prestige Excellence Water Boiler LI STED Part 1 of 2 * I N S TALLAT I O N AN D MAI N T E NAN C E * M A N U A L NOTICE Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installation 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.
Table of Contents Product & Safety Information Definitions .........................................................................................................1 Qualified Installer: .........................................................................................................2 Homeowner: .........................................................................................................2 Section I - Pre-Installation Items 1.1 Code Compliance.............................................
Table of Contents 4.8 Expansion Tank and Makeup Water .....................................................................16 4.8.1 Diaphragm Expansion Tank ........................................................................16 4.8.2 Closed-Type Expansion Tank......................................................................16 4.9 Circulator .........................................................................................................16 4.10 Sizing Primary Piping ........................
Table of Contents SECTION IX - ACVMax Operation 9.1 ACVMax Navigation ............................................................................................39 9.2 ACVMax Menu Structure.....................................................................................40 9.3 Home Screen .........................................................................................................41 9.4 Status Line Messages......................................................................................
Table of Contents 10.4 Check For Gas Leaks............................................................................................56 10.5 Check Thermostat Circuit .....................................................................................56 10.6 Inspection of Condensate Drain Assembly...........................................................56 SECTION XI - Start-Up Procedures 11.1 Final Checks Before Start-Up...............................................................................
Table of Contents 17.17 17.18 17.19 17.20 17.21 17.22 17.23 17.24 Check Burner Flame .............................................................................................71 Check Flame Signal ..............................................................................................72 Check Combustion Levels ....................................................................................72 Check Flue Gas Temperature.............................................................................
Product & Safety Information 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. DANGER NOTICE Indicates the presence of a hazardous situation which, if ignored, will result in death, serious injury or substantial property damage.
Product & Safety Information DANGER WARNING Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system which has been under water. Qualified Installer: Prior to installing this product read all instructions included in this manual and all accompanying manuals/documents with this appliance. Perform all installation steps required in these manuals in the proper order given.
1.0 Pre-Installation Items SECTION I - PRE-INSTALLATION ITEMS 1.1 Before locating the PRESTIGE Excellence check for convenient locations to: Code Compliance - - - - - All applicable local, state, national and provincial codes, ordinances, regulations and laws. Electrical service Venting Gas supply piping Ensure the boiler location allows the combustion air/vent piping to be routed directly through the building and terminate properly outside with a minimum amount of length and bends.
1.0 Pre-Installation Items 1.4 Recommended Clearances 1.5 The PRESTIGE Excelence is approved for zero clearance to combustibles, excluding vent and boiler piping. - - When installing the PRESTIGE Solo in a residential garage, the following special precautions per NFPA 54/ANSI Z223.1 must be taken: - Boiler Piping - 1/4 inch from combustible materials. Reference the appropriate vent supplement for clearance requirements.
2.0 Combustion Air & Venting SECTION II - COMBUSTION AIR AND VENTING 2.1 Potential contaminating products - Combustion Air Contamination - - WARNING - If the PRESTIGE Excellence combustion air inlet is located in any area likely to cause or contain contamination, or if products, which would contaminate the air cannot be removed, the combustion air must be repiped and terminated to another location.
2.0 2.2 Combustion Air Venting Ventilation and Combustion Air Requirements - Direct Vent 2.3 A Direct Vent appliance utilizes uncontaminated outdoor air (piped directly to the appliance) for combustion. A Category IV appliance utilizes uncontaminated indoor or outdoor air (surrounding the appliance) for combustion. For Direct Vent installations, involving only the PRESTIGE Excellence, in which the minimum service clearances are maintained as listed on page 4, no ventilation openings are required.
2.0 Combustion Air Venting 2.4 2.4.1 Methods of Accessing Combustion Air Into A Space - Category IV - Indoor Combustion Air NOTICE The methods listed in this section for accessing Indoor Combustion Air assume that the infiltration rate is adequate and not less than .40 ACH. For infiltration rates less than .40 ACH, reference the NFPA 54 National Fuel Gas Code for additional guidance. 2.4.
2.0 Combustion Air Venting Fig. 2: All Combustion Air from Outdoors Through One Permanent Air Opening Fig. 3: 2.4.2.2 Two Permanent Openings Method Two permanent openings, one commencing within 12 in. of the top and one commencing within 12 in. of the bottom of the enclosure, shall be provided.
2.0 Combustion Air Venting 2.4.3 Combination of Indoor and Outdoor Combustion Air uncontaminated outdoor air (piped directly to the appliance) for combustion. Indoor Openings: Where used, openings connecting the interior spaces shall comply with the Indoor Combustion Air section on page 7.
2.0 2.6 Combustion Air Venting Removal of an Existing Boiler from a Common Vent System 5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe. BEST PRACTICE 6.
2.0 2.7 Combustion Air Venting Commonwealth of Massachusetts Installations Only For direct-vent appliances, mechanicalvent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied: 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.
3.0 Unit Preparations SECTION III - UNIT PREPARATIONS 3.1 3.3 1. The wall-mounting bracket is designed for stud spacing of 12 inch or 16 inch on centers. For unconventional stud spacing, a solid / secure mounting surface must be provided for installation of the bracket. Handling Instructions The PRESTIGE Solo is generally easier to handle and maneuver once removed from the shipping carton. 2. For applications using wood studs, install the bracket using the lag screws provided with the boiler.
3.0 Unit Preparations 3.4 Wall Bracket Installation - Stud Walls 3.6 Boiler Mounting 1. Obtain assistance in lifting the boiler onto the wall bracket. 1. To distribute the weight of the boiler evenly when mounting onto a stud wall it is recommended to use the PRESTIGE Solo Wall Frame kit. 2. Install the boiler making sure the boiler mounting lip located along the upper edge of the rear jacket panel engages the wallmounting bracket. Ensure the boiler is seated properly and is secure. 2.
4.0 Boiler Piping 4.1 General Piping Requirements - Support all piping using hangers. DO NOT support piping by the unit or its components. - SECTION IV - BOILER PIPING - All plumbing must meet or exceed all local, state and national plumbing codes. - Use isolation valves to isolate system components. - - - Install unions for easy removal of the PRESTIGE Excellence from the system piping. Use a two wrench method when tightening piping onto the boiler connections.
4.0 Boiler Piping Fig. 5: Pressure Relief Valve and Boiler Drain Valve Installation 4.4 - - - Low Water Cutoff Device 4.5 The PRESTIGE Excellence is equipped with a factory installed pressure sensor type Low Water Cut Off device. Additional 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 guidelines must be followed: The minimum operating system pressure allowable with this device is 10 psig.
4.0 - - 4.6 4.7 - Boiler Piping Consult heat exchanger for maximum set point of limit. CAUTION Undersized expansion tanks will cause system water to be lost through the pressure 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. For wiring of the limit, reference Fig. 15, page 29, using the external manual reset terminals on the low voltage terminal strip.
4.0 Boiler Piping The circulator, when wired directly to the PRESTIGE Excellence, will allow for domestic hot water priority and provide circulation for the freeze protection feature of the boiler control. See Graph 1 on page 78 for pressure drop and minimum flow rate through the boiler. 4.10 Sizing Primary Piping 4.11 Domestic Hot Water System Piping NOTICE To ensure an adequate flow rate through the PRESTIGE Excellence, the boiler supply and return piping size must be a minimum of 1 inch. 4.
4.0 Boiler Piping 4.16 System Application CAUTION DO NOT install a SMART tank along with the PRESTIGE in systems with non-oxygen barrier tubing. Failure to comply could result in premature failure of the SMART tank. - Special If the boiler is used in conjunction with a chilled water/medium system, the boiler and chiller must be piped in parallel. Install flow/check valves to prevent the chilled medium from entering into the boiler.
4.0 Boiler Piping Fig. 6: Piping Component Legend 664A0100 - Rev.
4.0 Boiler Piping Note: Reference Fig. 20, page 36 for Prestige Wiring. Fig. 7: System Piping - Zoning with Zone Circulators Note: Reference Fig. 21, page 36 for Prestige Wiring. Fig. 8: System Piping - Zoning with Zone Valves NOTICE 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. 20 664A0100 - Rev.
4.0 Boiler Piping Note: Reference Fig. 22, page 37 for Prestige Wiring. Note: Verify CH circulator is properly sized to overcome the system pressure drop and provide adequate flow through the boiler system. Fig. 9: System Piping - Multiple Zone Valve with Single System/Boiler Circulator Note: Verify CH circulator is properly sized to overcome the system pressure drop and provide adequate flow through the boiler system. Note: Reference Fig. 23, page 37 for Prestige Wiring. Fig.
5.0 Installing Vent/Combustion Air & Condensate Drain SECTION V - INSTALLING VENT / COMBUSTION AIR & CONDENSATE DRAIN 5.1 WARNING Ensure installation of the condensate drain assembly included the metal washer. Failure to comply could result in the trap assembly dislocating from the boiler.
5.0 Installing Vent/Combustion Air & Condensate Drain 9. 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. NOTICE The drain line materials must be an approved material by the authority having jurisdiction. In absence of such authority, PVC and CPVC piping must comply with ASTM D1785 or D2845.
6.0 Gas Piping 6.1 Gas Supply Piping Connection SECTION VI - GAS PIPING 7. Use pipe dope compatible with natural and propane gases. Apply sparingly only to the male threads of pipe joints so that pipe dope does not block gas flow. NOTICE WARNING The gas supply piping must be installed in accordance to all applicable local, state and national codes and utility requirements. Failure to apply pipe dope as detailed above can result in severe personal injury, death or substantial property damage. 1.
6.0 Gas Piping 6.2.1 Pipe Sizing 6.2 Natural Gas 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 lockup pressure regulator for 13”w.c maximum. Refer to Table 1 for schedule 40 metallic pipe length and diameter requirements for natural gas, based on rated PRESTIGE Excellence input (divide by 1,000 to obtain cubic feet per hour). - - WARNING DO NOT adjust or attempt to measure gas valve outlet pressure.
6.0 Gas Piping 6.3.1 Pipe Sizing - Propane Gas 6.3 Propane Gas 6.3.2 Propane Gas Supply Pressure Requirements 1. Adjust the propane supply regulator provided by the gas supplier for 13”w.c. maximum pressure WARNING 2. Pressure required at the gas valve inlet supply pressure port: The unit was shipped with a propane conversion kit which is located on the top of the unit in the instructions packet.
6.0 Gas Piping Fig. 13: Gas Valve / Venturi Assembly - PRESTIGE Excellence 664A0100 - Rev.
7.0 Internal Wiring SECTION VII - INTERNAL WIRING WARNING ELECTRICAL SHOCK HAZARD. For your safety, disconnect electrical power supply to the unit before servicing or making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. CAUTION 7.1 - - 7.2 Prior to servicing, label all wires before disconnecting. Wiring errors can cause improper and dangerous operation. Verify proper wiring and operation after servicing. Fig.
7.
8.0 External Wiring 8.1 Installation Compliance SECTION VIII - EXTERNAL WIRING 2. Route the incoming 120 VAC power wire through the provided openings in the bottom jacket panel. 3. The unit is provided with a service switch located on the front panel, check local code requirements for compliance. All field wiring made during installation must comply with: - NOTICE National Electrical Code NFPA 70 and any other national, state, provincial or local codes or requirements. - In Canada, CSA C22.
8.0 External Wiring secondary CH loop when zoning with zone valves or as a dedicated circulator to a space heating zone. NOTICE CH and DHW call connections to the PRESTIGE require a dry contact with no external voltage present. Ensure no external voltage is present on each set of wires before connecting to the PRESTIGE. If external voltage is present, the use of an isolation relay is required to prevent damage to the ACVMax controller. 5.
8.0 External Wiring 2. Follow thermostat manufacturer’s instructions for proper installation. Thermostat should be located on an inside wall away from any heat or cold influences such as drafts, lights, fireplaces, etc. 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. 3. Set the thermostat anticipator (If applicable) as follows: - - NOTICE Set for 0.2 amps when wired directly to the PRESTIGE.
8.0 External Wiring 8.12 CAUTION The ACVMax control includes the ability to communicate with building management systems (BMS) through a Modbus interface. Consult the PRESTIGE ACVMax Control Supplement for more information. Locate the system temperature sensor where it can accurately measure the supply temperature to the heating system. Inaccurate system temperature readings could lead to overheating or under heating resulting in property damage. 1.
8.0 External Wiring Fig. 18: Multiple Zone Field Wiring Using Zone Valves & Zone Valve Panel 34 664A0100 - Rev.
8.0 External Wiring Fig. 19: Multiple Zone Field Wiring using Zone Circulators & Zone Relay Panel 664A0100 - Rev.
8.0 External Wiring Note: Reference Fig. 7, page 20 for System Piping. Fig. 20: Prestige Wiring - Zoning with Zone Circulators Note: Reference Fig. 8, page 20 for System Piping. Fig. 21: Prestige Wiring - Zoning with Zone Valves 36 664A0100 - Rev.
8.0 External Wiring Note: Reference Fig. 9, page 21 for System Piping. Fig. 22: Prestige Wiring - Multiple Zone Valve with Single System/Boiler Circulator Note: Reference Fig. 10, page 21 for System Piping. Fig. 23: Prestige Wiring - Single Zone System with Single System/Boiler Circulator 664A0100 - Rev.
9.0 ACVMax Operation SECTION IX - ACVMAX OPERATION The ACVMax Boiler Management System is designed to be flexible yet easy to use. ACVMax monitors and controls the Prestige to provide heat as efficiently as possible. ACVMax includes many advanced features which previously were not available in the Prestige. • Two central/space heating (CH) call inputs with separate outdoor reset curves. • Cascade function allows up to six Prestige boilers to operate together in a single heating system.
9.0 9.1 ACVMax Operation ACVMax Navigation Navigation is performed through four arrow buttons UP, DOWN, LEFT, RIGHT with a center OK button for making selections and entering information. The INSTALLER button (the small round button) provides the installing contractor with full access to all available features after entering a password. Reference the ACVMax Control Supplement for Installer level functions.
9.0 9.2 ACVMax Operation ACVMax Menu Structure 40 664A0100 - Rev.
9.0 9.3 ACVMax Operation 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 five minutes. Press the UP or DOWN buttons to turn on the backlight while at the Home Screen without making any changes.
9.0 9.4 ACVMax Operation Status Line Messages Status Line Message Standby CH Demand DHW Demand CH / DHW Demand DHW Priority Priority Timeout External Demand Slave Operation Manual Operation CH Burner Delay DHW Burner Delay CH Setpoint Reached DHW Setpoint Reached Description Indicates that the Prestige is ready to respond when a demand is received. A central heating call has been received. A domestic hot water call has been received.
9.0 9.5 ACVMax Operation 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 of the display. Menus can be entered by highlighting the desired icon and pressing the OK button. 664A0100 - Rev.
9.0 9.6 ACVMax Operation EZ Setup Navigation: Home Screen>Main Menu>EZ Setup The EZ Setup menus provide a simple way to quickly customize the TriMax for each installation. EZ Setup prompts the user to make selections which allows the Prestige to be setup very quickly without searching through long lists of settings and manually making adjustments. 9.
9.0 ACVMax Operation the LEFT or RIGHT buttons to adjust the CH2 Setpoint then press the OK button to store the setting. 9.7.4 Select CH1 Reset Curve Default: Finned Tube Baseboard Select CH1 Reset Curve prompts the installer to select an outdoor reset curve for a CH1 heating call when an Outdoor Reset option is chosen in Select CH Demand. Outdoor reset curve presets are available to cover most applications. The outdoor reset curve can also be adjusted to any desired settings in the Installer Menu.
9.0 9.8 ACVMax Operation Domestic Hot Water EZ Setup Navigation: Home Screen>Main Menu>EZ Setup>DHW EZ Setup Domestic Hot Water EZ Setup allows the installer to quickly customize the domestic hot water settings for the application. 9.8.1 Select DHW Demand Default: Switch Select DHW Demand prompts the installer to select the type of device which will generate a DHW call. Press the UP or DOWN buttons to select the DHW Demand type then press the OK button to store the setting.
9.0 ACVMax Operation 9.8.4 DHW Priority Timeout Default: Off DHW Priority Timeout prompts the installer to enter an optional time limit that a domestic hot water call has priority over a central heating call. Press the LEFT or RIGHT buttons to adjust the DHW Priority Timeout then press the OK button to store the setting. 9.7.7 CH EZ Setup Complete EZ Setup Complete informs the installer upon completion of all necessary steps that the EZ setup is complete.
9.0 ACVMax Operation 9.11 CH/DHW Operation Navigation: Home Screen>Main Menu>CH / DHW Operation CH / DHW Operation provides a simple way to disable either the central heating or domestic hot water functions of the Prestige. Operation can be enabled and disabled by selecting the central heating or domestic hot water icon then pressing the OK button to toggle between enabled and disabled. An icon with an X through it indicates that function has been disabled.
9.0 9.12.2 ACVMax Operation Information Items Information Item Boiler Status Heating Call DHW Call Boiler Firing Rate Ionization Current Boiler Setpoint Supply Temp. Return Temp. Boiler Flue Temp. Outdoor Temp. DHW Storage Temp. External Modulation Signal Pressure CH Ignitions CH Runtime DHW Ignitions DHW Runtime Mix Zone Temperature 664A0100 - Rev. A Description Displays the current operating state of the Prestige. This is the same as the status line on the home screen.
9.0 ACVMax Operation 9.13 Lockout History b bbb f bbb b bb f ed cebd cba de f b b ed cba a abcc de f ab d e abc b bbb f ed bbb b bb f ed cb cba de f a abc de f bb d cba gb c b f a d abc Navigation: Home Screen>Main Menu>Boiler Information>Lockout History Lockout History records the last eight lockouts. Each line contains a lockout description followed by how long ago the lockout occurred. Six lockouts are displayed on the screen at one time.
9.0 9.13.2 ACVMax Operation Lockout Screen The Lockout Screen replaces the Home Screen if a lockout occurs. The screen backlight will also illuminate constantly while the Prestige is locked out. Pressing any arrow button will return to the Home Screen so that additional troubleshooting can be performed. See pages 54 and 55 for a list of lockouts and descriptions. 664A0100 - Rev.
9.0 ACVMax Operation Code Lockout Message E2 False Flame E1 Manual Reset Hard Lockouts Failed Ignition E3 High Boiler Temperature E8 Flame Circuit Error E5 Blower Speed E9 Gas Valve Circuit Error E15 Sensor Drift E13 E16 Reset Limit Reached Supply Sensor Stuck E17 Return Sensor Stuck E21 Internal Control Fault E18 Sensor Failure Description The burner failed to light after 5 ignition attempts. A flame is being detected prior to ignition.
9.0 ACVMax Operation Code Lockout Message Automatic Reset Soft Lockouts Description E7 High Flue Temperature Flue temperature exceeds high limit. E25 Internal Control Fault CRC check error.
10.0 Start-Up Preparation SECTION X - START-UP PREPARATION 10.1.3 Chlorinated Water Do not use the PRESTIGE Excellence to heat a swimming pool or spa directly. NOTICE Maintain the chlorine level of the water at levels considered safe for drinking. Requirements below must be met for warranty coverage of Prestige heat exchangers. A thorough cleaning of any existing system, using approved heating system cleaning agents is required prior to installation of the Prestige boiler.
10.0 Start-Up Preparation 10.1.7 Check and Test Antifreeze NOTICE For boiler systems containing antifreeze solutions, follow the antifreeze manufacturer’s instructions in verifying the inhibitor level and to ensure the fluid characteristics are within specification requirements. 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.
10.0 10.3 - Start-Up Preparation Check Low Water Cut-Off Device - The PRESTIGE Excellence is provided with a factory installed LWCO device that monitors system pressure. NOTICE Access the Boiler Information Menu by following instructions in Section 9.12 on page 48. Scroll down to see the current system pressure displayed and verify it is within the recommended numbers given in Section 10.2 on page 53. 10.4 - Check For Gas Leaks 2.
11.0 Start-Up Procedures SECTION XI - START-UP PROCEDURES 11.1 c c c c c c 11.2 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. Final Checks Before Start-Up 2. Read and follow the Operating Instructions outlined on page 61. Read Section IX regarding the operation of the ACVMax Boiler Management System.
11.0 c Start-Up Procedures be performed with calibrated equipment to ensure proper reading and accuracy. Purge any remaining air from the system piping. Air in the system piping will interfere with circulation creating heat distribution problems and system noise. 2. Test for CO2 or O2 and for CO during high firing rate. The combustion readings should be within the range listed in Table 3 on page 59. The CO level should not exceed 100 ppm when combustion is correct.
11.0 Start-Up Procedures e. Press the LEFT and RIGHT buttons to adjust the firing rate from 1% to 100%. Hold down the LEFT or RIGHT button to rapidly increase or decrease the firing rate. Table 3: Recommended Combustion Levels 4. If the CO2 combustion level during low fire (1%) is not within +/- 0.2 of the combustion level measured at high fire, adjust the plastic OFFSET SCREW under the cover screw on the top of the gas valve (see Figs. 13 on page 27) according to Table 6. O2 Min.
11.0 c Start-Up Procedures Test High Temperature Limit 8. Initiate a CH or DHW call and confirm that a High Boiler Temperature lockout occurs once the supply temperature reaches 102ºF [39ºC]. The high temperature limit can be temporarily lowered from 210ºF [99ºC] to 102ºF [39ºC] for testing. 9. Press any ARROW button to return to the Home Screen. 1. Press the round INSTALLER button. Reference Fig. 25, page 39. 10. Press the round INSTALLER button. 11.
11.0 Start-Up Procedures FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is • If you cannot reach your gas supplier, call the fire department. equipped with an ignition device which automatically lights the burner. DO NOT try to light the burner by hand. C. Use only your hand to turn the external manual gas valve.
12.0 Outdoor Reset Control SECTION XII - OUTDOOR RESET CONTROL 4. Avoid mounting the outdoor sensor in areas subjected to excessive moisture. 5. Once an area on the exterior wall has been determined, follow the mounting instructions included with the outdoor sensor. The use of the outdoor reset function is required to optimize boiler efficiency, see notice below. If the outdoor sensor is not installed before turning on the boiler, an Outdoor Sensor Open error (E96) will be displayed.
13.0 External Modulating Control SECTION XIII - EXTERNAL MODULATING CONTROL 13.2 The ACVMax control must be programmed to accept the 0-10 VDC signal from the external modulating boiler control. The boiler can directly accept an analog 0-10 VDC signal to control the firing rate from an external modulating boiler controller. 13.1 1. Use the Heating EZ Setup function to set the CH Demand to 0-10V Modulation Signal. Reference page 46 for the Heating EZ Setup function.
13.
14.0 Check-Out Procedures SECTION XIV- Check-Out Procedures c NOTICE c Perform the following check-out procedures as outlined and check off items as completed. When procedures are completed, the installer should complete the installation record on page 68. c c c c c c c c c c Boiler system fluid chemistry checked and verified as outlined on page 56. Boiler system was completely flushed to remove any debris/sediment. c Any automatic air vents placed within the system are open one full turn.
15.0 Installation Record SECTION XV - INSTALLATION RECORD PRESTIGE Model Number: Serial Number: Date of Installation: Fuel: Natural Gas Propane Measured Rate of Input: Btu/hr Combustion Readings: CO2 % O2 % CO ppm The following items were completed during installation: Installation instructions have been followed and completed Check-out procedures have been followed and completed Information regarding the unit and installation received and left with owner / maintenance personnel.
16.0 Maintenance Schedule SECTION XVI - MAINTENANCE SCHEDULE 16.1 16.2 Periodically: Service Technician - At least on an annual basis the following maintenance should be performed by a qualified service technician: - General - Inspect the interior of the boiler jacket area; clean and vacuum if necessary. - Check boiler fluid pH on systems. - - - - - - - - - - Attend to any reported problems. - - Clean the condensate drain assembly and fill with fresh water.
17.0 Maintenance Procedures 17.1 Maintenance Procedures SECTION XVII- MAINTENANCE PROCEDURES 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 products 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. WARNING 17.
17.0 Maintenance Procedures 17.6 Clean Assembly Condensate Drain WARNING 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. Loosen the retaining nut from the condensate drain assembly and disconnect the assembly from the boiler. Empty any water from the trap and drain assembly. Flush with fresh water as necessary to clean. 17.
17.0 Maintenance Procedures 17.10 Check Expansion Tank WARNING Refer to Section IV - Boiler Piping for recommended location of the expansion tank and air eliminators. Before 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 discharge piping must be full size without restriction and installed to permit complete drainage of both the valve and line.
17.0 Maintenance Procedures 17.14 Check Control Wiring Carefully remove the burner plate assembly from the heat exchanger. Ensure that the combustion chamber 2-in-1 insulation is not damaged during removal of burner mounting plate assembly. See WARNING on page 73. Inspect all control wiring. Ensure wiring is in good condition and properly connected. 17.15 Check Control Settings Remove the burner head mounting screws and remove the burner head. Inspect the burner head for deterioration.
17.0 Maintenance Procedures 17.18 Check Flame Signal Disconnect the wiring harness connectors from the blower and remove the blower clamp. Remove the blower from the unit. The flame signal can be read from the Boiler Information screen. It should be a min. 1μ Α −DC. Remove the mounting nuts securing the burner plate to the heat exchanger and set aside. Check the ignitor for fouling or damaged insulation if a low flame signal is read. Carefully remove the burner plate assembly from the heat exchanger.
17.0 Maintenance Procedures 17.22 Review With Owner WARNING Ensure the owner understands the importance to perform the maintenance schedule specified in this manual. The combustion chamber insulation contains ceramic fibers, which are classified as a possible human carcinogen. When exposed to extremely high temperatures, the ceramic fibers, which contain crystalline silica, can be converted into cristobalite.
18.0 Product Specifications SECTION XVIII PRODUCT SPECIFICATIONS Boiler Model Fuel Input DOE Heating Capacity Net AHRI Rating DOE Seasonal Efficiency AFUE Shipping Weight Lbs / Kg Excellence Natural Propane 110,000 99,000 86,000 95% 250 / 115 Note 1: Note 2: Note 3: Note 4: The heating capacity of the PRESTIGE Excellence is based on the test requirements of the U.S. Department of Energy. The AHRI rating is based on a piping and pick up allowance of 1.15.
18.0 Product Specifications 24-7/8” [632 mm] 2-1/8” [52 mm] 3” Vent Outlet 3” Combustion Air Inlet 39-3/8” [1000 mm] 3/4” NPSC Pressure Relief Valve 17” [432 mm] 10-1/4” [258 mm] 7-5/8” [191 mm] 15-7/8” [403 mm] 20-7/8” [528 mm] Fig. 26: Front View PRESTIGE Excellence 664A0100 - Rev.
18.0 Product Specifications 23-5/8” [600 mm] 4-3/4” 3”Vent Outlet [120 mm] 3” Combustion Air Inlet 9” [226 mm] 16-7/8” [428 mm] Boiler Drain 1” NPT Boiler Supply 1” NPT Boiler Return Fig. 27: Right Side View PRESTIGE Excellence 76 664A0100 - Rev.
18.0 Product Specifications 10-3/8” [262 mm] 3/4” NPT DHW Outlet 7-5/8” [191 mm] Manual Air Vent 4-3/4” 3/4” NPSC Aux. Connection (Rear) [121 mm] 3/4” NPT DHW Inlet 664A0100 - Rev. A 77 11-1/2” [292 mm] 6” [151 mm] Fig.
18.0 Product Specifications Graph 1: Pressure Loss Through Boiler - Taco Circulators Note: Minimum allowable flow rate at full input: 5 gpm 78 664A0100 - Rev.
19.0 Notes SECTION XIX NOTES 664A0100 - Rev.
19.0 Notes 80 664A0100 - Rev.
19.0 Notes 664A0100 - Rev.
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prestige Excellence Water Boiler Part 2 of 2 LI STED * I N S TALLAT I O N AN D MAI N T E NAN C E * M A N U A L WARNING IMPORTANT • • • • • • 7/13/16 Before proceeding with installation and operation, read entire manual carefully. Failure to do so can cause injury or property damage. When receiving the PRESTIGE Excellence, any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.
Tables of Contents Section I: Product & Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Section II: Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Section III: Installation - Domestic Piping 3.1 Temperature & Pressure (T&P) Relief Valve . . . . . . . . . . . . . . .5 3.2 Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 3.3 Automatic Air Vent . . . . . . . . . . . . . . . . . . . . . . . .
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. DANGER NOTICE Indicates the presence of a hazardous situation which, if ignored, will result in death, serious injury or substantial property damage. Indicates special instructions on installation, operation or maintenance, which are important to equipment but not related to personal injury hazards.
Product & Safety Information WARNING CAUTION Protection must be taken against excessive temperature and pressure! Bacteria can develop in the domestic water system if certain minimum water temperatures are not maintained. TO PROTECT AGAINST EXCESSIVE TEMPERATURE AND PRESSURE • DANGER HOT WATER CAN SCALD! Water temperature over 125ºF [52ºC] can cause severe burns instantly or death from scalds. • • • Children, disabled and elderly are at highest risk of being scalded.
Pre-Installation Codes Compliance 2. The pressure of the heat transfer medium is maintained less than the normal minimum operating pressure of the potable water system Installation of the Excellence Water Heater must conform with the instructions in this manual and where applicable: • • Exception: Steam complying with section #1 above. local, state, provincial, and national codes, laws, regulations and ordinances. 3.
Pre-Installation BEST PRACTICE BEST PRACTICE To provide serviceability to the unit it is recommended that the following clearances be maintained: In hard water areas (more than 7 grains of hardness) soften the cold domestic supply water to the appliance to prevent scaling. Top boiler jacket - 24 inches. Front - 24 inches. NOTICE Bottom boiler piping - 24 inches. Any water conditioning system must be installed and maintained in accordance with manufacturer’s specifications.
Installation - Domestic Piping Temperature & Pressure (T&P) Relief Valve • CAUTION To reduce risk of excessive pressures and temperatures in the water heater, install temperature and pressure protective equipment required by local codes, but no less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials, as meeting the requirements for Relief Valves and Automatic Ga
Installation - Domestic Piping Drain Valve 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 expansion from repeatedly forcing open T&P relief valve. Drain valve and fittings are supplied by others. Standard Installation • • Install a tee connection at the domestic cold water inlet, as shown in Fig. 4, pages 9.
Installation - Domestic Piping General Piping • • For applications with a domestic recirculation loop, the recirculation pump should be controlled by an aquastat. The maximum recommended setting of the aquastat is 10ºF lower than the thermostatic mixing valve setting. For domestic water piping diagrams, see pages 9 and 10. All plumbing must meet or exceed all local, state and national plumbing codes. • Use pipe dope or tape suitable for potable water systems.
Installation - Domestic Piping DHW Aux. Connection (T&P Relief Valve) Manual Air Vent DHW Cold Water Inlet DHW Hot Water Outlet Fig. 2: Standard Installation of the T&P Relief Valve Drain Dip Tube 3/4” Brass Close Nipple D T&P Relief Valve w/ 3/4” Tee C DHW Aux. Connection C Air Vent Connection DHW Cold Water Inlet DHW Hot Water Outlet Fig. 3: Commonwealth of Massachusetts Installation 664A0300 - Rev.
Installation - Piping Diagrams Fig. 4: Standard Installation Domestic Piping Excellence Series Fig. 5: Standard Installation Domestic Piping with Optional Recirculation Excellence Series 1. 2. 3. 4. 5. Shut-off valve Flow check valve Mixing valve with check valve Vacuum Breaker * Unions 6. 7. 8 9. 9 Backflow preventer or pressure reducing valve(*) Circulator (controlled by aquastat) Domestic drain valve Thermal expansion tank (potable) (*) Optional devices may be required by local codes.
Installation - Piping Diagrams Fig. 6: Domestic Piping with Optional Storage Tank 1. 2. 3. 4. 6. 7. 8 9. Mixing valve with check valve Flow check valve Shut-off valve Backflow preventer or pressure reducing valve(*) 664A0300 - Rev. B Thermal expansion tank Circulator (controlled by aquastat) Domestic drain valve Vacuum Breaker * (*) Optional devices may be required by local codes.
Water Heater Start-Up Filling the Inner (Domestic Water) Tank • • WARNING CAUTION Never use the Excellence unless inner and outer tank of the water heater is completely filled with water. Inner tank of the Excellence water heater must be completely filled and pressurized before pressurizing outer tank. 1. Close domestic water drain valve. 2. Open domestic water isolation valves on the water heater piping. 3. Vent air from inner (domestic water) tank by opening nearest hot water faucet.
Water Heater Start-Up DANGER HOT WATER CAN SCALD! • • • • • Water temperatures over 125ºF can cause severe burns instantly, or death from scalds. Feel water before bathing or showering. Consumer Product Safety Commission and some states recommend temperatures settings of 130ºF or less. Setting thermostat higher than 130ºF will increase risk of scald injury and cause severe personal injury or death.
Water Heater Start-Up Domestic Hot Water EZ Setup Navigation: Home Screen>Main Menu>EZ Setup>DHW EZ Setup Domestic Hot Water EZ Setup allows the installer to quickly customize the domestic hot water settings for the application. Select DHW Demand Default: Sensor Select DHW Demand prompts the installer to select the type of device which will generate a DHW call. Press the UP or DOWN buttons to select the DHW Demand type then press the OK button to store the setting.
Additional DHW Feature DHW Frost Protection The Indirect Water Heater (IDWH) Sensor used in the Prestige Excellence provides a Frost Protection feature to the water heater. The Frost Protection feature is designed to protect the Excellence water heater from a potential freeze up. Frost Protection will generate a DHW call once the IDWH temperature falls below 42º F [6ºC].
Additional DHW Feature HEATING SETTING Heating Operation Demand Type Absolute Max CH Setpoint CH1 Maximum Setpoint CH1 Minimum Setpoint Outdoor Curve Coldest Day Outdoor Curve Warmest Day CH2 Circuit Factory ACVMax Setting FACTORY DEFAULT Enabled Thermostat & Outdoor Reset Enabled 80°F [27°C] OFF 5 Minutes Enabled -22°F [-30°C] DOMESTIC SETTING FACTORY DEFAULT CH Call Blocking DHW Operation Demand Type Boiler DHW Setpoint DHW Setpoint DHW On Differential DHW Storage Adder DHW Post Pump Time
Water Heater Maintenance Maintenance Schedule Check function of field-installed controls and valves. See component manufacturer’s instructions. Annual service by qualified service technician should include the following: Review homeowner’s maintenance responsibilities and their frequencies, including any not listed in the following section. Any procedure required by local codes. Check air vent operation. Verify system pressure.
Water Heater Maintenance If antifreeze is used in boiler water, check concentration. Boiler water (including additives) must be practically non-toxic, having toxicity rating or class of 1, as listed in Clinical Toxicology of Commercial Products. A maximum 50/50 mixture of inhibited propylene glycol is recommended. Follow antifreeze manufacturer’s instruction. WARNING Do not use automotive, ethylene glycol or petroleum-based antifreeze. Do not use any undiluted antifreeze.
Replacement Parts WARNING Replacement parts must be purchased through a local ACV-Triangle Tube distributor. When ordering part please provide 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 appliance and improper operation of appliance. Contact ACVTriangle Tube at 856-228-8881 or www.triangletube.com for list of distributors nearest you. 3 2* 1 Fig.
Water Heater Specifications 24-7/8” [632 mm] 2-1/8” [52 mm] 17” [432 mm] 10-1/4” [258 mm] 3/4” NPSC Pressure Relief Valve 3” Vent Outlet 39-3/8” [1000 mm] 3” Combustion Air Inlet 7-5/8” [191 mm] 15-7/8” [403 mm] Front View PRESTIGE Excellence 110 20-7/8” [528 mm] 19 1” NPT Boiler Return 1/2” NPT Gas Connection 1” NPT Boiler Supply 664A0300 - Rev.
Water Heater Specifications 23-5/8” [600 mm] 4-3/4” 3”Vent Outlet [120 mm] 3” Combustion Air Inlet 9” [226 mm] 16-7/8” [428 mm] Side View PRESTIGE Excellence 110 664A0300 - Rev.
Water Heater Specifications 10-3/8” [262 mm] 3/4” NPT DHW Outlet 7-5/8” [191 mm] Manual Air Vent 4-3/4” 3/4” NPSC Aux. Connection (Rear) [121 mm] 3/4” NPT DHW Inlet 11-1/2” [292 mm] 6” [151 mm] Top View PRESTIGE Excellence 110 21 664A0300 - Rev.
Water Heater Specifications Performance 664A0300 - Rev.
Notes 664A0300 - Rev.
Notes 664A0300 - Rev.
Notes 664A0300 - Rev.
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