Triangle Tube PEA110 User Manual

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Excellence Water Boiler

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

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

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

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

iii

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

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

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.

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.

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.

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.

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

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.

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.

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.

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

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

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

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

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.

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.

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.

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.

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.

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.

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.

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

4.0 Boiler Piping

Fig. 6: Piping Component Legend

664A0100 - Rev. A

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.

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.

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.

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

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

664A0100 - Rev. A

6.0 Gas Piping

6.2 Natural Gas

6.2.1 Pipe Sizing

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

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

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

6.2.2 Supply Pressure Requirements

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

- Maximum 13”w.c. at flow or no flow

conditions to the burner.

- Minimum 5”w.c. during flow conditions

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

2. Install 100% lockup gas pressure regulator in the gas supply line if inlet pressure can exceed 13”w.c at any time. Adjust the lockup pressure regulator for 13”w.c maximum.

WARNING

DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane and requires no field adjustment. Attempts by the installer to adjust or measure the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death or substantial property damage.

NOTICE

The natural gas orifice requirements are:

PRESTIGE Excellence: 0.242” (6.15

mm)

Length of Pipe in

664A0100 - Rev. A

Table 1: Gas Piping Sizing - Natural Gas

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

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

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

6.0 Gas Piping

6.3 Propane Gas

6.3.1 Pipe Sizing - Propane Gas

WARNING

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

WARNING

Prior to start up, ensure the unit is set to fire propane. Check the rating label for the type of fuel. Check the gas valve for propane conversion label. If there is a conflict or doubt on the burner set up, remove the gas valve and check for the propane orifice, see Fig. 16 on page 27. Failure to ensure proper burner setup could result in severe personal injury, death or substantial property damage.

6.3.2 Propane Gas Supply Pressure

Requirements

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

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

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

NOTICE

The propane orifice requirements are:

PRESTIGE Excellence: 0.185” (4.7 mm)

664A0100 - Rev. A

6.0 Gas Piping

664A0100 - Rev. A

Fig. 13: Gas Valve / Venturi Assembly - PRESTIGE Excellence

7.0 Internal Wiring

SECTION VII - INTERNAL WIRING

WARNING

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

CAUTION

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

7.1 General Requirements

Fig. 14: ACVMax Control Module Fuse Location

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

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

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

7.2 Fuse Locations

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

19.

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

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

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

664A0100 - Rev. A

Y Y Y Y Y Y

7YY 8

9YY

10YY

Cascade

Master

ACV MAX

Control Board

X15

X10

X12

P13

X16

W W W W W W

Prestige Excellence Internal Wiring

Wire Legend

- Line Voltage

- Ingnition Cable

Wire Color Legend

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

123

21234123456

F00

GND

Ignitor

On / Off

Switch

Blower

Gas Valve

(Excellence 110)

2 1

3 2 1

GND

Blower

Power Terminals

CH2

Thermostat

System

Sensor

Modulation

Signal

CH1

Thermostat

Outdoor

Sensor

Modbus

DHW Sensor

R W

1 2 4 5

Blower

Signal Terminals

3-Way Valve

Water Pressure

Sensor

2 A B C D

- Low Voltage

Flue Temperature Sensor

Return Temperature Sensor

Supply Temperature Sensor

GND

Auto Reset Limit

Mix Sensor

Manual Reset Limit

R BK O W

1 2 3

Cascade

Slave

ACV MAX

Display

7 8 9

Flame

P4 Pump

P3 Pump

DHW Pump

Power Supply

Alarm

CH Pump

A1002507

7.0 Internal Wiring

Fig. 15: Prestige Solo Boiler Factory Wiring

664A0100 - Rev. A

8.0 External Wiring

SECTION VIII - EXTERNAL WIRING

8.1 Installation Compliance

All field wiring made during installation must comply with:

- National Electrical Code NFPA 70 and any other national, state, provincial or local codes or requirements.

- In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any other local codes.

WARNING

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

NOTICE

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

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

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

NOTICE

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

8.3 Circulator Wiring

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

NOTICE

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

8.2 Line Voltage Connections

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

21.

Figure 16: Terminal Strip Location

2. Connect the CH circulator to the line voltage terminal on the terminal block, Fig. 15 on page 29, located internally in the lower right corner, as shown in Fig. 16. This circulator is typically used as the primary/boiler circulator to supply heat to the central/space heating loop.

3. Connect the DHW circulator to the line voltage terminal on the terminal block, Fig. 15 on page 29, located internally in the lower right corner, as shown in Fig. 16. The DHW circulator is enabled during a DHW call. This circulator is typically used to supply heat to an indirect hot water heater.

4. Connect the P3 circulator to the line voltage terminal on the terminal block, Fig. 15 on page 29, located internally in the lower right corner, as shown in Fig. 16. This circulator is typically used to circulate water in the

664A0100 - Rev. A

8.0 External Wiring

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

5. Connect the P4 circulator to the line voltage terminal on the terminal block, Fig. 15 on page 29, located internally in the lower right corner, as shown in Fig. 16 on page 30. This circulator is typically used as a dedicated circulator to a second space heating zone.

8.4 Alarm Wiring

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

1. Connect the external monitoring device to the line voltage terminal on the terminal block, Fig. 15 on page 29, located internally in the lower right corner, as shown in Fig. 16 on page 30.

NOTICE

CH and DHW call connections to the

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

NOTICE

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

8.5 Low Voltage Connections

NOTICE

Line and Low Voltage wiring should be

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

Figure 17: Low Voltage Connections

8.6 Thermostat Wiring

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

WARNING

Simultaneous CH1 and CH2 calls will

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

1. Connect the room thermostat or dry contact end switch to the low voltage terminal strip located on the bottom of the main control board as shown in Fig. 14 on page 28 & Fig

17.

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8.0 External Wiring

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

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

- Set for 0.2 amps when wired directly to

the PRESTIGE.

- Set to match the electrical power

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

NOTICE

The use of power stealing thermostats

which draw their power from the PRESTIGE can lead to erratic or unpredictable operation.

vide a “hard” lockout requiring a manual reset of the PRESTIGE or a “soft” lockout in which the PRESTIGE will automatically reset when the limit resets.

NOTICE

Manual Reset Limit and Auto Reset

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

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

2. Connect the additional boiler limit to the low voltage reset limit terminal strip located on the bottom right of the main control board as shown in Fig. 14 on page 28.

8.7 Outdoor Sensor Wiring

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

8.8 Domestic Hot Water Wiring

An indiriect water heater sensor is prewired to the low voltage terminal strip on the wiring panel below he PRESTIGE control module.

8.9 Additional Boiler Limits

Additional boiler limits (High Limit, LWCO, etc.) can be wired into either the Manual Reset Limit or Auto Reset Limit terminals of the PRESTIGE. These limit connections will pro-

8.10 External Modulation Control

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

8.11 System Sensor Wiring

An optional system temperature sensor can be placed on the central heating loop to control the temperature in the central heating loop instead of the boiler loop. When connected, the PRESTIGE will automatically modulate to maintain the target temperature in the central heating loop. The boiler supply temperature sensor will continue to be used as a high temperature limit.

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8.0 External Wiring

CAUTION

Locate the system temperature sensor

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

1. Connect the system temperature sensor to the low voltage terminal strip on the wiring panel below the PRESTIGE control module, as shown in Fig. 14 on page 28 & Fig 17 on page 28.

8.12 Modbus Wiring

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

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Fig. 18: Multiple Zone Field Wiring Using Zone Valves & Zone Valve Panel

664A0100 - Rev. A

8.0 External Wiring

Fig. 19: Multiple Zone Field Wiring using Zone Circulators & Zone Relay Panel

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8.0 External Wiring

Note: Reference Fig. 7, page 20 for

System Piping.

Fig. 20: Prestige Wiring - Zoning with Zone Circulators

Note: Reference Fig. 8, page 20 for

System Piping.

Fig. 21: Prestige Wiring - Zoning with Zone Valves

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8.0 External Wiring

Note: Reference Fig. 9, page 21 for

System Piping.

Fig. 22: Prestige Wiring - Multiple Zone Valve with Single System/Boiler Circulator

Note: Reference Fig. 10, page 21 for

System Piping.

Fig. 23: Prestige Wiring - Single Zone System with Single System/Boiler Circulator

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9.0 ACVMax Operation

SECTION IX - ACVMAX OPERATION

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

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

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

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

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

• Modbus interface for integrating with building management systems.

All ACVMax features are easy to use through a graphical display where information is presented either graphically or in plain English, so code charts are not required. Figure 24 shows a ACVMax display example of the Prestige fired for a domestic hot water demand.

Fig. 24: ACVMax User Interface

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9.1 ACVMax Navigation

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

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

Figure 25 – ACVMax Navigation Buttons

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

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9.2 ACVMax Menu Structure

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9.0 ACVMax Operation

9.3 Home Screen

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

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

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

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9.4 Status Line Messages

Status Line Message Description

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

CH Demand A central heating call has been received.

DHW Demand A domestic hot water call has been received.

CH / DHW Demand

DHW Priority

Priority Timeout

External Demand An external modulation call has been received.

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

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

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

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

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

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

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

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

CH Setpoint Reached

DHW Setpoint Reached

CH Post Pump

DHW Post Pump

Freeze Protection

Boiler Protection

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

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

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

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

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

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

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

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9.0 ACVMax Operation

9.5 Main Menu

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

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9.0 ACVMax Operation

9.6 EZ Setup

Navigation: Home Screen>Main Menu>EZ Setup

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

9.7 Heating EZ Setup

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

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

9.7.1 Select CH Demand Default: Switch & Outdoor Reset

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

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

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

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

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

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

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

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

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

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

to be controlled by an external control system.

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

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

OK button to store the setting.

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

CH2 Setpoint prompts the installer to enter the fixed setpoint for a CH2 heating call when a Setpoint option is chosen in Select CH Demand. Press

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9.0 ACVMax Operation

the LEFT or RIGHT buttons to adjust the CH2 Setpoint then press the OK button to store the setting.

9.7.4 Select CH1 Reset Curve Default: Finned Tube Baseboard

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

9.7.5 Select CH2 Reset Curve Default: Low Mass Radiant

Select CH2 Reset Curve prompts the installer to select an outdoor reset curve for a CH2 heating call when an Outdoor Reset option is chosen in Select CH Demand. Outdoor reset curve presets are available to cover most applications. The outdoor reset curve can also be adjusted to any desired settings in

Table 2: Outdoor Reset Preset Selections

Preset Minimum Setpoint Maximum Setpoint

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

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

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

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

Radiators 120ºF [49ºC] 170ºF [77ºC]

Fan Coil 140ºF [60ºC] 180ºF [82ºC]

the Installer Menu. Press the UP or DOWN buttons to select the outdoor reset curve appropriate for the type of heating system then press the OK but- ton to store the setting.

9.7.6 Set Warm Weather Shutdown Temperature Default: OFF

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

9.7.7 CH EZ Setup Complete

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

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9.0 ACVMax Operation

9.8 Domestic Hot Water EZ Setup

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

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

9.8.1 Select DHW Demand Default: Switch

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

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

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

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

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

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

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

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

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

NOTICE

The Boiler DHW Setpoint will automatically be set 46°F [25°C]

higher than the DHW Storage Setpoint setting.

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9.0 ACVMax Operation

9.8.4 DHW Priority Timeout Default: Off

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

9.7.7 CH EZ Setup Complete

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

9.9 EZ Setup Reset

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

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

9.10 Display EZ Setup

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

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

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9.0 ACVMax Operation

9.11 CH/DHW Operation

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

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

9.12 Boiler Information

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

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

9.12.1 Boiler Information Logging

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

• Boiler Firing Rate

• Ionization Current

• Boiler Setpoint

• Boiler Supply Temperature

• Boiler Return Temperature

• Boiler Flue Temperature

• Outdoor Temperature

• DHW Storage Temperature

• External Modulation Signal

• Pressure

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9.0 ACVMax Operation

9.12.2 Information Items

Information Item Description

Boiler Status

Heating Call

DHW Call

Boiler Firing Rate

Ionization Current

Boiler Setpoint

Supply Temp.

Return Temp.

Boiler Flue Temp.

Outdoor Temp.

DHW Storage Temp.

External Modulation Signal

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

Displays if a central heating call is present.

Displays if a domestic hot water call is present.

Displays the current firing rate of the Prestige.

Displays the current flame ionization current from the ignitor.

Displays the current setpoint of the Prestige.

Displays the current supply temperature of the Prestige.

Displays the current return temperature to the Prestige.

Displays the current flue temperature of the Prestige.

Displays the current outdoor temperature.

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

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

Pressure

CH Ignitions

CH Runtime

DHW Ignitions

DHW Runtime

Mix Zone Temperature

664A0100 - Rev. A

Displays the current system pressure.

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

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

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

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

Displays the temperature of the low temperature mixed circuit.

9.0 ACVMax Operation

9.13 Lockout History

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

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

9.13.1 Lockout Details

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

• Boiler Status

• Heating Call

• Domestic Call

• Boiler Firing Rate

• Flame Ionization Current

• Boiler Setpoint

• Boiler Supply Temperature

• Boiler Return Temperature

• Boiler Flue Temperature

• Outdoor Temperature

• System Temperature

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9.13.2 Lockout Screen

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

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9.0 ACVMax Operation

Manual Reset Hard Lockouts

Code Lockout Message Description

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

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

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

E5 Blower Speed

E8 Flame Circuit Error Flame circuit test failed.

E9 Gas Valve Circuit Error Gas valve circuit test failed.

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

E15 Sensor Drift Supply or return sensor reading has drifted.

E16 Supply Sensor Stuck Supply sensor reading is not changing.

E17 Return Sensor Stuck Return sensor reading is not changing.

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

E21 Internal Control Fault A / D conversion error.

E30 Supply Sensor Shorted

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

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

E31 Supply Sensor Open

E43 Return Sensor Shorted

E44 Return Sensor Open

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

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

E87 External Limit Open An external manual reset limit has opened

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

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

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

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9.0 ACVMax Operation

Automatic Reset Soft Lockouts

Code Lockout Message Description

E7 High Flue Temperature Flue temperature exceeds high limit.

E12 Internal Control Fault EEPROM misconfiguration

E25 Internal Control Fault CRC check error.

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

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

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

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

E45 Flue Sensor Shorted

E46 Flue Sensor Open

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

E81 Sensor Drift Supply and return temperatures are not equal.

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

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

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

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

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

E94 Internal Display Fault Display memory error.

E95 Supply Sensor Error Supply sensor reading is invalid.

E96 Outdoor Sensor Open

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

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

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

E97 Cascade Mismatch Cascade configuration has changed.

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

E99 Controller Bus Error

664A0100 - Rev. A

Communication between boiler display and control module has been lost.

10.0 Start-Up Preparation

SECTION X - START-UP PREPARATION

NOTICE

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

10.1 Boiler System Fluid Requirements

WARNING

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

NOTICE

10.1.3 Chlorinated Water

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

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

10.1.4 Flush Boiler to Remove Sediment

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

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

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

10.1.5 Cleaning of Old Boiler/System:

• Drain the existing system.

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

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

10.1.1 Boiler Fluid pH Level 6.0 to 8.0

Maintain the boiler fluid pH between 6.0 and

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

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

10.1.2 Boiler Fluid Hardness Less Than 7 Grains

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

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

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

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

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

10.1.6 Cleaning of New Boiler/System:

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

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

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

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10.1.7 Check and Test Antifreeze

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

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

10.1.8 Use of Antifreeze in the Boiler System

WARNING

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

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

The water volume of the PRESTIGE Excellence is approximately 5 gallons [19 L]. 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.

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

NOTICE

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

10.2 Filling the Boiler System

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

2. Open all system isolation valves.

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

NOTICE

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

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

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

WARNING

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

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10.3 Check Low Water Cut-Off Device

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

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

48. Scroll down to see the current system pressure displayed and verify it is within the recommended numbers given in Section 10.2 on page 53.

10.4 Check For Gas Leaks

WARNING

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

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

NOTICE

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

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

10.6 Inspection of Condensate Drain

Assembly

1. Inspect and ensure the Condensate Drain Assembly is properly installed as described on page 22 and shown in Fig. 11 on page 23.

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

WARNING

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

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

10.5 Check Thermostat Circuit

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

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

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

NOTICE

The condensate drain assembly must be filled with water when the PRESTIGE Excellence 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.

- There should NEVER be voltage measured

at the wire ends.

664A0100 - Rev. A

11.0 Start-Up Procedures

SECTION XI - START-UP PROCEDURES

11.1 Final Checks Before Start-Up

c Read Section IX regarding the operation of

the ACVMax Boiler Management System.

c Verify the PRESTIGE Excellence 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, 78.

c Verify Start-up Preparation items outlined in

Section X 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 Excellence vent supplement.

c Verify burner configuration - Propane only.

11.2 PRESTIGE Excellence Start-Up

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

2. Read and follow the Operating Instructions outlined on page 61.

If PRESTIGE Excellence Does Not Start Correctly

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

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

3. Check the system pressure in the Boiler Information Menu by following the instructions in Section 9.12 on page 48.

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

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

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

- If there is doubt on the burner configuration, remove the gas valve and check for proper propane gas orifice size. Refer to 25 for orifice sizes. Refer to Fig. 13 on page 27 for location of the propane gas orifice.

NOTICE

For natural gas applications the Prestige Excellence requires an orifice: 0.242” (6.15mm)

c Ensure the vent Condensate Drain

Assembly is filled with water.

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 Excellence TroubleShooting Guide or contact ACV-Triangle Tube Technical Support.

11.3 Check the PRESTIGE Excellence

and System

c Check Boiler Piping.

Check Boiler system piping and com-

ponents for leaks. If found, shut down the unit and repair immediately.

664A0100 - Rev. A

11.0 Start-Up Procedures

Purge any remaining air from the system

piping. Air in the system piping will interfere with circulation creating heat distribution problems and system noise.

c Check Vent Piping and Combustion Air

Piping.

Check for gas-tight seal at every con-

nection 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 fol-

lowing the procedure outlined in this manual on Page 61.

be performed with calibrated equipment to ensure proper reading and accuracy.

2. Test for CO2 or O2 and for CO during

high firing rate. The combustion readings should be within the range listed in Table 3 on page 59. The CO level

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

following procedure to manually place the burner into high fire.

a. Press the round INSTALLER button.

Reference Fig. 25, page 39.

b. Enter the installer access code “054” by

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

c. Press the RIGHT button to highlight

the Manual Operation icon then press the OK button.

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.

c Verify Flame Pattern and Combustion

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

WARNING

The combustion testing and adjustments must be performed by a qualified installer, service agency or the gas supplier. All combustion measurements must

d. Press the OK button while the FAN

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

NOTICE

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

664A0100 - Rev. A

11.0 Start-Up Procedures

e. Press the LEFT and RIGHT buttons to

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

Table 3: Recommended Combustion Levels

Natural Gas

All Models

O2 Min. 2.30% 2.70%

O2 Max. 5.30% 4.70%

CO2 Min. 8.80% 10.70%

CO2 Max. 10.50% 12.00%

CO Max. 100 ppm 100 ppm

Propane

Excellence

f. Press the OK button while the FAN icon

is highlighted to shutdown the burner.

g. Cycle power to the Prestige once com-

bustion testing is complete to return to normal operation.

4. If the CO2 combustion level during low fire (1%) is not within +/- 0.2 of the combustion level measured at high fire, adjust the plastic OFFSET SCREW under the cover screw on the top of the gas valve (see Figs. 13 on page 27) according to Table 6.

Direction Exellence

Clockwise

Counter-Clockwise

Table 4: Throttle Screw - High Fire

Direction Excellence

Clockwise

Counter-Clockwise

Table 5: Offset Screw - Low Fire

Increase CO

Decrease O

Decrease CO

Increase O

Increase CO

Decrease O

Decrease CO

Increase O

WARNING

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

If the combustion levels during HIGH FIRE (100%) is outside the recommended combustion settings adjust the THROTTLE SCREW (see Fig. 13 on page 27) according to Table 5.

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

c Measure Input - Natural Gas Only

1. Ensure the boiler is firing at maximum firing rate. To manually place the boiler into high fire mode, reference page 58.

2. Operate the unit for approximately 10 minutes.

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

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

5. Calculate Natural gas input using the following equation:

3600 x 1000 / number of second recorded

for one cubic foot of gas = BTU/H.

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

664A0100 - Rev. A

11.0 Start-Up Procedures

c Test High Temperature Limit

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

1. Press the round INSTALLER button.

Reference Fig. 25, page 39.

2. Enter the installer access code “054” by

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

3. Press the OK button while CH & DHW

Settings icon is highlighted.

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

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

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

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

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

10. Press the round INSTALLER button.

11. Press the OK button while the CH & DHW

Settings icon is highlighted.

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

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

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

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

16. Press the OK button to reset the lockout and return the unit to service.

7. Press the DOWN button twice to highlight

the Home Screen icon then press the OK button.

664A0100 - Rev. A

11.0 Start-Up Procedures

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

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

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

B. BEFORE OPERATING, smell all around the

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

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

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

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

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above. This

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

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

“CLOSE” (valve handle shall be perpen-

dicular to gas piping).

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

4. Remove the front jacket panel on the unit.

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

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

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

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

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

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

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

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

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

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

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

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

TO TURN OFF GAS TO APPLIANCE

1. Set the room thermostat to lowest setting.

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

664A0100 - Rev. A

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

12.0 Outdoor Reset Control

SECTION XII - OUTDOOR RESET CONTROL

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

12.1 Mounting the Outdoor Sensor

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

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

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

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

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

12.2 Wiring the Sensor

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

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

NOTICE

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

3. Connect the outdoor sensor wires to the outdoor sensor terminals on the low voltage terminal strip located on the boiler control module inside the enclosure (see Fig. 15 on page 29 and Fig. 17 on page 31). The outdoor sensor wires do not have polarity.

IMPORTANT

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

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

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

• This boiler is not used for any space heating

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

• This boiler is equipped with a tankless coil.

664A0100 - Rev. A

13.0 External Modulating Control

SECTION XIII - EXTERNAL MODULATING CONTROL

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

13.1 Wiring the Modulating Controller

Run two 18 gauge wires from the external modulating boiler controller’s 0-10 VDC boiler output to the modulation signal terminals on the low voltage terminal strip located on the boiler control module inside the enclosure (see Fig. 15 on page 29 and Fig. 17 on page 31). This signal will both enable and modulate the boiler. No wiring is required at the thermostat terminals.

NOTICE

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

13.2 ACVMax Adjustment

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

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

13.3 Programming of External

Modulating Control

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

664A0100 - Rev. A

13.0 External Modulating Control

Factory ACVMax Setting

HEATING SETTING FACTORY DEFAULT EZ SETUP RESET INSTALLER RESET

Heating Operation

Enabled

Demand Type

Absolute Max CH Setpoint

CH1 Maximum Setpoint

CH1 Minimum Setpoint

Outdoor Curve Coldest Day

Outdoor Curve Warmest Day

CH2 Circuit

CH2 Maximum Setpoint

CH2 Minimum Setpoint

Warm Weather Shutdown

Circulation Pump Permanent

CH Post Pump Time

Freeze Protection

Frost Protection Setpoint

Parallel Shift Value

CH Call Blocking

DOMESTIC SETTING FACTORY DEFAULT EZ SETUP RESET INSTALLER RESET

DHW Operation

Demand Type

Boiler DHW Setpoint

DHW Setpoint

DHW On Differential

DHW Storage Adder

DHW Post Pump Time

DHW Priority Timeout

DHW Priority

DHW Call Blocking

DHW to CH Call Blocking

Antilegionella Function

Thermostat &

Outd. Curve

188°F [87°C]

180°F [82°C]

120°F [49°C]

0°F [-18°C]

64°F [18°C]

Enabled

140°F [60°C]

80°F [27°C]

OFF

Disabled

5 Minute

Enabled

-22°F [-30°C]

0°F [0°C]

1 Minute

Enabled

Thermostat (Solo)

Sensor (Excellence)

167°F [75°C]

140°F [60°C]

6°F [3°C]

28°F [15°C]

1 Minute

Off

Enabled

0 Minute

1 Minute

Disabled

3 3

3 3 3 3

3 3

3 3 3 3 3 3 3

3 3

BOILER SETTING FACTORY DEFAULT EZ SETUP RESET INSTALLER RESET

Prestige Model

Lockout Temp.

Modbus Address 0=BCST

Pump Settings Solo/Excellence 2

Ignition Level NAT

Solo (2 pumps)

Solo/Excel. (3 way valve)

210°F [99°C]

664A0100 - Rev. A

14.0 Check-Out Procedures

SECTION XIV- Check-Out Procedures

Test high temperature limit as outlined on page 62.

NOTICE

Perform the following check-out procedures as outlined and check off items as completed. When procedures are completed, the installer should complete the installation record on page 68.

c Boiler system fluid chemistry checked and

verified as outlined on page 56.

c Boiler system was completely flushed to

remove any debris/sediment.

c Any automatic air vents placed within the

system are open one full turn.

c Air is purged from the heating zones and

boiler system piping.

c If applicable, confirm that the burner has

been properly configured for Propane as outlined on page 28.

c Thermostat circuit wiring checked and ver-

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

c Checked the incoming gas pressure to the

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

c Adjusted balancing valves and system limit

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

c In multiple zone applications, adjusted for

correct flow of boiler water to each zone.

c Checked and verified room thermostat(s)

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

c Observed several operating cycles for

proper operation of the PRESTIGE Excellence and the system.

c Set the room thermostat(s) to the desired

room temperature.

c Reviewed all instructions shipped with the

PRESTIGE Excellence with the homeowner or maintenance personnel.

c Operating Instructions on page 63 were fol-

lowed during start-up.

c Combustion levels and flame pattern veri-

fied as outlined on page 60.

c Measured the rate of input on Natural Gas

as outlined on page 61.

664A0100 - Rev. A

c Completed the Installation Record on page

68.

c Ensure all manuals and other documents

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

15.0 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 XV - INSTALLATION RECORD

664A0100 - Rev. A

16.0 Maintenance Schedule

SECTION XVI - MAINTENANCE SCHEDULE

16.1 Service Technician

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

General

- Attend to any reported problems.

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

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

- Check boiler fluid pH on systems.

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

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

- Check boiler water pressure, piping and expansion tank.

16.2 Owner Maintenance

Periodically:

- Check the area around the unit.

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

- Check the temperature and pressure gauges.

Monthly:

- Check vent piping.

- Check combustion air inlet piping.

- Check the pressure relief valve.

- Check the condensate drain system.

Every 6 months:

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

- Operate the pressure relief valve.

- Check control settings.

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

- Check ignition wiring and ground wiring.

- Check all control wiring and connections.

- Check burner flame pattern (stable and uniform).

Additional items if combustion or performance is poor:

- Clean heat exchanger and flue ways.

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

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

WARNING

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

664A0100 - Rev. A

17.0 Maintenance Procedures

SECTION XVII- MAINTENANCE PROCEDURES

17.1 Maintenance Procedures

WARNING

The PRESTIGE Excellence 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 67 and further explained on pages 68 through 73 should be performed to assure maximum efficiency and reliability of the unit. Failure to service and maintain the PRESTIGE Excellence and the system components could result in equipment failure, causing possible severe personal injury, death or substantial property damage.

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

17.4 Inspect Burner Area

Remove the boiler front jacket panel and venturi inlet elbow.

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

Check the burner plate mounting nuts for tightness, see Section 17.24 on page 73 for torque specification.

Check burner plate gasket for discoloration or damage.

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

NOTICE

The following information provides detailed instruction for completing the maintenance items outline in the maintenance schedule on page 67. In addition to this maintenance, the PRESTIGE Excellence should be serviced at the beginning of the heating season by a qualified service technician.

17.2 Reported Problems

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

17.3 Check Surrounding Area

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

WARNING

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

17.5 Check System Piping

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

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

WARNING

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

664A0100 - Rev. A

17.0 Maintenance Procedures

17.6 Clean Condensate Drain

Assembly

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

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

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

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

Remove the fill plug on the condensate drain assembly and fill with water. See Fig. 11 on page 23.

Replace the fill plug on drain assembly.

17.7 Check Ventilation Air Openings

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

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

WARNING

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

17.9 Check Boiler System

Verify all system components are correctly installed and operating properly.

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

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

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

Verify boiler fluid pH level is between 6.0 and

8.0.

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

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

17.8 Inspect Vent and Combustion Air

Piping

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

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

664A0100 - Rev. A

17.0 Maintenance Procedures

17.10 Check Expansion Tank

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

Closed -Type Tank:

- Ensure tank is partially filled with

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

- Ensure the tank is fitted with a device

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

- Ensure no automatic air vents are used

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

Diaphragm Tank:

- Ensure the system contains a minimum of

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

- Remove the tank from the system and

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

WARNING

Before manually operating the pressure relief valve, ensure the discharge piping is directed to a suitable place of disposal to avoid a potential scald hazard. The discharge piping must be full size without restriction and installed to permit complete drainage of both the valve and line.

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

17.12 Inspection of Ignitor

Remove the ignitor from the burner mounting plate.

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

When replacing the ignitor, ensure the gasket is in good condition and correctly positioned. Replace the gasket if necessary. Torque screws to specification in Section 17.24 on page 73.

17.13 Check Ignition Wiring and Ground Wiring

17.11 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.

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

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

Ensure wiring is in good condition and securely connected.

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

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

664A0100 - Rev. A

17.0 Maintenance Procedures

17.14 Check Control Wiring

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

17.15 Check Control Settings

Review all boiler settings in the Heating & DHW EZ Setup menus. Adjust settings as necessary, see page 44-47

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

17.16 Perform Start-up and Checkout

Procedures

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

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

Complete the checkout procedures as referenced in this manual.

Carefully remove the burner plate assembly from the heat exchanger. Ensure that the combustion chamber 2-in-1 insulation is not damaged during removal of burner mounting plate assembly. See WARNING on page 73.

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

Remove the venturi and gas valve assembly from the blower.

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

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

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.

17.17 Check Burner Flame

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

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

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

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

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

664A0100 - Rev. A

Re-assemble the burner plate assembly onto the heat exchanger. Ensure the combustion chamber 2-in-1 insulation is in place, positioned correctly, and not damaged, replace if necessary. See WARNING on page 73.

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

Re-assemble the gas supply connection and wire harness to gas valve. Open the external manual gas valve. Check gas piping for any leaks as outlined on page 56 and repair if necessary.

Torque all screws, bolts, and nuts in accordance with specifications in Section 17.24 on page 73.

Place the unit back into service.

17.0 Maintenance Procedures

17.18 Check Flame Signal

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

−DC.

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

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

17.19 Check Combustion Levels

Refer to page 58 of this manual for measuring combustion levels and burner adjustments.

17.20 Check Flue Gas Temperature

Manually place the boiler into high fire. See page 58 for procedure.

Navigate to the Boiler Information Menu to observe the flue gas temperature. See page 48 for procedure.

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

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

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

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

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

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

Torque all screws, bolts, and nuts in accordance with specifications in Section 17.24 on page 73.

17.21 Clean Heat Exchanger

Shut down the boiler:

- Follow the instructions on Page 61 "To Turn Off Gas to Appliance"

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

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

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

Disconnect the gas piping and gas valve wire harness connector.

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

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

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

Perform the required startup and checkout procedures as outlined on pages in Section X.

664A0100 - Rev. A

17.0 Maintenance Procedures

17.22 Review With Owner

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

WARNING

The combustion chamber insulation con-

tains ceramic fibers, which are classified as a possible human carcinogen. When exposed to extremely high temperatures,

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

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

17.23 Handling Previously Fired Combustion Chamber Insulation

Avoid Breathing and Contact with Skin and Eyes

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

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

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

NIOSH Stated First Aid:

Eye/Skin: Immediately irrigate Breathing: Clean fresh air

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

3. Assure adequate ventilation.

4. Wash with soap and water after contact.

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

17.24 Torque Specifications Table

Item

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

664A0100 - Rev. A

Torque Req'd (in-lbs)

Min. Max.

44 53

26.5 31 62 71 31 35 31 35

26.5 31

18.0 Product Specifications

SECTION XVIII PRODUCT SPECIFICATIONS

Boiler

Model

Excellence

Note 1: The heating capacity of the PRESTIGE

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

Note 3: Based on the given AFUE the PRESTIGE

Fuel Input

Natural

Propane

Excellence is based on the test requirements of the U.S. Department of Energy.

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

Excellence meets the energy efficiency guidelines established by Energy Star.

110,000 99,000 86,000 95% 250 / 115

DOE

Heating Capacity

Net AHRI

Rating

Note 4: Input and output ratings are shown for sea

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

DOE Seasonal

Efficiency AFUE

Shipping

Weight

Lbs / Kg

DOE

664A0100 - Rev. A

18.0 Product Specifications

24-7/8” [632 mm]

2-1/8” [52 mm]

20-7/8” [528 mm]

15-7/8” [403 mm]

7-5/8”

[191 mm]

39-3/8” [1000 mm]

10-1/4” [258 mm]

17” [432 mm]

3” Combustion Air Inlet

3” Vent Outlet

3/4” NPSC Pressure

Relief Valve

1” NPT Boiler Return

1” NPT Boiler Supply

1/2” NPT Gas Connection

Fig. 26: Front View PRESTIGE Excellence

664A0100 - Rev. A

18.0 Product Specifications

23-5/8” [600 mm]

16-7/8” [428 mm]

9” [226 mm]

4-3/4”

[120 mm]

3”Vent Outlet 3” Combustion Air Inlet

1” NPT Boiler Supply 1” NPT Boiler Return

Boiler Drain

Fig. 27: Right Side View PRESTIGE Excellence

664A0100 - Rev. A

18.0 Product Specifications

6” [151 mm]

4-3/4”

[121 mm]

7-5/8” [191 mm]

10-3/8” [262 mm]

11-1/2” [292 mm]

3/4” NPT DHW Outlet

Manual Air Vent

3/4” NPSC Aux. Connection (Rear) 3/4” NPT DHW Inlet

Fig. 28: Top View PRESTIGE Excellence

664A0100 - Rev. A

18.0 Product Specifications

Graph 1: Pressure Loss Through Boiler - Taco Circulators

Note: Minimum allowable flow rate at full input: 5 gpm

664A0100 - Rev. A

19.0 Notes

SECTION XIX NOTES

664A0100 - Rev. A

19.0 Notes

664A0100 - Rev. A

19.0 Notes

664A0100 - Rev. A

Additional quality water heating equipment available

from ACV-Triangle Tube

Maxi-Flo and Spa Heat Exchangers

SMART Indirect Fired Water Heaters

- Construction of high quality corrosion resistant stainless steel (AISI 316) or titanium

- Specially designed built-in flow restrictor to assure maximum heat exchange

- Compact and light weight

- Available in 8 sizes that can accommodate any size pool or spa

TTP Brazed Plate Heat Exchangers

- Exclusive Tank-in-Tank design

- Stainless steel construction

- Available in 7 sizes

- Limited LIFETIME residential warranty

- 6 year limited commercial warranty

- Self cleaning/self descaling design

- For domestic water, snow melting, radiant floor, refrigeration

- Plates made of stainless steel, with a 99.9 % copper and brazed, ensuring a high resistance to corrosion

- Self cleaning and self descaling

- Computerized sizing available from ACV-Triangle Tube

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

Triangle Tube - 1 Triangle Lane - Blackwood, NJ 08012 - Tel: (856) 228 8881 - Fax: (856) 228 3584 E-mail: sales@triangletube.com

Part 2 of 2

prestige

Excellence 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

WARNING

IMPORTANT

7/13/16

• Before proceeding with installation and operation, read entire manual carefully. Failure to do so can cause injury or property damage.

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

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

• Retain and affix this manual near the water heater for future reference

• Installation and service should only be performed by a qualified installer or service technician.

• Installations and service should be performed by a license plumber or gas fitter in the Commonwealth of Massachusetts.

2011-61 Manual Prestige Excellence_IWH

664A0300 - Rev. B

Tables of Contents

Section I: Product & Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Section II: Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Section III: Installation - Domestic Piping

3.1 Temperature & Pressure (T&P) Relief Valve . . . . . . . . . . . . . . .5

3.2 Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3.3 Automatic Air Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3.4 Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3.5 Water Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3.6Vacuum Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3.7 General Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3.8 Domestic Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3.9 Thermostatic Mixing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3.10 Recirculation Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3.11 Storage Tank Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Section IV: Installation - Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . .9-10

Section V: Water Heater Start-Up

5.1 Filling the Inner (Domestic Water) Tank . . . . . . . . . . . . . . . . . .11

5.2 Filling the Outer (Boiler Water) Tank . . . . . . . . . . . . . . . . . . . .11

5.3 Setting the Thermostatic Mixing Valve . . . . . . . . . . . . . . . . . . .11

5.4 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

5.5 Domestic Hot Water EZ Setup . . . . . . . . . . . . . . . . . . . . . . . . . .13

5.6 Additional DHW Feature

5.6.1 DHW Frost Protection . . . . . . . . . . . . . . . . . . . . . . . . . . .14

5.6.2 Factory Trimax Setting . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Section VI: Water Heater Maintenance

6.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

6.2 Filling Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

6.3 Draining Water Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17

6.4 Draining Outer (Boiler Water) Tank . . . . . . . . . . . . . . . . . . . . . .17

6.5 Draining Inner (Domestic Water) Tank . . . . . . . . . . . . . . . . . . .17

Section VII: Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Section VIII: Water Heater Specifications

8.1 Excellence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-21

Section IX: Performance

9.1 Excellence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

664A0300 - Rev. B

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

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 ACV-Triangle Tube Technical Support.

NOTICE

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

664A0300 - Rev. B

Product & Safety Information

WARNING CAUTION

Bacteria can develop in the domestic water system if certain minimum water temperatures are not maintained.

Protection must be taken against excessive temperature and pressure!

TO PROTECT AGAINST EXCESSIVE TEMPERATURE AND PRESSURE

DANGER

HOT WATER CAN SCALD!

Water temperature over 125ºF [52ºC] can cause severe burns instantly or death from scalds.

• Children, disabled and elderly are at highest risk of being scalded.

- Never leave them unattended in or

near shower, bathtub or sink.

- Never allow small children to use a hot

water faucet or draw their own bath.

• To avoid any potential scald hazard or if codes require specific water temperatures at the hot water faucet, the installer must:

- Install the factory supplied thermostatic mixing valve at this appliance and ensure it is working property

and

• Check if the Temperature & Pressure (T&P) relief valve is installed in the location provided (DHW Side).

• Check if the 30 psi relief valve supplied is installed in the location provided (CH Side)

• To avoid injury, install the relief devices to comply with local code requirements.

- Set the domestic storage temperature to the lowest temperature which satisfies your hot water needs.

- Feel and adjust water temperature before bathing or showering.

- Water drained from the system drain valves may be extremely hot.

TO AVOID INJURY:

- Make sure all connections are tight.

- Direct water flow away from any person.

664A0300 - Rev. B

CAUTION

To prevent damage to the inner tank, the

Installer must:

• Always fill inner tank prior to outer tank and always drain outer tank prior to inner tank.

• Relieve primary system pressure below 15 psig prior to draining inner tank.

Pre-Installation

Codes Compliance

Installation of the Excellence Water Heater must conform with the instructions in this manual and where applicable:

• local, state, provincial, and national codes, laws, regulations and ordinances.

• in Canada - CAN / CGA B149.1 or B149.2 Installation Code.

Excellence water heater is exempt from ASME Section VIII, Division 1 Code construction per Interpretation VIII-86-136. Check with local codes for applicability.

NOTICE

The Excellence water heater will absorb less than 200,000 BTU/hr when domestic water outlet temperature is 194ºF and boiler water supply temperature is 240ºF. Listed outputs are based on ASME Section VIII Interpretation VIII-1-86-136.

Where recommendations in this manual differ from local, or national codes, the local or national codes take precedence.

Codes Restrictions

Single wall heat exchanger in the Excellence water heater complies with National Standard Plumbing Code, provided that:

– boiler water (including additives) is practically

non-toxic, having toxicity rating or class of 1, as listed in Clinical Toxicology of Commercial Products, and

– boiler water pressure is limited to maximum

30 psig by approved relief valve.

Single wall heat exchangers are permitted under the Uniform Plumbing Code - Paragraph L3.2. and L3.3 if they satisfy all of the following requirements.

2. The pressure of the heat transfer medium is maintained less than the normal minimum operating pressure of the potable water system

Exception: Steam complying with sec-

tion #1 above.

3. The equipment is permanently labeled to indicate that only additives recognized as safe by the FDA shall be used in the heat transfer medium.

Other heat exchanger designs may be permitted where approved by the Administrative Authority.

Operating Restrictions

• Maximum DHW outlet temperature is 120ºF, when factory supplied mixing valve is installed.

• Maximum boiler water temperature rating is 210ºF.

• Maximum working pressure for inner (domestic water) tank is 150 psig.

• Maximum working pressure for outer (boiler water) tank is 30 psig.

• Water quality limitations (based on E.P.A National Secondary Drinking Water Regulations):

- Chloride, less than 150 ppm or mg/l

- pH value min. 6, max. 8

- Total hardness 3 - 7 grains/gallon or 50-120

ppm or mg/l.

- Total Dissolved Solids (TDS), less than

120 ppm or mg/l.

- Iron less than 0.3 ppm or mg/l.

- Aluminum, less than 0.2 ppm or mg/l.

- Copper, less than 1 ppm or mg/l.

- Manganese, less than 0.05 ppm or mg/l.

- Zinc, less than 5 ppm or mg/l.

1. The heat transfer medium is potable water or contains only substances which are recognized as safe by the U.S. Food and Drug Administration.

664A0300 - Rev. B

Pre-Installation

BEST PRACTICE

In hard water areas (more than 7 grains of hardness) soften the cold domestic supply water to the appliance to prevent scaling.

NOTICE

Any water conditioning system must be

installed and maintained in accordance with manufacturer’s specifications.

NOTICE

Do not install the Excellence water heater on

any application if the boiler piping contains non-oxygen barrier tubing or if the boiler piping is considered an “open system”. Exposing the outer tank of the Excellence water heater to oxygen contamination will lead to premature tank failure and denial of the warranty.

Locating Water Heater

• The Excellence is not intended for outdoor installations.

• Locate Excellence so that any leakage from the tank or water connections will not cause damage to the area adjoining the water heater or to lower floors in the structure.

BEST PRACTICE

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

Top boiler jacket - 24 inches.

Front - 24 inches.

Bottom boiler piping - 24 inches.

Rear - 0 inches

Sides - 6 inches

NOTICE

When maintaining zero clearance or less than recommended clearances, some product labeling may become hidden and unreadable

WARNING

When installing the 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. Reference the Excellence Boiler Manual for additional guidelines.

- When such a loation is unavoidable, a suitable drain pan with adequate drainage should be placed under the water heater.

Recommended Clearances

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

- Vent & Boiler Piping - 1/4 inch from com-

bustible materials.

664A0300 - Rev. B

Residential Garage Installations

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

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

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

Installation - Domestic Piping

Temperature & Pressure (T&P) Relief Valve

CAUTION

To reduce risk of excessive pressures and temperatures in the water heater, install temperature and pressure protective equipment required by local codes, but no less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials, as meeting the requirements for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22. This valve must be marked with a maximum working pressure of the water heater.

• The Excellence water heater must be protected with a T&P relief valve.

• Size the Excellence T&P relief valve by the following specifications, unless they conflict with local codes: 3/4” NPT with an AGA Rating of 100,000 BTU/hr (Watts 100XL-8 or equivalent).

• Install the T&P in the run (straight through leg) of a tee located at the domestic hot water outlet. Use a long element T&P relief valve, as shown in Fig. 3 page 8.

T&P Relief Valve Discharge Piping

T&P relief valve discharge piping must be:

- made of material serviceable for temperatures of 250ºF or greater.

- directed so that hot water flows away from all persons.

- directed to a suitable place for disposal.

- installed so as to allow complete draining of the T&P relief valve and discharge line.

T&P relief valve discharge piping must not

be:

- excessively long. Using more than 2 elbows or 15 feet of piping can reduce discharge capacity.

- directly connected to a drain. Terminate discharge piping within 6” from drain. Refer to local codes.

- plugged, reduced or restricted.

- subject to freezing.

NOTICE

For proper operation of the T&P and to pre-

vent the T&P from activating due to boiler water temperature, use a T&P relief valve with extended element. A 8” minimum length is recommended.

Standard Installation

• Install T&P relief valve in the Auxiliary con-

nection located near the air vent on the top of the water heater as shown Fig. 2 page 8.

Commonwealth of Massachusetts

Installation

Follow this procedure for jurisdictions requiring a vacuum breaker to be installed on the domestic cold water inlet.

WARNING

Do not install any valve between T&P relief valve and tank connection or on T&P relief valve discharge piping. Do not plug T&P relief valve or discharge piping. Improper placement and piping of T&P relief valve can cause severe personal injury, death or substantial property damage.

664A0300 - Rev. B

Installation - Domestic Piping

Drain Valve

Drain valve and fittings are supplied by others.

Standard Installation

• Install a tee connection at the domestic cold water inlet, as shown in Fig. 4, pages 9.

• Pipe the drain piping with drain valve from the tee connection to:

- a suitable place for disposal or

- terminate within 12” of the floor

Commonwealth of Massachusetts Installation

• Thread a 3/4” brass close nipple onto the Auxiliary connection and insert an openend dip tube into the Auxiliary connection on top of water heater. As shown in Fig. 3, page 8.

• Install a 3/4” NPT elbow to the Auxiliary connection.

• Pipe the drain piping with drain valve from the elbow connection to:

- a suitable place for disposal or

- terminate within 12” of the floor

Thermal Expansion

If a backflow preventer, check valve or pressure reducing valve is piped on cold water supply piping of water heater, install an expansion tank on cold water supply line to prevent normal thermal expansion from repeatedly forcing open T&P relief valve.

CAUTION

T&P relief valve is not intended for constant duty, such as relief of pressure due to repeated normal system expansion. Correct this condition by installing a properly sized expansion tank in domestic water system. Refer to expansion tank manufacturer’s installation instructions for proper sizing.

Water Hammer

Dishwashers, clothes washers and fast-closing positive shut-off valves incorporated in the system all contribute to creating water shock. Install a water hammer arrester to prevent damage to pipes and appliances. See device manufacturer’s instructions for application and installation.

Manual Air Vent

1. Open manual air vent at the top of the unit. Once air has stopped escaping, close the manual air vent.

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

664A0300 - Rev. B

NOTICE

Water hammering within the domestic piping system can cause premature failure of the inner tank of the water heater. This type of failure is NOT covered under warranty.

Vacuum Breaker

Installing a vacuum breaker on the domestic cold water outlet will prevent damage to the inner tank if a negative pressure is developed in the domestic supply line. See manufacturer’s instructions for application and installation of the vacuum breaker.

Installation - Domestic Piping

Adapter

Check Valve

Mixed

General Piping

• For domestic water piping diagrams, see pages 9 and 10.

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

• Use pipe dope or tape suitable for potable water systems.

• Use isolation valves to isolate system components.

Domestic Piping

• Union on domestic hot water outlet should be piped at a higher elevation than domestic water drain valve. This will make draining the water heater easier.

• Use dielectric unions or couplings to protect hot and cold water fittings from corrosion when connecting dissimilar materials such as copper and galvanized iron pipe.

• If copper pipe is used for domestic water connections, first solder pipe to a threaded adapter and then screw adapter into cold water inlet on top of Excellence. Cold Water Inlet contains an internal plastic dip tube which can be damaged by heat from soldering.

For applications with a domestic recirculation loop, the recirculation pump should be controlled by an aquastat. The maximum recommended setting of the aquastat is 10ºF lower than the thermostatic mixing valve setting.

DANGER

For proper operation of the thermostatic mixing valve and to prevent potential scalding hazards, the recirculation loop should be controlled by an aquastat. DO NOT use continuous recirculation.

Recirculation Piping

Fig. 1: Mixing Valve Assembly

NOTICE

Do not apply heat to the cold water inlet when making sweat connections to water heater. Sweat tubing to adapter before fitting adapter to cold water inlet of heater. It is imperative that no heat be applied to the cold water inlet, as it contains a non metallic dip tube.

• When the water supply pressure is higher than 70 psig, it is recommended to install a pressure reducing valve on cold water supply line to prevent water loss through T&P relief valve.

Thermostatic Mixing Valve

The Excellence is factory supplied with a thermostatic mixing valve with built-in check valve. The mixing valve must be installed as shown in Fig. 1.

The operating range of the thermostatic mixing is 85ºF [30ºC] to 150ºF [65ºC].

• Recirculation piping must be installed in the cold water inlet as shown Fig. 5, page 9.

• A stainless steel or bronze circulator is recommended.

Storage Tank Application

For applications requiring large volumes of domestic hot water in a short time period, the installer may include a storage type tank (see Fig. 6 page 10) in the domestic piping.

The installer must:

1. Relocate the thermostatic mixing valve from

the Excellence to the outlet of the storage tank.

2. Provide recirculation from the storage tank

back to the Excellence using a bronze type circulator. Maximum recommended recirculation flow rate is 1 gpm.

664A0300 - Rev. B

Installation - Domestic Piping

DHW Hot Water Outlet

DHW Cold Water Inlet

Manual Air Vent

DHW Aux. Connection (T&P Relief Valve)

DHW Hot Water Outlet

DHW Cold Water Inlet

Air Vent Connection

DHW Aux. Connection

T&P Relief Valve w/ 3/4” Tee

Drain Dip Tube

3/4” Brass Close Nipple

Fig. 2: Standard Installation of the T&P Relief Valve

Fig. 3: Commonwealth of Massachusetts Installation

664A0300 - Rev. B

Installation - Piping Diagrams

Fig. 4:

Standard Installation Domestic Piping Excellence Series

Fig. 5:

1. Shut-off valve

2. Flow check valve

3. Mixing valve with check valve

4. Vacuum Breaker *

5. Unions

Standard Installation Domestic Piping with Optional Recirculation Excellence Series

6. Backflow preventer or pressure reducing valve(*)

7. Circulator (controlled by aquastat) 8 Domestic drain valve

9. Thermal expansion tank (potable)

(*) Optional devices may be required by local codes.

664A0300 - Rev. B

Installation - Piping Diagrams

Fig. 6:

1. Mixing valve with check valve

2. Flow check valve

3. Shut-off valve

4. Backflow preventer or pressure reducing valve(*)

Domestic Piping with Optional Storage Tank

6. Thermal expansion tank

7. Circulator (controlled by aquastat) 8 Domestic drain valve

9. Vacuum Breaker *

(*) Optional devices may be required by local codes.

664A0300 - Rev. B

Triangle Tube PEA110 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Definitions

Qualified Installer:

Homeowner:

SECTION I - PRE-INSTALLATION ITEMS

1.2 Determining Product Location

1.3 Boiler Replacement

1.4 Recommended Clearances

1.5 Residential Garage Installations

1.6 Boiler Freeze Protection Feature

SECTION II - COMBUSTION AIR AND VENTING

2.2 Ventilation and Combustion Air Requirements - Direct Vent

2.3 Ventilation and Combustion Air Requirements - Category IV

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

Opening Size and Location

Opening Size and Location

2.4.2.1 One Permanent Opening Method

2.4.2.2 Two Permanent Openings Method

2.4.3 Combination of Indoor and Outdoor Combustion Air

2.5 Combustion Air and Vent Piping

2.7 Commonwealth of Massachusetts Installations Only

3.2 Wall Mounting Installation

3.3 Wall Mounting Guidelines

3.6 Boiler Mounting

4.2 Pressure Relief Valve

4.3 Boiler Air Vent

4.4 Low Water Cutoff Device

4.5 Additional Limit Control

4.6 Backflow Preventer

4.7 Boiler System Piping Applications

4.8.1 Diaphragm Expansion Tank

4.8.2 Closed-Type Expansion Tank

4.8 Expansion Tank and Makeup Water

9.7.7 CH EZ Setup Complete