Prestige Excellence Installation And Maintenance Manual Download Page 6

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Table of Contents

Cleaning of New Boiler/System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Check and Test Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Use of Antifreeze in the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Filling the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Check Low Water Cut-Off Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Check for Gas Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Check Thermostat Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Inspection of Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 55

SECTION XI- START-UP PROCEDURES

Final Checks Before Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

PRESTIGE Excellence Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

If PRESTIGE Excellence does Not Start Correctly. . . . . . . . . . . . . . . . . . . 56

Check the PRESTIGE Excellence and System . . . . . . . . . . . . . . . . . . . . . . 56-59

Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

SECTION XII - OUTDOOR RESET CONTROL

Mounting the Outdoor Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Wiring the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

SECTION XIII - EXTERNAL MODULATING CONTROL

Wiring the Modulating Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Trimax Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Programming of External Modulating Control . . . . . . . . . . . . . . . . . . . . . . 62

Factory Trimax Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

SECTION XIV - CHECK-OUT PROCEDURES

Check-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

SECTION XV - INSTALLATION RECORD

Installation Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

SECTIONS XVI - MAINTENANCE SCHEDULE

Service Technician - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Owner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Summary of Contents for Excellence

Page 1: ...ual PRESTIGE Excellence Revised 2 6 14 If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or death 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 swi...

Page 2: ...ent and or the various optional vent kit instructions For instructions regarding the PRESTIGE Excellence Domestic Water Heater Installation requirements and piping reference the PRESTIGE Excellence Indirect Water Heater Manual beginning after page 82 of PRESTIGE Excellence Water Boiler Manual The PRESTIGE Vent Supplement is included in the unit s installation envelope For instructions or informati...

Page 3: ...y IV 6 Methods of Accessing Combustion Air into a Space Category IV 7 Indoor Combustion Air 7 Outdoor Combustion Air 7 8 Combination of Indoor and Outdoor Combustion Air 9 Combustion Air and Vent Piping 9 Removal of an Existing Boiler from a Common Vent System 10 Commonwealth of Massachusetts Installation 11 SECTION III UNIT PREPARATIONS Handling Instructions 12 Wall Mounting Installation 12 Wall ...

Page 4: ...stem Piping Diagrams 20 21 SECTION V INSTALLING VENT COMBUSTION AIR CONDENSATE DRAIN Installing Vent and Combustion Air 22 Installing Condensate Drain Assembly 22 23 SECTION VI GAS PIPING Gas Supply Piping Connection 24 Natural Gas Pipe Sizing Natural Gas 25 Natural Gas Supply Pressure Requirements 25 Propane Gas Pipe Sizing Propane Gas 26 Propane Gas Supply Pressure Requirements 26 Gas Valve Vent...

Page 5: ...n 38 Trimax Menu Structure 39 Home Screen 40 Status Line Messages 41 Main Menu 42 EZ Setup Menu 43 Heating EZ Setup 43 44 Domestic Hot Water EZ Setup 45 EZ Setup Reset 46 Display EZ Setup 46 CH DHW Operation 47 Boiler Information 47 Information Items 48 Lockout History 49 Lockout Screen 50 Manual Reset Hard Lockouts 51 Automatic Reset Soft Lockouts 52 SECTION X START UP PREPARATION Check Boiler Sy...

Page 6: ... If PRESTIGE Excellence does Not Start Correctly 56 Check the PRESTIGE Excellence and System 56 59 Operating Instructions 60 SECTION XII OUTDOOR RESET CONTROL Mounting the Outdoor Sensor 61 Wiring the Sensor 61 SECTION XIII EXTERNAL MODULATING CONTROL Wiring the Modulating Controller 62 Trimax Adjustment 62 Programming of External Modulating Control 62 Factory Trimax Settings 63 SECTION XIV CHECK ...

Page 7: ...k Expansion Tank 69 Check Boiler Relief Valve 69 Inspection of Ignition Electrode 69 Check Ignition Wiring and Ground Wiring 69 Check Control Wiring 70 Check Control Settings 70 Perform Start Up and Checkout Procedure 70 Check Burner Flame 70 Check Flame Signal 71 Check Combustion Levels 71 Check Flue Gas Temperature 71 Clean Heat Exchanger 71 Review with Owner 72 Handling Previously Fired Combust...

Page 8: ...ructions on installa tion operation or maintenance which are important to equipment but not related to personal injury hazards Indicates recommendations made by ACV Triangle Tube for the installers which will help to ensure optimum oper ation and longevity of the equipment NOTICE WARNING CAUTION BEST PRACTICE DANGER The following terms are used throughout this manual to bring attention to the pres...

Page 9: ...rform 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 Pl...

Page 10: ... space installations ONLY 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 combus tion 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 ...

Page 11: ...dition Residential Garage Installations When installing the PRESTIGE Excellence in a residential garage the following special precau tions 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...

Page 12: ...e 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 Potential contaminating products Spray cans containing chloro fluorocar bons Permanent Wave Solut...

Page 13: ... free area for the openings is not required Failure to provide or properly size the openings could result in severe personal injury death or substantial property damage Ventilation and Combustion Air Requirements Category IV A Category IV appliance utilizes uncontami nated indoor or outdoor air surrounding the appliance for combustion In order to reduce the potential risks associated with indoor c...

Page 14: ...ces are con nected by one or more openings in doors or floors having a total minimum free area of 2 sq in 1000 Btu hr of total input rating of all gas utilization equipment Outdoor Combustion Air Isolating the combustion appliance room from the rest of the building and bring ing in uncontaminated outside air for combustion and ventilation is always preferred Opening Size and Location The minimum d...

Page 15: ...ng 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 rat ing of all equipment in the enclosure See Fig 3 Where communicating with the out doors 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 equ...

Page 16: ...ce 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 uncontaminated outdoor air piped directly to ...

Page 17: ...aximum 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 5 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or can dle or smoke from a cigarette cigar or pipe 6 After it has b...

Page 18: ... 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 Installer must provide tag identification plate and ensure the lettering meets...

Page 19: ...nts could result in personal injury death or sub stantial property damage Wall Mounting Guidelines 1 The wall mounting bracket is designed for stud spacing of 12 inch or 16 inch on cen ters For unconventional stud spacing a solid secure mounting surface must be provided for installation of the bracket 2 DO NOT mount or attempt to mount the wall bracket to hollow sheet rock or lath walls using anch...

Page 20: ...pper edge of the bracket is away from the wall 3 Level the bracket and use a pencil to mark the location of the mounting slots on the wall 4 Remove the bracket from the wall and drill a 5 8 diameter hole by 1 3 8 deep posi tioned 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 w...

Page 21: ... 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...

Page 22: ...g 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 mem brane 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 hygroscop...

Page 23: ...low preventer valve in the make up water supply to the unit as required by local codes Boiler System Piping Applications It is recommended on all piping applica tions to utilize a primary secondary pip ing arrangement as a means to provide freeze protection of the boiler which is an integral function of the boiler control Maintain the minimum boiler flow rate see Graph 2 on page 81 For other pip i...

Page 24: ... recommended piping arrangements based on various applications Size the piping and sys tem components required in the space heating system using recognized design methods System Piping Zone Circulators Connect the PRESTIGE Excellence to the sys tem piping as shown in Fig 9 page 20 when zoning with zone circulators The installer must provide a separate circulator for each zone of space heating To e...

Page 25: ...adiant system To ensure an adequate flow rate through the PRESTIGE Excellence the boiler supply and return piping size must be a minimum of 1 inch The addition of the high temperature limit is important when the PRESTIGE Excellence has completed a DHW call which requires a high primary supply water temperature System Piping Special Application If the boiler is used in conjunction with a chilled wa...

Page 26: ...19 Boiler Piping Fig 6 Piping Component Legend ...

Page 27: ... System Piping Zoning with Zone Valves The boiler system piping shown must be a closed system to avoid any oxygen contamination and potential failure of the outer tank of the water heater NOTICE Note Reference Fig 23 page 35 for Prestige Wiring Note Reference Fig 24 page 35 for Prestige Wiring Note ZC1 and ZC2 circulators controlled by SZC5 Zone Panel ...

Page 28: ... to overcome the system pressure drop and pro vide adequate flow through the boiler system Note Verify AUX circulator is properly sized to overcome the system pressure drop and provide adequate flow through the boiler system The boiler system piping shown must be a closed system to avoid any oxygen contamination and potential failure of the outer tank of the water heater NOTICE Note Reference Fig ...

Page 29: ...e condensate drain assembly without rubber gaskets Use the condensate drain assembly as a tool to press the retain ing nut with metal washer onto the polypropylene condensate pan The installer may want to fill the con densate trap with water prior to assem bling on the unit 3 Reassemble the condensate drain assembly onto the boiler by tightening the retaining nut with rubber seal onto the boiler E...

Page 30: ...the pipe from the drain assembly to a floor drain or condensate pump When selecting and installing a conden sate pump ensure the pump is approved for use with condensing boilers and fur naces The pump should be equipped with an overflow switch to prevent prop erty damage from potential condensate spillage 9 The PRESTIGE Solo will typically produce a condensate that is considered slightly acidic wi...

Page 31: ...c Disconnect the PRESTIGE Excellence and its gas valve from the gas supply piping during any pressure test greater than 13 w c Do not check for gas leaks with an open flame Use a gas detection device or bub ble test Failure to check for gas leaks can cause severe personal injury death or substantial property damage 7 Use pipe dope compatible with natural and propane gases Apply sparingly only to t...

Page 32: ...ing 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 lock up pressure regulator for 13 w c maximum DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pres sure This setting is suitable for natural gas and propane and requires no field adjustment Attempts by th...

Page 33: ...or pro vided by the gas supplier for 13 w c max imum pressure 2 Pressure required at the gas valve inlet sup ply 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 DO NOT adjust or attempt to measure gas valve outlet pressure The ...

Page 34: ...27 Gas Piping Venturi LP Orifice if required Throttle Screw Gas Valve Gasket Gas Valve Offset Pressure Cover Screw Inlet Gas Pressure Port Fig 16 Gas Valve Venturi Assembly PRESTIGE Excellence ...

Page 35: ...alent as a minimum The PRESTIGE must be electrically grounded as required by National Electrical Code ANSI NFPA 70 latest edi tion and or the Canadian Electrical Code Part 1 CSA C22 1 Electrical Code Fuse Locations The TriMax control module contains 2 internal replaceable 5A fuses as shown in Figure 18 Additional fuses are also located on the line voltage terminals as shown in Fig 18A and Fig 19 T...

Page 36: ...29 Internal Wiring Fig 19 PRESTIGE Excellence Boiler Factory Wiring ...

Page 37: ...d Boiler circulator as well as a Diverter Valve The Boiler circulator is enabled for any CH1 CH2 or DHW call The Diverter Valve will direct water flow to the CH Supply Connection at the bottom of the boiler during a CH1 or CH2 call or to the internal Indirect Water Heater during a DHW call 1 The Boiler circulator is prewired to the line voltage terminal strip on the wiring panel below the PRESTIGE...

Page 38: ...ing The Trimax 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 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 SM...

Page 39: ...rip on the wiring panel below the PRESTIGE control mod ule as shown in Fig 19 on page 29 External Modulation Control The PRESTIGE firing rate can be controlled by an external modulating boiler controller See page 62 for external modulation signal wiring and setup System Sensor Wiring An optional system temperature sensor can be placed on the central heating loop to control the temperature in the c...

Page 40: ...33 External Wiring Diverter Valve CH 1 Pump AUX Fig 20 Multiple Zone Field Wiring Using Zone Valves ...

Page 41: ...34 External Wiring Diverter Valve CH 1 Pump AUX Fig 21 Multiple Zone Field Wiring using Zone Circulators ...

Page 42: ...ump AUX SYS DiverterValve CH 1 Pump AUX ZC1 ZC2 Fig 23 Prestige Wiring Zoning with Zone Circulators Fig 24 Prestige Wiring Zoning with Zone Valves Note Reference Fig 9 page 20 for System Piping Note Reference Fig 10 page 20 for System Piping ...

Page 43: ...1 Pump AUX Fig 25 Prestige Wiring Multiple Zone Valve with Single System Boiler Circulator Fig 26 Prestige Wiring Single Zone System with Single System Boiler Circulator Note Reference Fig 11 page 21 for System Piping Note Reference Fig 12 page 21 for System Piping ...

Page 44: ... Hot Water DHW call input with optional priority EZ Setup feature allows the installer to quickly customize Trimax 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 Trimax features are easy to use through a graphical display where information is presented eith...

Page 45: ...ler level functions Figure 31 Trimax 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 currently 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 Sc...

Page 46: ... f bbb b abc de f bb abc d a b c d e f b b b b a b c d e f b b a b c d e a b c d e f b b b b a b c d e f b b f b g a b c d Boiler Information Boiler Information Menu CH DHW Operation Menu EZ Setup Menu Main Menu Home Screen Heating Enabled Trimax Menu Structure ...

Page 47: ...return temperatures are displayed as well as current burner status A flame symbol is displayed when the unit is fired The flame size changes to indicate the current firing rate 1 2 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 rem...

Page 48: ...all blocking time has elapsed CH Setpoint Reached The burner is not fired because the supply system water temperature 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 DHW Setpoint Reached The burner is not fired because the supply system water temperature exceeds the setpoint Th...

Page 49: ...h 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 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 a reversed image with a text description shown at the top of t...

Page 50: ...e Prestige and the setpoint will be fixed for central heating calls Constant Outdoor Reset This option is only displayed when the outdoor temperature sensor is connected The Prestige will maintain set point without an external call from a thermostat or zone panel The set point will vary with the outdoor temperature for central heating calls Constant Setpoint The Prestige will maintain setpoint wit...

Page 51: ...riate for the type of heating system then press the OK but ton to store the setting 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 circu lators placed into constant circulation with the pump constant circulation setting The Prestige will continue to respo...

Page 52: ...te a domestic hot water call when the temperature drops below the DHW Storage Setpoint by 6ºF 3ºC 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...

Page 53: ...and to Switch Use Domestic Hot Water EZ Setup to change back to a sen sor demand Navigation Home Screen Main Menu EZ Setup Display EZ Setup Display EZ Setup allows the installer to select the type of temperature units displayed as well as the language used for all text Press the UP or DOWN buttons to select then press the OK button to store the setting NOTICE EZ Setup Reset EZ Setup Reset Press OK...

Page 54: ...llowed 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 48 for a list of all information items Boiler Information Logging Some information items include a logging function which records one sam ple every 12 minutes to produce a graph of the last 24 hours Select the infor mation it...

Page 55: ...tige Boiler Flue Temperature Displays the current flue temperature of the Prestige Outdoor Temperature Displays the current outdoor temperature DHW Storage Temperature Displays the current DHW storage temperature External Modulation Signal Displays the current external modulation signal being received from an external controller CH Ignitions Displays the number of central heating ignitions since t...

Page 56: ...Press the UP or DOWN buttons to scroll through the recorded information The fol lowing 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 Lockout History Lockout History 1 Low wat...

Page 57: ...ome Screen to help diagnose the problem Select the Home Screen icon at the bottom of any menu screen to return to the Lockout Screen Water level has fallen below an acceptable operating level Increase pressure to normal range Boiler will automatically reset once water level returns to normal Low Water If problem persists call for service E37 Lockout Screen The Lockout Screen replaces the Home Scre...

Page 58: ...fted 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 A short circuit has been detected in the boiler supply temperature sensor circuit E31 Supply Sensor Open An open circuit has ...

Page 59: ...n 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 Ope...

Page 60: ...unusually hard water hardness above 7 grains consult a water treatment company Chlorinated Water Do not use the PRESTIGE Excellence to heat a swimming pool or spa directly Maintain the chlorine level of the water at lev els considered safe for drinking Flush Boiler to Remove Sediment The installer must flush the boiler system to remove any sediment to allow proper operation of the PRESTIGE Excelle...

Page 61: ... used Ensure the concentration of antifreeze to water does not exceed a 50 50 ratio 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 Ensure the domestic inner tank of the PRESTIGE Excellence water heater is properly filled and pressurized prior to filling the boiler system Reference the PRE...

Page 62: ...pplier check and verify the odorant level Check Thermostat Circuit Disconnect the external thermostat wires from the low voltage terminal strip Connect a voltmeter across the wire ends of the external thermostat wiring Close each thermostat zone valve and relay in the external circuit one zone at a time and check the voltage reading across the wire ends There should NEVER be voltage measured at th...

Page 63: ...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 60 If PRESTIGE Excellence Does Not Start Correctly 1 Check for loose electrical connections blown fuses on control module and in ter minals or an open service switch 2 Verify CH and DHW operation is enabled A radiator or f...

Page 64: ...ormed by a qualified installer service agency or the gas suppli er All combustion measurements must be performed with calibrated equipment to ensure proper reading and accuracy 2 Test for CO2 or O2 and for CO during high firing rate The combustion read ings should be within the range listed in Table 4 The CO level should not exceed 100 ppm when combustion is correct Perform the following proce dur...

Page 65: ... 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 4 If the CO2 combustion level during low fire 1 is not within 0 2 of the com bustion level measured at high fire adjust the plastic OFFSET SCREW under the cover screw on the top of the gas valve see Fig 16 page 27 Counter clockwise adjustment of the OFF SET SCREW at...

Page 66: ...ton to highlight 102ºF 39ºC then press the OK button 7 Press the DOWN button twice to highlight the Home Screen icon then press the OK button 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...

Page 67: ...ping 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 If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life 1 Set the room thermost...

Page 68: ... has been determined follow the mounting instruc tions included with the outdoor sensor 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 Excellence ensuring the wires are not run parallel to telephone or power cables If the sensor wires are located in an area with sources of potential electromagnetic interference EMI the ...

Page 69: ...terminals Ensure that the polarity of the connec tions from the external modulating boil er controller to the boiler are correct Reversed polarity will lead to no response from the boiler Trimax Adjustment The Trimax 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 Signa...

Page 70: ...bled CH2 Maximum Setpoint 140 F 60 C CH2 Minimum Setpoint 80 F 27 C Warm Weather Shutdown OFF Pump Constant Circulation Disabled CH Post Pump Time 1 minute Freeze Protection Enabled Frost Protection Setpoint 22 F 30 C Parallel Shift Value 0 F 0 C CH Call Blocking 1 minute System Pump CH1 CH2 DOMESTIC SETTING FACTORY DEFAULT EZ SETUP RESET INSTALLER RESET DHW Operation Enabled Demand Note 2 Sensor ...

Page 71: ...asured the rate of input on Natural Gas as outlined on page 58 c Test high temperature limit as outlined on page 59 c Checked the incoming gas pressure to the PRESTIGE Excellence to ensure a mini mum pressure of 5 w c during flow condi tions to all gas appliances and a maximum pressure of 13 w c during non flow condi tions for Natural and Propane c Adjusted balancing valves and system limit contro...

Page 72: ...eted Check out procedures have been followed and completed Information regarding the unit and installation received and left with owner maintenance personnel Installer Information Company Address Address Phone Number Btu hr ____________________________________________________________________ ____________________________________________________________________ ______________________________________...

Page 73: ... stable and uni form 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 Owner Maintenance Periodically Check the area around the unit Check and remove any blockage from the combustion air inlet and ventilation open i...

Page 74: ...m mable materials or flammable vapors or liq uids Remove immediately if found 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 prod ucts are in the area from which the unit takes its combustion air they must be removed immediately or the combustion air intake must be relocated to another area Inspect Burner Are...

Page 75: ...bustion 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 Failure to inspect the vent system and combustion air inlet piping and to have any conditions repaired can result in severe personal injury or death Check Boiler System Verify all system components are correctly installed...

Page 76: ... 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 dis charge piping must be full size without restriction and installed to permit com plete 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 c...

Page 77: ... set aside Carefully remove the burner mounting plate assembly from the heat exchanger Ensure combustion chamber insulation is not damaged during removal of burner mounting plate assembly See WARNING on page 72 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 ga...

Page 78: ... the wiring harness connectors from the blower and remove the blower retaining screws or nuts Remove the blow er from the unit 5 Remove the mounting nuts securing the burner mounting plate to the heat exchang er and set aside 6 Carefully remove the burner mounting plate assembly from the heat exchanger Ensure combustion chamber insulation is not damaged during removal of burner mounting plate asse...

Page 79: ...clothing gloves and eyes protection 3 Assure adequate ventilation 4 Wash with soap and water after contact 5 Wash potentially contaminated clothes separately from other laundry and rinse washing machine thoroughly 6 Discard used insulation in an air tight plastic bag NIOSH Stated First Aid Eye Skin Immediately irrigate Breathing Clean fresh air WARNING Handling Previously Fired Combustion Chamber ...

Page 80: ...cess 8 PSRKIT21 Wall Mounting Bracket with Hardware 9 PTJKTSUP03 Support Boiler Return Piping Replacement parts must be purchased through a local ACV Triangle Tube dis tributor When ordering part please pro vide the model number and description and or part number of replacement part Use only genuine ACV Triangle Tube replacement parts to ensure warranty coverage and to avoid damage to appli ance a...

Page 81: ... 5 PTRKIT123 Flue Temperature Sensor 6 PGRKIT20 LWCO Pressure Device 7 PSRKIT05 Condensate Drain Assembly 8 PSRKIT59 Boiler Piping Return Assembly 9 PSRKIT60 Boiler Piping Supply Outlet Assembly 10 PSRKIT61 Boiler Piping Supply Long Assembly 11 PSRKIT54 Boiler Piping Supply Short Assembly 12 PSRKIT62 Boiler Piping Relief Valve Assembly 13 HMCIR01 Circulator 14 PSRKIT56 EXCELLENCE Water Heater Tank...

Page 82: ...hamber Insulation 2 PSRKIT10 Burner Head with Gasket Natural PSRKIT11 Burner Head with Gasket Propane 3 PTRKIT114 Blower with Gasket 4 PSRKIT12 Burner Plate 5 PSGSK15 Burner Plate Gasket 6 PTRKIT111 Gas Valve 7 PSRKIT81 Venturi 002 8 PTRKIT313 Igniter and Cable with Gasket 9 PSRKIT16 Sight Glass Assembly Glass Gasket and Bracket ...

Page 83: ...I01 Power Switch 3 PTSWI02 Power Switch Cover 4 PTRKIT108 Control Enclosure 5 PTRKIT205 TriMax Control Module 6 PTRKIT207 TriMax Display Module 7 PTCON19 Control Enclosure Cover 8 PTGRO01 Igniter Cable Grommet 9 PTFUSE02 TriMax Control Module 5A Fuse Not Shown 10 PTFUSE01 Circulator 2 5A Fuses Not Shown 11 PTFUSE03 In Line Voltage 8A Fuse Not Shown ...

Page 84: ... mm 12 1 4 310 mm 21 1 4 540 mm 16 405 mm 1 2 NPSC Boiler Drain 1 2 NPT Gas Connection 3 4 NPSC Pressure Relief Valve 3 Combustion Air Inlet 3 Vent Outlet 19 479 mm 11 3 4 300 mm 7 1 2 190 mm 1 NPT Boiler Return 1 NPT Boiler Supply Front View PRESTIGE Excellence 110 ...

Page 85: ... 70mm 16 3 8 416 mm 7 3 4 200 mm 15 1 4 390 mm 1 2 NPT Gas Connection 1 NPT Boiler Supply 1 NPT Boiler Return 1 2 NPSC Boiler Drain 3 Vent Outlet 3 Combustion AIr Inlet 3 4 NPSC Pressure Relief Valve 21 1 4 540 mm Side View PRESTIGE Excellence 110 ...

Page 86: ...ct Specifications 3 4 NPT DHW Inlet 3 4 NPSC Aux Connection Rear 1 2 NPSC Air Vent Connection 3 4 NPT DHW Outlet 11 1 4 286 mm 7 1 2 190 mm 3 1 2 87 mm 8 1 2 216 mm 4 3 8 110 mm Top View PRESTIGE Excellence 110 ...

Page 87: ...nts of the U S Department of Energy Note 2 The AHRI rating is based on a piping and pick up allowance of 1 15 This allowance should be sufficient for the standard radiation requirements for a building load Note 3 Based on the given AFUE the PRESTIGE Excellence meets the energy efficiency guidelines established by Energy Star Note 4 Input and output ratings are shown for sea level applications The ...

Page 88: ...81 Product Specifications Note Minimum allowable flow rate at full input 5 gpm Graph 2 Pressure Drop Comparison Excellence vs Grundfos UPS 15 58F ...

Page 89: ...any claims for damage or shortage in shipment must be filed immediately against the transporta tion 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 qu...

Page 90: ... Piping Diagrams 9 10 Water Heater Start Up Filling the Inner Domestic Water Tank 11 Filling the Outer Boiler Water Tank 11 Setting the Thermostatic Mixing Valve 11 General Notes 12 Domestic Hot Water EZ Setup 13 Additional DHW Feature DHW Frost Protection 14 Factory Trimax Setting 15 Water Heater Maintenance Maintenance Schedule 16 Filling Water Heater 16 Draining Water Heater 16 17 Draining Oute...

Page 91: ...l help to ensure optimum operation and longevity of the equipment WARNING NOTICE CAUTION DANGER BEST PRACTICE The following terms are used throughout this manual to bring attention to the presence of poten tial hazards or important information concerning the product Definitions 1 ACV Triangle Tube reserves the right to modify the technical specifications and components of its products without prio...

Page 92: ...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 Protection must be taken against exces sive temperature and pressure TO PROTECT AGAINST EXCESSIVE TEMPERATURE AND PRESSURE ...

Page 93: ...the Uniform Plumbing Code Paragraph L3 2 and L3 3 if they satisfy all of the following requirements 1 The heat transfer medium is potable water or contains only substances which are recog nized as safe by the U S Food and Drug Administration 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...

Page 94: ...rials To provide serviceability to the unit it is rec ommended 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 When maintaining zero clearance or less than recommended clearances some prod uct labeling may become hidden and unreadable When installing the Excellence in a confined space sufficient air...

Page 95: ...y con nection located behind 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 Install the T P in the run straight through leg of a tee located at the domestic hot water out let Use a long element T P relief valve as shown in...

Page 96: ... internal membrane 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 expan sion from repeatedly forcing open T P relief valve T P relief valve is not intended for constant duty such as relief of pressure due to repeated normal system expa...

Page 97: ...e to prevent water loss through T P relief valve Thermostatic Mixing Valve The Excellence is factory supplied with a thermo static 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 For applications with a domestic recirculation loop the recirculation pump should be controlled by an a...

Page 98: ...Outlet T P Valve Drain Piping Not Shown Fig 2 Standard Installation of the T P Relief Valve Drain Dip Tube 3 4 Brass Close Nipple DHW Aux Connection DHW Hot Water Outlet DHW Cold Water Inlet Air Vent Connection 3 4 Brass Tee T P Valve Drain Piping Not Shown Fig 3 Commonwealth of Massachusetts Installation ...

Page 99: ...flow 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 Standard Installation Domestic Piping Excellence Series Fig 4 Standard Installation Domestic Piping with Optional Recirculation Excellence Series Fig 5 ...

Page 100: ...heck valve 3 Shut off valve 4 Backflow preventer or pressure reducing valve 6 Thermal expansion tank 7 Circulator controlled by aquastat 8 Domestic drain valve 9 Vacuum Breaker Optional devices may be required by local codes Domestic Piping with Optional Storage Tank Fig 6 ...

Page 101: ...ce the PRESTIGE Excellence boiler manual for boiler start up and guidelines for filling the boiler If antifreeze is used in boiler water check concen tration Boiler water including additives must be practically non toxic having toxicity rating or class of 1 as listed in Clinical Toxicology of Commercial Products Do not use automotive ethylene glycol or petroleum based antifreeze Do not use any und...

Page 102: ...ion or if state laws or local codes require certain water temperatures at hot water faucets take special precautions Install the factory supplied automatic mix ing valve at water heater and or install a point of use mixing valve at each hot water faucet bath and shower outlet Selection and installation of point of use mixing valves must comply with valve manufactur er s recommendation and instruct...

Page 103: ...erate a domestic hot water call when the temperature drops below the DHW Storage Setpoint by 6ºF 3ºC 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 ...

Page 104: ...a potential freeze up Frost Protection will generate a DHW call once the IDWH temperature falls below 42º F 6ºC Once Frost Protection is activated the internal circulator and diverter valve will direct water flow to the water heater and the burner will fire Frost Protection will end once the IDWH temperature is raised to 60ºF 16ºC This feature is always active and cannot be disabled Frost Protecti...

Page 105: ...HW Call Blocking 0 minute DHW to CH Call Blocking 1 minute Antilegionella Function Disabled BOILER SETTING FACTORY DEFAULT EZ SETUP RESET INSTALLER RESET Prestige Model Note 1 Excellence Lockout Temperature 210 F 99 C Modbus Address 0 BCST HEATING SETTING FACTORY DEFAULT EZ SETUP RESET INSTALLER RESET Heating Operation Enabled Demand Switch Outdoor Reset Absolute Max CH Setpoint 188 F 87 C CH1 Max...

Page 106: ...ntial property damage Follow instructions on circulator to oil it if required Check mixing valve valves pipes and fit tings for leaks Check function of field installed controls and valves See component manufacturer s instructions Review homeowner s maintenance responsi bilities and their frequencies including any not listed in the following section Homeowner monthly maintenance to include Check ai...

Page 107: ...ower supply to water heater 2 Close boiler water isolation valves between boiler and water heater 3 Connect hose to boiler water drain valve at water heater Open and drain water to a safe place 4 To speed draining procedure loosen air vent on top of tank 5 When draining is complete close drain valve and retighten air vent Draining Inner Domestic Water Tank See Domestic Piping Fig 4 page 9 1 Discon...

Page 108: ...local ACV Triangle Tube distrib utor When ordering part please provide the model number and description and or part number of replacement part Use only gen uine ACV Triangle Tube replacement parts to ensure warranty coverage and to avoid damage to appliance and improper opera tion of appliance Contact ACV Triangle Tube at 856 228 8881 or www triangle tube com for list of distributors nearest you W...

Page 109: ...mm 16 405 mm 1 2 NPSC Boiler Drain 1 2 NPT Gas Connection 3 4 NPSC Pressure Relief Valve 3 Combustion Air Inlet 3 Vent Outlet 19 479 mm 11 3 4 300 mm 7 1 2 190 mm 1 NPT Boiler Return 1 NPT Boiler Supply Water Heater Specifications 19 Front View PRESTIGE Excellence 110 ...

Page 110: ... mm 15 1 4 390 mm 1 2 NPT Gas Connection 1 NPT Boiler Supply 1 NPT Boiler Return 1 2 NPSC Boiler Drain 3 Vent Outlet 3 Combustion AIr Inlet 3 4 NPSC Pressure Relief Valve 21 1 4 540 mm Water Heater Specifications 20 Side View PRESTIGE Excellence 110 ...

Page 111: ... Inlet 3 4 NPSC Aux Connection Rear 1 2 NPSC Air Vent Connection 3 4 NPT DHW Outlet 11 1 4 286 mm 7 1 2 190 mm 3 1 2 87 mm 8 1 2 216 mm 4 3 8 110 mm Water Heater Specifications 21 Top View PRESTIGE Excellence 110 ...

Page 112: ...Water Heater Specifications 22 Performance ...

Page 113: ...Notes ...

Page 114: ...sted Construction of high quality corrosion resistant stainless steel AISI 316 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 Maxi flo Pool and Spa Heat Exchangers Triangle Tube 1 Triangle Lane Blackwood NJ 08012 856 228 8881 Fax 856 228 3584 www triangletube com info triangletube c...

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