Prestige Solo 110 Installation And Maintenance Manual Download Page 37

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7.0

Internal Wiring

X11

X13

Y
Y
Y
Y
Y
Y

Cascade

Slave

Cascade

Master

ACV MAX

Display

ACV MAX

Control Board

Flame

P4 Pump

P3 Pump

DHW Pump

CH Pump

Power Supply

Alarm

X15

X10

X12

P14

P13

X16

W
W
W
W
W
W

Prestige Solo 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

GND

nit

On / Off

Switch

Blower

Gas Valve

(Solo 80/110)

CH2
Thermostat
System
Sensor
Modulation
Signal

CH1
Thermostat
Outdoor
Sensor

Modbus

R
W
V

1
2
4
5

Blower

Signal Terminals

Water Pressure

Sensor

- Low Voltage

Flue Temperature Sensor

Return Temperature Sensor

Supply Temperature Sensor

GND

G
N

Auto Reset
Limit

Mix
Sensor

Manual Reset
Limit

1
2
3

7
8
9

Gas Valve

(Solo 155/175/250)

V1
V1

V2
V2

GND

Gas Valve

(Solo 299/399)

1
3

GND

4
3
2
1

1
2

3
2
1

GND

Blower

Power Terminals

DHW Sensor
or Aquastat

Fig. 20: Prestige Solo Boiler Factory Wiring

Summary of Contents for Solo 110

Page 1: ...y 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 switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas sup...

Page 2: ...cation 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...

Page 3: ...ombustion Air Condensate Drain 5 1 Installing Vent and Combustion Air 24 5 2 Installing Condensate Drain Assembly 24 SECTION VI Gas Piping 6 1 Gas Supply Piping Connection 26 6 2 Natural Gas 27 6 2 1 Pipe Sizing 27 6 2 2 Supply Pressure Requirements 27 6 3 Propane Gas 28 6 3 1 Pipe Sizing Propane Gas 28 6 3 2 Propane Gas Supply Pressure Requirements 28 SECTION VII Internal Wiring 7 1 General Requi...

Page 4: ...EZ Setup 48 9 8 1 Select DHW Demand 48 9 8 2 Boiler DHW Setpoint 48 9 8 3 DHW Storage Setpoint 48 9 8 4 DHW Priority Timeout 49 9 9 EZ Setup Reset 49 9 10 Display EZ Setup 49 9 11 CH DHW Operation 50 9 12 Boiler Information 50 9 12 1 Boiler Information Logging 50 9 12 2 Information Items 51 9 13 Lockout History 52 9 13 1 Lockout Details 52 9 13 2 Lockout Screen 53 SECTION X Start Up Preparation 10...

Page 5: ...Wiring the Modulating Controller 65 13 2 ACVMax Adjustment 65 13 3 Programming of External Modulating Control 65 SECTION XV Installation Record SECTION XVI Maintenance Schedule 16 1 Service Technician 69 16 2 Owner Maintenance 69 SECTION XVII Maintenance Procedures 17 1 Maintenance Procedures 70 17 2 Reported Problems 70 17 3 Check Surrounding Area 70 17 4 Inspect Burner Area 70 17 5 Check System ...

Page 6: ...onents 78 PRESTIGE Solo 299 399 Jacket Components 79 PRESTIGE Solo 80 110 Internal Components 80 PRESTIGE Solo 155 175 250 Internal Components 81 PRESTIGE Solo 399 Internal Components 82 PRESTIGE Solo 80 110 Burner Components 83 PRESTIGE Solo 155 175 250 Burner Components 84 PRESTIGE Solo 299 399 Burner Components 85 PRESTIGE Solo Display Enclosure 86 PRESTIGE Solo Control Enclosure 86 Section XIX...

Page 7: ...stalla 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 presence of potent...

Page 8: ... 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 ...

Page 9: ...or indoor conditioned space installations ONLY Before locating the PRESTIGE SOLO 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 insta...

Page 10: ...rage Installations When installing the PRESTIGE Solo in a resi dential 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 ...

Page 11: ...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 Solutions ...

Page 12: ...a for the open ings 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 uncontami nated indoor or outdoor air surrounding the appliance for combustion In order to reduce the potential risks associated with indoor conta...

Page 13: ... 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 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 dimension of air openings shall be not l...

Page 14: ...ommunication 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 equip ment in the enclosure See Fi...

Page 15: ... requires a Category IV venting system which is designed for pressur ized venting and condensate The PRESTIGE Solo is certified per ANSI Z21 13 as a Category IV or Direct Vent sealed combustion appliance A Category IV appli ance utilizes uncontaminated indoor or outdoor air surrounding the appliance for combustion A Direct Vent appliance utilizes uncontaminat ed outdoor air piped directly to the a...

Page 16: ...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 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 h...

Page 17: ...r 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 c...

Page 18: ...l 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 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 applica...

Page 19: ...TIGE Solo Wall Frame kit 2 When using the wall frame to mount the boiler reference the kit installation instruc tions and ensure the frame is securely fas tened 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 boi...

Page 20: ... 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 ...

Page 21: ...tional 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 guide lines must be followed The LWCO device must be designed for water installations electrode probe type is recommended The LWCO device must be installed in a tee connection on the boiler supply piping above the boiler Wiring of the LWCO devic...

Page 22: ...ESTIGE Solo 299 399 and the system volume and temperature Undersized expansion tanks will cause system water to be lost through the pres sure 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 The expansion tank must be located as shown in Fig 7 and Fig 8 on page 18 when using a prim...

Page 23: ...4 0 Boiler Piping 17 Fig 6 Piping Component Legend ...

Page 24: ... Boiler Return System Supply Cold Water Fill System Return 12 Max Minimum Piping Fig 8 Near Boiler Piping Closed Type Expansion Tank Fig 7 Near Boiler Piping Diaphragm Expansion Tank Note Pitch horizontal piping upwards 1 of pitch per 5 ft of piping towards expansion tank 18 4 0 Boiler Piping ...

Page 25: ...ator for each zone of space heating as well as the boiler circulator To ensure an adequate flow rate through the PRESTIGE Solo the boiler supply and return piping size must be a minimum of 1 inch for the PRESTIGE Solo 80 110 1 1 4 inch for the PRESTIGE Solo 155 175 250 and 1 1 2 inch for the PRESTIGE Solo299 399 4 13 System Piping Zone Valves Connect the PRESTIGE Solo to the system pip ing as show...

Page 26: ...10 1 1 4 inch for the PRESTIGE Solo 155 175 250 and 1 1 2 inch for the PRES TIGE Solo 299 399 The addition of the high temperature limit is important if the PRESTIGE is connect ed to a domestic hot water system which requires a high primary supply water temperature 4 16 System Piping Special Application If the boiler is used in conjunction with a chilled water medium system the boiler and chiller ...

Page 27: ...ng Zoning with Zone Circulators Fig 10 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 Smart NOTICE Note Reference Fig 25 page 38 for Prestige Wiring Note Reference Fig 26 page 38 for Prestige Wiring ...

Page 28: ...perly sized to overcome the system pressure drop and pro vide adequate flow through the boiler system Note Verify CH circula tor is properly sized to overcome the system pres sure drop and provide ade quate 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 Smart NOTICE Note Referenc...

Page 29: ... Supply System Return 12 Max Fig 13 Multiple PRESTIGE Solo Boiler Piping Primary Secondary Note Consult the PRESTIGE ACVMax Control Supplement for information on wiring and configuring the boilers using the built in Cascade function ...

Page 30: ...ssem bling on the unit 2 Install the condensate drain assembly on the boiler condensate drain by pushing the con densate drain assembly up until it stops 3 Tighten the condensate drain assembly retaining nut with rubber seal Ensure installation of the condensate drain assembly included the metal wash er Failure to comply could result in the trap assembly dislocating from the boiler Ensure the cond...

Page 31: ...n 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 with a pH content below 3 0 Install a neutralizing filter if required by authority having jurisdiction The condensate drain must remain filled and unobstructed and allow unrestricted flow of condensate The condensate should not ...

Page 32: ...check and test all connections for leaks Close the manual shutoff valve during any pressure test with less than 13 w c Disconnect the PRESTIGE Solo and its gas valve from the gas supply piping during any pressure test greater than 13 w c 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 ...

Page 33: ...essure 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 the installer to adjust or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury ...

Page 34: ...p gas regulator 6 3 2 Propane Gas Supply Pressure Requirements 1 Adjust the propane supply regulator 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 appliance...

Page 35: ...rifice if required Throttle Screw Gas Valve Gasket Gas Valve Offset Pressure Cover Screw Inlet Gas Pressure Port Fig 17 Gas Valve Venturi Assembly PRESTIGE Solo 155 175 250 Venturi O Ring Venturi Gas Valve Throttle Screw Offset Pressure Cover Screw O Ring Orifice Venturi Clip Inlet Gas Pressure Port Fig 16 Gas Valve Venturi Assembly PRESTIGE Solo 80 110 Note Orifice orifice o ring and gas valve co...

Page 36: ...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 edi tion and or the Canadian Electrical Code Part 1 CSA C22 1 Electrical Code 7 2 Fuse Locations The ACVMax control module contains 3 inter nal replaceable 5A fuses...

Page 37: ... 4 1 2 3 4 5 6 F00 GND GND Ignitor On Off Switch Blower Gas Valve Solo 80 110 CH2 Thermostat System Sensor Modulation Signal CH1 Thermostat Outdoor Sensor Modbus R W V BK 1 2 4 5 Blower Signal Terminals Water Pressure Sensor BK V W R Low Voltage Flue Temperature Sensor Return Temperature Sensor Supply Temperature Sensor R R BL BL Y Y 4 3 2 1 2 1 W O O BR BR 3 2 1 6 5 4 9 8 7 12 11 10 15 14 13 18 1...

Page 38: ...ire 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 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 a...

Page 39: ...age wiring should be separated to prevent possible electrical noise on the low voltage circuits Line and Low Voltage wiring should use sepa rate electrical knockouts on the PRES TIGE cabinet and should remain sepa rated inside the PRESTIGE CH and DHW call connections to the PRESTIGE require a dry contact with no external voltage present Ensure no exter nal voltage is present on each set of wires b...

Page 40: ...n page 33 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 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 Manual Reset Limit and Auto Reset Limit c...

Page 41: ...re sensor to the low voltage terminal strip on the wiring panel below the PRESTIGE control mod ule as shown in Fig 19 on page 31 Fig 22 on page 33 8 12 Cascade Wiring The ACVMax control includes the ability to operate up to six boilers together as one with out the need for external controllers Consult the PRESTIGE ACVMax Control Supplement for more information 8 13 Modbus Wiring The ACVMax control...

Page 42: ... ZONE 4 ZONE 1 T T ZONE 2 T T ZONE 3 T T ZONE 4 T T POWER IN 1 2 3 4 ZONE 4 RELAY N O N C COM PUMP ENDSW B BOILER ENDSW A MODE RESET NORMAL SLAVE MASTER POWER CONTROLS FUSE 7 AMP MAX EXPANSION PLUG IN CARDS ON OFF ZONE 4 PRIORITY 68 68 Zone 3 Thermostat Motor 1 2 3 4 End Switch Zone 1 Zone Valve Motor 1 2 3 4 End Switch Zone 2 Zone Valve Motor 1 2 3 4 End Switch Zone 3 Zone Valve CH2 Thermostat Sy...

Page 43: ...NAL PRIORITY MODE RESET NORMAL SLAVE MASTER FUSE 1 AMP ON OFF ZONE 4 PRIORITY 68 68 Zone 3 Thermostat CH2 Thermostat System Sensor Modulation Signal CH2 Thermosta t CH1 Thermostat Outdoor Sensor DHW Sensor or Aquastat Modbus DHW Sensor ZONE4 ZONE3 ZONE2 ZONE1 PLUG IN CARDS 1 2 3 4 EXPANSION INPUT POWER 120 VOLT CIRCULATORS ZONE4 ZONE3 ZONE2 ZONE1 ZR ZC X X END SWITCH 120 VAC INPUT H N 37 8 0 Exter...

Page 44: ... Service Fig 25 Prestige Wiring Zoning with Zone Circulators P3 DHW Low Voltage Connections CH L G N L G N L G N L G N L G N L G N L G N FLAME PUMP 4 PUMP 3 DHW PUMP CH PUMP POWER SUPPLY ALARM CH2 Thermostat System Sensor Modulation Signal CH2 Thermosta t CH1 Thermostat Outdoor Sensor DHW Sensor or Aquastat Modbus Outdoor Sensor DHW Sensor Line Voltage Connections Reset Limit Connections Manual Au...

Page 45: ...itch Fig 27 Prestige Wiring Multiple Zone Valve with Single System Boiler Circulator DHW Low Voltage Connections CH L G N L G N L G N L G N L G N L G N L G N FLAME PUMP 4 PUMP 3 DHW PUMP CH PUMP POWER SUPPLY ALARM CH2 Thermostat System Sensor Modulation Signal CH2 Thermosta t CH1 Thermostat Outdoor Sensor DHW Sensor or Aquastat Modbus Outdoor Sensor DHW Sensor Line Voltage Connections Reset Limit ...

Page 46: ...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 graphica...

Page 47: ...nstaller level functions Figure 30 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...

Page 48: ...enu Boiler Information Menu Main Menu Heating EZ Setup Heating Enabled Boiler Information abc de f bbb b abc de f bb abc de abc de 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 9 2 ACVMax Menu Structure ...

Page 49: ... indicate the current firing rate The status line displays the current operating state of the Prestige See page 44 for a list of all Status Line Messages 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 fiv...

Page 50: ...t fire until the call blocking time has elapsed DHW Burner Delay The burner will not fire until the call 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 Setpoin...

Page 51: ...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 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...

Page 52: ...e 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 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...

Page 53: ...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 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 ...

Page 54: ...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 cho sen in Select DHW Demand Press the LEFT or RIGHT buttons to adjust the Boiler DHW Setpoint then press the OK button to ...

Page 55: ...etup settings back to the original factory defaults Follow the onscreen instructions to reset all EZ Setup settings back to the original factory defaults 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 ...

Page 56: ...ion 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 sam ple every 12 minutes to produce a graph of the last 24 hours Select t...

Page 57: ... Outdoor Temp Displays the current outdoor temperature DHW Storage Temp Displays the current DHW storage temperature when Indirect Water Heater Sensor PSRKIT22 is installed External Modulation Signal Displays the current external modulation signal being received from an external controller Pressure Displays the current system pressure CH Ignitions Displays the number of central heating ignitions s...

Page 58: ... the recorded information 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 9 13 Lockout Hi...

Page 59: ... can then be entered from the Home 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 0 5bar Increase pressure to normal range Low Water If problem persists call for service E37 9 13 2 Lockout Screen The Lockout Screen replaces the Home Screen if a lockout occurs The screen backlight will als...

Page 60: ...nsor 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 been detected in the boiler supply tem...

Page 61: ...pen 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 O...

Page 62: ...onsult a water treatment company 10 1 3 Chlorinated Water Do not use the PRESTIGE Solo to heat a swimming pool or spa directly Maintain the chlorine level of the water at lev els 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 Solo Flush the systems until the water runs c...

Page 63: ... cold water fill or make up water supply line Massachusetts Code requires the instal lation of a backflow preventer if antifreeze is 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 10 2 Filling the Boiler Sy...

Page 64: ...ltage 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 the wire ends If voltage is measured at the panel under any condition checkandcorrecttheexternalwiring In systems using 3 wir...

Page 65: ... 10 7 mm c Ensure the vent Condensate Drain Assembly is filled with water 11 2 PRESTIGE Solo 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 63 If PRESTIGE Solo Does Not Start Correctly 1 Check for loose electrical connections blown fuses on cont...

Page 66: ...formed 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 on page 61 The CO level should not exceed 100 ppm when combustion is correct Perform the followi...

Page 67: ...m bustion level measured at high fire adjust the plastic OFFSET SCREW under the cover screw on the top of the gas valve see Figs 16 17 18 on page 29 according to Table 6 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 60 2 Operate the unit for approximately 10 minutes 3 Turn off all gas appliances...

Page 68: ...utton 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 ...

Page 69: ...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 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 thermo...

Page 70: ...follow the mounting instruc tions 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 If the sensor wires are located in an area with sources of potential electromagnetic interference EMI the sensor wires sh...

Page 71: ...ermostat 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 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 Mo...

Page 72: ...otection Enabled 3 Frost Protection Setpoint 22 F 30 C 3 Parallel Shift Value 0 F 0 C 3 CH Call Blocking 1 Minute 3 DOMESTIC SETTING FACTORY DEFAULT EZ SETUP RESET INSTALLER RESET DHW Operation Enabled 3 Demand Type Thermostat Solo Sensor Excellence Boiler DHW Setpoint 167 F 75 C 3 3 DHW Setpoint 140 F 60 C 3 3 DHW On Differential 6 F 3 C 3 DHW Storage Adder 28 F 15 C 3 DHW Post Pump Time 1 Minute...

Page 73: ... Measured the rate of input on Natural Gas as outlined on page 61 c Test high temperature limit as outlined on page 62 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 ...

Page 74: ...pleted 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 75: ...attern 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 16 2 Owner Maintenance Periodically Check the area around the unit Check and remove any blockage from the combustion air inlet and ventila...

Page 76: ...e vapors or liquids 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 immedi ately or the combustion air intake must be relo cated to another area 17 4 Inspect Burner Area Remove the boiler fro...

Page 77: ... 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 17 9 Check Boiler System Verify all system components are correctly ins...

Page 78: ...perating 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 cause of the...

Page 79: ... assembly from the heat exchanger Ensure that the com bustion chamber 2 in 1 insulation is not dam aged during removal of burner mounting plate assembly See WARNING on page 75 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 Us...

Page 80: ...t 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 Carefully remove the burner plate assembly from the heat exchanger Ensure that the com bustion chamber 2 in 1 insulation is not dam aged during removal of burner mounting plate assembly See WARNING on page...

Page 81: ...ht plastic bag NIOSH Stated First Aid Eye Skin Immediately irrigate Breathing Clean fresh air 17 23 Handling Previously Fired Combustion Chamber Insulation 17 22 Review With Owner Ensure the owner understands the importance to perform the maintenance schedule specified in this manual Remind the owner of the importance to call a licensed contractor should the unit or system exhibit any unusual beha...

Page 82: ... part please provide the model number and description and or part num ber of replacement part Use only genuine ACV Triangle Tube replacement parts to ensure warranty coverage and to avoid damage to appliance and improper operation of appliance Contact ACV Triangle Tube at 856 228 8881 or www triangletube com for list of distributors nearest you WARNING ...

Page 83: ... 80 110 Jacket Components Item Part Description 1 PAJKT01 Front Jacket Panel with insulation 2 PAJKT03 Left Side Jacket Panel with insulation 3 PAJKT21 Right Side Jacket Panel with insulation 4 PAJKT04 Top Panel 5 PSRKIT21 Wall Mounting Bracket with Hardware ...

Page 84: ...175 250 Jacket Components Item Part Description 1 PAJKT01 Front Jacket Panel with insulation 2 PAJKT03 Left Side Jacket Panel with insulation 3 PAJKT21 Right Side Jacket Panel with insulation 4 PAJKT12 Top Panel 5 PSRKIT21 Wall Mounting Bracket with Hardware ...

Page 85: ... Components Item Part Description 1 PAJKT15 Front Jacket Panel with insulation 2 PAJKT16 Left Side Jacket Panel with insulation 3 PAJKT22 Right Side Jacket Panel with insulation 4 PAJKT17 Top Panel Front 5 PAJKT18 Top Panel Rear 6 PSRKIT21 Wall Mounting Bracket with Hardware ...

Page 86: ...TADPT07 Vent Outlet Combustion Air Inlet Adapter 3 PARKIT02 Polypropylene Vent Pipe 4 PTRKIT123 Supply Return Temperature Sensor 5 PARKIT01 Flue Temperature Sensor 6 PARKIT04 LWCO Pressure Sensor 7 PARKIT05 Condensate Drain Assembly 8 PARKIT06 Boiler Piping Return Assembly 9 PARKIT07 Boiler Piping Supply Assembly 10 PARKIT13 Polypropylene Condensate Pan ...

Page 87: ...ody Solo 250 2 PTADPT07 Vent Outlet Combustion Air Inlet Adapter 3 PARKIT08 Polypropylene Vent Pipe 4 PTRKIT122 Supply Return Temperature Sensor 5 PARKIT01 Flue Temperature Sensor 6 PARKIT04 LWCO Pressure Sensor 7 PSRKIT44 Condensate Drain Assembly 8 PARKIT46 Boiler Piping Return Assembly 9 PARKIT47 Boiler Piping Supply Assembly 10 PARKIT43 Polypropylene Condensate Pan Solo 155 PARKIT53 Polypropyl...

Page 88: ...r Body Solo 399 2 PTADPT08 Vent Outlet Combustion Air Inlet Adapter 3 PARKIT09 Polypropylene Vent Pipe 4 PARKIT78 Supply Return Temperature Sensor 5 PARKIT01 Flue Temperature Sensor 6 PARKIT04 LWCO Pressure Sensor 7 PSRKIT44 Condensate Drain Assembly 8 PARKIT76 Boiler Piping Return Assembly 9 PARKIT77 Boiler Piping Supply Assembly 10 PARKIT73 Polypropylene Condensate Pan Solo 155 ...

Page 89: ...1 PARKIT12 Combustion Chamber 2 in 1 Insulation 2 PARKIT14 Burner Head Assembly with Gasket 3 PARKIT11 Blower Assembly with Gasket 4 PARKIT18 Blower Clamp 5 PARKIT19 Blower Gasket 6 PARKIT15 Burner Plate Assembly 7 PARKIT17 Gas Valve 8 PARKIT10 Venturi Solo 80 PARKIT20 Venturi Solo 110 9 PARKIT16 Igniter Assembly ...

Page 90: ...n Solo 175 250 2 PARKIT54 Burner Head Assembly with Gasket 3 PARKIT51 Blower Assembly with Gasket Solo 155 175 PARKIT61 Blower Assembly with Gasket Solo 250 4 PARKIT18 Blower Clamp 5 PARKIT19 Blower Gasket 6 PARKIT45 Burner Plate Assembly Solo 155 PARKIT55 Burner Plate Assembly Solo 175 250 7 PARKIT59 Gas Valve 8 PARKIT30 Venturi Solo 155 PARKIT40 Venturi Solo 175 PARKIT50 Venturi Solo 250 9 PARKI...

Page 91: ...nts Item Part Description 1 PARKIT72 Combustion Chamber 2 in 1 Insulation 2 PARKIT74 Burner Head Assembly with Gasket 3 PARKIT71 Blower Assembly with Gasket 4 PARKIT18 Blower Clamp 5 PARKIT19 Blower Gasket 6 PARKIT75 Burner Plate Assembly 7 PARKIT79 Gas Valve 8 PARKIT16 Igniter Assembly ...

Page 92: ...1 6 5 Fig 40 PRESTIGE Solo Control Display Enclosures Item Part Description 1 PTRKIT109 Pressure Gauge 2 PTSWI01 Power Switch 3 PTSWI02 Power Switch Cover 4 PADIS02 Display Module 5 PACON01 Control Module 6 PAHNG01 Control Box Hinges ...

Page 93: ... Weight Lbs Kg Solo 399 Natural Propane 399 000 379 000 330 000 94 1 95 1 216 98 Note 1 The heating capacity of the PRESTIGE Solo 80 110 155 175 250 is based on the test requirements 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...

Page 94: ... B C D E F G H Connection 3 4 NPSC Pressure Relief Valve 3 Combustion Air Inlet 3 Vent Outlet 1 NPT Boiler Return 1 2 NPT Gas Connection 1 NPT Boiler Supply Boiler Width Boiler Height Dimension in mm 16 5 8 423 15 13 16 402 8 13 16 224 2 7 8 73 5 7 8 150 16 7 16 418 19 3 4 502 36 9 16 928 ...

Page 95: ...ht Side View PRESTIGE Solo 80 110 I J K L M Connection 3 4 NPSC Pressure Relief Valve 3 Combustion Air Inlet 3 Vent Outlet 1 2 NPT Gas Connection 1 NPT Boiler Return Supply Boiler Depth Dimension in mm 11 1 4 286 5 9 16 141 4 102 13 7 16 341 17 5 16 440 ...

Page 96: ...0 A B C D E F G H Connection 3 4 NPSC Pressure Relief Valve 3 Combustion Air Inlet 3 Vent Outlet 1 1 4 NPT Boiler Return 3 4 NPT Gas Connection 1 1 4 NPT Boiler Supply Boiler Width Boiler Height Dimension in mm 17 432 16 5 16 415 4 5 16 110 2 9 16 65 7 5 16 186 17 432 19 3 4 502 36 9 16 928 ...

Page 97: ... View PRESTIGE Solo 155 175 250 I J K L M Connection 3 4 NPSC Pressure Relief Valve 3 Combustion Air Inlet 3 Vent Outlet 3 4 NPT Gas Connection 1 1 4 NPT Boiler Return Supply Boiler Depth Dimension in mm 11 5 16 288 6 15 16 175 1 7 8 48 11 5 16 288 17 5 16 440 ...

Page 98: ...B C D E F G H Connection 3 4 NPSC Pressure Relief Valve 4 Combustion Air Inlet 4 Vent Outlet 1 1 2 NPT Boiler Return 1 NPT Gas Connection 1 1 2 NPT Boiler Supply Boiler Width Boiler Height Dimension in mm 18 5 8 473 13 1 4 336 20 1 4 514 3 1 4 82 9 1 4 236 17 7 8 454 24 7 8 632 39 3 8 1000 ...

Page 99: ...Side View PRESTIGE Solo 299 399 I J K L M Connection 3 4 NPSC Pressure Relief Valve 4 Combustion Air Inlet 4 Vent Outlet 1 NPT Gas Connection 1 1 2 NPT Boiler Return Supply Boiler Depth Dimension in mm 5 3 8 136 15 1 4 388 16 1 4 412 14 5 8 372 23 5 8 600 ...

Page 100: ...2 4 6 8 10 12 14 16 4 5 6 7 8 9 10 11 12 Pressure Drop Ft W C Flow Rate GPM Pressure Drop Comparison Grundfos Solo 80 Solo 110 Grundfos UPS15 58F FC Spd 1 Grundfos UPS15 58F FC Spd 2 Grundfos UPS15 58F FC Spd 3 Graph 1 Pressure Loss Through Boiler Taco Circulators Note Minimum allowable flow rate at full input 3 gpm SOLO 80 4 gpm SOLO 110 Graph 2 Pressure Loss Through Boiler Grundfos Circulators ...

Page 101: ...12 16 20 24 28 32 36 4 8 12 16 20 24 Pressure Drop Ft W C Flow Rate GPM Pressure Drop Comparison Grundfos Solo 155 Solo 175 Solo 250 Grundfos UP43 75F UP50 75F Grundfos UP26 99F Grundfos UP26 116F Graph 3 Pressure Loss Through Boiler Taco Circulators Note Minimum allowable flow rate at full input 6 gpm SOLO 155 7 gpm SOLO 175 9 gpm SOLO 250 Graph 4 Pressure Loss Through Boiler Grundfos Circulators...

Page 102: ...012 0 4 8 12 16 20 24 28 16 18 20 22 24 26 28 30 32 34 Pressure Drop Ft W C Flow Rate GPM Pressure Drop Comparison Grundfos Solo 299 Solo 399 Grundfos UP43 75F UP50 75F Grundfos UP26 116F Grundfos UP26 99F Graph 5 Pressure Loss Through Boiler Taco Circulators Note Minimum allowable flow rate at full input 12 gpm SOLO 299 16 gpm SOLO 399 Graph 6 Pressure Loss Through Boiler Grundfos Circulators ...

Page 103: ...97 20 0 Notes SECTION XX NOTES ...

Page 104: ... 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 SMART Indirect Fired Water Heaters Maxi Flo and Spa Heat Exchangers Construction of high quality corrosion resistant stainless steel AISI 316 or titanium Specially designed built in flow restrictor to assure ma...

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