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PRESTIGE Excellence
HX Field Replacement Kit
Quantity Kit Part
Number
1 PSRKIT01 Heat Exchanger Assembly X
1 PTRKIT124 Heat Exchanger Assembly X
1 PSRKIT76 Heat Exchanger Assembly X
1 PTRKIT125 Heat Exchanger Assembly X
Description
Each Heat Exchanger (HX) Replacement Kit includes
the following items already installed on the heat
exchanger:
- Combustion chamber insulation
- Burner head and gasket
- Sight glass assembly
- Burner mounting plate gasket
Model
Stainless Steel
Condensate Pan
PE 110 Natural Gas
Polypropylene
PT 110 Natural Gas
PE 110 LP
Condensate Pan
Stainless Steel
PT 110 LP
Polypropylene
Condensate Pan
Condensate Pan
The following items are shipped in a PARTS BOX and
must be installed as part of the HX replacement:
- Vent outlet gasket
- Blower gasket
- Boiler piping gaskets
- Long handle phillips head screwdriver
- Long handle T-20 Torx screwdriver
- Igniter, igniter gasket, screws
- Temperature sensors and harness adapters
Recommended tools:
A. Pipe wrenches
B. Phillips and flat head screw drivers
C. 10 mm socket and/or 10 mm wrench
WARNING
Indicates a potentially hazardous situation
which, if ignored, can result in serious injury
or substantial property damage.
WARNING
For your safety, turn off electrical power supply at service panel and allow unit to cool
before proceeding to avoid possible electrical
shock and scald hazard. Failure to do so can
cause severe personal injury or death.
WARNING
Use a two wrench method when tightening piping
onto the boiler piping 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.
D. Adjustable wrench
E. Needle nose pliers
F. Diagonal cutting pliers
G. Calibrated combustion analyzer
NOTICE
Indicates special instructions on installation,
operation or maintenance, which are important to equipment but not related to personal
injury hazards.
WARNING
Failure to follow instructions below can result
in severe personal injury or damage if ignored.
• Instructions are for a qualified installer/
service technician only.
• Read all instructions before proceeding.
• Follow instructions in proper order.
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PRESTIGE Excellence
4
5
3
2
1
HX Field Replacement Kit
Preliminary Instructions
1. Verify that the heat exchanger kit is correct for
the model of boiler. See table on page 1.
2. Turn off power to the unit at the main service
panel and allow the unit to cool.
WARNING
ELECTRICAL SHOCK HAZARD!
Ensure power to the boiler has been switched off
prior to servicing the unit.
3. Remove the front jacket panel of the boiler by
removing the thumbscrew located on the upper
edge of the unit. Lift the panel up and pull forward to remove the front panel from the unit.
4. Using a voltmeter verify there is no electrical
power to the boiler by checking for power on
Fig. 1: Prestige Excellence
the boiler’s power supply terminals L and N
Removal of Venting Connection
5. Shut off gas supply to the inlet of the unit at the
external main manual shutoff valve.
6. Close external system isolation valves to the
boiler supply and return piping and on the system make up / fill piping.
7. Attach a hose to external boiler drain. Place
other end of this hose to a suitable drain.
1. Use a flat head screw driver to loosen the banding
clamp located on the vent outlet adapter. (Fig. 2).
2. Remove vent piping from vent outlet adapter as
the internal flue tube / vent outlet adapter must be
removed.
3. Disconnect the yellow wire leads/Molex plug
from the flue temperature sensor (shown as
Item 1 in Fig. 1). The flue temperature sensor
8. Open external boiler drain valve and begin
draining the boiler.
may be located in the vent pipe or the condensate pan depending on the model. Use care
when disconnecting the wire leads as not to
NOTICE
damage the sensor terminals or the wire leads.
To assist in the draining of the boiler, remove the
air vent at the top of the unit or manually lift
open the pressure relief valve.
NOTICE
Before disconnecting any wire connections mark and
label all connections and location of the connections.
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PRESTIGE Excellence
V
ent Outlet
A
dapter
T
est
Port
Banding
Clamp
Mounting
S
crews
(4) Each
Flue Gasket
Heat Exchanger
Flue Adapter
Vent Outlet
Pipe
HX Field Replacement Kit
Stainless Steel Vent Outlet Adapter Removal
1. Dismount the vent outlet adapter from top of boiler cabinet by removing the 4 mounting screws.
Do not discard the mounting screws and vent outlet adapter as they will be reused. (Fig. 2)
3. In case of insufficient space above the boiler,
remove combustion air inlet piping and boiler
relief valve / air vent assembly from the top of
the boiler. Close the DHW cold water supply
isolation valve and open a hot water faucet to
relieve water pressure in the water heater.
Remove all DHW piping including T&P relief
valve from the DHW connections on the top of
the boiler. Remove all screws securing the top
jacket panel from the side panels and remove
vent outlet adapter and top jacket panel together from the boiler cabinet. Put all items in a safe
place as they will all be reused.
4. Once the vent outlet adapter is removed from the
boiler, it should be inspected for deformation
damage or corrosion.
WARNING
Fig. 2: Vent Outlet Adapter Mounting
2. Remove entire vent outlet adapter by lifting vertically upward and out of the boiler cabinet
using a twisting / rocking motion (Fig. 3).
Fig. 3: Removal of Vent Outlet Adapter
If there are any signs of deformation, damage or
corrosion on the vent outlet adapter, replace it
immediately. Check condition of flue sensor
mounting, replace vent outlet adapter if necessary.
Failure to comply could result in flue gas leakage
resulting in severe personal injury or death.
Polypropylene Vent Outlet Adapter Removal
1. Dismount the vent outlet adapter from top of boiler cabinet by twisting the vent outlet adapter
counter clockwise to disengage the retaining tabs.
Remove the vent outlet adapter by lifting vertically to disengage it from the internal vent pipe.
2. Remove the internal vent pipe from the unit by
lifting vertically upward and out of the boiler
cabinet using a twisting / rocking motion.
Removal of Electrical Connections (MCBA)
NOTICE
Before disconnecting any wire connections mark and
label all connections and location of the connections.
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PRESTIGE Excellence
I
gnition
Cable
Igniter
Venturi
HX Field Replacement Kit
1. Remove both top access panels located above
the heat exchanger and water heater on the top
jacket panel.
2. Remove ignition cable and green ground wire
from the igniter. (Fig. 4).
Fig. 4: Top of Heat Exchanger
3. Disconnect the ignition cable from the MCBA
control module and remove air intake pipe from
venturi. (Shown as item 2 in Fig 1). Place the
intake pipe and ignition cable aside, DO NOT
discard as they will be re-used.
4. Disconnect the electrical connection(s) for the
blower at the blower housing.
5. Remove the mounting screw and disconnect the
black rectifier plug from the gas valve.
6. Disconnect the grey flat ribbon cable from the
display board at the MCBA control module.
7. Disconnect the orange low voltage and high voltage wiring terminal strips by unplugging the bottom strips from the upper portion.
8. Remove the retaining screw for control mounting panel and swing open the control mounting
panel. The high voltage and low voltage terminals should pass through the lower cutouts of
the panel to allow movement of the panel.
9. Disconnect the red wire leads from supply temperature sensor (Shown as item 3 in Fig. 1)
located at the top of the heat exchanger.
10. Disconnect the blue wire leads from return temperature sensor (Shown as item 4 in Fig. 1)
located at the bottom of the heat exchanger.
11. Disconnect the orange wire leads from the Low
Water Cut-Off (LWCO) pressure switch
(Shown as item 5 in Fig. 1). Use care when disconnecting the wire leads as not to damage the
LWCO terminals or the wire leads.
Removal of Electrical Connections (TriMax)
NOTICE
Before disconnecting any wire connections mark and
label all connections and locations of the connections.
1. Remove both top access panels located above
the heat exchanger and water heater on the top
jacket panel.
2. Slide left and right tabs of control panel inward
and lower control panel.
3. Pull the retaining tabs on top of the rear cover to
remove the rear control box cover.
4. Remove green ground wire from the igniter and the
ignition cable from the TriMax control module.
5. Remove air intake pipe (Shown as item 2 in Fig.
1) from venturi. Place the intake pipe aside, DO
NOT discard as it will be re-used.
6. Disconnect the electrical connection(s) for the
blower at the blower housing.
7. Disconnect the Molex plug from the gas valve.
8. Disconnect the Molex plug from supply temperature sensor (Shown as item 3 in Fig. 1)
located at the top of the heat exchanger.
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PRESTIGE Excellence
Venturi/Gas Valve
Assembly
Blower
Blower
Gasket
Burner
P
l
ate
Brass
Union
Brass
Union
Diverter
Valve
Brass Union
HX Field Replacement Kit
9. Disconnect the Molex plug from return temperature sensor (Shown as item 4 in Figs. 1-3)
located at the bottom of the heat exchanger.
10. Disconnect the orange wire leads from the Low
Water Cut-Off (LWCO) pressure switch
(Shown as item 5 in Fig. 1). Use care when disconnecting the wire leads as not to damage the
LWCO terminals or the wire leads.
Removal of Gas Connection
1. Disconnect the gas supply piping inside the
boiler at the brass union located just below the
gas valve using two wrenches.
2. The gas piping can remain inside the boiler or
be removed for additional clearance / access.
Removal of Blower/Gas Valve/Venturi Assembly
Removal of Water Connections
1. Remove condensate trap and cabinet gasket
from the boiler. Do not discard, as they will be
reused. Cut serrated washer on polypropylene
condensate pan to remove retaining nut.
2. Remove electrical wiring from the internal circulator. Mark and label all wires. Disconnect
the Molex plug from the diverter valve actuator.
3. Using a pipe or adjustable wrench, disconnect
the brass union on the boiler piping at the top of
the DHW tank. (Fig. 6)
1. Remove 4 blower mounting screws from the
burner plate using the extended Phillips/Torx
head screw driver provided in the kit and remove
the blower/gas valve/venturi. Gas valve and venturi assembly can remain connected to the blower
housing. Discard old blower gasket. (Fig. 5).
Fig. 6: Excellence Top View
4. Loosen brass union nuts located above and
below the diverter valve body. (Fig. 7)
Fig. 5 Blower/Gas Valve and Venturi Assembly
Fig. 7: Excellence Front View
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PRESTIGE Excellence
HX Field Replacement Kit
5. Remove the DHW tank boiler piping from the
boiler.
6. Disconnect the upper flange of the internal circulator. Remove the internal circulator and
diverter valve assembly from the boiler.
7. Loosen the brass union nut located at the internal
supply connection of the heat exchanger. The
piping assembly can be rotated to allow access to
the heat exchanger without removal of the relief
valve / air vent assembly. Push the piping assembly up through the top of the boiler jacket to disengage the anti torque fitting and rotate out of the
way. Discard boiler piping gasket.
8. Loosen the brass union nut located at the internal return connection of the heat exchanger.
The piping assembly does not need to be
removed to access the heat exchanger. Discard
boiler piping gasket.
9. Cut tie strap holding the heat exchanger in place
at the bottom of the unit (if present).
2. Lift the heat exchanger about 4” to 6” to disengage from the rear jacket panel and clear the
condensate tube from the bottom panel. Tilt
heat exchanger forward from the top and carefully rotate it forward in order to remove from
the boiler cabinet.
Preparation of New Heat Exchanger
NOTICE
Do not damage or throw away shipping box,
foam packs, and HX Tracking Form as all these
items are used to return the old heat exchanger,
if required for warranty evaluation.
1. Carefully open and unpack the PARTS BOX
from its shipping carton.
2 . Carefully remove heat exchanger from shipping
box. Do not discard packing materials, as the
shipping box should be reused to return the old
heat exchanger back to Triangle Tube if
required for warranty consideration.
Removal of Heat Exchanger
NOTICE
Obtain assistance in lifting the heat exchanger
from the cabinet as 2 people will be required.
1. Remove the sheet metal “anti-bounce” bracket
insert (if present) from the upper mounting
brackets located behind the heat exchanger
(Fig. 8). This clip is used to avoid vertical
motion of the heat exchanger during transport
and is not required to be installed with the
replacement heat exchanger.
3. Check new heat exchanger for any damage.
Check position of the flue gasket in the new heat
exchanger.
4. Install new temperature sensors with O-ring gaskets in return and supply sensing locations.
5. Install new temperature sensor with O-ring gasket in flue sensing location (PSRKIT01 &
PSRKIT76 only)
6. Install the new igniter gasket and igniter in the
burner plate using 2 screws provided. Tighten
screws evenly. See Table 2, page 14 for torque
specifications.
Fig. 8: Heat Exchanger “Anti-bounce” Bracket
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PRESTIGE Excellence
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4
3
1
HX Field Replacement Kit
Installation of New Heat Exchanger
NOTICE
Prior to installation of the new heat exchanger,
carefully check the interior of the boiler cabinet.
Dry the cabinet / insulation when signs of moisture are present. Check integrity of all wiring.
Repair / replace when necessary.
1. Lift new heat exchanger into place by engaging
the rear HX brackets (top and bottom) into the
rear boiler jacket panel provisions.
Installation of Blower/Gas Valve/Venturi Assembly
1. Mount the blower/gas valve/venturi assembly
on top of the heat exchanger. Use the new
blower gasket provided in the kit. Install 4 new
blower mounting screws (M4 x 12) ensuring
they are properly tightened and the blower is
mounted securely to the burner plate (Fig. 9).
See Table 2, page 14 for torque specifications.
Installation of Water Connection
1. Connect boiler return piping back to return connection of new heat exchanger. Use a new boiler
piping gasket provided in the kit between heat
exchanger and return pipe. Tighten the brass union
nut ensuring a leak tight seal.
2. Rotate the boiler supply piping back into position
and connect to the supply connection of the new
heat exchanger. Use a new boiler piping gasket
provided in the kit between heat exchanger and
supply pipe. Tighten the brass union nut ensuring
a leak tight seal.
NOTICE
Use care when tightening the heat exchanger union
nuts. If excessive torque is applied to the union nut,
damage can occur to the boiler piping or the gasket
seal resulting in leakage.
3. Install the internal circulator and diverter valve
assembly in the boiler using a new flange gasket
between the circulator flange and boiler piping
flange. Tighten the flange nuts and bolts to secure
the flange connection. Ensure the flange gasket is
not pinched between the flanges.
1. Gas Valve
2. Venturi
3. “Straight” Gas Valve Fitting
4. Blower
Fig. 9: Prestige Burner Assembly
4. Connect the CH supply pipe to the bottom of the
diverter valve by tightening the brass union nut by
hand.
5. Install the DHW tank boiler piping using a new
boiler piping gasket provided in the kit between the
piping and the DHW tank. Tighten the brass union
on the boiler piping at the top of the DHW tank by
hand. Tighten the brass union nut at the diverter
valve by hand.
6. After all piping is connected, tighten all connections using the two wrench method.
7. Connect the Molex plug to the diverter valve
actuator and the electrical wiring to the internal
circulator.
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PRESTIGE Excellence
F
lexible Tubing
(or 3/4 PVC/
CPVC Piping
t
o Drain)
C
ompression
Nut with
Rubber Seal
F
ill Plug
with Vaccum
B
reak Port
C
ondensate
Drain Assembly
Plastic Ball
(Not shown)
R
etaining Nut
P
lace the Metal
W
asher and (2)
Rubber Gaskets
i
n this Order for
Proper Seal.
HX Field Replacement Kit
8. Install cabinet gasket where heat exchanger
condensate drain nipple penetrates the cabinet.
9. Install the condensate drain assembly as shown
in Fig. 10.
10. A new metal washer must be installed when
installing the condensate drain assembly onto a
polypropylene condensate pan. The new metal
washer must first be cut using a pair of diagonal
cutting pliers to make it into a split washer.
Insert the split metal washer into the retaining
nut and screw onto the condensate drain assembly without rubber gaskets. Use the condensate
drain assembly as a tool to press the retaining
nut with split metal washer onto the polypropylene condensate pan. Unscrew the condensate
drain assembly and proceed to the next step.
Fig.10: Condensate Drain Assembly
WARNING
Ensure the installation of the condensate drain
assembly included the metal washer when
attaching to a polypropylene condensate pan.
Failure to comply could result in the trap assembly dislocating from the boiler.
11. Slide the retaining nut, and rubber seals from the
condensate drain assembly over the heat exchanger condensate drain nipple. Connect the condensate
drain assembly to the retaining nut and tighten.
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.
Installation of Gas Connection
1. Install the gas piping inside the unit if it was
removed for additional clearance/access.
2. Connect gas piping to the gas valve at the brass
union located just below the gas valve. Tighten
the union using two wrenches. See Table 2, page
14 for torque specifications.
Installation of Stainless Steel Vent Outlet
Adapter
1. Ensure flue gasket is seated properly in the heat
exchanger adapter. Apply clean water to the bottom of the vent outlet adapter and flue gasket.
(Fig. 11).
2. Insert vent outlet adapter through the top jacket
panel into the heat exchanger adapter. (Fig. 11).
Use a slight twist motion with a downward
force as it is inserted into the adapter. Ensure
the gasket remains seated in the heat exchanger
adapter.
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PRESTIGE Excellence
Ensure Adapter
i
s Clean of All
Debris
Gasket
Mo
is
ten
G
as
k
et
P
r
io
r
to
I
n
s
er
tio
n
o
f
F
lu
e
Tu
b
e
En
s
u
r
e
A
d
ap
ter
is
C
lean
o
f
A
ll
D
eb
r
is
HX Field Replacement Kit
t
e
sk
a
G
e
b
u
T
e
u
Fl
r/
e
g
n
a
h
c
Ex
t
a
e
H
:
11
.
g
Fi
3. In case of limited top boiler clearance, insert vent
outlet adapter through the removed top jacket
panel. Bring this entire assembly in place together on top of the boiler side panels. Use a slight
twist motion with a downward force as the vent
outlet adapter is inserted into the heat exchanger
adapter. Ensure the gasket remains seated in the
heat exchanger adapter. Secure the entire top jacket panel to the side panels with the original screws.
Install all DHW piping including T&P relief valve
to the DHW connections on the top of the boiler.
Open the DHW cold water isolation valve and test
for water leaks.
Fig. 12: Vent Outlet Adapter Gasket
Installation of Polypropylene Vent Outlet
Adapter
1. Ensure flue gasket is seated properly in the heat
exchanger adapter. Apply clean water to the bottom of the internal vent pipe. (Fig. 11)
2. Insert the internal vent pipe into the heat
exchanger adapter. Use a slight twist motion
with a downward force as it is inserted into the
adapter. Ensure the gasket remains seated in the
heat exchanger adapter.
4. Install new vent outlet gasket provided in the kit
in vent outlet adapter. Ensure the combustion test
port of the vent outlet adapter is facing toward the
3. Ensure flue gasket is seated properly in the top of
the internal vent pipe. Apply clean water to the
bottom of the vent outlet adapter.
front of the boiler. Re-use the existing 4 mounting screws and secure vent outlet adapter to top of
boiler jacket panel. (Fig. 12).
4. Install the vent outlet adapter on top of boiler
cabinet by twisting the vent outlet adapter clockwise to engage the retaining tabs. Ensure the flue
WARNING
If during the install of the flue tube into the heat
exchanger the flue gasket becomes dislodged, it
is extremely important that the install is halted
and the gasket is reseated in the adapter. Failure
to comply could result in leakage of flue products into the surrounding area resulting in death
or personal injury.
gasket remains seated in the internal vent pipe.
5. Install new vent outlet gasket provided in the kit
in vent outlet adapter. Ensure the combustion
test port of the vent outlet adapter is facing
toward the front of the boiler. (Fig. 12)
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PRESTIGE Excellence
Run Channel
Wire Harness
Adapter Wire
Wire Harness
Sensor Wire
U-Connection
HX Field Replacement Kit
WARNING
If during the install of the internal vent pipe or
vent outlet adapter the flue gasket becomes dislodged, it is extremely important that the install
is halted and the gasket is reseated. Failure to
comply could result in leakage of flue products
into the surrounding area resulting in death or
personal injury.
Installation of Electrical Connections (MCBA)
1. Connect the orange wire leads to the Low Water
Cut-Off (LWCO) pressure switch.
2. Connect the Harness Adapter to the blue return
temperature sensor wires of the boiler wiring
harness using the included Wire Taps.
3. Connect the Harness Adapter to the red supply
- Place the unstripped wire harness wire into
the run channel of the Wire Tap and close
the side cover (Fig. 13).
- Insert the Harness Adapter unstripped wire
into the Wire Tap and use pliers to squeeze
the U-Connection into the Wire Tap.
- Close the hinged cover and make sure it
latches.
- Plug the Harness Adapter into the return
temperature sensor
temperature sensor wires of the boiler wiring
harness using the included Wire Taps. Follow
the Harness Adapter instructions above then
plug the Harness Adapter into the supply temperature sensor.
Fig. 13: Harness Adapter Installation
4. Reconnect the yellow flue temperature wires to
the flue temperature sensor if the sensor was not
replaced. If the flue temperature sensor was
replaced, connect the Harness Adapter to the
yellow flue temperature sensor wires of the
boiler wiring harness using the included Wire
Taps. Follow the Harness Adapter instructions
above then plug the Harness Adapter into the
flue temperature sensor.
5. Connect the black rectifier plug to the gas valve
and secure with provided screw.
6. Connect the electrical connection(s) for the
blower to the blower housing.
7. Connect the green ground wire to the igniter
ground terminal.
8. Pass the orange low voltage and high voltage
wiring terminal strips through the lower cutouts
of the control mounting panel. Close the control
mounting panel and secure with the retaining
screw. Connect the orange low and high voltage
wiring terminal strips to the upper portion.
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PRESTIGE Excellence
HX Field Replacement Kit
9. Connect the gray ribbon cable from the display
board to the MCBA control module.
10. Connect the ignition cable to the igniter and the
MCBA control module.
11. Install the air intake pipe back on the venturi air
inlet connection. Make sure the ignition cable is
secured with a cable tie to the air intake pipe. Also
make sure the ignition cable is not in contact with
any metal surfaces or routed over the sight glass.
12. Install both top access panels located above the
heat exchanger and water heater on the top jacket panel.
Installation of Electrical Connections (TriMax)
1. Connect the orange wire leads to the Low Water
Cut-Off (LWCO) pressure switch.
2. Connect the Molex plug to the return temperature sensor located at the bottom of the heat
exchanger.
Also make sure the ignition cable is not in contact with any metal surfaces or routed over the
sight glass.
10. Flip control panel up until retaining tabs lock
into place.
11. Install both top access panels located above the
heat exchanger and water heater on the top jacket panel.
Installation of Vent Connection
1. Ensure vent outlet gasket is seated properly in
the vent outlet adapter.
2. Apply clean water to the insertion end of the
pipe to ease insertion into the adapter.
3. Insert vent pipe into the adapter until it is fully
seated.
WARNING
3. Connect the Molex plug to the supply temperature sensor located at the top of the heat
exchanger.
4. Connect the Molex plug to the flue temperature
sensor.
5. Connect the Molex plug to the gas valve.
6. Connect the electrical connections for the blower to the blower housing.
7. Connect the green ground wire to the igniter
ground terminal.
8. Connect ignition cable to the TriMax control
module and install rear control box cover.
9. Install the air intake pipe back on the venturi air
inlet connection. Make sure the ignition cable
is secured with a cable tie to the air intake pipe.
Do not apply excessive force, twist or bend the
adapter or vent pipe when inserting. The vent
outlet gasket could be damaged resulting in possible flue gas leakage.
4. Secure the vent pipe by tightening the vent outlet adapter banding strap. Do not over tighten
the strap. The seal is made with the gasket
inside the adapter.
Start-Up Procedures
CAUTION
Ensure the domestic inner tank of the PRESTIGE Excellence water heater is properly
filled and pressurized prior to filling the boiler
system. Failure to comply could result in damage of the inner tank.
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PRESTIGE Excellence
HX Field Replacement Kit
1. Ensure the pressure relief valve / air vent is
properly piped to the supply piping at the top of
the boiler.
2. Fill boiler with water and purge all air from the
system. Set boiler pressure between 12 and 15 psi.
Test for water leaks. Repair any leaks.
3. Turn on gas supply to the inlet of the unit at the
external main manual shutoff valve to the unit.
4. Check and test all gas connections for leaks.
Repair leaks if found.
WARNING
Do not check for gas leaks with an open flame.
Use a bubble test. Failure to check for gas leaks
can cause severe personal injury, death or substantial property damage.
5. Turn on power to the unit. The unit is now ready
to be placed back in service.
WARNING
The combustion testing and adjustments must be
performed by a qualified installer, service agency
or the gas supplier. All combustion measurements must be performed with calibrated equipment to ensure proper readings and accuracy.
WARNING
Failure to perform a complete combustion test at
both high and low input rates may result in incomplete combustion and the production of carbon
monoxide, which can cause severe personal injury,
death or substantial property damage.
MCBA Instructions
1. Manually place the boiler into high fire mode by
pressing the “MODE” button with “+” button
simultaneously on the control panel display
while in the Standby (STBY) mode.
NOTICE
Combustion Test and Adjustments
1. The installer MUST perform a complete combustion check to ensure the following combustion levels are met at high and low input firing rates and
the burner is operating at optimum conditions.
Natural Gas Propane
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
Table 1: Recommended Combustion Settings
The control panel will display a H followed by the
current boiler temperature when placed into
high fire test mode.
2. If the combustion levels during high fire is outside the recommended combustion settings
adjust the THROTTLE SCREW (see Fig. 14)
using a flat-blade screwdriver as follows:
Counter-clockwise adjustment of the
THROTTLE SCREW at High Fire:
O2 decreases and CO2 increases
Clockwise adjustment of the THROTTLE
SCREW at High Fire:
O2 increases and CO2 decreases
3. Once the combustion level is set at high fire,
manually place the boiler into low fire mode by
pressing the “MODE” button with “-” button
simultaneously on the control display while in
the Standby (STBY) mode.
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PRESTIGE Excellence
Installer
Button
Manual Operation
Released
O
O
O
CH
CH1
FAN
DHW
SYS
CH2
Throttle
Screw
Offset Pressure
Cover Screw
HX Field Replacement Kit
Fig. 14: Combustion Adjustment - Prestige Burner
NOTICE
Fig. 15: Trimax Navigation Buttons
3. Press the RIGHT button to highlight the
Manual Operation icon then press the OK
button.
4. Press the OK button while the FAN icon is
highlighted to manually fire the burner and
power the CH circulator.
The control panel will display a L followed by
the current boiler temperature when placed into
low fire test mode.
4. If the CO2combustion level during low fire is
not within +/- 0.2 of the combustion level measured at high fire, remove the offset cover screw
and adjust the plastic OFFSET SCREW (see Fig
14) using a T-40 Torx wrench as follows:
Counter-clockwise adjustment of the OFFSET
SCREW at Low Fire:
O2 increases and CO2 decreases
Clockwise adjustment of the OFFSET SCREW
at Low Fire:
O2 decreases and CO2 increases
TriMax Control Procedure
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.
5. Press the RIGHT button to adjust the firing rate
to 100% (high fire). Hold down the RIGHT
button to rapidly increase the firing rate.
1. Press the round INSTALLER button. See Fig.
15.
2. 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.
6. If the combustion levels during high fire are
outside the recommended combustion settings
adjust the THROTTLE SCREW (see Fig. 14)
using a flat-blade screwdriver as follows:
13
Page 14
PRESTIGE Excellence
HX Field Replacement Kit
Counter-clockwise adjustment of the THROTTLE SCREW at High Fire (100% firing rate):
O2decreases and C02increases
Clockwise adjustment of the THROTTLE
SCREW at High Fire (100% firing rate):
O2increases and CO2decreases
7. Once the combustion level is set at high fire,
manually place the boiler into low fire mode by
pressing the LEFT button to adjust firing rate
down to 1% (low fire).
8. If the CO2combustion level during low fire is
not within +/-0.2 of the combustion level measured at high fire, remove the offset cover screw
and adjust the plastic OFFSET SCREW (see
Fig. 14) using a T-40 Torx wrench as follows:
Table 2: Torque Specifications
orque Specifications
T
Assembly Screws
Sight Glass 11 13
Burner Head 27 31
Igniter 27 31
Gas Valve Couplings 27 31
Blower - Outlet 27 31
Venturi to Gas Valve 31 35
Venturi to Blower 31 35
Burner Plate 44 59
Min.
Inch- Pounds
Max.
Inch- Pounds
Counter-clockwise adjustment of OFFSET
SCREW at Low Fire (1% firing rate):
O2increases and CO2decreases
Clockwise adjustment of OFFSET SCREW at
Low Fire (1% firing rate):
O2decreases and CO2increases
9. Press the OK button while the fan icon is highlighted to shutdown the burner.
10. Press the DOWN button to highlight the home
screen icon then press OK to return to the
home screen.
Revised date: 07/21 /13
14
2011-16 Prestige Excellence HX_Repl Kit
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