secondary pip­ing arrangement as a means to provide
freeze protection of the boiler, which is an
integral function of the boiler control.
Maintain the minimum boiler flow rate
shown in Graphs 1 through 6 on pages 94
through 96. For other piping arrange­ments, contact ACV-Triangle Tube
Technical Support or consult other
approved/recognized design arrange­ments.

BEST PRACTICE

CAUTION

Undersized expansion tanks will cause

system water to be lost through the pres­sure relief valve and cause additional
makeup water to be added to the system.
Eventual boiler heat exchanger failure
can result due to this excessive makeup
water addition.

Refer to the expansion tank manufacturer
instructions for additional installation details.

Connect the expansion tank to an air separator
only if the air separator is located on the suc­tion side (inlet) of the system circulator.
Always locate and install the system fill con­nection at the same location as the expansion
tank connection to the system.

4.8.1 Diaphragm Expansion Tank

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

4.8.2 Closed-Type Expansion Tank

It is recommended to pitch any horizontal piping
upwards toward the expansion tank 1 inch per 5
feet of piping. Use 3/4” piping for the expansion
tank to allow air within the system to rise.

On piping applications utilizing a single
zone or other recognized piping design
arrangements, it is recommended that the
installer uses flow/check valves with
weighted seats at or near the appliance to
prevent gravity circulation.

4.8 Expansion Tank and Makeup Water

Ensure the expansion tank is properly sized for
the boiler volume (3 gallons [12 L]) and the
system volume and temperature.

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.

4.9 Circulator

The PRESTIGE Excellence requires an external
circulator to provide circulation through the boiler.

16

4.0 Boiler Piping

The circulator, when wired directly to the PRES­TIGE Excellence, will allow for domestic hot
water priority and provide circulation for the
freeze protection feature of the boiler control. See
Graph 1 on page 78 for pressure drop and mini­mum flow rate through the boiler.

4.10 Sizing Primary Piping

See Fig. 7 through 10, pages 20 - 21, for recom­mended piping arrangements based on various
applications. Size the piping and system com­ponents required in the space heating system
using recognized design methods.

4.11 Domestic Hot Water System Piping

See Fig. 7 through 10, pages 20 - 21 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.

NOTICE

To ensure an adequate flow rate through
the PRESTIGE Excellence, the boiler sup­ply and return piping size must be a mini­mum of 1 inch.

4.13 System Piping - Zone Valves

Connect the PRESTIGE Excellence to the system
piping as shown in Fig. 11 on page 20 when zon­ing with zone valves. The primary / secondary
piping ensures that the boiler loop has sufficient
flow.

NOTICE

To ensure an adequate flow rate through
the PRESTIGE Excellence, the boiler sup­ply and return piping size must be a mini­mum of 1 inch.

4.14 System Piping - Through Boiler

In applications in which primary/secondary
arrangement is not utilized, the PRESTIGE
Excellence allows this flexibility due to a lower
boiler pressure drop, see Graph 1 on pages 78.

4.12 System Piping - Zone Circulators

Connect the PRESTIGE Excellence to the sys­tem piping as shown in Fig. 7 on page 20 when
zoning with zone circulators.

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

Figure 9 on page 21 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 10 on page 21 illustrates a single zone uti­lizing the boiler circulator as the system circulator.

4.15 System Piping - Radiant Heating

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

The design and construction of the PRESTIGE
heat exchanger allows the installation of the boiler
on systems with non - oxygen barrier tubing.

17

664A0100 - Rev. A

4.0 Boiler Piping

CAUTION

DO NOT install a SMART tank along

with the PRESTIGE in systems with
non-oxygen barrier tubing. Failure to
comply could result in premature failure
of the SMART tank.

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

It is recommended for the installer to install a
high temperature limit to ensure that the pri­mary supply temperature does not exceed the
maximum allowable temperature for the radi­ant tubing.

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

4.16 System Piping - Special
Application

If the boiler is used in conjunction with a
chilled water/medium system, the boiler and
chiller must be piped in parallel. Install
flow/check valves to prevent the chilled medi­um from entering into the boiler.

If the boiler is used to supply hot water to the
heating coils of an air handler where they may
be exposed to chilled air circulation, install
flow/check valves or other automatic means
to prevent gravity circulation of the boiler
water during cooling cycles.

NOTICE

To ensure an adequate flow rate through
the PRESTIGE Excellence, the boiler sup­ply and return piping size must be a min­imum of 1 inch.

NOTICE

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

664A0100 - Rev. A

18

4.0 Boiler Piping

Fig. 6: Piping Component Legend

664A0100 - Rev. A

19

4.0 Boiler Piping

Note: Reference Fig. 20, page 36 for

Prestige Wiring.

Fig. 7: System Piping - Zoning with Zone Circulators

Note: Reference Fig. 21, page 36 for

Prestige Wiring.

Fig. 8: System Piping - Zoning with Zone Valves

NOTICE

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

20

664A0100 - Rev. A

4.0 Boiler Piping

Note: Reference Fig. 22, page 37 for

Prestige Wiring.

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

Fig. 9: System Piping - Multiple Zone Valve with Single System/Boiler Circulator

Note: Reference Fig. 23, page 37 for

Prestige Wiring.

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

Fig. 10: System Piping - Single Zone System with Single System/Boiler Circulator

NOTICE

664A0100 - Rev. A

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

21

5.0 Installing Vent/Combustion Air & Condensate Drain

SECTION V - INSTALLING VENT
/ COMBUSTION AIR &
CONDENSATE DRAIN

5.1 Installing Vent and Combustion Air

DANGER

The PRESTIGE Excellence must be vent­ed and supplied with combustion air as
shown in the PRESTIGE Excellence 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 installation of the condensate
drain assembly included the metal wash­er. Failure to comply could result in the
trap assembly dislocating from the boiler.

WARNING

Ensure the condensate drain assembly
contains the plastic seated ball. Do not
install the condensate drain assembly if
the ball is lost or missing, replace the
entire assembly.

4. Remove the compression nut and rubber
seal from the condensate drain assembly
drain outlet.

5. Using 3/4” x 2’ flexible PVC tube provid­ed, slide the compression nut and rubber
seal over the pipe

NOTICE

5.2 Installing Condensate Drain
Assembly

1. Locate the condensate drain assembly and
ensure the metal washer is installed as
shown in Fig. 11 on page 23.

NOTICE

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

2. Install the condensate drain assembly on the
boiler condensate drain by pushing the con­densate drain assembly up until it stops.

3. Tighten the condensate drain assembly
retaining nut with rubber seal.

The use of 3/4” PVC or CPVC pipe is
also acceptable. If 3/4” pipe is used
deburr and chamfer pipe to allow mat­ing onto the drain assembly.

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

7. Seat the pipe onto the drain assembly and
tighten the compression nut. Hand tight

only!

NOTICE

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

22

664A0100 - Rev. A

5.0 Installing Vent/Combustion Air & Condensate Drain

NOTICE

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

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

NOTICE

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

9. The PRESTIGE Excellence 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. 11: Condensate Drain Assembly

664A0100 - Rev. A

23

6.0 Gas Piping

SECTION VI - GAS PIPING

6.1 Gas Supply Piping Connection

NOTICE

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

1. Install a 1/2” NPT for PRESTIGE
Excellence

2. Install a manual shutoff valve in the gas
supply piping as shown in Fig. 12. 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 Excellence gas train as shown in Fig.

12.

7. Use pipe dope compatible with natural and
propane gases. Apply sparingly only to the
male threads of pipe joints so that pipe
dope does not block gas flow.

WARNING

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

WARNING

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

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

5. Purge all air from the gas supply piping.

6. Before placing the PRESTIGE Excellence
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 Excellence

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. 12: Recommended Gas Supply Piping

24

664A0100 - Rev. A