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PRESTIGE Excellence

HX Field Replacement

Kit 

1

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

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

D.  Adjustable wrench

E.  Needle nose pliers

F.  Diagonal cutting pliers

G. Calibrated combustion analyzer

Quantity

Kit Part

Number

Description

Model

PE

 1

10

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PT

 1

10

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n

PE

 1

10

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PT

 1

10

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1

PSRKIT01 Heat Exchanger Assembly

X

1

PTRKIT124 Heat Exchanger Assembly

X

1

PSRKIT76 Heat Exchanger Assembly

X

1

PTRKIT125 Heat Exchanger Assembly

X

Indicates  a  potentially  hazardous  situation

which, if ignored, can result in serious  injury

or substantial property damage.

Indicates  special  instructions  on  installation,

operation  or  maintenance,  which  are  impor-

tant to equipment but not related to personal

injury hazards.

NOTICE

WARNING

For your safety, turn off electrical power sup-

ply  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. 

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. 

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.

WARNING

WARNING

WARNING

Summary of Contents for PRESTIGE Excellence PSRKIT01

Page 1: ...1 PSRKIT01 Heat Exchanger Assembly X 1 PTRKIT124 Heat Exchanger Assembly X 1 PSRKIT76 Heat Exchanger Assembly X 1 PTRKIT125 Heat Exchanger Assembly X Indicates a potentially hazardous situation which...

Page 2: ...Attach a hose to external boiler drain Place other end of this hose to a suitable drain 8 Open external boiler drain valve and begin draining the boiler To assist in the draining of the boiler remove...

Page 3: ...d from the boiler it should be inspected for deformation damage or corrosion If there are any signs of deformation damage or corrosion on the vent outlet adapter replace it immediately Check condition...

Page 4: ...ated at the top of the heat exchanger 10 Disconnect the blue wire leads from return tem perature sensor Shown as item 4 in Fig 1 located at the bottom of the heat exchanger 11 Disconnect the orange wi...

Page 5: ...hillips Torx head screw driver provided in the kit and remove the blower gas valve venturi Gas valve and ven turi assembly can remain connected to the blower housing Discard old blower gasket Fig 5 Re...

Page 6: ...avoid vertical motion of the heat exchanger during transport and is not required to be installed with the replacement heat exchanger 2 Lift the heat exchanger about 4 to 6 to disen gage from the rear...

Page 7: ...ly 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 Use care when t...

Page 8: ...le Connect the condensate drain assembly to the retaining nut and tighten Ensure the condensate drain assembly contains the plastic seated ball Do not install the conden sate drain assembly if the bal...

Page 9: ...and the gasket is reseated in the adapter Failure to comply could result in leakage of flue prod ucts into the surrounding area resulting in death or personal injury Installation of Polypropylene Vent...

Page 10: ...erature 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 tem perature sensor 4 Reconne...

Page 11: ...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...

Page 12: ...ents must be performed with calibrated equip ment to ensure proper readings and accuracy Failure to perform a complete combustion test at both high and low input rates may result in incom plete combus...

Page 13: ...enter the access code 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...

Page 14: ...the plastic OFFSET SCREW see Fig 14 using a T 40 Torx wrench as follows Counter clockwise adjustment of OFFSET SCREW at Low Fire 1 firing rate O2 increases and CO2 decreases Clockwise adjustment of OF...

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