TriangleTube Prestige Excellence Installation And Maintenance Manual
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TriangleTube Prestige Excellence Installation And Maintenance Manual

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prestige
Excellence
Water Boiler
Part 1 of 2
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Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installa-
NOTICE
tion in order to gain warranty coverage.
When receiving the PRESTIGE Excellence unit, any claims for damage or shortage in shipment must be
filed immediately against the transportation company by the consignee.
Leave all documentation received with appliance with owner for future reference.
WARNING
If the information in this manual is not followed exactly, a fire or explosion may
result causing property damage, personal injury or death.
• 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
- If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or the
gas supplier.
DATE: 2/18/08
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supplier's instructions.
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FOR YOUR SAFETY
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2007-20 Manual Prestige Excellence

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Summary of Contents for TriangleTube Prestige Excellence

  • Page 1 NOTICE tion in order to gain warranty coverage. When receiving the PRESTIGE Excellence unit, any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. Leave all documentation received with appliance with owner for future reference.
  • Page 2 WARNING This manual outlines the requirements for installation of the PRESTIGE Excellence. Those require- ments include Boiler Piping, Venting/Combustion Air, Start-Up and Maintenance. For detailed instructions regarding the installation of the vent/combustion air system reference the PRESTIGE Vent Supplement and/or the various optional vent kit instructions.

  • Page 3: Table Of Contents

    Table of Contents PRODUCT AND SAFETY INFORMATION Definitions........... 1 Product and Safety Information .
  • Page 4 Table of Contents Backflow Preventer..........16 Boiler System Piping Applications.
  • Page 5 Final Checks Before Start-Up........40 PRESTIGE Excellence Start-Up ....... . . 40 If PRESTIGE Excellence Does Not Start Correctly .
  • Page 6 Table of Contents Summer/Winter Switch at Boiler ....... . . 50 Boiler Target Temperature Setting .
  • Page 7 Table of Contents Review with Owner ........60 Handling Previously Fired Combustion Chamber Insulation .

  • Page 8: Definitions

    Product & Safety Information Definitions The following terms are used throughout this manual to bring attention to the presence of potential hazards or important information concerning the product. NOTICE DANGER Indicates special instructions on installa- Indicates the presence of a hazardous tion, operation or maintenance, which situation which, if ignored, will result in are important to equipment but not...

  • Page 9: Product And Safety Information

    Product & Safety Information DANGER WARNING Do not use this appliance if any part Should overheating occur or the gas has been under water. Immediately call supply fails to shut off, turn OFF the a qualified service technician to inspect manual gas control valve external to the appliance and to replace any part of the appliance.

  • Page 10: Section I - Pre-Installation Items

    Ensure the area chosen for the installation of the PRESTIGE Excellence is free of any com- For installations in Massachusetts - bustible materials, gasoline and other flamma- code requires the boiler to be installed ble liquids.

  • Page 11: Recommended Clearances

    Pre-Installation Items Recommended Clearances Residential Garage Installations The PRESTIGE Excellence is approved for When installing the PRESTIGE Excellence in a zero clearance to combustibles, excluding residential garage, the following special precau- vent and boiler piping. tions per NFPA 54/ANSI Z223.1 must be taken: Mount the unit with a minimum 18 Vent &...

  • Page 12: Section Ii - Combustion Air And Venting

    Antistatic fabric softeners used in clothe dryers WARNING Chlorine-type bleaches, detergents, and Do not operate a PRESTIGE Excellence cleaning solvents found in household if its combustion air inlet is located near laundry rooms a laundry room or pool facility. These...

  • Page 13: Ventilation And Combustion Air Requirements - Direct Vent

    For Direct Vent installations, involving only the BEST PRACTICES PRESTIGE Excellence, in which the minimum service clearances are maintained as listed on In order to reduce the potential risks page 4, no ventilation openings are required.

  • Page 14: Methods Of Accessing Combustion Air Into A Space - Category Iv

    Combustion Air and Venting Methods of Accessing Combustion Air Into A inches of the bottom of the enclosure. Space - Category IV The minimum dimension of air open- ings shall be not less than 3 inches. Indoor Combustion Air Combining spaces in different stories. The volumes of spaces in different sto- NOTICE ries shall be considered as communicat-...

  • Page 15: Combination Of Indoor And Outdoor Combustion Air

    Combustion Air and Venting Not less than the sum of the areas of all vent connectors in the space. Fig. 3: All Combustion Air from Outdoors Through Ventilated Attic Fig. 2: All Combustion Air from Outdoors Through One Permanent Air Opening Two Permanent Openings Method.

  • Page 16: Combustion Air And Vent Piping

    Supplement included in the boiler installation envelope. Refer to optional DANGER vent kit instructions for additional vent installation instructions. Do not install the PRESTIGE Excellence into a common vent with other gas or oil appliances. This may cause flue gas DANGER...

  • Page 17: Removal Of An Existing Boiler From A Common Vent System

    DANGER the space in which the appliances remain- Do not install the PRESTIGE Excellence ing connected to the common venting sys- into a common vent with other gas or oil tem are located and other spaces of the appliances.

  • Page 18: Commonwealth Of Massachusetts Installation

    Combustion Air and Venting Commonwealth of Massachusetts Installations Only For direct-vent appliances, mechanical- 4. A metal or plastic identification plate vent heating appliances or domestic hot shall be mounted at the exterior of the water equipment, where the bottom of the building, four feet directly above the vent terminal and the air intake is installed location of vent terminal.

  • Page 19: Section Iii - Unit Preparations

    Handling Instructions 2. DO NOT mount or attempt to mount the wall bracket to hollow sheet rock or lathe The PRESTIGE Excellence is generally easier walls using anchors. Only install boiler to to handle and maneuver once removed from studs or equivalent wood structure.

  • Page 20: Wall Bracket Installation - Solid Walls

    Unit Preparations Wall Bracket Installation - Solid Walls 6. Reposition the bracket on the wall and align mounting slots/holes. Insert the two 1. Locate the general area of the boiler place- bolts (provided) through the mounting ment. slots/holes and loosely tighten. 2.

  • Page 21: Section Iv - Boiler Piping

    / twisting. Failure Low Water Cutoff Device to support the boiler piping and connec- The PRESTIGE Excellence is equipped with tions in this manner could cause damage a factory installed pressure switch type Low to the boiler and its components.

  • Page 22: Boiler Piping

    Boiler Piping Pressure Relief Valve (Supplied with Boiler) 3/4" Street Elbow Air Vent Drain Piping Directed to a Suitable Place of Drainage CH Supply Connection CH Return Connection Fig. 5: Pressure Relief Valve Installation...

  • Page 23: Additional Limit Control

    Boiler Piping Additional Limit Control Boiler System Piping Applications If a separate LWCO device is required by cer- BEST PRACTICE tain local jurisdictions or when the boiler is installed above the system piping, the follow- It is recommended on all piping applica- ing guidelines must be followed: tions to utilize a primary/secondary pip- ing arrangement as a means to provide...

  • Page 24: Diaphragm Expansion Tank

    System Piping - Zone Circulators nection at the same location as the expansion tank connection to the system. Connect the PRESTIGE Excellence to the sys- tem piping as shown in Fig. 9 page 21 when Diaphragm Expansion Tank zoning with zone circulators.

  • Page 25: System Piping - Through Boiler

    When To ensure adequate flow rate through pumping through with more than one zone, a the PRESTIGE Excellence, maintain a pressure differential bypass valve is required to minimum 1 inch diameter on the system avoid dead heading the pump through the post piping connecting to the boiler.

  • Page 26: Near Boiler Piping Diagram

    Boiler Piping System System Supply Return 12" Max. Cold Water Fill Boiler Boiler Supply Return Fig. 6: Near Boiler Piping - Diaphragm Expansion Tank 1. System circulator 6. Isolation valve 2. Automatic air vent 7. Drain/purge valve 3. Air separator 8.
  • Page 27 Boiler Piping System System Supply Return Cold Water Fill 12" Minimum Max. 3/4" Piping Note: Pitch horizontal pip- ing upwards (1” of pitch per 5 ft of piping) towards Boiler Boiler expansion tank. Supply Return Fig. 7 : Near Boiler Piping - Closed Type Expansion Tank 1.

  • Page 28: Central Heating (Ch) System Piping Diagrams

    Additional Zone Load Zone Load 12" Max. Fig. 9: CH System Piping - Zoning with Zone Circulators 1. PRESTIGE Excellence boiler 7. Pressure relief valve 2. CH circulator (provided) 8. Air separator 3. Flow/check valve 9. Automatic air vent 4 Isolation valve 10.
  • Page 29 Fig. 11: CH System Piping - Multiple Zone Valve with Single System/Boiler Circulator 1. PRESTIGE Excellence boiler 8. Air separator 2. CH circulator 9. Automatic air vent 4 Isolation valve 10.
  • Page 30 Note: Manifold mounted valve actuators may be used in lieu of zone valves. Fig. 13: CH System Piping - Radiant/Low Temp. Heating 1. PRESTIGE Excellence boiler 8. Air separator 2. CH circulator (provided) 9. Automatic air vent 3. Flow/check valve 10.
  • Page 31 Boiler Piping...

  • Page 32: Section V - Installing Vent / Combustion Air & Condensate Drain

    DANGER the ball is lost or missing, replace the entire assembly. The PRESTIGE Excellence must be vented and supplied with combustion air 3. Remove the compression nut and rubber as shown in the PRESTIGE Vent seal from the drain outlet.
  • Page 33 8. The PRESTIGE Excellence will typically produce a condensate that is considered slightly acidic with a pH content below 3.0. Install a neutralizing filter if required by authority having jurisdiction.

  • Page 34: Section Vi - Gas Piping

    PRESTIGE Excellence gas train as shown cent piping. Failure to support the boil- in Fig. 16. er gas piping connection could damage 4.

  • Page 35: Natural Gas

    2. Install 100% lockup gas pressure regulator length and diameter requirements for natural in the gas supply line if inlet pressure can gas, based on rated PRESTIGE Excellence exceed 13”w.c at any time. Adjust the lock- input (divide by 1,000 to obtain cubic feet per up pressure regulator for 13”w.c maximum.

  • Page 36: Propane Gas

    Fig. 17 page 30. Failure to ensure proper burner setup NOTICE could result in severe personal injury, The propane orifice requirement for death or substantial property damage. PRESTIGE Excellence is 0.204” (#52)

  • Page 37: Gas Piping

    Gas Piping Inlet Supply Pressure Port Venturi Gas Valve Propane Orifice Gas Valve Gas Valve Pipe Fitting Gasket Fig. 17: Gas Valve / Venturi Assembly...

  • Page 38: Section Vii - Internal Wiring

    Fig.19. (190ºF) wire or equivalent as a minimum. 5. Push wiring tool in towards the terminal The PRESTIGE Excellence must be elec- block and insert wire in slot at bottom of trically grounded as required by National terminal block.

  • Page 39: Internal Wiring Diagram

    Internal Wiring Fig. 20: PRESTIGE Excellence Boiler Factory Wiring...

  • Page 40: Section Viii - External Wiring

    ELECTRICAL SHOCK HAZARD. areas of draft, lighting fixtures and fire- Before making any electrical connec- places. tions to the PRESTIGE Excellence, dis- connect electrical power supply at the 3. Set the thermostat anticipator (if applica- service panel. Failure to comply can ble) as follows: cause severe personal injury or death.

  • Page 41: System Circulator - Zone Valve Application

    Valves with isolated end switch such as Honewell V8043 or equivalent. Additional 24V Limit Wiring Outdoor Reset Control The PRESTIGE Excellence provides 24V ter- 1. The PRESTIGE Excellence may operate minal connections for additional limit controls with a variable boiler operating tempera- as shown in Fig.
  • Page 42 External Wiring 4 Wire Zone Valve V.A.C. High Voltage Transformer (Power) V.A.C. Room Zone Valve Thermostat Zone 1 Room Thermostat Zone 2 Zone Valve Additional zones may Additional zones be added as shown above To Prestige 24V Terminal Strip 3 Wire Zone Valve V.A.C.
  • Page 43 External Wiring Thermostat Honeywell Fig. 23: Field Wiring with Zone Circulators. zone 1 R845A Relay Circulator Zone 1 Thermostat zone 2 Circulator Zone 2 Additional zones may be added as shown above To Prestige 24V Terminal Strip Thermostat Thermostat Thermostat Fig.

  • Page 44: Section Ix - Start-Up Preparation

    For areas with 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.

  • Page 45: Use Of Antifreeze In The Boiler System

    The water volume of the PRESTIGE Excellence 2. Open all system isolation valves. is approximately 5 gallons (includes Boiler and DHW outer tank). Remember to include the vol- 3.

  • Page 46: Check Low Water Cut-Off Device

    Check Low Water Cut-Off Device There should NEVER be voltage measured at the wire ends. The PRESTIGE Excellence is provided with a factory installed LWCO device that If voltage is measured at the panel under any measures system pressure of more than 10 condition, check and correct the external psi.

  • Page 47: Section X- Start-Up Procedures

    PRESTIGE Excellence Parameter Section of the manual starting control. on page 45 for more information. Verify the PRESTIGE Excellence and the 2. Check for loose electrical connections, boiler system is full of water and all system blown fuse...
  • Page 48 45 carbon monoxide emissions, which will of the PRESTIGE Excellence control result in severe personal injury or death. section on how to set the firing rate. If...

  • Page 49: Operating Instructions

    DO NOT 8. Set room thermostat(s) to desired setting(s). try to light the burner by hand. 9. The PRESTIGE Excellence control panel display Set room thermostat(s) to lowest setting. Turn the will show a sequence of numbers (0,1,2,3,4,etc.) external manual gas valve handle clockwise as the left digit.

  • Page 50: Set Boiler Ch Target Temperature

    0ºF. ily prior to the prepurge cycle. When the outdoor temperature is higher than 0ºF the PRESTIGE Excellence con- 1140 ] This is the prepurge cycle. The trol will calculate the target temperature...

  • Page 51: Set Dhw Storage Temperature

    Start-Up Procedures digits on the display shows the DHW stor- 3140 ] This is the normal operation cycle. age temperature setting. After the flame is proven and stabilized the burner will fire at low input for 3. Press the “+” or “-” button to change the approximately 1 minute.

  • Page 52: Boiler Control Display

    Start-Up Procedures Boiler Control Display 4180 ] This indicates normal operation for DHW. The burner will begin modulat- Standby Mode StbY ing its input based on the length of demand by the DHW setting. The burner will not go After the boiler is turned on, the control panel into the low input rate for the 1 minute will display STANDBY mode as shown in the flame stabilization period that occurs in CH...
  • Page 53 Start-Up Procedures Standby Mode Display TO TEMPORARILY PLACE THE BURN- ER INTO LOW FIRE TEST MODE: press Display Boiler function StbY the MODE button until “ ” is displayed. Then press and hold both the mode and “-” but- STANDBY, no demand for heat ton simultaneously until the first digit flashes Fan prepurge (10 seconds) or post purge cycle “L”.

  • Page 54: Setting The Boiler Parameters

    Start-Up Procedures Setting The Boiler Parameters Note 3: This parameter should not be changed from the factory setting of “01”. The perfor- mance of the CH (Central/Space Heating) will Parameter mode be affected and can become unreliable. Accessing Boiler Information To access PARAMETER mode when the sys- Information mode tem is in STANDBY mode, press the MODE...

  • Page 55: Error (Hard Lockout) Mode

    Start-Up Procedures Error (Hard Lockout) Mode Display Hard Lockout If a system fault occurs while the boiler is run- E 00 Flame detected prior to burner startup ning, the system goes into lockout and the dis- Failed ignition after 5 attempts play starts to flash with the first digit as an E and the next two digits give the code for this Gas valve harness not properly connected...

  • Page 56: Section Xi - Outdoor Reset Control

    Outdoor Reset Control SECTION XI - Outdoor Reset Control 8. Tap the enclosed plastic anchors into the pilot holes. Use care not to damage the anchors. Plastic Anchors (2) Sensor Enclosure Mounting Screws(2) 9. Mount the sensor enclosure using the screws provided.

  • Page 57: Summer/Winter Switch At Boiler

    Outdoor Reset Control Summer / Winter Switch at Boiler • The boiler target temperature setpoints are based on outdoor air temperatures between 0ºF and 68ºF and are linearly proportional. If required the CH (Central Heating) system See Graph 1 and Table 3 on page 51 for a can be turned off at the boiler, similar to man- sample setting.
  • Page 58 Outdoor Reset Control Parameter 4 Set Point Outdoor Air Temperature ( F) Graph 1: Outdoor Air Temperature Reset Curve (Example) Table 3: Outdoor Air Temperature Reset (Example) Outdoor Boiler Target Temp. Temperature Based on Outdoor Temp. 0ºF or Lower 140ºF 23ºF 122ºF 40ºF...

  • Page 59: Section Xii - Check-Out Procedures

    53. Reviewed all instructions shipped with the Check-out Procedures PRESTIGE Excellence with the homeown- er or maintenance personnel. Boiler system water chemistry checked and verified as outlined on page 37. Completed the Installation Record on page...

  • Page 60: Section Xiii - Installation Record

    Installation Record SECTION XIII - Installation Record PRESTIGE Excellence Model Number: Serial Number: Date of Installation: Fuel: Natural Gas Propane Measured Rate of Input: Btu/hr Combustion Readings: The following items were completed during installation: Installation instructions have been followed and completed...

  • Page 61: Sections Xiv - Maintenance Schedule

    Maintenance Schedule SECTION XIV - Maintenance Schedule Owner Maintenance Service Technician Periodically: At least on an annual basis the following main- Check the area around the unit. tenance should be performed by a qualified ser- Check and remove any blockage from the vice technician: combustion air inlet and ventilation open- General...

  • Page 62: Section Xv - Maintenance Procedures

    WARNING area. The PRESTIGE Excellence should be inspected and serviced annually, prefer- Inspect Burner Area ably at the start of the heating season, by a qualified service technician. In addi-...

  • Page 63: Clean Condensate Drain Assembly

    Maintenance Procedures Clean Condensate Drain Assembly Inspect Vent and Combustion Air Piping 1. Loosen the slip ring nut from the conden- Visually inspect the venting system and com- sate drain assembly disconnecting the bustion air piping for blockage, deterioration assembly from the boiler. or leakage.

  • Page 64: Check Expansion Tank

    Maintenance Procedures Check Expansion Tank WARNING Refer to Section IV - Boiler Piping for rec- Before manually operating the pressure ommended location of the expansion tank relief valve, ensure the discharge piping is and air eliminators. directed to a suitable place of disposal to avoid a potential scald hazard.

  • Page 65: Check Control Wiring

    Maintenance Procedures Check Control Wiring Carefully remove the burner mounting plate assembly from the heat exchanger. Ensure Inspect all control wiring. Ensure wiring is in combustion chamber insulation is not damaged good condition and properly connected. during removal of burner mounting plate assembly.

  • Page 66: Check Flame Signal

    Maintenance Procedures Check Flame Signal 2. Allow the boiler to cool down to room tem- perature before servicing. The flame signal should be a min. 3µ Α −DC. 3. Disconnect the gas piping and rectifier plug to the gas valve. Check the ignitor for fouling or damaged insulation if a low flame signal is read.

  • Page 67: Review With Owner

    Maintenance Procedures Review With Owner 14. Attach a hose to the boiler drain valve and flush the boiler thoroughly with fresh water Ensure the owner understands the impor- by using the purge valves to allow water to tance to perform the maintenance schedule enter through the make-up water line to the specified in this manual.

  • Page 68: Replacement Parts

    Replacement Parts Fig. 26: PRESTIGE Excellence Jacket Components Item Part No. Description PSCS01 Display/Control Panel PSCS02 Display/Control Panel Extension (Not Shown) PSJKT04B Base Panel PSJKT02F Front Jacket Panel PSJKT03R Rear Jacket Panel PSJKT03S Side Jacket Panel (Left and Right) PSJKT07T...
  • Page 69 Replacement Parts Fig. 27: PRESTIGE Excellence Internal Components Item Part No. Description PSRKIT01 Heat Exchanger Body PSRKIT02 Vent Outlet Adapter PSRKIT03 Combustion Air Inlet Adapter PSRKIT04 NTC Sensor (NTC1, NTC2 and NTC5) (Not shown) PGRKIT20 LWCO Pressure Device PSRKIT05 Condensate Drain Assembly (Not shown)
  • Page 70 Replacement Parts Fig. 28: PRESTIGE Excellence Burner Components Item Part No. Description PSRKIT09 Combustion Chamber Insulation PSRKIT10 Burner Head with Gasket - Natural PSRKIT11 Burner Head with Gasket - Propane PSRKIT12 Burner Plate PSRKIT13 Blower with Gasket PGRKIT01 Gas Valve...

  • Page 71: Replacement Parts

    Replacement Parts Fig. 29: PRESTIGE Excellence Electronic Components Item Part No. Description PSRKIT58 Prestige Control Module PSRKIT19 Transformer with Surge Protection PSRKIT20 Prestige Control Module Display...

  • Page 72: Product Specifications

    Product Specifications 24.7" 628 mm 20.4" 3” Vent Outlet 516 mm 14.8" 3” Combustion 377 mm Air Inlet 12" 3/4” NPSC 306 mm Pressure Relief Valve Connection 1/2” NPSC Boiler Drain 7.2" 183 mm 15.9" 1” NPT Boiler Return 405 mm 15.9"...

  • Page 73: Specifications

    Product Specifications 20.8" 529 mm 15" 3/4” NPSC Pressure Relief Valve 381 mm Connection 3” Vent Outlet 11.4" 3” Combustion Air Inlet 289 mm 37.2” 945 mm 2.4" - 61 mm 1/2” NPT Gas Connection 1/2” NPSC 8.0" 205 mm Boiler Drain 16"...
  • Page 74 Product Specifications 3/4” NPT DHW Outlet 11.3" 286 mm 3/4” NPSC Aux. Connection (Rear) 7.3" 1/2” NPSC Air Vent Connection 186 mm 3.4” 3/4” NPT 87 mm DHW Inlet 4.1” 105 mm 8” 204 mm Top View (Domestic Connections)
  • Page 75 Product Specifications Net IBR DOE Seasonal Shipping Boiler Fuel Input Heating Capacity Efficiency AFUE Model Rating Weight Note 1 & 4 Note 4 Note 3 Note 2 Lbs / Kg Excellence 110,000 86,000 Natural 99,000 190 / 86 Excellence Propane 97,000 76,000 87,000...
  • Page 76 Graph 2: Pressure Drop Comparison Excellence 110 vs Grundfos UPS 15-58F-FC Available System Head in Feet Delta T Spd 1 Spd 2 Spd 3 11.2 10.9 14.2 Note: Minimum allowable flow rate at full input: 5.0 gpm...
  • Page 77 Additional Quality Water Heating Equipment Available from Triangle Tube 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 maximum heat exchange Compact and light weight Available in 5 sizes that can accommodate any size pool or spa Smart Indirect Fired Water Heaters...

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