prestige sii manual€¦ · - avoid electrical shock by discon-necting the electrical supply prior...

Warranty Registration Card must be filled out by the customer and mailed within thirty (30) days of installa-tion in order to gain warranty coverage.

When receiving the PRESTIGE Solo unit, any claims for damage or shortage in shipment must be filedimmediately against the transportation company by the consignee.

Leave all documentation received with appliance with owner for future reference.

WARNING

* I N S* I N S TT AA LL LL AA TT I O NI O N AA N D MN D M AA I NI N TT E NE N AA N C E *N C E *MM AA N UN U AA LL

NOTICE

2007-2 Manual Prestige Solo 60/175/250/399 - Revised 09/22/08

If the information in this manual is not followed exactly, a fire or explosion mayresult 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

supplier’s instructions.- If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or thegas supplier.

prestigeSolo 60Solo 175Solo 250Solo 399Water Boiler

Series III

L I S T E D

Table of Contents

i

PRODUCT AND SAFETY INFORMATION

Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Product and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SECTION I - PRE-INSTALLATION ITEMS

Code Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Determining Product Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Boiler Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Recommended Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Residential Garage Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Boiler Freeze Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION II - COMBUSTION AIR AND VENTING

Combustion Air Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ventilation and Combustion Air Requirements - Direct Vent . . . . . . . . . . . 6Ventilation and Combustion Air Requirements - Category IV . . . . . . . . . . 6Methods of Accessing Combustion Air into a Space - Category IV . . . . . . 7

- Indoor Combustion Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- Outdoor Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8- Combination of Indoor and Outdoor Combustion Air. . . . . . . . . . 8-9

Combustion Air and Vent Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Removal of an Existing Boiler from a Common Vent System . . . . . . . . . . 10Commonwealth of Massachusetts Installation . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION III - UNIT PREPARATIONS

Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Wall Mounting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Wall Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Wall Bracket Installation - Stud Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Wall Bracket Installation - Solid Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Boiler Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION IV - BOILER PIPING

General Piping Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Low Water Cut Off Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Additional Limit Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Backflow Preventer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Table of Contents

ii

Boiler System Piping Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Expansion Tank and Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17

Diaphragm Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Closed-Type Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Sizing Primary Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Domestic Hot Water System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17System Piping - Zone Circulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Near Boiler Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18System Piping - Zone Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19System Piping - Through Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19System Piping - Radiant Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19System Piping - Special Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19System Piping - Multiple Units Installation . . . . . . . . . . . . . . . . . . . . . . . . . 19DHW Boiler Piping with PRESTIGE Solo and SMART . . . . . . . . . . . . . . 20Central Heating System Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24

SECTION V - INSTALLING VENT / COMBUSTION AIR & CONDENSATE DRAIN

Installing Vent and Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Installing Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-26

SECTION VI - GAS PIPING

Gas Supply Piping Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Natural Gas

Pipe Sizing -Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Natural Gas Supply Pressure Requirements. . . . . . . . . . . . . . . . . . . 28

Propane GasPipe Sizing - Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Propane Gas Supply Pressure Requirements . . . . . . . . . . . . . . . . . . 29Gas Valve/Venturi Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SECTION VII - INTERNAL WIRING

General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Control Module Circulator AMP Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . 31Wiring Tool Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Internal Factory Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

SECTION VIII - EXTERNAL WIRING

Installation Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Line Voltage Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

iii

Table of Contents

Domestic Hot Water Aquastat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Thermostat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-34CH and DHW Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34System Circulator - Zone Valve Application . . . . . . . . . . . . . . . . . . . . . . . . 34External Modulating Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Outdoor Reset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Additional 24V Limit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34External Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-36

SECTION IX - START-UP PREPARATION

Check Boiler System Water ChemistryWater pH Level 6.0 to 8.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Water Hardness Less Than 7 Grains. . . . . . . . . . . . . . . . . . . . . . . . . 37Chlorinated Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Flush Boiler and Domestic System to Remove Sediment . . . . . . . . . . . . . . 37Check and Test Antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Use of Antifreeze in the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Filling the Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Check Low Water Cut-Off Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Check for Gas Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Check Thermostat Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Inspection of Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 39

SECTION - START-UP PROCEDURES

Final Checks Before Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40PRESTIGE Solo Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40If PRESTIGE Solo Does Not Start Correctly . . . . . . . . . . . . . . . . . . . . . . . 40Check the PRESTIGE Solo and System . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Set Boiler CH Target Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Operation Verification - Space Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-44Operation Verification - Domestic Hot Water . . . . . . . . . . . . . . . . . . . . . . . 44Boiler Control Display

Standby Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-46Setting the Boiler Parameters

Parameter Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Accessing Boiler Information

Information Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Error (Hard Lockout) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

iv

Table of Contents

SECTION XI - OUTDOOR RESET CONTROL

Mounting the Outdoor Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Wiring the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Summer/Winter Switch at Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Adjusting Outdoor Reset Curve

CH Maximum Boiler Operating Setpoint (Parameter 4) . . . . . . . . . 51CH Minimum Boiler Operating Setpoint (Parameter 10) . . . . . . . . 51CH Reset Curve Coldest Day (Parameter 11) . . . . . . . . . . . . . . . . . 51CH Reset Curve Warmest Day (Parameter 12) . . . . . . . . . . . . . . . . 52

Entering MCBA Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Changing a Parameter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Outdoor Reset Curve Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

SECTION XII - EXTERNAL MODULATING CONTROL

Wiring the Modulating Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Parameter Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Programming of External Modulating Control . . . . . . . . . . . . . . . . . . . . . . 54Factory Setting for Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

SECTION XIII - CHECK-OUT PROCEDURES

Check-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

SECTION XIV - INSTALLATION RECORD

Installation Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

SECTIONS XV - MAINTENANCE SCHEDULE

Service Technician - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Owner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

SECTION XVI - MAINTENANCE PROCEDURES

Maintenance ProceduresReported Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Check Surrounding Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Inspect Burner Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Check System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Clean Condensate Drain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 60Check Ventilation Air Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

v

Table of Contents

Inspect Vent and Combustion Air Piping . . . . . . . . . . . . . . . . . . . . . 60Check Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Check Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Check Boiler Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Inspection of Ignition Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Check Ignition Wiring and Ground Wiring . . . . . . . . . . . . . . . . . . . 61Check Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Check Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Perform Start-Up and Checkout Procedure . . . . . . . . . . . . . . . . . . . 62Check Burner Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Check Flame Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Check Combustion Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Check Flue Gas Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Clean Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-64Review with Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Handling Previously Fired Combustion Chamber Insulation . . . . . 64

REPLACEMENT PARTS

Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-71

PRODUCT SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-81

Product & Safety Information

1

Indicates the presence of a hazardoussituation which, if ignored, will result indeath, serious injury or substantialproperty damage.

Indicates a potentially hazardous situa-tion which, if ignored, can result indeath, serious injury or substantialproperty damage.

Indicates a potentially hazardous situa-tion which, if ignored, may result inminor injury or property damage.

Indicates special instructions on installa-tion, operation or maintenance, whichare important to equipment but notrelated to personal injury hazards.

Indicates recommendations made byTriangle Tube for the installers whichwill help to ensure optimum operationand longevity of the equipment

BEST PRACTICES

NOTICE

CAUTION

WARNING

DANGER

The following terms are used throughout this manual to bring attention to the presence ofpotential hazards or important information concerning the product.

Triangle Tube reserves the right to modify the technical specifications and components ofits products without prior notice.

NOTICE

Definitions

2

Do not use this appliance if any parthas been under water. Immediately calla qualified service technician to inspectthe appliance and to replace any part ofthe control system which has beenunder water.

WHAT TO DO IF YOU SMELL GAS- Do not try to light any appliance

- Do not touch any electrical switch; donot use any phone in your building.

- Immediately call your gas supplierfrom a neighbor’s phone. Follow thegas supplier’s instructions.

- If you cannot reach your gas suppli-er, call the fire department.

Installation and service must be per-formed by a qualified installer, serviceagency or the gas supplier.

Should overheating occur or the gassupply fails to shut off, turn OFF themanual gas control valve external tothe appliance.

DO NOT add cold make up water whenthe boiler is hot. Thermal shock cancause potential cracks in the heatexchanger.

When servicing the boiler:- Avoid electrical shock by discon-

necting the electrical supply prior toperforming maintenance.

CAUTION

WARNING

WARNING

WARNING

DANGER

Product & Safety Information

Qualified Installer:

Prior to installing this product read allinstructions included in this manual and allaccompanying manuals/documents with thisappliance. Perform all installation stepsrequired in these manuals in the properorder given. Failure to adhere to the guide-lines within these manuals can result insevere personal injury, death or substantialproperty damage.

Homeowner:

- This product should be maintained /serviced and inspected annually by aqualified service technician.

- This manual is intended for use by aqualified Installer/Service Technician.

Please reference the unit’s model num-ber and the serial number from the rat-ing label, on the backside of the controlpanel when inquiring about service ortroubleshooting.

Triangle Tube accepts no liability for anydamage resulting from incorrect instal-lation or from the use of components orfittings not specified by Triangle Tube.

NOTICE

NOTICEWARNING

Pre-Installation Items

3

SECTION I - Pre-Installation Items

Code Compliance

This product must be installed in accordance tothe following:

- All applicable local, state, national andprovincial codes, ordinances, regula-tions and laws.

- For installations in Massachusetts, coderequires the boiler to be installed by alicensed plumber or gas fitter, and ifantifreeze is utilized, the installation ofa reduced pressure backflow preventerdevice is required in the boiler’s coldwater fill or make up water supply line.

- For installation in Massachusetts all directvented appliances must comply with theguidelines as outlined on page 11.

- The National Fuel Gas Code NFPA54/ANSI Z 223.1 - Latest edition.

- National Electric Code ANSI/NFPA 70.

- For installations in Canada -“InstallationCode for Gas Burning Equipment”CGA/B149.1 or B149.2 CanadianElectrical Code Part 1 CSA C22.1.

- Standards for Controls and SafetyDevices for Automatically Fired Boilers,ANSI/ASME CSD-1, when required.

The PRESTIGE Solo boiler gas manifoldand gas controls meet the safe lighting andother performance requirements as speci-fied in ANSI Z21.13 latest edition.

Determining Product Location

Before locating the PRESTIGE SOLO checkfor 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 throughthe building and terminate properly outside witha minimum amount of length and bends.

Ensure the area chosen for the installation of thePRESTIGE Solo is free of any combustiblematerials, gasoline and other flammable liquids.

Failure to remove or maintain the areafree of combustible materials, gasolineand other flammable liquids or vaporscan result in severe personal injury,death or substantial property damage.

Ensure the PRESTIGE Solo and its controlsare protected from dripping or spraying waterduring normal operation or service.

The PRESTIGE Solo should be installed in alocation so that any water leaking from theboiler or piping connections or relief valve willnot cause damage to the area surrounding theunit or any lower floors in the structure.

Boiler Replacement

If the PRESTIGE Solo is replacing an existingboiler, the following items should be checkedand corrected prior to installation:

- Boiler piping leaks and corrosion.

- Improper location and sizing of theexpansion tank on the boiler heatingloop.

- If applicable, level and quality of freezeprotection within the boiler system.

Recommended Clearances

The PRESTIGE Solo is approved for zeroclearance to combustibles, excluding vent andboiler piping.

- Boiler Piping - 1/4 inch from com-bustible materials.

WARNING

NOTICE

Pre-Installation Items

- Reference the appropriate vent supple-ment for clearance requirements.

To provide serviceability to the unit it isrecommended that the following clear-ances be maintained:

Top boiler jacket - 24 inches [610 mm].

Front - 24 inches [610 mm].

Bottom boiler piping - 24 inches [610mm].

Rear - 0 inches

Sides - 6 inches [153 mm]

If the clearances listed above cannot bemaintained or the enclosure in which theboiler is installed is less than 85 cubic feet,the space must be ventilated. See page 6for ventilation requirements.

When maintaining zero clearance or lessthan recommended clearances, someproduct labeling may become hiddenand unreadable.

When installing the PRESTIGE Solo ina confined space, sufficient air must beprovided for proper combustion andventing and to allow, under normal oper-ating conditions, proper air flow aroundthe product to maintain ambient temper-atures within safe limits to comply withthe National Fuel Gas Code NFPA 54 -latest edition.

Residential Garage Installations

When installing the PRESTIGE Solo in a resi-dential garage, the following special precautionsper NFPA 54/ANSI Z223.1 must be taken:

- Mount the unit a minimum 18 inches[458 mm] above the floor level of thegarage. Ensure the burner and ignitiondevices / controls are no less than 18inches [458 mm] above the floor level.

- Locate or protect the unit in a mannerso it cannot be damaged by a movingvehicle.

Boiler Freeze Protection Feature

The boiler control has a freeze protection featurebuilt in. This feature monitors the boiler temper-ature and responds as follows when no call forheat is present:

- 46ºF Boiler circulator is ON

- 38ºF Boiler circulator is ON and burneroperates at low fire

- 50ºF Burner OFF and boiler circulatoroperates for approximately 10 minutes

The boiler freeze protection feature isdisabled during a hard lockout, howeverthe CH circulator will operate.

The boiler freeze protection feature isdesigned to protect the boiler. The boilershould be installed in a primary/sec-ondary piping arrangement if it isinstalled in an unheated space orexposed to water temperatures of 46ºF orless. See Section IV for primary/sec-ondary piping examples. See Section IXfor antifreeze guides.

CAUTION

CAUTION

WARNING

NOTICE

WARNING

BEST PRACTICES

4

Combustion Air and Venting

5

SECTION II - Combustion Air andVenting

Combustion Air Contamination

If the PRESTIGE Solo combustion airinlet is located in any area likely to causeor contain contamination, or if products,which would contaminate the air cannotbe removed, the combustion air must berepiped and terminated to another loca-tion. Contaminated combustion air willdamage the unit and its burner system,resulting in possible severe personalinjury, death or substantial propertydamage.

Do not operate a PRESTIGE Solo if itscombustion air inlet is located near alaundry room or pool facility. Theseareas will always contain hazardous con-taminants.

Pool and laundry products and commonhousehold and hobby products oftencontain fluorine or chlorine compounds.When these chemicals pass through theburner and vent system, they can formstrong acids. These acids can create cor-rosion of the heat exchanger, burnercomponents and vent system, causingserious damage and presenting a possi-ble threat of flue gas spillage or waterleakage into the surrounding area.

Please read the information listed below.If contaminating chemicals are locatednear the area of the combustion air inlet,the installer should pipe the combustionair inlet to an outside area free of thesechemicals per SECTION V of thisinstallation manual.

Potential contaminating products

- Spray cans containing chloro/fluorocar-bons

- Permanent Wave Solutions

- Chlorinated wax

- Chlorine - based swimming pool chem-icals / cleaners

- Calcium Chloride used for thawing ice

- Sodium Chloride used for water soft-ening

- Refrigerant leaks

- Paint or varnish removers

- Hydrochloric acid / muriatic acid

- Cements and glues

- Antistatic fabric softeners used inclothes dryers

- Chlorine-type bleaches, detergents, andcleaning solvents found in householdlaundry rooms

- Adhesives used to fasten building prod-ucts and other similar products

Areas likely to contain these products

- Dry cleaning / laundry areas and estab-lishments

- Beauty salons

- Metal fabrication shops

- Swimming pools and health spas

- Refrigeration Repair shops

- Photo processing plants

- Auto body shops

- Plastic manufacturing plants

- Furniture refinishing areas and estab-lishments

- New building construction

- Remodeling areas

- Garages with workshops

WARNING

WARNING

6


Ventilation and Combustion AirRequirements - Direct Vent

A Direct Vent appliance utilizes uncontaminedoutdoor air (piped directly to the appliance) forcombustion.

For Direct Vent installations, involving onlythe PRESTIGE Solo, in which the minimumservice clearances are maintained as listed onpage 4, no ventilation openings are required.

For Direct Vent, zero clearance installationsinvolving only the PRESTIGE Solo, the space/ enclosure must provide two openings for ven-tilation. The openings must be sized to provide1 square inch of free area per 1,000 BTUH ofboiler input. The openings shall be placed 12inches from the top of the space and 12 inchesfrom the floor of the space.

For installations in which the PRESTIGE Soloshares the space with air movers (exhaust fan,clothes dryers, fireplaces, etc.) and other com-bustion equipment (gas or oil) the space mustbe provided with adequate air openings to pro-vide ventilation and combustion air to theequipment. To properly size the ventilation /combustion air openings, the installer mustcomply with the National Fuel Gas CodeNFPA 54, ANSI Z223.1 for installations in theU.S or CSA B149.1 and B149.2 for installa-tions in Canada.

The space must be provided with venti-lation / combustion air openings proper-ly sized for all make-up air requirements(exhaust fans, clothes dryers, fireplaces,etc.) and the total input of all applianceslocated in the same space as the PRES-TIGE Solo, excluding the input of aDirect Vent PRESTIGE Solo which usescombustion air directly from the outside,thus additional free area for the open-ings is not required. Failure to provideor properly size the openings couldresult in severe personal injury, death orsubstantial property damage.

Ventilation and Combustion AirRequirements - Category IV

A Category IV appliance utilizes uncontami-nated indoor or outdoor air (surrounding theappliance) for combustion.

In order to reduce the potential risksassociated with indoor contaminates(listed on page 5), flammable vapors andtight housing construction (little or noinfiltration air), it is recommended topipe uncontaminated combustion airdirectly from the outdoors to the appli-ance. This practice also promotes highersystem efficiency by reducing heatedindoor air from being exhausted fromthe house and replaced by cold infiltra-tion air into the house.

For installations in which the PRESTIGE Soloshares the space with air movers (exhaust fan,clothes dryers, fireplaces, etc.) and other com-bustion equipment (gas or oil) the space must beprovided with adequate air openings to provideventilation and combustion air to the equipment.To properly size the ventilation / combustion airopenings, the installer must comply with theNational Fuel Gas Code NFPA 54, ANSI Z223.1for installations in the U.S or CSA B149.1 andB149.2 for installations in Canada, as referencedin this section of the manual and titled Methodsof Accessing Combustion Air into a Space.

The space must be provided with venti-lation / combustion air openings proper-ly sized for all make-up air requirements(exhaust fans, clothes dryers, fireplaces,etc.) and the total input of all appliances,including the PRESTIGE Solo whenlocated in the same space. Failure to pro-vide or properly size the openings couldresult in severe personal injury, death orsubstantial property damage.

WARNING

BEST PRACTICES

WARNING

7


Methods of Accessing Combustion Air Into ASpace - Category IV

Indoor Combustion Air

The methods listed in this section foraccessing Indoor Combustion Airassume that the infiltration rate is ade-quate and not less than .40 ACH. Forinfiltration rates less than .40 ACH, ref-erence the NFPA 54 National Fuel GasCode for additional guidance.

Opening Size and Location

Openings used to connect indoor spaces shallbe sized and located in accordance with thefollowing see Fig. 1:

- Combining spaces on the same story.Each opening shall have a minimumfree area of 1 sq. in./1000 Btu/hr of thetotal input rating of all gas utilizationequipment in the space, but not less than100 sq. inches. One opening shall com-mence within 12 inches of the top, andone opening shall commence within 12inches of the bottom of the enclosure.

The minimum dimension of air open-ings shall be not less than 3 inches.

- Combining spaces in different stories.The volumes of spaces in different sto-ries shall be considered as communicat-ing spaces where such spaces are con-nected by one or more openings indoors or floors having a total minimumfree area of 2 sq. in./1000 Btu/hr oftotal input rating of all gas utilizationequipment.

Outdoor Combustion Air

Isolating the combustion appliance roomfrom the rest of the building and bring-ing in uncontaminated outside air forcombustion and ventilation is alwayspreferred.

Opening Size and Location

The minimum dimension of air openings shallbe not less than 3 inches

Openings used to supply combustion and ven-tilation air shall be sized and located in accor-dance with the following:

One Permanent Opening Method. See Fig. 2

One permanent opening, commencing within 12in. of the top of the enclosure, shall be provided.The equipment shall have clearances of at least 1inch from the sides and 6 in. from the front of theappliance. The opening shall directly communi-cate with the outdoors or shall communicatethrough a vertical or horizontal duct to the out-doors or spaces that freely communicate with theoutdoors and shall have a minimum free area ofthe following:

- 1sq. in./3000 Btu/hr of the total inputrating of all equipment located in theenclosures, and

- Not less than the sum of the areas of allvent connectors in the space.

BEST PRACTICES

NOTICE

All Combustion Air from AdjacentIndoor Spaces Through IndoorCombustion Openings

Fig. 1:

8


Two Permanent Openings Method.

Two permanent openings, one commencingwithin 12 in. of the top and one commencingwithin 12 in. of the bottom of the enclosure,shall be provided. The openings shall commu-nicate directly, or by ducts, with the outdoorsor spaces that freely communicate with the out-doors, as follows:

- Where directly communicating with theoutdoors or where communication to theoutdoors is through vertical ducts, eachopening shall have a minimum free areaof 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, eachopening shall have a minimum freearea of not less than 1 sq.in./2000Btu/hr of total input rating of all equip-ment in the enclosure. See Fig. 4.

Combination of Indoor and OutdoorCombustion Air

Indoor Openings: Where used, openings con-necting the interior spaces shall comply withthe Indoor Combustion Air section on page 7.

All Combustion Air from OutdoorsThrough One Permanent AirOpening

Fig. 2: All Combustion Air from OutdoorsThrough Ventilated Attic

Fig. 3:

All Combustion Air from OutdoorsThrough Horizontal Ducts

Fig. 4:

9


Outdoor Opening(s) Location. Outdoor open-ing(s) shall be located in accordance with theOutdoor Combustion Air section.

Outdoor Opening(s) Size. Outdoor opening(s) shallbe calculated in accordance with the following:

- The ratio of the interior spaces shall bethe available volume of all communi-cating spaces divided by the requiredvolume.

- The outdoor size reduction factor shallbe 1 minus the ratio of interior spaces.

- The minimum size of outdoor open-ing(s) calculated in accordance with theabove outdoor air section multiplied bythe reduction factor. The minimumdimension of air openings shall not beless than 3 in.

Do not install the PRESTIGE Solo into acommon vent with other gas or oil appli-ances. This may cause flue gas spillage orappliance malfunction, resulting in possi-ble severe personal injury, death or sub-stantial property damage.

Combustion Air and Vent Piping

The PRESTIGE Solo requires a Category IVventing system, which is designed for pressur-ized venting and condensate.

The PRESTIGE Solo is certified per ANSIZ21.13 as a Category IV or Direct Vent (sealedcombustion) appliance. A Category IV appli-ance utilizes uncontamined indoor or outdoorair (surrounding the appliance) for combustion.A Direct Vent appliance utilizes uncontaminat-ed outdoor air (piped directly to the appliance)for combustion.

In order to reduce the potential risksassociated with indoor contaminates(listed on page 5), flammable vaporsand tight housing construction (little orno infiltration air), it is recommendedto pipe uncontaminated combustion airdirectly from the outdoors to the appli-ance. This practice also promotes highersystem efficiency by reducing heatedindoor air from being exhausted fromthe house and replaced by cold infiltra-tion air into the house.

Install combustion air and vent pipe asdetailed in the PRESTIGE Solo VentSupplement included in the boilerinstallation envelope. Refer to optionalvent kit instructions for addition ventinstallation instructions.

Verify installed combustion air and ventpiping are sealed gas tight and meet allprovided instructions and applicablecodes, failure to comply will result insevere personal injury of death.

DANGER

NOTICE

BEST PRACTICES

DANGER

10


Removal of an Existing Boiler from aCommon Vent System

When an existing boiler is removed from acommon venting system, the common ventingsystem is likely to be too large for properventing of the remaining appliances. At thetime of removal of an existing boiler, the fol-lowing steps shall be followed with eachappliance remaining connected to the com-mon venting system placed in operation,while the other appliances remaining con-nected to the common venting system are notin operation.

1. Seal any unused openings in the commonventing system.

2. Visually inspect the venting system forproper size and horizontal pitch and deter-mine there is no blockage or restriction,leakage, corrosion and other deficiencieswhich could cause an unsafe condition.

3. Insofar as is practical, close all buildingdoors and windows and all doors betweenthe space in which the appliances remain-ing connected to the common venting sys-tem are located and other spaces of thebuilding. Turn on clothes dryers and anyappliance not connected to the commonventing system. Turn on any exhaust fans,such as range hoods and bathroomexhausts, so they will operate at maximumspeed. Do not operate a summer exhaustfan. Close fireplace dampers.

4. Place in operation the appliance beinginspected. Follow the lighting instructions.Adjust thermostat so appliance will operatecontinuously.

5. Test for spillage at the draft hood reliefopening after 5 minutes of main burneroperation. Use the flame of a match or can-dle, or smoke from a cigarette, cigar or pipe.

6. After it has been determined that eachappliance remaining connected to the com-mon venting system properly vents whentested as outlined above, return doors, win-dows, exhaust fans, fireplace dampers, andany other gas-burning appliance to theirprevious condition of use.

7. Any improper operation of the commonventing system should be corrected so theinstallation conforms with the NationalFuel Gas Code, ANSI Z223.1/NFPA 54and/or CAN/CGA B149, Installation codes.When resizing any portion of the commonventing system, the common venting sys-tem should be resized to approach the min-imum size as determined using the appro-priate tables in Part II of the National FuelGas Code ANSI Z223.1/NFPA 54 and/orCAN/CGA B149, Installation codes.

Do not install the PRESTIGE Solo into acommon vent with other gas or oil appli-ances. This may cause flue gas spillage orappliance malfunction, resulting in possi-ble severe personal injury, death or sub-stantial property damage.

DANGER

BEST PRACTICES

11


For direct-vent appliances, mechanical-vent heating appliances or domestic hotwater equipment, where the bottom of thevent terminal and the air intake is installedbelow four feet above grade the followingrequirements must be satisfied:

1. If there is not one already present, oneach floor level where there are bed-room(s), a carbon monoxide detectorand alarm shall be placed in the livingarea outside the bedroom(s). The car-bon monoxide detector shall complywith NFPA 720 (2005 Edition).

2. A carbon monoxide detector shall alsobe located in the room that houses theappliance or equipment and shall:

a. Be powered by the same electricalcircuit as the appliance or equip-ment such that only one serviceswitch services both the applianceand the carbon monoxide detector;

b. Have battery back-up power;

c. Meet ANSI/UL 2034 Standards andcomply with NFPA 720 (2005Edition); and

d. Have been approved and listed bythe Nationally Recognized TestingLaboratory as recognized under 527CMR.

3. A Product-approved vent terminal mustbe used, and if applicable, a Product-approved air intake must be used.Installation shall be in strict compliancewith the manufacturer’s instructions. Acopy of the installation instructionsshall remain with the appliance orequipment at the completion of theinstallation.

4. A metal or plastic identification plateshall be mounted at the exterior of thebuilding, four feet directly above thelocation of vent terminal. The plateshall be of sufficient size to be easilyread from a distance of eight feet away,and read “Gas Vent Directly Below”.

Installer must provide tag identificationplate and ensure the lettering meets coderequirements.

For direct-vent appliances, mechanical-vent heating appliances or domestic hotwater equipment, where the bottom of thevent terminal and the air intake are installedabove four feet above grade the followingrequirements must be satisfied:

1. If there is not one already present, oneach floor level where there are bed-room(s), a carbon monoxide detectorand alarm shall be placed in the livingarea outside the bedroom(s). The car-bon monoxide detector shall complywith NFPA 720 (2005 Edition).

2. A carbon monoxide detector shall:

a. Be located in the room that housesthe appliances or equipment;

b. Be either hard wired or batterypowered or both; and

c. Shall comply with NFPA 720 (2005Edition)

3. A Product-approved vent terminal mustbe used, and if applicable, a Product-approved air intake must be used.Installation shall be in strict compliancewith the manufacturer’s instructions. Acopy of the installation instructionsshall remain with the appliance orequipment at the completion of theinstallation.

NOTICE

Commonwealth of Massachusetts Installations Only

12

Unit Preparations

SECTION III - Unit Preparations

Handling Instructions

The PRESTIGE Solo is generally easier tohandle and maneuver once removed from theshipping carton.

To remove the shipping carton:

Use care not to lift the unit from, or placethe unit on the front plastic controlpanel, damage can occur. Use care not todrop, bump or rotate the boiler upsidedown, as damage to the boiler will result.

1. Remove any shipping straps and open theside of the shipping carton.

2. Slide the unit with the foam inserts out ofthe carton.

3. Discard all packing materials.

Wall Mounting Installation

The PRESTIGE Solo should be wall mountedusing the bracket provided with the boiler. ThePRESTIGE Solo is not designed for floorinstallation. If floor installation is required anoptional floor stand is available throughTriangle Tube.

The wall used for mounting the PRES-TIGE Solo must be vertically plumbedand capable of supporting a minimum130 pounds [59 kg] for the PRESTIGESolo 60, 175 pounds [80 kg] for PRES-TIGE Solo 175/250 and 250 pounds [115Kg] for PRESTIGE Solo 399. Failure tocomply with these requirements couldresult in personal injury, death or sub-stantial property damage.

Wall Mounting Guidelines

1. The wall-mounting bracket is designed forstud spacing of 12 inch or 16 inch on cen-ters. For unconventional stud spacing, asolid / secure mounting surface must beprovided for installation of the bracket.

2. For applications using wood studs, installthe bracket using the lag screws providedwith the boiler. Ensure both lag screws areinstalled securely in the studs.

3. For applications using metal studs, installthe bracket to the studs using 3/16” togglebolts and washers.

4. DO NOT mount or attempt to mount thewall bracket to hollow sheet rock or lathwalls using anchors. Only install boiler tostuds or equivalent wood structure.

5. For applications using solid walls (rock,concrete, brick, cinder block, etc.), installthe wall bracket using anchors (doubleexpansion shields) and bolts with washersprovided with the boiler.

6. The boiler is too heavy and bulky for a sin-gle person to lift and attempt to mount; aminimum of 2 people is required formounting the boiler.

Use extreme care not to drop the boileror cause bodily injury while lifting ormounting the boiler onto the bracket.Once mounted verify that the boiler issecurely attached to the bracket andwall. Failure to comply with the aboveguidelines could result in property dam-age, personal injury or death.

WARNING

WARNING

CAUTION

13

Unit Preparations

PRESTIGE Solo 60/175/250 Stud Walls -Installation

1. Locate the studs in the general area of theboiler placement.

2. Place the wall-mounting bracket on thewall centering the mounting slots with thestud centers and ensuring the upper edge ofthe bracket is away from the wall.

3. Level the bracket, while maintaining it’scentering with the studs and use a pencil tomark the location of the mounting slots.

4. Remove the bracket from the wall and drill1/4” diameter hole by 3” deep positioned inthe center of each mark. For applicationsusing metal studs and 3/16” toggle bolts,drill the required clearance hole.

5. Reposition the bracket onto the wall andalign mounting slots/holes. Insert the twolag screws provided (or toggle bolts formetal studs) through the mountingslots/holes and loosely tighten.

6. Level bracket and tighten screws (bolts formetal studs) securely making sure not toover-tighten to avoid damaging drywall orplaster.

PRESTIGE Solo 399 Stud Walls -Installation

1. To distribute the weight of the boiler even-ly when mounting onto a stud wall it is rec-ommended to use the PRESTIGE SoloWall Frame kit.

2. When using the wall frame to mount theboiler reference the kit installation instruc-tions and ensure the frame is securely fas-tened to the wall.

3. If the structure of wall is questionable, insupporting a minimum weight of 250pounds [115 kg.], it is recommended to usethe optional floor stand.

Wall Bracket Installation - Solid Walls

1. Locate the general area of the boiler place-ment.

2. Place the wall-mounting bracket on thewall ensuring the upper edge of the bracketis away from the wall.

3. Level the bracket and use a pencil to markthe location of the mounting slots on thewall.

4. Remove the bracket from the wall and drilla 5/8” diameter hole by 1-3/8” deep posi-tioned in the center of each mark.

5. Install the anchors (provided) flush orslightly recessed in the drilled holes withthreaded side facing down.

6. Reposition the bracket on the wall andalign mounting slots/holes. Insert the twobolts (provided) through the mountingslots/holes and loosely tighten.

7. Level bracket and tighten bolts securely.

Boiler Mounting

1. Obtain assistance in lifting the boiler ontothe wall bracket.

2. Install the boiler making sure the boilermounting lip located along the upper edgeof the rear jacket panel engages the wall-mounting bracket. Ensure the boiler isseated properly and is secure.

Boiler Piping

SECTION IV - Boiler Piping

General Piping Requirements

- All plumbing must meet or exceed all local,state and national plumbing codes.

- Support all piping using hangers. DO NOTsupport piping by the unit or its components.

- Use isolation valves to isolate system com-ponents.

- Install unions for easy removal of thePRESTIGE Solo from the system piping.

Use a two wrench method when tighten-ing piping onto the boiler connections.Use one wrench to prevent the boilerpiping from turning / twisting. Failureto support the boiler piping and connec-tions in this manner could cause damageto the boiler and its components.

Pressure Relief Valve

1. The PRESTIGE Solo is supplied with a 30psi pressure relief valve and must be pipedusing the PRV connection as shown in Fig.5 page 15.

2. To avoid potential water damage to the sur-rounding area or potential scalding hazarddue to the operation of the relief valve, thedischarge piping:

- Must be connected to the discharge out-let of the relief valve and directed to asafe place of disposal.

- Length should be as short and direct aspossible. The size of the discharge lineshould not be reduced, maintain thesame size as the outlet of the relief valve.

- Should be directed downward towardsthe floor at all times. The piping shouldterminate at least 6 inches [153 mm]above any drain connection to allowclear visibility of the discharge.

- Should terminate with a plain end, notwith a threaded end. The material ofthe piping should have a serviceabletemperature rating of 250ºF or greater.

- Should not be subject to conditionswhere freezing could occur.

- Should not contain any shut-off valvesor obstructions. No shut-off valveshould be piped between the boiler andrelief valve.

Failure to comply with the guidelines oninstalling the pressure relief valve anddischarge piping can result in personalinjury, death or substantial propertydamage.

Low Water Cutoff Device

- The PRESTIGE Solo is equipped with a fac-tory installed pressure switch type Low WaterCut Off device.

- The minimum operating system pressureallowable with this device is 10 psig.

- Check local codes if a Low Water CutoffDevice is required. If so, determine if thisdevice meets the requirements of the localcodes.

The PRESTIGE Solo control system alsosenses the system water temperaturesentering and exiting the heat exchangerto provide protection against low waterconditions Where local codes and juris-diction do not accept a pressure devicefor low water protection, the jurisdic-tions may accept these PRESTIGE Solointegral control functions as a means ofproviding low water protection.

NOTICE

WARNING

WARNING

14

15

Boiler Piping

Boiler Return Connectionwith Tee Fitting andBoiler Drain Valve

Boiler Supply Connection

1

Pressure Relief Valve(Supplied with Boiler)

3/4" Street Elbow

Air Vent

Drain Piping Directedto a Suitable

Place of Drainage

Fig. 5: Pressure Relief Valve and Boiler Drain Valve Installation

Boiler Piping

Additional Limit Control

If a separate LWCO device is required by cer-tain local jurisdictions or when the boiler isinstalled above the system piping, the follow-ing guidelines must be followed:

- The LWCO device must be designedfor water installations, electrode probe-type is recommended.

- The LWCO device must be installed ina tee connection on the boiler supplypiping above the boiler.

- Wiring of the LWCO device to thePRESTIGE Solo is done directly ontothe 24V terminal strip, reference Fig.20 page 32 for available terminals foran external limit (manual or auto reset).

If the installation is to comply with ASME orCanadian requirements, an additional hightemperature limit may be needed. Consultlocal code requirements to determine compli-ance. The limit should be installed as follows:

- Install the limit in the boiler supply pip-ing between the boiler and any isolationvalve.

- Maximum set point for the limit is194ºF.

- For wiring of the limit reference Fig. 20,page 32, using the external limit/manualreset terminals on the 24V terminal strip.This will provide a "hard" lockoutrequiring a manual reset of the control.

Backflow Preventer

- Use a backflow preventer valve in themake-up water supply to the unit asrequired by local codes.

Boiler System Piping Applications

It is recommended on all piping applica-tions to utilize a primary/secondary pip-ing arrangement as a means to providefreeze protection of the boiler, which is anintegral function of the boiler control.Maintain the minimum boiler flow rate,see Graphs 2 through 5 on pages 72 & 73.For other piping arrangements, consultthe Engineering Department at TriangleTube or consult other approved/recog-nized design arrangements.

On piping applications utilizing a singlezone or other recognized piping designarrangements, it is recommended that theinstaller uses flow/check valves withweighted seats at or near the appliance toprevent gravity circulation.

Expansion Tank and Makeup Water

Ensure the expansion tank is properly sized forthe boiler volume (3 gallons [12 L] for thePRESTIGE Solo 60, 5 gallons [19 L] for thePRESTIGE Solo 175/250, 7 gallons [26 L] forPRESTIGE Solo 399) and the system volumeand temperature.

Undersized expansion tanks will causesystem water to be lost through the pres-sure relief valve and cause additionalmakeup water to be added to the system.Eventual boiler heat exchanger failurecan result due to this excessive makeupwater addition.

CAUTION

BEST PRACTICE

BEST PRACTICE

16

Boiler Piping

The expansion tank must be located as shownin Fig. 6 and Fig. 7 on page 18 when using aprimary/secondary piping arrangement or asper recognized design methods. Refer to theexpansion tank manufacturer instructions foradditional installation details.

Connect the expansion tank to an air separatoronly if the air separator is located on the suc-tion side (inlet) of the system circulator.Always locate and install the system fill con-nection at the same location as the expansiontank connection to the system.

Diaphragm Expansion Tank

Always install an automatic air vent on the topof the air separator to remove residual air fromthe system.

Closed-Type Expansion Tank

It is recommended to pitch any horizontal pip-ing upwards toward the expansion tank 1 inchper 5 feet of piping. Use 3/4” piping for theexpansion tank to allow air within the systemto rise.

DO NOT install automatic air vents on aclosed-type expansion tank system. Airmust remain in the system and bereturned to the expansion tank to pro-vide an air cushion. An automatic airvent would cause air to be vented fromthe system resulting in a water-loggedexpansion tank.

Circulator

The PRESTIGE Solo must be supplied with aCentral Heating (CH) circulator. The circulatorwhen wired directly to the PRESTIGE Solowill allow for domestic hot water priority andto provide circulation for the freeze protectionfeature of the boiler control. See Graphs 2through 5 on pages 72 & 73 for pressure dropand minimum flow rate through the boiler.

Sizing Primary Piping

See Fig. 8 through 14, pages 20 - 24, for rec-ommended piping arrangements based on vari-ous applications. Size the piping and systemcomponents required in the space heating sys-tem, using recognized design methods.

Domestic Hot Water System Piping

See Fig. 8 , page 20 for recommended piping toa DHW system. This recommended pipingconfiguration ensures priority is given to theproduction and recovery of the DHW.

The piping for the DHW is separate from theboiler system piping and does not require a pri-mary / secondary piping configuration.

To wire the DHW circulator to the boiler con-trol module, reference Section VIII - ExternalWiring.

System Piping - Zone Circulators

Connect the PRESTIGE Solo to the systempiping as shown in Fig. 9 page 21 when zoningwith zone circulators.

The installer must provide a separate circulatorfor each zone of space heating as well as theboiler circulator.

To ensure an adequate flow rate throughthe PRESTIGE Solo, the boiler supplyand return piping size must be a mini-mum of 1 inch for the PRESTIGE Solo60, 1-1/4 inch for the PRESTIGE Solo175/250 and 1-1/2 inch for the PRES-TIGE Solo 399.

NOTICE

CAUTION

17

18

Boiler Piping

Max.12"

Boiler

SupplySystem

ReturnSystem

ColdWater Fill

BoilerSupply Return

7

10

1

2

3

546

66

11 12

71

10

9

8

4

3

6

66

ColdWater Fill

BoilerSupply

Minimum3/4" Piping

BoilerReturn

ReturnSystem

SupplySystem

Max.12"

11 12

Fig. 7 : Near Boiler Piping - Closed Type Expansion Tank

Fig. 6: Near Boiler Piping - Diaphragm Expansion Tank

1. System circulator2. Automatic air vent3. Air separator4. Automatic fill valve5. Diaphragm expansion tank6. Isolation valve

7. Drain/purge valve8. Tank fitting9. Closed type expansion tank10. Primary/secondary connection 11. Boiler circulator12. Flow/check valve

Note: Pitch horizontal pip-ing upwards (1” of pitchper 5 ft of piping) towardsexpansion tank.

19

Boiler Piping

System Piping - Zone Valves

Connect the PRESTIGE Solo to the system pip-ing as shown in Fig. 10 page 21 when zoningwith zone valves. The primary / secondary pipingensures that the boiler loop has sufficient flow.

To ensure an adequate flow rate throughthe PRESTIGE Solo, the boiler supplyand return piping size must be a mini-mum of 1 inch for the PRESTIGE Solo 60,1-1/4 inch for the PRESTIGE Solo175/250 and 1-1/2 inch for the PRESTIGESolo 399.

System Piping - Through Boiler

In new or retrofit applications in whichprimary/secondary arrangement is not utilized, thePRESTIGE Solo allows this flexibility due to alower boiler pressure drop, see Graphs 2 through7 on pages 75 through 77.

Figure 11, page 22 illustrates a multiple zonevalve system with a single system/boiler circu-lator. A by-pass loop with a pressure differentialvalve must be installed on the system piping.

Figure 12, page 22 illustrates a single zone utiliz-ing the boiler circulator as the system circulator.

System Piping - Radiant Heating

The heat exchanger design of the PRESTIGESolo allows operation in a condensing mode.This feature requires no regulation of the returnwater temperature back to the boiler in radiantheating applications.

The boiler water supply temperature can bemaintained by the PRESTIGE Solo, eliminat-ing the need for a mix system to achieve thedesired temperature.

It is recommended for the installer to add ahigh temperature limit as shown in Fig.13 page23. This will ensure that the primary supplytemperature does not exceed the maximumallowable temperature for the radiant tubing.

The addition of the high temperaturelimit is important if the PRESTIGE Solois connected to a domestic hot water sys-tem, which requires a high primary sup-ply water temperature.

Size the system piping and circulator to providethe flow needed for the radiant system.

To ensure an adequate flow rate throughthe PRESTIGE Solo, the boiler supplyand return piping size must be a mini-mum of 1 inch for the PRESTIGE Solo60, 1-1/4 inch for the PRESTIGE Solo175/250 and 1-1/2 inch for the PRES-TIGE Solo 399.

System Piping - Special Application

If the boiler is used in conjunction with achilled water/medium system, the boiler andchiller must be piped in parallel. Installflow/check valves to prevent the chilled medi-um from entering into the boiler.

If the boiler is used to supply hot water to theheating coils of an air handler where they maybe exposed to chilled air circulation, installflow/check valves or other automatic meansto prevent gravity circulation of the boilerwater during cooling cycles.

System Piping - Multiple Units Installation

Use a balanced manifold system as the prima-ry / secondary connection to the space heatingpiping as shown in Fig. 14 page 24.

Maintain a minimum of 6 inches [153 mm] ofclearance between units to allow for servicing.

Refer to Figs. 6 and 7 page 18 to install air sep-arator and expansion tank.

For the space heating piping refer to the appli-cations mentioned in this manual or use recog-nized design methods.

NOTICE

BEST PRACTICE

NOTICE

20

Boiler Piping

1. PRESTIGE Solo boiler2. SMART water heater3. Isolation valve4. DHW circulator 5. CH circulator

6. Flow/check valve7. Pressure relief valve8. Drain/purge valve

2

1

7

56

6

3

3

4

SupplySystem

System

Hot

ColdDomestic

DomesticReturn

8

Fig. 8: DHW Boiler Piping with a PRESTIGE Solo and SMART

The boiler system piping shown in Fig. 8must be a “closed” system to avoid anyoxygen contamination and potential fail-ure of the outer tank of the Smart.

NOTICE

21

Boiler Piping

5

5

4

6

1

2

3

3

3

3

3

9

8

1011

4

4

4

4

44

Zone Load

Additional

7

6

Max.12"

Zone Load

2

6

5

5

4

6

1

3

12

9

8

1011

4

4

4

4

44

Zone Load

7

Additional

Max.12"

Zone Load

Fig. 9: CH System Piping - Zoning with Zone Circulators

1. PRESTIGE Solo boiler2. CH circulator 3. Flow/check valve4 Isolation valve5. Zone circulator 6. Drain/purge valve

7. Pressure relief valve8. Air separator9. Automatic air vent10. Diaphragm expansion tank11. Automatic fill valve

Fig. 10: CH System Piping - Zoning with Zone Valves

1. PRESTIGE Solo boiler2. CH circulator 3. Flow/check valve4 Isolation valve5. Zone valve6. Drain/purge valve

7. Pressure relief valve8. Air separator9. Automatic air vent10. Diaphragm expansion tank11. Automatic fill valve12. System circulator

22

Boiler Piping

12

7

6

4AdditionalZone Load

4 5

4

4

4

2

Zone Load

9

8

10114

5

12P

12

7

64

2

SingleZone load

9

8

10114

3

Fig. 11: CH System Piping - Multiple Zone Valve with Single System/Boiler Circulator

1. PRESTIGE Solo boiler2. CH circulator 4 Isolation valve5. Zone circulator 6. Drain/purge valve7. Pressure relief valve

8. Air separator9. Automatic air vent10. Diaphragm expansion tank11. Automatic fill valve12. Pressure Differential Valve

Fig. 12: CH System Piping - Single Zone System with Single System/Boiler Circulator

1. PRESTIGE Solo boiler2. CH circulator 3. Flow/check valve4 Isolation valve5. Zone valve6. Drain/purge valve

7. Pressure relief valve8. Air separator9. Automatic air vent10. Diaphragm expansion tank11. Automatic fill valve

Note: Verify CH circula-tor is properly sized toovercome the system pres-sure drop and provide ade-quate flow through theboiler system.

Note: Verify CH circula-tor is properly sized toovercome the system pres-sure drop and provide ade-quate flow through theboiler system.

23

Boiler Piping

2

5

5

4

6

1

3

1312

9

8

1011

4

4

4

Radiant Zone

Additional

4

44

6

7

Radiant Zone

Max.12"

Note: Manifold mounted valveactuators may be used in lieu ofzone valves.

1. PRESTIGE Solo boiler2. CH circulator 3. Flow check valve4 Isolation valve5. Zone valve6. Drain/purge valve7. Pressure relief valve

8. Air separator9. Automatic air vent10. Diaphragm expansion tank11. Automatic fill valve12. System circulator13. High temperature limit control

Fig. 13: CH System Piping - Radiant/Low Temp. Heating

24

Boiler Piping

3 2

22

2

Toth

eS

yste

m

5

55

1

11

Fro

mth

eS

yste

m4

6

7

89

2

12"

Max

.

3 2

3 2

55

5

1.B

oile

rci

rcul

ator

2.Is

olat

ion

valv

e3.

Flow

/che

ckva

lve

4.Sy

stem

circ

ulat

or5.

Dra

in/p

urge

valv

e6.

Aut

omat

icai

rve

nt7.

Air

sepa

rato

r8.

Dia

phra

gmex

pans

ion

tank

9.A

utom

atic

fill

valv

e

Fig

.14:

Mul

tipl

eP

RE

STIG

ESo

loB

oile

rP

ipin

g-

Pri

mar

y/S

econ

dary

/Pip

ing

usin

gB

alan

ced

Man

ifol

dSy

stem

25

Installing Vent/ Combustion Air & Condensate Drain

SECTION V - Installing Vent /Combustion Air & Condensate Drain

Installing Vent and Combustion Air

The PRESTIGE Solo must be ventedand supplied with combustion air asshown in the PRESTIGE Solo VentSupplement, included in the boilerinstallation envelope. Refer to optionalvent kit instructions for additional ventinstallation instructions. Once installa-tion is completed, inspect the vent andcombustion air system thoroughly toensure systems are airtight and complywith the instructions given in the ventingsupplement and are within all require-ments of applicable codes. Failure tocomply with the installation require-ments on the venting and combustion airpiping will cause severe personal injuryor death.

Installing Condensate Drain Assembly

1. Locate the condensate drain assembly andinstall as shown in Fig. 15 page 26.

The installer may want to fill the con-densate trap with water prior to assem-bling on the unit.

2. Remove the retaining nut and rubber sealfrom the condensate drain assembly andslide over the heat exchanger condensatedrain nipple. Connect the condensate drainassembly to the retaining nut and tighten.Hand tight only!

Ensure the condensate drain assemblycontains the plastic seated ball. Do notinstall the condensate drain assembly ifthe ball is lost or missing, replace theentire assembly.

3. Remove the compression nut and rubberseal from the drain outlet.

4. Using 3/4” x 2’ flexible PVC tube provid-ed, slide the compression nut and rubberseal over the pipe

The use of 3/4” PVC or CPVC pipe isalso acceptable. If 3/4” pipe is useddeburr and chamfer pipe to allow mat-ing onto the drain assembly.

5. Thread the rubber seal into the compres-sion nut to ease installation of the pipe tothe drain assembly.

6. Seat the pipe onto the drain assembly andtighten the compression nut. Hand tightonly!

The installer may opt to using 13/16" IDtubing in lieu of rigid piping.

The drain line materials must be anapproved material by the authority hav-ing jurisdiction. In absence of suchauthority, PVC and CPVC piping mustcomply with ASTM D1785 or D2845.The cement and primer used on the pip-ing must comply with ASME D2564 orF493. For installations in Canada, useCSA or ULC certified PVC or CPVCpipe, fittings and cement/primer.

7. Continue the pipe from the drain assemblyto a floor drain or condensate pump.

NOTICE

NOTICE

NOTICE

WARNING

NOTICE

DANGER

26

Installing Vent/ Combustion Air & Condensate Drain

When selecting and installing a conden-sate pump, ensure the pump is approvedfor use with condensing boilers and fur-naces. The pump should be equippedwith an overflow switch to prevent prop-erty damage from potential condensatespillage.

8. The PRESTIGE Solo will typically producea condensate that is considered slightlyacidic with a pH content below 3.0. Installa neutralizing filter if required by authorityhaving jurisdiction.

The condensate drain must remain filledand unobstructed and allow unrestrictedflow of condensate. The condensateshould not be subject to conditionswhere freezing could occur. If the con-densate is subjected to freezing orbecomes obstructed , it can leak, result-ing in potential water damage to the boil-er and surrounding area.

CAUTIONNOTICE

Flexible Tubing(or 3/4 PVC/ CPVC Piping

to Drain)

CompressionNut with Rubber Seal

Fill Plugwith VaccumBreak Port

CondensateDrain Assembly

Plastic Ball

Retaining Nutwith Rubber Seal(Hand Tight Only)

Heat ExchangerCondensateDrain Nipple

Fig. 15: Condensate Drain Assembly

27

Gas Piping

SECTION VI - Gas Piping

Gas Supply Piping Connection

The gas supply piping must be installedin accordance to all applicable local,state and national codes and utilityrequirements.

1. Install a 1/2” NPT for PRESTIGE Solo 60,3/4” NPT for PRESTIGE Solo 175/250 or1” NPT for PRESTIGE Solo 399 pipeunion at the factory supplied gas nipple, forease of service.

2. Install a manual shutoff valve in the gassupply piping as shown in Fig. 16. Forinstallations in Canada the installer musttag and identify the main shutoff valve.

3. Install a sediment trap (drip leg) on the gassupply line prior to connecting to the PRES-TIGE Solo gas train as shown in Fig. 16.

4. Support the gas piping using hangers. Donot support the piping by the unit or itscomponents.

5. Purge all air from the gas supply piping.

6. Before placing the PRESTIGE Solo intooperation, check and test all connectionsfor leaks.

- Close the manual shutoff valve duringany pressure test with less than 13”w.c..

- Disconnect the PRESTIGE Solo and itsgas valve from the gas supply pipingduring any pressure test greater than13”w.c..

Do not check for gas leaks with an openflame. Use a gas detection device or bub-ble test. Failure to check for gas leakscan cause severe personal injury, deathor substantial property damage.

7. Use pipe dope compatible with natural andpropane gases. Apply sparingly only to themale threads of pipe joints so that pipedope does not block gas flow.

Failure to apply pipe dope as detailedabove can result in severe personalinjury, death or substantial propertydamage.

Use a two-wrench method of tighteninggas piping near the unit and its gas pip-ing connection. Use one wrench to pre-vent the boiler gas line connection fromturning and the second to tighten adja-cent piping. Failure to support the boil-er gas piping connection could damagethe gas line components.

WARNING

WARNING

WARNING

NOTICE

Sediment Trap Min. Length of 3"

Union FittingCap

Tee Fitting

External ManualGas Shut OffValve (Must BeWithin 6' of the Boiler)

Gas Flow

Fig. 16: Recommended Gas Supply Piping

28

Gas Piping

NATURAL GAS

Pipe Sizing - Natural Gas

Refer to Table 1 for schedule 40 metallic pipelength and diameter requirements for naturalgas, based on rated PRESTIGE Solo input(divide by 1,000 to obtain cubic feet per hour).

- Table 1 is based on Natural Gas with a spe-cific gravity of 0.60 and a pressure dropthrough the gas piping of 0.30”w.c..

- For additional gas piping sizing informa-tion, refer to ANSI Z223.1. For Canadianinstallations refer to B149.1 or B149.2.

Natural Gas Supply Pressure Requirements

1. Pressure required at the gas valve inletsupply pressure port:

- Maximum 13”w.c. at flow or no flowconditions to the burner.

- Minimum 5”w.c. during flow conditionsto the burner. Must be verified duringstart up and with all other gas appliancesoperating within the building.

2. Install 100% lockup gas pressure regulatorin the gas supply line if inlet pressure canexceed 13”w.c at any time. Adjust the lock-up pressure regulator for 13”w.c maximum.

DO NOT adjust or attempt to measuregas valve outlet pressure. The gas valveis factory-set for the correct outlet pres-sure. This setting is suitable for naturalgas and propane and requires no fieldadjustment. Attempts by the installer toadjust or measure the gas valve outletpressure could result in damage to thevalve, causing potential severe personalinjury, death or substantial propertydamage.

The natural gas orifice requirements are:

PRESTIGE Solo 60: 0.204” (5.2 mm)

PRESTIGE Solo 175: None Required

PRESTIGE Solo 250: None Required


NOTICE

WARNING

Table 1: Gas Piping Sizing - Natural Gas

29

Gas Piping

PROPANE GAS

Pipe Sizing - Propane Gas

Contact the local propane gas supplier for rec-ommended sizing of piping, tanks and 100%lockup gas regulator.

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 flowconditions to the burner

- Minimum 5”w.c. during flow conditionsto the burner. Must be verified duringstart up and with all other gas appliancesoperating within the building.

DO NOT adjust or attempt to measuregas valve outlet pressure. The gas valveis factory-set for the correct outlet pres-sure. This setting is suitable for naturalgas and propane and requires no fieldadjustment. Attempts by the installer toadjust or measure the gas valve outletpressure could result in damage to thevalve, causing potential severe personalinjury, death or substantial propertydamage.

Prior to start up, ensure the unit is set tofire propane. Check the rating label forthe type of fuel. Check the gas valve forpropane conversion label. If there is aconflict or doubt on the burner set up,remove the gas valve and check for thepropane orifice, see Fig. 17 or 18, page30. Failure to ensure proper burnersetup could result in severe personalinjury, death or substantial propertydamage.

The propane orifice requirements are:





NOTICE

WARNING

WARNING

30

Gas Piping

Gas Valve

Orifice

Gaskets

Venturi

Fig. 18: Gas Valve / Venturi Assembly - PRESTIGE Solo 399

Venturi

Inlet SupplyPressure Port

PropaneOrifice

Gas ValveGasket

Gas ValvePipe Fitting

Gas Valve

Fig. 17: Gas Valve / Venturi Assembly - PRESTIGE Solo 60/175/250

31

Internal Wiring

SECTION VII - Internal Wiring

ELECTRICAL SHOCK HAZARD. Foryour safety, disconnect electrical powersupply to the unit before servicing ormaking any electrical connections toavoid possible electric shock hazard.Failure to do so can cause severe person-al injury or death.

Prior to servicing, label all wires beforedisconnecting. Wiring errors can causeimproper and dangerous operation.Verify proper wiring and operation afterservicing.

General Requirements

- Wiring must be N.E.C Class 1.

- If original wiring as supplied with the unitmust be replaced, use only Type T 90ºCwire or equivalent as a minimum.

- The PRESTIGE Solo must be electricallygrounded as required by NationalElectrical Code ANSI/NFPA 70 - latest edi-tion and / or the Canadian Electrical CodePart 1, CSA C22.1, Electrical Code.

Control Module Circulator AMP Ratings

- AMP draw of the CH circulator not toexceed 2 amps.

- AMP draw of the DHW circulator not toexceed 2 amps.

Wiring Tool Instructions

1. Locate the wiring tools on the PRESTIGESolo just below the MCBA control in aplastic bag and below the extra fuses.

2. Locate the terminal blocks on the PRES-TIGE Solo below the MCBA control.

The 120V Terminals are located on theleft set of Terminal Blocks. The 24VTerminals are located on the right set ofterminal blocks.

3. Carefully pull down on the lower half ofthe terminal block to remove.

4. Hook the wiring tool into the desired slot ofthe terminal block as shown in Fig.19.

5. Push wiring tool in towards the terminalblock and insert wire in slot at bottom ofterminal block.

6. Repeat steps 4 & 5 until all wiring is com-plete.

7. Re-connect the lower half of the terminalblock to the upper half.

8. Place the wiring tool back into the plasticbag or leave tool hooked to a slot on the24V terminal block.

When wiring the PRESTIGE Solo allowadditional length of wire for the accesspanel to swing open during servicing.

BEST PRACTICE

NOTICE

CAUTION

WARNING

Terminal Block

Wiring Tool

Fig. 19: Using the Wiring Tool on theTerminal Blocks

32

Internal Wiring

O-1

0vE

xter

nalI

nput

s(+

)

DH

WS

enso

ror

Ther

mos

tat

DH

WS

enso

ror

Ther

mos

tat

O-1

0vE

xter

nalI

nput

s(-

)

Gas

Val

veP

RE

ST

IGE

Sol

o39

9O

nly

Hea

tin

gci

rcu

lato

r(su

pp

lied

on

the

PRES

TIG

ESo

lo11

0o

nly

)

Topr

oper

lyco

nnec

twir

esto

term

inal

bloc

k,us

ew

irin

gto

olin

clud

edw

ithPR

EST

IGE

Solo

.Se

ew

irin

gto

olin

stru

ctio

ns,p

age

31.

Fig. 20: Prestige Solo Boiler Factory Wiring

33

External Wiring

SECTION VIII- External Wiring

Installation Compliance

All field wiring made during installation mustcomply with:

- National Electrical Code NFPA 70 andany other national, state, provincial orlocal codes or requirements.

- In Canada, CSA C22.1 CanadianElectrical Code Part 1, and any otherlocal codes.

ELECTRICAL SHOCK HAZARD.Before making any electrical connec-tions to the PRESTIGE Solo, disconnectelectrical power supply at the servicepanel. Failure to comply can causesevere personal injury or death.

Line Voltage Connections

1. Connect a 120 VAC/15A service to the120V terminal strip on the wiring panelbelow the PRESTIGE Solo control mod-ule, as shown in Fig. 20, page 32.

2. Route the incoming 120 VAC power wirethrough the provided openings in the bot-tom jacket panel.

3. The unit is provided with a service switchlocated on the front panel, check local coderequirements for compliance.

If local electrical codes or conditionsrequire an additional service switch, theinstaller must provide and install a fuseddisconnect or 15 amp (minimum) serviceswitch.

Domestic Hot Water Aquastat Wiring

1. Connect the DHW thermostat (aquastat) tothe 24V terminal strip on the wiring panellocated below the PRESTIGE Solo controlmodule as shown in Fig. 20, page 32.

2. Route all wiring through the providedopenings, in the bottom jacket panel. Allowenough wire for access panel to swing openduring servicing.

Thermostat Wiring

Isolate 120V wiring from 24V wiring toprevent any potential electrical “noise”.

1. Connect room thermostat or the end switch(isolated contact only) of a relay controlpanel to the 24V terminal strip on thewiring panel below the PRESTIGE Solocontrol module, as shown in Fig. 20, page32.

2. For proper operation install the room ther-mostat on an inside wall away from influ-ences of heat and cold, i.e. water pipes,areas of draft, lighting fixtures and fire-places.

3. Set the thermostat anticipator (if applica-ble) as follows:

- Set for 0.2 amps when wired directly tothe PRESTIGE Solo.

- Set to match the total electrical powerrequirements of the connected deviceswhen wired to zone relays or otherdevices. Refer to the relay manufactur-ers’ specifications and the thermostatinstructions for additional informationon the anticipator setting.

NOTICE

NOTICE

WARNING

34

External Wiring

24 VTransformerby Others

Honeywell V8043Zone Valves

or Equivalent

Honeywell R8285DTransformer / Relayor Equivalent

24V Terminal Strip

System Circulator

24V Low Voltage Wiring

120V High Voltage Wiring

Room Thermostats

H N120V R C

G

1 3 4 6

7

8

To Prestige

Fig. 21: Secondary System Circulator Wiring

When making low voltage connections tothe Prestige, ensure no external voltageis present in the thermostat circuits. Ifexternal voltage is present, provide anisolated contact to prevent damage tothe boiler control.

CH and DHW Circulator

1. Connect the CH primary circulator to thePRESTIGE Solo 120 V terminals 1,2 and 3as shown in Fig. 20, page 32.

2. Connect the DHW circulator to the PRES-TIGE Solo 120 V terminals 4, 5 and 6 asshown in Fig. 20, page 32.

3. Maximum circulator continuous currentdraw is 2A for each circulator.

System Circulator - Zone Valve Application

To energize the system circulator shown asitem 12 in Fig. 10 page 21 reference Fig. 21.Installer to provide a Transformer / Relay suchas Honeywell R8285 or equivalent and ZoneValves with isolated end switch such asHoneywell V8043 or equivalent.

External Modulating Control

The PRESTIGE Solo firing rate can be con-trolled by an external modulating boiler con-troller. See page 32 for wiring and Page 54 forcontrol module setup.

Outdoor Reset Control

The PRESTIGE Solo may operate with a vari-able boiler operating temperature using theTriangle Tube outdoor sensor, see pages 50through 53 for installation and set-up.

If the installer opts for a fixed operatingtemperature for the boiler system, theoutdoor sensor is not required andshould not be installed.

Additional 24V Limit Wiring

The PRESTIGE Solo provides 24V terminalconnections for additional limit controls asshown in Fig. 20 page 32. These limit terminalconnections will provide a "hard" lockoutrequiring a manual reset of the PRESTIGESolo control, or a “soft” lockout in which thePRESTIGE Solo will automatically reset.

NOTICE

NOTICE

35

External Wiring

H N

High Voltage

120V.A.C.

24V.A.C.

RoomThermostat

RoomThermostat

Zone 1

Zone 2

Additional zones Additional zones maybe added as shown above

To Prestige 24V Terminal Strip

Transformer(Power)

ZoneValve

Zone Valve

7 8


H N

High Voltage

120V.A.C.

24V.A.C.

RoomThermostat

RoomThermostat

Zone 1

Zone 2

Additional zones Additional zones maybe added as shown above

Transformer(Power)

ZoneValve

Zone Valve

* Isolation relay

7

8

*Use isolation relay on 3-wire zone valve with non-isolated end switch. Transformer and the Prestige MCBA control can burn out if isolation relay is not used.

NOTICE:

4 Wire Zone Valve

3 Wire Zone Valve

Fig. 22: Multiple Zone Field Wiring Using Zone Valves

36

External Wiring

T T


CirculatorZone 1

Thermostatzone 1

HoneywellR845ARelay

120H

VACN

CirculatorZone 2

Thermostatzone 2

Additional zones may beadded as shown above

7 8

62 1 4 3 5

62 1 4 3 5

T T

T T

Fig. 23: Field Wiring with Zone Circulators

ThermostatZone 1

Zone 1Circulator

120 VAC

N

To Prestige24V Terminal Strip

Zone 2Circulator

Zone 3Circulator

ThermostatZone 2

ThermostatZone 3

R C T1 T1 T2T2 T3 T3

C3C3C2C2C1C1PRPRX2X1L1L2 ZC

H 7 8

Fig. 24: Typical Zone Relay Panel Wiring

37

Start-Up Preparation

SECTION IX - Start-Up Preparation

Check Boiler System Water Chemistry

Do not use petroleum-base cleaning orsealing compounds in the boiler system.Damage to seals and gaskets in the sys-tem components could occur, resulting insubstantial property damage.

System water including additives must bepractically non-toxic, having a toxicityrating or Class of 1, as listed in ClinicalToxicology of Commercial Products.

Water pH Level 6.0 to 8.0

Maintain the boiler water pH between 6.0 and8.0. Check using litmus paper or contact a watertreatment company for a chemical analysis.

If the pH does not meet this requirement, donot operate the PRESTIGE Solo or leave theunit filled until the condition is corrected.

Water Hardness Less Than 7 Grains

For areas with unusually hard water (hardnessabove 7 grains) consult a water treatmentcompany.

Chlorinated Water

Do not use the PRESTIGE Solo to heat aswimming pool or spa directly.

Maintain the chlorine level of the water at lev-els considered safe for drinking.

Flush Boiler and Domestic System toRemove Sediment

The installer must flush the boiler system toremove any sediment to allow proper operationof the PRESTIGE Solo .

Flush the systems until the water runs cleanand is free of sediment.

For zoned systems, each zone should beflushed through a purge valve. Purge valvesand isolation valves should be installed on eachzone to allow proper flushing of the system.

Check and Test Antifreeze

For boiler systems containing antifreeze solu-tions, follow the antifreeze manufacturer’sinstructions in verifying the inhibitor level andto ensure the fluid characteristics are withinspecification requirements.

Due to the degradation of inhibitors over time,antifreeze fluids must be periodically replaced.Refer to the manufacturer of the antifreeze foradditional instructions.

System water including additives must bepractically non-toxic, having a toxicityrating or Class of 1, as listed in ClinicalToxicology of Commercial Products.

NOTICE

NOTICE

WARNING

38


Use of Antifreeze in the Boiler System

NEVER use automotive or ethylene gly-col antifreeze or undiluted antifreeze inthe primary system as freeze protection.This can cause severe personal injury,death or substantial property damage ifignored.

Determine the antifreeze fluid quantity usingthe system water content volume and followingthe antifreeze manufacturer instructions.

The water volume of the PRESTIGE Solo isapproximately 3 gallons [12 L] for PRESTIGESolo 60 or 5 gallons [19 L] for PRESTIGE Solo175/250 or 7 gallons [26 L] for PRESTIGE Solo399 . Remember to include the volume of theexpansion tank.

Check with local codes requirements for theinstallation of backflow preventers or actualdisconnection from the boiler’s cold water fillor make up water supply line.

Massachusetts Code requires the installa-tion of a backflow preventer if antifreezeis used.

Ensure the concentration of antifreeze to waterdoes not exceed a 50/50 ratio.

System water, including additives, mustbe practically non-toxic, having a toxicityrating or Class of 1, as listed in ClinicalToxicology of Commercial Products.

Filling the Boiler System

1. Close the boiler drain valve located on thebottom of the unit and any manual or auto-matic air vent in the system.

2. Open all system isolation valves.

3. Fill the boiler system to correct systempressure. Correct pressure will vary witheach application.

Typical residential system fill pressure is12 psi. System pressure will increasewhen system temperature increases.Operating pressure of the system shouldnever exceed 25 psi.

4. Purge air and sediment in each zone of theboiler system through the purge valve.Open air vents to allow air to be purged inthe zones.

5. Once the system is completely filled andpurged of all air and sediment, check thesystem pressure and check/repair anyleaks.

Unrepaired system leaks will cause con-tinual makeup water to be added to theboiler. Continual makeup water couldcause mineral buildup within the heatexchanger, reducing the heat transfer,causing possible heat buildup and even-tual heat exchanger failure.

Check Low Water Cut-Off Device

- The PRESTIGE Solo is provided with afactory installed LWCO device that mea-sures system pressure of more than 10 psi.

- Remove the front jacket panel and check forcontinuity across the low water cut-offdevice wire terminals. The contacts shouldbe closed when system pressure is greaterthan 10 psi. See item 6, on Fig. 27 page 66(PRESTIGE Solo 60) or on Fig. 27A page67 (PRESTIGE Solo 175/250) or Fig. 27Bpage 68 (PRESTIGE Solo 399) for locationof the LWCO.

WARNING

NOTICE

NOTICE

NOTICE

WARNING

39


Check For Gas Leaks

Prior to start-up and during initial opera-tion, smell near the floor and around theunit for gas odorant or any unusual odor.Do not proceed with the start-up if thereis any indication of a gas leak. Any leaksfound must be repaired immediately.

Propane installations only - The propanesupplier mixes an odorant with thepropane to make its presence detectable.In some cases the odorant can fade andthe gas may no longer have an odor.

Prior to start-up of the unit and periodi-cally after start-up have the propanesupplier check and verify the odorantlevel.

Check Thermostat Circuit

- Disconnect the external thermostat wiresfrom the 24V terminal strip on the wiringpanel.

- Connect a voltmeter across the wire ends ofthe external thermostat wiring.

- Close each thermostat, zone valve andrelay in the external circuit one zone at atime and check the voltage reading acrossthe wire ends.

- There should NEVER be voltage measuredat the wire ends.

- If voltage is measured at the panel under anycondition, check and correct the externalwiring.

In systems using 3-wire zone valves,backfeed of voltage to the unit is a com-mon problem. Use an isolation relay toprevent voltage from the external circuitentering the PRESTIGE Solo controlpanel.

- Reconnect the external thermostatwires to the 24V terminal strip on thewiring panel.

Inspection of Condensate Drain Assembly

1. Inspect and ensure the Condensate DrainAssembly is properly installed as describedon page 25 and shown in Fig. 15 on page26.

2. Remove the plug from the CondensateDrain Assembly and fill with fresh water.

The condensate drain assembly must befilled with water when the PRESTIGESolo is in operation. The condensatedrain assembly prevents flue gas emis-sions from entering the condensate line.Failure to ensure trap is filled with watercould result in severe personal injury ordeath.

3. Re-Install plug in condensate drain assem-bly.

NOTICE

NOTICE

WARNING

WARNING

40

Start-Up Procedures

SECTION - Start-Up ProceduresFinal Checks Before Start-Up

c Read page 45 through 48 regarding theoperation of the PRESTIGE Solo control.

c Verify the PRESTIGE Solo and the boilersystem are full of water and all systemcomponents are correctly set for operation,including the minimum flow rate throughthe boiler, see pages 79 through 81.

c Verify Start-up Preparation items outlined onpages 37 thru 39 have been completed.

c Verify all electrical connections are correctand securely fastened.

c Inspect vent and combustion air piping forsigns of deterioration from corrosion, physicaldamage or sagging. Verify combustion airand vent piping are intact and correctlyinstalled and supported. Reference the PRES-TIGE Solo vent supplement.

c Verify burner configuration - Propane only.

- Check for proper labeling on the gasvalve and the rating label for propaneconfiguration.

- If there is doubt on the burner configura-tion, remove the gas valve and check forproper propane gas orifice size: 0.120” or3.1 mm for PRESTIGE Solo 60, 0.221” or5.6mm for PRESTIGE Solo 175, 0.250” or6.3 mm for PRESTIGE Solo 250 or 0.264”or 6.7 mm for PRESTIGE Solo 399. Referto Figs. 17 & 18, page 30 for location ofthe propane gas orifice.

For natural gas applications the Prestige60 requires an orifice: 0.204” (52mm), andthe Prestige 399 requires and orifice:0.330” (8.6 mm)

c Ensure the vent Condensate DrainAssembly is filled with water.

PRESTIGE Solo Start-Up

1. Turn the ON-OFF switch located on the frontcontrol panel to the OFF position. Turn ONthe electrical supply/service to the unit.

2. Read and follow the Operating Instructionsoutlined on page 42.

If PRESTIGE Solo Does Not Start Correctly

1. Verify DHW (parameter 2) and CH (para-meter 3) systems are turned ON or set to“01”. Read the Boiler Display Standby andParameter Section of the manual startingon page 47 for more information.

2. Check for loose electrical connections,blown fuse (external or internal to theMCBA Control) or open service switch.

3. Check continuity across the L.W.C.Odevice for a closed circuit. See item 5 onFig. 27, page 66 and item 6 Fig. 27A, page67 and Fig. 27B, page 68.

4. Is the external limit control (if applicable)open? Ensure the external limit is reset tothe closed position.

5. Is the gas supply valve(s) open at the unitand meter?

6. Is incoming gas supply pressure at the unitmore than 5”w.c. and less than 13” w.c. fornatural or propane with all gas appliancesON or OFF.

7. Are the heating thermostats set above roomtemperature?

If none of these conditions correct the problem,refer to the PRESTIGE Solo Trouble-ShootingGuide or contact Triangle Tube Tech Service.

Check the PRESTIGE Solo and System

c Check Boiler Piping.

Check Boiler system piping and com-ponents for leaks. If found, shut downthe unit and repair immediately.

Purge any remaining air from the systempiping. Air in the system piping willinterfere with circulation creating heatdistribution problems and system noise.

NOTICE

41

Start-Up Procedures

c Check Vent Piping and Combustion AirPiping.

Check for gas-tight seal at every con-nection and seam of the venting andcombustion air piping.

Venting system must be sealed gas-tightto prevent flue gas spillage and potentialcarbon monoxide emissions, which willresult in severe personal injury or death.

c Check Gas Piping

Check around the unit for gas odor fol-lowing the procedure outlined in thismanual on Page 39.

If any gas leaks are found or suspected,shut the unit down immediately. Use agas detection device or bubble test tolocate the source of the gas leak andrepair at once. Do not operate the unituntil the leak is corrected. Failure tocomply with this procedure could resultin severe personal injury, death or sub-stantial property damage.

c Verify Flame Pattern and Combustion

Check the flame pattern through theinspection port of the heat exchanger.The flame should be blue and stable.The flame should be the length of theburner head openings.

The combustion testing and adjustmentsmust be performed by a qualifiedinstaller, service agency or the gas suppli-er. All combustion measurements must beperformed with calibrated equipment toensure proper reading and accuracy.

Test for CO2 or O2 and for CO duringhigh firing rate. To manually place theboiler into high fire mode, referencepage 45. The combustion readingshould be within the range listed inTable 2. The CO level should notexceed 100 ppm when combustion iscorrect.

The combustion levels should be mea-sured at high firing rate, refer to page 45of the PRESTIGE Solo control sectionon how to set the firing rate. If the com-bustion levels are not within the rangegiven in Table 2 for the firing rate, shutthe boiler down and contact TriangleTube Engineering Department. Failureto comply with this requirement couldresult in severe personal injury, death orsubstantial property damage.

c Measure Input - Natural Gas Only

1. Ensure the boiler is firing at maximum firingrate. To manually place the boiler into highfire mode, reference page 45.

2. Operate the unit for approximately 10minutes.

3. Turn off all gas appliances within the build-ing, except the PRESTIGE Solo.

4. At the gas meter, record the time requiredto use one cubic foot of gas.

WARNING

WARNING

WARNING

WARNING

Table 2: Recommended Combustion Levels

42

Start-Up Procedures

WARNING

FOR YOUR SAFETY READ BEFORE LIGHTING

OPERATING INSTRUCTIONS

TO TURN OFF GAS TO APPLIANCE

1. STOP! Read the safety information above. Thisappliance is equipped with an ignition devicewhich automatically lights the burner. DO NOTtry to light the burner by hand.

2. Set room thermostat(s) to lowest setting. Turn theexternal manual gas valve handle clockwise

“CLOSE” (valve handle shall be per-pendicular to gas piping).

3. Turn the service switch on the PRESTIGE con-trol panel OFF.

4. Remove the front jacket panel on the unit.

5. Turn the external manual gas valve handlecounter clockwise to “OPEN” gas sup-ply (valve handle shall be parallel to gas piping).

6. Wait five (5) minutes to clear out any gas. If youthen smell gas in the jacket enclosure or aroundthe unit, STOP! Follow “B” in the safety infor-mation above. If you don’t smell gas, go to thenext step.

7. Turn the service switch on the PRESTIGE con-trol panel “ON”.

8. Set room thermostat(s) to desired setting(s).

9. The PRESTIGE control panel display will showa sequence of numbers (0,1,2,3,4,etc.) as the leftdigit. Sequence digit 3 or 4 indicates the boiler isfiring. Sequence digit 0 means there is no call forheat (all external thermostats are satisfied).

10. If the unit will not operate with a call for heat and thesystem piping is not hot, follow the instructions “ToTurn Off Gas to Appliance”, below and call yourservice technician or gas supplier.

11. Replace the front jacket panel. Make sure the panel isseated firmly in place and all mounting screws aretightened.

If you do not follow these instructions exactly, a fire or explosionmay result causing property damage, personal injury or loss of life.

1. Set the room thermostat to lowest setting.

2. Turn the service switch on the PRESTIGE con-trol panel to “OFF”

3. Turn the external manual gas valve handle clock-wise to “CLOSE”.

A. This appliance does not have a pilot. It isequipped with an ignition device which automat-ically lights the burner. DO NOT try to light theburner by hand.

B. BEFORE OPERATING, smell all around theappliance area for gas. Be sure to smell next tothe floor because some gas is heavier than air andwill settle on the floor.

WHAT TO DO IF YOU SMELL GAS• Do not try to light any appliance.

• Do not touch any electric switch; do not useany phone in your building

• Immediately call your gas supplier from aneighbor’s phone. Follow the gas supplier’sinstructions.

• If you cannot reach your gas supplier, call thefire department.

C. Use only your hand to turn the external manual gasvalve. Never use tools. If the valve will not turn byhand, don’t try to repair it; call a qualified servicetechnician. Force or attempted repair may result ina fire or explosion.

D. Do not use this appliance if any part has beenunder water. Immediately call a qualified servicetechnician to inspect the appliance and to replaceany part of the control system and any gas controlwhich has been under water.

43

Start-Up Procedures

5. Calculate Natural gas input using the fol-lowing equation:

3600 x 1000 / number of second recordedfor one cubic foot of gas = BTU/H.

6. The BTU/H calculated should approximatethe input rating listed on the unit.

Set Boiler CH Set Point

1. Press the MODE button until the displayshows PARA. This is the parameter modeof the control.

2. Press the STEP button until the first digiton the display shows "4". The last threedigits on the display shows the CHMaximum Boiler Operating Setpoint.

3. Press the "+" or "-" button to change thesetting.

When an outdoor sensor is used, the set-ting of Parameter 4 is the CH setpointwhen the outdoor temperature is at orbelow 0ºF. When the outdoor tempera-ture is above 0ºF, the PRESTIGE Solocontrol will calculate the boiler setpointbetween the minimum and maximumtemperature settings.

4. Press the "STORE" button to save the setting.

Operation Verification - Space Heating

Digits and characters shown as [00000000],in the following outline, represent thecontrol panel display. The last three dig-its on the display represent the measuredboiler water temperature and may differfrom what is shown in the manual.

1. Disconnect the DHW (Domestic HotWater) thermostat wiring from the PRES-TIGE Solo or turn down DHW tank aquas-tat (if used) to ensure the boiler does notreceive a DHW call for heat.

2. Set the room thermostat to the lowest setting.

3. Turn off power to the boiler, wait a fewseconds and turn on power to the boiler.

4. The following displays should occur:

[U1.22] Software version

[A140] Self check on power up

[0140] No call for heat

5. Initiate a call for heat by raising the setpoint of the room thermostat to the highestsetting. The following display shouldoccur.

[5140] This is a fan / air flow check. Theburner blower will be energized momentar-ily prior to the prepurge cycle.

[1140] This is the prepurge cycle. Theburner blower and the CH (CentralHeating) circulator become energized. Theblower has a 10 second prepurge cycle.

[2140] This is the ignition cycle. The con-trol module will energize and open the gasvalve and begin the spark for ignition.

- If the burner flame proves, the burnerwill continue to fire at the ignition fanspeed for approximately 10 seconds tostabilize the flame.

- If the burner flame is not proven thecontrol module will repeat the ignitionsequence. If the flame is not provenafter five attempts the control will lock-out and the display will show [E-02]

- To verify flame failure lockout, closethe manual shut off valve on the gassupply piping to the boiler and repeatignition sequence. When verification iscompleted, ensure the manual shut offvalve is returned to the open position.

NOTICE

NOTICE

44

Start-Up Procedures

[3140] This is the normal CH operationcycle. After the flame is proven and stabi-lized the burner will fire at low input forapproximately 1 minute. After this timeperiod, the control module will begin tomodulate the burner firing rate based onactual boiler outlet temperature and the setpoint temperature.

6. Allow the boiler to operate and allow theboiler outlet temperature to reach the setpoint temperature.

[6180] This begins the burner shutdownand post purge cycle. The CH circulatorwill continue to run until the room thermo-stat is satisfied.

7. Lower the room thermostat set point belowthe room temperature to end the call forheat.

[1180] This begins a post purge cycle.When the room thermostat is satisfied, theboiler will shutdown. The control modulewill close the gas valve and the blower willcontinue for 30 seconds for a post purgecycle before shutting down. If another callfor heat is initiated, the boiler will remainoff for an additional 30 seconds beforestarting a new ignition sequence.

[7180] The CH circulator will continue torun for a 1 minute post pump cycle.

[0180]The boiler is in standby MODEwaiting for a call for heat.

8. Verify the operation of the boiler by repeat-ing the operational sequence several times.

9. Return the room thermostat to a desired set-ting. Reconnect the DHW wiring or returnthe DHW aquastat to desired setting, plac-ing the DHW system into operation.

Operation Verification - Domestic HotWater (if applicable)

1. As outlined in the verification for spaceheating, repeat STEPS 2 through 4.

2. Raise the DHW aquastat setting to initiate acall for heat. As in the space heating opera-tion the display should show:

[5140] This is a fan / air flow check. Theburner blower will be energized momen-tary prior to the prepurge cycle.

[1180] This is prepurge cycle. The burnerblower and DHW circulator become ener-gized and the 10 second prepurge cyclebegins.

[2180] The boiler will begin the ignitionsequence. The same sequence of establish-ing flame, trail for ignition and attempts forignition as described in the space heatingapplies for domestic water heater.

[4180] This indicates normal operationfor DHW. The burner will begin modulat-ing its input to maintain the DHW set point.The burner will not go into the low inputrate for the 1 minute flame stabilizationperiod that occurs in CH mode.

3. Lower the DHW aquastat to satisfy the callfor heat.

[1180] The post purge cycle begins. Thecontrol module closes the gas valve and theblower continues for a 30 second postpurge.

[8180] The DHW circulator will continuefor a 30 second post pump cycle. If anoth-er DHW call for heat is initiated the boilerignition sequence will begin immediately.

[0180] Boiler is in standby MODE wait-ing for a CH or DHW call for heat.

4. Verify the DHW operation of the boiler byrepeating the outlined operation sequenceseveral times.

5. Return the DHW aquastat and room ther-mostat to the desired setting.

45

Start-Up Procedures

Boiler Control Display

Standby Mode

This is the standard mode for the PRESTIGESolo. The control automatically returns to thismode after 20 minutes if no keys have beenpressed on the display. Any parameters thatwere modified are then stored.

The first character shows (on left side of dis-play) the current status of the boiler dependingon the condition of both the boiler and theburner. The last 3 characters indicate the boilersupply temperature.

If the burner is blocked due to a “soft” lockout,the display alternates between a 9 followed bythe boiler supply temperature and a “b” with atwo digit error code.

TO TEMPORARILY PLACE THE BURN-ER INTO HIGH FIRE TEST MODE: pressthe MODE button until “StbY” is displayed.Then press and hold both the MODE and “+”buttons simultaneously until the first digitflashes “H”.

While in the test mode:

- high limit will function

- boiler CH circulator will function

- domestic circulator will not function

- the test mode will time out in approxi-mately 10 minutes

TO TEMPORARILY PLACE THE BURN-ER INTO LOW FIRE TEST MODE: pressthe MODE button until “StbY” is displayed.Then press and hold both MODE and “-” but-tons simultaneously until the first digit flashes“L”.

TO DEACTIVATE THE HIGH OR LOWFIRE TEST MODE: press the MODE buttonuntil “StbY” is displayed. Then press andhold both the “+” and “-” buttons simultane-ously to deactivate the high or low fire testmode.

If the “+” button is held in, the CH system(parameter 3) will be turned OFF and thedisplay will show “cOFF”. Press andhold the “+” button to turn the CH sys-tem back ON, the display will show “c”followed by CH set point. If the “-” but-ton is held in while in the “StbY” mode,domestic system (parameter 2) will beturned OFF and the display will show“dOFF”. Press and hold “-” button toturn the domestic system back ON, thedisplay will show “d” followed by domes-tic set point temperature.

NOTICE

StbY

Test function: Burner on, high fire mode

Test function: Burner on, low fire mode

180180

HL

Display Boiler function

46

Start-Up Procedures

STANDBY, no demand for heat

Fan prepurge or post purge cycle

Ignition sequence

Burner ON for space heating (CH)

Burner ON for domestic hot water (DHW)

Pre-check for air flow prior to prepurge cycle

Burner OFF due to reaching temperature setpoint

Domestic hot water (DHW) post pump cycle

Space Heating (CH) post pump cycle

Burner blocked:

Supply temperature too high (202 F) . Burner will remain OFF until temperature dropsbelow 200 F

Return temperature too high (202 F). Burner will remain OFF until temperature drops below 200 F

Return temperature is higher than supply temperature. Burner will remain OFFuntil corrected.

Supply temperature increased too quickly. Burner will remain OFF for a 10 minute period. Burner will recycle, increasing waiting period 1 minute for a max. 15 minutes

Factory supplied LWCO device or external limit (terminals 15 & 16) is OPEN. Burner off for 150 seconds, auto reset.

01180180180180180180180180180180

23456789

18b

19b

24b

25b

26b

2

Display Boiler function

No blower signal

Blower signal present with no demand, Burnerwill remain OFF until condition terminates

Temperature difference between the supply and return is more than 72 F. Burner will remain OFFfor 150 seconds. Burner will recycle increasing wating period 1 minute for a max. 20 cycle.

Flue temperature sensor is short-circuited. Burner OFF until corrected

Flue temperature senor is “open” Burner OFFuntil corrected.

Flue temperature greater than 240 F but less than 250 F. Burner off for 150 seconds

Wait for the blower to start

8b229b

30b

35b40b

Indirect water heater temperature sensor is short-circuited. Burner OFF until corrected.

Indirect water heater temperature sensor is“open” or disconnected. Burner OFF until corrected.

33b

38b

52b65b

Power frequency deviation11 6bFlame current signal lost18b1

Standby Mode Display

47

Start-Up Procedures

Setting The Boiler Parameters

Parameter mode

To access PARAMETER mode when the sys-tem is in STANDBY mode, press the MODEbutton once.

To scroll through the list of parameters, simplypress the “STEP” button. The first digit is theparameter number followed by the parametervalue. To modify a parameter value, use the +or - keys. Then press “STORE” to save thevalue you just changed. The display flashesonce to confirm the data has been stored.

To activate the parameters you changed, press“RESET”. However, if you do not press a key,the system returns to STANDBY mode after 20minutes and automatically stores the changes.

Note 1: This parameter is factory set to 140ºF.It is important to note the control adds 46ºF tothis setting, therefore the actual domestic hotwater boiler setpoint is 140ºF + 46ºF = 186ºF.

Note 2: This parameter should not be changedfrom the factory setting of 01. The perfor-mance of the DHW will be affected and canbecome unreliable.

Note 3: This parameter should not be changedfrom the factory setting of 01. The perfor-mance of the CH (Central/Space Heating) willbe affected and can become unreliable.

ARAP

Domestic Hot Water Setting (See Note 1)

DHW Application Selection (See Note 2)

CH Application Selection (See Note 3)

CH Maximum Boiler Operating Setpoint

1.2140010181 6

34

.

.

.

.

STEP

STEP

STEP

STEP

Key: Display Description of parameters

ARAPMODE

Key: Display

Pressing MODE once

48

Start-Up Procedures

Accessing Boiler Information

Information mode

To switch from STANDBY mode to INFOR-MATION mode, press MODE twice.

Press STEP until the system displays the infor-mation you need. The first digit is the informa-tion item number followed by the items value.The decimal point located behind the first posi-tion flashes to indicate that the boiler is inINFO mode.

The ignition counters and burner hoursare split into three two digit numbers.For example:

Write the numbers down from left to rightto arrive at 123,456 CH ignitions.

In the INFO Mode a temperature read-ing of -22 typically indicates an “open”circuit. A temperature reading of 240typically indicates a short-circuit.

NOTICE

NOTICE

NFOI

ARAPMODE

NFOIMODE

Key: Display

Pressing MODE once

Pressing MODE twice

Item Value1 Supply Water Temperature ºF2 Return Water Temperature ºF3 DHW Water Temperture ºF (Optional)4 Outdoor Temperture ºF (Optional)5 Flue Temperature ºF6 Boiler Setpoint ºF7 Rate of Increase of Supply Water Temperature ºF/Sec.8 Rate of Increase of Return Water Temperature ºF/Sec.9 Rate of Increase of DHW Water Temperature ºF/Sec.A Not UsedB Not UsedC Not UsedD Not UsedE Ionization Current in micro-ampereF Analog Input VoltageG Not UsedH MCBA Internal Temperture ºFI CH Ignition Counter (100 thousands / 10 thousands)

Seg. e CH Ignition Counter (thousands / hundreds)Seg. 'c CH Ignition Counter (ten / ones)

J CH Ignition Hours (100 thousands / 10 thousands)Seg. e CH Ignition Hours (thousands / hundreds)Seg. 'c CH Ignition Hours (ten / ones)

L DHW Ignition Counter (100 thousands / 10 thousands)Seg. e DHW Ignition Counter (thousands / hundreds)Seg. 'c DHW Ignition Counter (ten / ones)

N DHW Burner Counter (100 thousands / 10 thousands)Seg. e DHW Burner Counter (thousands / hundreds)Seg. 'c DHW Burner Counter (ten / ones)

J 12.34.56

Display DigitSegments

49

Start-Up Procedures

Error (Hard Lockout) Mode

If a serious fault occurs, the system enters ahard lockout condition which requires a manu-al reset by pressing the RESET button. A hardlock is indicated by displaying an E for the firstdigit, followed by the error code.

For a detailed description of the error codes, ref-erence the PRESTIGE Solo TroubleshootingGuide.

The boiler freeze protection feature isdisabled during a Hard Lockout, howev-er the CH circulator will operate.

During a hard lockout or low water con-dition the boiler will not re-start withoutservice. If the heating system is left unat-tended in cold weather appropriate safe-guards or alarms should be installed toprevent property damage.

CAUTION

CAUTION

Gas valve harness not properly connected

Failed ignition after 5 attempts

Power supply lost after lockout occured

Internal control failure


EE

020304

0809

EE

E

Display Hard Lockout

Internal control failure05E Internal control failure06E Internal control failure07E

Flame detected prior to burner startupE 00


External limit (terminals 13 & 14) is OPEN

Blower signal does not reset to zero

No blower signal present

Supply Temperature sensor is short circuited

1112

1516

2928

E

EE

EE

E Flue Temperature exceeds 250 F52E Internal control error - failure to read parameters

61

E

Return Temperature sensor is short circuited

Supply Temperature sensor is OPEN

Return Temperature sensor is OPEN



Inadequate power supply to the fan

EE

3132

3637

44

60

65

EE

E

EE

Flue Temperature sensor is short circuit

40E

Return Temperature exceeds 212 F

Supply Temperature increased too rapidly





Internal control failure17

1925

13

E

EE

E

Supply Temperature exceeds 212 F18E

E 14

Flue Temperature sensor is OPEN

35E

E Internal control failure15E Supply or Return Temperature sensor drift

23

Invalid power frequency

Supply or Return Temperature failure

Supply or Return Temperature not changing

1311111

22

24

E

EE

50


SECTION XI - Outdoor Reset Control

The boiler setpoint for a heating call can befixed or vary with the outdoor temperature. Ifthe application requires a constant supply tem-perature from the boiler, the outdoor tempera-ture sensor should not be connected to the boil-er. If an outdoor temperature sensor is con-nected to the boiler, the outdoor reset functionis automatically enabled and will vary the CHsetpoint with the change in outdoor tempera-ture. The outdoor reset function has no affecton the DHW setpoint during a domestic call.

Mounting the Outdoor Sensor

1. Remove the front cover and mountingscrews / anchors from the sensor enclosure.

2. When mounting the enclosure the exteriorwall selected should represent the heat loadof the building. Typically a northern ornortheastern wall will suit most buildings.A southern facing wall may suit buildingsthat have large glass walls or windows onthe southern face.

3. Ensure the sensor enclosure is shieldedfrom direct sunlight or the effects of heat orcold from other sources (exhaust fans,appliance vents...) to prevent false temper-ature sensing.

4. Mount the sensor enclosure at an elevationon the exterior wall to prevent accidentaldamage or tampering.

5. Avoid mounting the enclosure in areas sub-jected to excessive moisture.

6. Once an area on the exterior wall has beendetermined, to affix the enclosure use theenclosure as a template to mark the locationof the mounting screws.

7. Using a 3/16” drill bit, drill 2 pilot holes onthe marked locations.

8. Tap the enclosed plastic anchors into thepilot holes. Use care not to damage theanchors.

9. Mount the sensor enclosure using thescrews provided.

Wiring the Sensor

1. Remove the sealing nut and sealing gasketfrom the sensor enclosure.

2. Route two 18 gauge wires through the seal-ing nut and gasket. Connect the wires tothe sensor terminals 1 and 2.

3. Re-insert the sealing gasket and tighten thesealing nut to the sensor enclosure.

4. Route the sensor wire back to the PRES-TIGE Solo boiler, ensuring the wires arenot run parallel to telephone or powercables.

If the sensor wires are located in an areawith sources of potential electromagneticinterference (EMI) the sensor wiresshould be shielded or the wires should berouted in a grounded metal conduit. Ifusing shielded cable, the shielding shouldbe connected to the common ground ofthe unit.

5. Connect the sensor wires to the outdoor sen-sor terminals on the 24V terminal strip locat-ed inside the boiler enclosure (see boilerwiring diagram, Fig. 20 page 32).

NOTICE

Fig. 25: Sensor Enclosure and Components

51


Summer / Winter Switch at Boiler

If required the CH (Central Heating) system canbe turned off at the boiler, similar to a manualsummer / winter switch by pressing and holding

the “+” button while in the “StbY” mode. The

display will show “cOFF”. Pressing and holdingthe “+” button turns the CH system back on.The display will show “c” followed by the CHset point temperature.

If a parameter setting is changed but theSTORE button is not pressed to save thesetting, the MCBA will automaticallystore the setting after 20 minutes. Ensureall parameters are at their factory set-tings or appropriately revised for theapplication prior to commissioning theboiler. Failure to comply could result inerratic or unreliable operation of thePrestige boiler.

Once a parameter setting has beenrevised and stored pressing the STEPbutton will display the setting of the nextparameter without showing P_XX. Toavoid confusion, it is advisable to contin-ue pressing the STEP button untilParameter 46 is reached. The next pressof the STEP button will cause the displayto roll over to Parameter 1. Continuepressing the STEP button until the nextparameter to be adjusted is reached andrevise the setting.

Adjusting Outdoor Reset Curve

Parameters 4, 10, 11, & 12 define the settingsof the outdoor reset curve. See Graph 1 andTable 3, page 53 for an example of modifyingthe outdoor reset curve.

CH Maximum Boiler Operating Setpoint(Parameter 4)

If an outdoor temperature sensor is not con-nected to the boiler, the boiler setpoint for aheating call will be set to the CH MaximumBoiler Operating Setpoint. If an outdoor tem-perature sensor is connected, the CHMaximum Boiler Operating Setpoint becomesthe boiler setpoint on the CH Reset CurveColdest Day. The outdoor temperature can bemonitored on the boiler display via item 4 ofthe INFO menu.

CH Minimum Boiler Operating Setpoint(Parameter 10)

This parameter is not applicable if an outdoorsensor is not connected to the boiler. When anoutdoor temperature sensor is connected, theCH Minimum Boiler Operating Setpointbecomes the boiler setpoint on the CH ResetCurve Warmest Day.

CH Reset Curve Coldest Day(Parameter 11)

This parameter is not applicable if an outdoorsensor is not connected to the boiler. When anoutdoor temperature sensor is connected, theCH Reset Curve Coldest Day is the coldestdesign temperature of the heating system.

NOTICE

WARNING

52


CH Reset Curve Warmest Day(Parameter 12)

This parameter is not applicable if an outdoorsensor is not connected to the boiler. When anoutdoor temperature sensor is connected, theCH Reset Curve Warmest Day is the warmestdesign temperature of the heating system.

Entering MCBA Access Code

The installer must enter the MCBA AccessCode to adjust the advanced parameter settingsof the MCBA. The Access Code can beentered as follows:

1. Press the MODE button until the displayshows STBY.

2. Press and hold the MODE and STEP but-tons together for 2 to 3 seconds until thedisplay shows CODE.

3. Press the STEP button once and the displaywill show C_XX where XX represents a ran-dom number.

4. Press the “+” or “–“ buttons to change thenumber displayed to read C_54.. Press andhold the “+” or “–“ button to rapidlychange the number.

5. When the display reads C_54, press theSTORE button to save the Access Code.The display should flash to indicate that theAccess Code was saved.

After the Access Code has been entered, theadvanced parameters can be accessed by press-ing the MODE button until the display showsPARA. Once the display shows PARA, pressthe STEP button to reach the appropriate para-meter. The display should follow the followingsequence:

Press STEP once- 1140Press STEP x2 - 2_01Press STEP x3 - 3_01Press STEP x4 - 4186Press STEP x5 - P_10Press STEP x6 - P_11 Etc......

After Parameter 4, the display will show P fol-lowed by the parameter number. Once a par-ticular parameter is reached, the display willchange to show the current setting of that para-meter.

The actual parameter values displayed onthe display may vary depending on theapplication, but the sequence will alwaysoccur in the order shown.

Changing a Parameter Setting

1. Use the “+” or “–“ button to change theparameter setting.

2. Press the STORE button to save thechange. The display should flash to indi-cate that the change was saved.

3. Press the RESET button to leave the AccessCode mode.

NOTICE

53


Graph 1 illustrates Parameter 4 adjusted to 140ºF target temperature at 0ºF outdoorair temperature

Table 3: Outdoor Air Temperature Reset (Example)

90

20

60

100

140

180

7064

50 30 10 0 -10

86

Boi

ler

Tem

pera

ture

( F

)

Outdoor Air Temperature ( F)

Parameter 4 Set Point

Parameter 10 Set Point

Par

amet

er 1

2 S

ettin

g

Par

amet

er 1

1 S

ettin

g

Graph 1: Outdoor Air Temperature Reset Curve (Example)

Note: Factory setting of Parameter 4 is 186ºF.

54

External Modulating Control

SECTION XII - EXTERNAL MODULAT-ING CONTROL

The boiler can directly accept an analog 0-10VDC signal to control the firing rate from anexternal modulating boiler controller.

Wiring the Modulating Controller

Run two 18 gauge wires from the externalmodulating boiler controllers 0-10 VDC boileroutput to the external input terminals on thelow voltage terminal strip inside the boiler. (seeboiler wiring diagram, Fig. 20 page 32). Thissignal will both enable and modulate the boil-er. No wiring is required at the thermostat (T-T) terminals 7 and 8 of the boiler.

Ensure that the polarity of the connec-tions from the external modulating boil-er controller to the boiler is correct.Reversed polarity could lead to erraticand/or no response from the boiler con-troller.

Parameter Adjustment

The Prestige MCBA control module must beprogrammed to accept the 0-10 VDC signalfrom the external modulating boiler control.

CH Operating Signal Section(Parameter 45)

Follow the procedure for entering the MCBAAccess Code on page 52, and then change thesetting of Paramater 45 from the factory settingof 00 to 02.

Ensure that Parameter 4 is set above thehighest setpoint of the external modulat-ing control. Paramater 4 is a boiler hightemperature limit when using an exter-nal modulating controller.

Programming of External ModulatingControl

The external modulating control must be pro-grammed to send 1.8 VDC to enable the boilerand run it at low fire, and 10 VDC to run theboiler at high fire. Once the control enables theboiler, it must wait 2 minutes to allow the burn-er to stabilize before modulating the boiler.

NOTICE

NOTICE

55

Factory Setting Parameters

FACTORY SETTING FOR PARAMETERS

56

Check-Out Procedures

SECTION XIII- Check-Out Procedures

Perform the following check-out proce-dures as outlined and check off items ascompleted. When procedures are com-pleted, the installer should complete theinstallation record on page 57.

Check-Out Procedures

c Boiler system water chemistry checked andverified as outlined on page 37.

c The boiler air vent and any automatic airvents placed within the system are openone full turn.

c Air is purged from the heating zones andboiler system piping.

c If applicable, confirm that the burner hasbeen properly configured for Propane asoutlined on page 29.

c Thermostat circuit wiring checked and ver-ified that no voltage is present to the lowvoltage terminals as outlined on page 39.

c Operating Instructions on page 42 were fol-lowed during start-up.

c Combustion levels and flame pattern veri-fied as outlined on page 41.

c Measured the rate of input on Natural Gasas outlined on page 41.

c Checked the incoming gas pressure to thePRESTIGE Solo to ensure a minimumpressure of 5”w.c during flow conditions toall gas appliances and a maximum pressureof 13”w.c during non-flow conditions forNatural and Propane.

c Adjusted balancing valves and system limitcontrols to provide design temperatures tothe primary space heating system.

c In multiple zone applications, adjusted forcorrect flow of boiler water to each zone.

c Checked and verified room thermostat(s)function properly and the thermostat(s)heat anticipator (if used) was properly set.

c Observed several operating cycles forproper operation of the PRESTIGE Soloand the system.

c Set the room thermostat(s) to the desiredroom temperature.

c Reviewed all instructions shipped with thePRESTIGE Solo with the homeowner ormaintenance personnel.

c Completed the Installation Record on page57.

c Ensure all manuals and other documentsare returned to the Installation envelopeand given to the owner for safekeeping.

NOTICE

57

Installation Record

SECTION XIV - Installation Record

PRESTIGE Model Number:

Serial Number:

Date of Installation:

Fuel: Natural Gas Propane

Measured Rate of Input:

Combustion Readings:

CO2

O2

CO

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.

Installer Information

(Company)

(Address)

(Address)

(Phone Number)

Btu/hr

____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

_________________________________________________________________

%

%

ppm

58

Maintenance Schedule

SECTION XV - Maintenance ScheduleService Technician

At least on an annual basis the following main-tenance should be performed by a qualified ser-vice technician:

General

- Attend to any reported problems.

- Inspect the interior of the boiler jacket area;clean and vacuum if necessary.

- Clean the condensate drain assembly andfill with fresh water.

- Check for leaks: water, gas, flue and con-densate.

- Verify flue vent piping and air inlet pipingare in good condition, sealed tight andproperly supported.

- Check boiler water pressure, piping andexpansion tank.

- Check control settings.

- Check ignition electrode (sand off anywhite oxide; clean and reposition).

- Check ignition wiring and ground wiring.

- Check all control wiring and connections.

- Check burner flame pattern (stable and uni-form).

Additional items if combustion or performanceis poor:

- Clean heat exchanger and flue ways.

- Remove burner assembly and clean burnerhead using compressed air only.

Once the maintenance items are completed,review the service with the owner.

Owner Maintenance

Periodically:

- Check the area around the unit.

- Check and remove any blockage from thecombustion air inlet and ventilation open-ings.

- Check the temperature and pressuregauges.

Monthly:

- Check vent piping.

- Check combustion air inlet piping.

- Check the pressure relief valve.

- Check the condensate drain system.

Every 6 months:

- Check boiler piping and gas supply pipingfor corrosion or potential signs of leakage.

- Operate the pressure relief valve.

Follow the maintenance proceduresgiven throughout this manual. Failureto perform the service and maintenanceor follow the directions in this manualcould result in damage to the PRES-TIGE Solo or in system components,resulting in severe personal injury, deathor substantial property damage.

WARNING

59

Maintenance Procedures

SECTION XVI - MaintenanceProcedures


The PRESTIGE Solo should be inspect-ed and serviced annually, preferably atthe start of the heating season, by a qual-ified service technician. In addition, themaintenance and care of the unit as out-lined on page 58 and further explainedon pages 59 through 64 should be per-formed to assure maximum efficiencyand reliability of the unit. Failure to ser-vice and maintain the PRESTIGE Soloand the system components could resultin equipment failure, causing possiblesevere personal injury, death or substan-tial property damage.

The following information providesdetailed instruction for completing themaintenance items outline in the mainte-nance schedule on page 58. In additionto this maintenance, the PRESTIGESolo should be serviced at the beginningof the heating season by a qualified ser-vice technician.

Reported Problems

Any problems reported by the owner should bechecked, verified and corrected before pro-ceeding with any maintenance procedures.

Check Surrounding Area

Verify that the area surrounding the PRES-TIGE Solo is free of combustible / flammablematerials or flammable vapors or liquids.Remove immediately if found.

Verify that combustion air inlet area is free ofany contaminates. Refer to the materials listedon page 5 of this manual. If any of these prod-ucts are in the area from which the unit takesits combustion air, they must be removedimmediately or the combustion air intake mustbe relocated to another area.

Inspect Burner Area

Remove the boiler front jacket panel and ven-turi inlet elbow.

Vacuum any dirt or debris from theburner/blower components.

Re-install venturi inlet elbow and front jacketpanel when completed.

Do not use solvents to clean any of theburner components. The componentscould be damaged, resulting in unreli-able or unsafe operation.

Check System Piping

Inspect all piping (water and gas) on the boilersystem for leaks and verify that the piping isleak free and properly supported.

Inspect the fittings and components on the unitand verify they are leak free.

Eliminate all boiler water system leaks.Continual fresh make-up water willreduce the heat exchanger life causingboiler failure. Leaking water may alsocause severe property damage to the sur-rounding area. Inspect the gas supplypiping using the procedure outlined onPage 41.

WARNING

WARNING

NOTICE

WARNING

60


Clean Condensate Drain Assembly

1. Loosen the retaining nut from the conden-sate drain assembly and disconnect theassembly from the boiler.

2. Empty any water from the trap and drainassembly. Flush with fresh water as neces-sary to clean.

3. Check the drain piping from the condensatedrain assembly to the drain. Flush to cleanas necessary.

4. Reassemble the condensate drain assemblyonto the boiler by tightening the retainingnut with rubber seal onto the boiler. Handtight only.

5. Remove the fill plug on the condensate drainassembly and fill with water. See Fig. 15 onpage 26.

6. Replace the fill plug on drain assembly.

Check Ventilation Air Openings

Verify that all ventilation openings to themechanical room or building are open andunobstructed. Check the operation and wiringof any automatic ventilation dampers.

Check and verify the vent discharge and thecombustion air intake are free of debris andobstructions.

Inspect Vent and Combustion Air Piping

Visually inspect the venting system and com-bustion air piping for blockage, deteriorationor leakage. Repair any deficiencies.

Verify that the combustion air inlet piping isconnected, sealed and properly supported.

Failure to inspect the vent system andcombustion air inlet piping and to haveany conditions repaired, can result insevere personal injury or death.

Check Boiler System

Verify all system components are correctlyinstalled and operating properly.

Check the cold fill pressure for the system, typ-ical cold water fill pressure is 12 psig.

Verify the system pressure, as the unit operates athigh temperature, to ensure the pressure does notexceed 25 psig. Excessive pressure reading indi-cates expansion tank sizing is incorrect or systemperformance problems.

Inspect air vent and air separators in the sys-tem. Remove the caps on automatic air ventsand briefly depress the valve stem to flushvent. Replace the cap when completed. Ensurevents do not leak, replace any leaking vents.

WARNING

61


Check Expansion Tank

Refer to Section IV - Boiler Piping for rec-ommended location of the expansion tankand air eliminators.

Closed -Type Tank:

- Ensure tank is partially filled withwater leaving an air gap as a cushion.Refer to the manufacturer’s instructionfor proper fill level.

- Ensure the tank is fitted with a devicethat reduces gravity circulation of air-saturated tank water back into the sys-tem. This device prevents air frombubbling up through the water as itreturns from the system.

- Ensure no automatic air vents are usedin the system. This will allow air toescape from the system instead ofreturning to the tank.

Diaphragm Tank:

- Ensure the system contains a minimum ofone automatic air vent. Recommendedlocation of the air vent should be atop anair eliminator.

- Remove the tank from the system andcheck the charge pressure. For residen-tial applications the charge pressure istypically 12 psig. If tank does not holda charge pressure, then the membrane isdamaged and the tank should bereplaced.

Check Boiler Relief Valve

Inspect the relief valve and lift the lever to ver-ify flow at least annually or as recommendedon the warning tag of the valve.

Before manually operating the pressurerelief valve, ensure the discharge piping isdirected to a suitable place of disposal toavoid a potential scald hazard. The dis-charge piping must be full size withoutrestriction and installed to permit com-plete drainage of both the valve and line.

If after closing the valve, the valve fails to seatproperly or continually weeps, replace therelief valve. Ensure the cause of the reliefvalve to weep is the valve itself, not due to sys-tem over-pressurization caused by an expan-sion tank that is waterlogged or undersized.

Inspection of Ignition Electrode

Remove the ignition electrode from the burnermounting plate.

Remove any white oxides accumulated on theelectrode using fine grit sandpaper or steel wool.If the electrode does not clean to a satisfactorycondition, replace the ignitor.

When replacing the ignition electrode, ensurethe gasket is in good condition and correctlypositioned, replace gasket if necessary.

Check Ignition Wiring and Ground Wiring

Inspect the burner wiring from the burner con-trol module to the ground terminal behind thecontrol panel.

Ensure wiring is in good condition and secure-ly connected.

Check ground continuity of the wiring to theboiler jacket or piping using a continuity meter.

Replace and correct ground wire if ground con-tinuity is not completed and satisfactory.

WARNING

62


Check Control Wiring

Inspect all control wiring. Ensure wiring is ingood condition and properly connected.

Check Control Settings

1. Set the control display to PARAMETERmode and check all boiler settings. Adjustsetting as necessary see page 47.

2. Check any external limit control settings (ifused). Adjust settings as necessary.

Perform Start-up and Checkout Procedures

Start the unit and perform the start-up proce-dure as listed in this manual.

Verify the cold water fill pressure is correct andthe operating pressure of the boiler is withinnormal operating range.

Complete the checkout procedures as refer-enced in this manual.

Check Burner Flame

Inspect the burner flame through the observa-tion port on the heat exchanger.

If flame pattern is not fully blue and covers theentire burner surface during high fire, shut theunit down and allow it to cool thoroughly beforedisassembly.

Close the external manual gas valve on the gassupply line and disconnect the gas piping andrectifier plug.

Disconnect the wiring harness connectors fromthe blower and remove the blower retainingscrews or nuts. Remove the blower from theunit.

Remove the mounting nuts securing the burnermounting plate to the heat exchanger and setaside.

Carefully remove the burner mounting plateassembly from the heat exchanger. Ensurecombustion chamber insulation is not damagedduring removal of burner mounting plateassembly. See WARNING on page 64.

Remove the burner head mounting screws andremove the burner head. Inspect the burnerhead for deterioration. Use compressed air ora vacuum to clean the burner head.

Remove the venturi and gas valve assemblyfrom the blower.

Use a vacuum cleaner or compressed air toclean the interior of the blower assembly.Inspect the blower blades to ensure they areclean and not damaged.

Re-assemble the venturi and gas valve onto theblower. Ensure the venturi gasket is in goodcondition, positioned correctly and replace gas-ket if necessary.

Re-assemble the burner head onto the burnermounting plate. Ensure the burner head gasketis in good condition, positioned correctly andreplace gasket if necessary.

Re-assemble the burner mounting plate assem-bly onto the heat exchanger. Ensure the burnerplate gasket and combustion chamber insula-tion is in place and not damaged, replace gas-ket and insulation if necessary. See WARNINGon page 64.

Re-assemble the blower onto the burnermounting plate and reconnect the wiring har-ness connectors.

Re-assemble the gas supply connection andrectifier to gas valve. Open the external manu-al gas valve. Check gas piping for any leaks asoutlined on page 41 and repair if necessary.Place the unit back into service.

63


Check Flame Signal

The flame signal can be read from item E of theinformation mode. It should be a min. 3µ Α −DC.

Check the ignitor for fouling or damagedinsulation if a low flame signal is read.

Check ground wiring and continuity as a causefor low flame signal. Replace ignitor if condi-tions are satisfactory.

Check Combustion Levels

Refer to page 41 of this manual for measuringcombustion levels and burner adjustments.

Check Flue Gas Temperature

1. Adjust the boiler to fire at HIGH fire, seepage 45. Place the control display to INFOR-MATION mode, see page 47 for procedures.

2. The flue gas temperature is indicated onthe display when the first digit is 5. Themeasured temperature (shown as the last 3digits) should not be more than 54ºF high-er than the measured supply water temper-ature.

3. The measured supply water temperature isindicated on the information display whenthe first digit is 1 and the temperatureshown as the last 3 digits.

4. If the measured flue gas temperature ishigher than 54ºF over the supply watertemperature, shut the boiler down and fol-low the procedures listed below to cleanthe heat exchanger.

Clean Heat Exchanger

1. Shut down the boiler:

- Follow the instructions on Page 42 "ToTurn Off Gas to Appliance"

- Do not drain the boiler unless the boil-er will be subject to freezing condi-tions.

- Do not drain the boiler if freeze protec-tion fluid is used in the system.

2. Allow the boiler to cool down to room tem-perature before servicing.

3. Disconnect the gas piping and rectifierplug to the gas valve.

4. Disconnect the wiring harness connectorsfrom the blower and remove the blowerretaining screws or nuts. Remove the blow-er from the unit.

5. Remove the mounting nuts securing theburner mounting plate to the heat exchang-er and set aside.

6. Carefully remove the burner mountingplate assembly from the heat exchanger.Ensure combustion chamber insulation isnot damaged during removal of burnermounting plate assembly. See WARNINGon page 64.

7. Carefully remove the combustion chamberinsulation from the heat exchanger and setaside. See WARNING on page 64.

8. Use a vacuum cleaner, compressed air orwater to remove any accumulation fromthe heat exchanger flue ways. Do not useany solvent.

9. Re-install the combustion chamber insula-tion onto the heat exchanger.

10. Re-assemble the burner mounting plateassembly onto the heat exchanger. Ensurethe burner plate gasket and combustionchamber insulation is in place and not dam-aged, replace gasket and insulation if nec-essary. See WARNING on page 64.

11. Re-assemble the blower onto the burnermounting plate and reconnect the wiringharness connectors.

12. Reconnect the gas piping and rectifier togas valve. Check for leaks, repair if neces-sary.

13. Close isolation valves on the boiler waterpiping to isolate the boiler from the heatingsystem.

64


The combustion chamber insulationcontains ceramic fibers, which are clas-sified as a possible human carcinogen.When exposed to extremely high tem-peratures, the ceramic fibers, whichcontain crystalline silica, can be con-verted into cristobalite.

Avoid Breathing and Contact with Skinand Eyes

When removing or repairing the combustionchamber insulation follow these precautionmeasures:

1. Use a NIOSH approved respirator whichmeets OSHA requirements for cristobalitedust, similar to N95. Contact NIOSH at1-800-356-4676 or on the web atwww.cdc.gov/niosh for latest recommen-dations.

2. Wear long sleeved, loose fitting clothing,gloves and eyes protection.

3. Assure adequate ventilation.

4. Wash with soap and water after contact.

5. Wash potentially contaminated clothesseparately from other laundry and rinsewashing machine thoroughly.

6. Discard used insulation in an air tightplastic bag.

NIOSH Stated First Aid:Eye/Skin: Immediately irrigateBreathing: Clean fresh air

WARNING

Handling Previously Fired Combustion Chamber Insulation

14. Attach a hose to the boiler drain valve andflush the boiler thoroughly with fresh waterby using the purge valves to allow water toenter through the make-up water line to theboiler.

15. Once the boiler has been completelyflushed, return the boiler and system pipingback to operation.

16. Perform the required startup and checkoutprocedures as outlined on pages 37 to 57.

Review With Owner

Ensure the owner understands the impor-tance to perform the maintenance schedulespecified in this manual.

Remind the owner of the importance to calla licensed contractor should the unit or sys-tem exhibit any unusual behavior.

65

Replacement Parts

5

9

81

3

5

2

6

7

Fig. 26: PRESTIGE Solo Jacket Components

66

Replacement Parts

8

5

9

2

3

4

4

67

1

Fig. 27: PRESTIGE Solo 60 Internal Components

67

Replacement Parts

8

5

4

4

10

9

7

1

3

2

6

Fig. 27A: PRESTIGE Solo 175/250 Internal Components

68

Replacement Parts

8

7

10

1

2

3

4

4

5

6

9

Fig. 27B: PRESTIGE Solo 399 Internal Components

69

5

2

4

8

1

3

9

67

Item

Part No.PRESTIGE

Solo 60

Part No.PRESTIGE Solo

175/250 Description

1 PSRKIT09 PSRKIT30 Combustion Chamber Insulation

2 PSRKIT11 PSRKIT31 Burner Head with Gasket

3 PSRKIT12 PSRKIT32 Burner Plate

4 PSRKIT55 PSRKIT13 Blower with Gasket

5 Gas Valve

6 Venturi - 055 (Solo 60) - 052 (Solo 175) - 051 (Solo 250)

7 Ignition Cable

8 Igniter with Gasket

9 Sight Glass Assembly (Glass, Gasket and Bracket)

10 Propane Orifice- Not Shown

11 Burner Plate Gasket - Not Shown

12 Gas Valve Rectifier Plug - Not ShownPGRKIT15

PSRKIT14

PSRKIT15

PSRKIT16

--

PGRKIT01

--

--

Fig. 28: PRESTIGE Solo 60/175/250 Burner Components

Replacement Parts

70

Replacement Parts

7

6

9

1

2

10

12

13

4

3

5

8

Fig. 28A: PRESTIGE Solo 399 Burner Components

71

3

Fig. 29: PRESTIGE Solo Electronic Components

Replacement Parts

72

Product Specifications

35.5

0” [9

02 m

m]

15.43” [392 mm]

9.87” [251 mm]

9.87” [251 mm]

2.2” [56 mm]

3” [76 mm]

1 ” NPT Boiler Supply

1/2” NPT Gas Connection

3/4” NPSC Pressure Relief Valve

3” Combustion AIr Inlet

3” Vent Outlet

19.75” [502 mm]

7.31” [186 mm] 1” NPT Boiler Return

Front View PRESTIGE Solo 60

73


Front View PRESTIGE Solo 175/250

74


37.2

0” [9

45 m

m]

24.70” [628 mm]

20.40” [516 mm]

18.60” [473 mm]

13.40” [340 mm]

9.25” [235 mm]

3.27” [83 mm]

1 1/2” NPT Boiler Supply

1” Gas Connection

1 1/2” NPT Boiler Return

4” Combustion Air Inlet


4” Vent Outlet

17.87” [454 mm]

Front View PRESTIGE Solo 399

75


11.66” [296 mm]

1.89” [48mm]

15.60” [396 mm]

2.28” [58mm]

12.04” [306 mm]

1/2” NPT Gas Connection

1” NPT Boiler Supply1” NPT Boiler Return

3” Vent Outlet3” Combustion AIr Inlet


Side View PRESTIGE Solo 60

76


Side View PRESTIGE Solo 175/250

77


20.80” [529 mm]

15.40” [490 mm]

14.72” [374 mm]

16.10” [409 mm]

5.90” [150 mm]

1 1/2” NPT Boiler Supply

1 1/2” NPT Boiler Return

1” Gas Connection

4” Combustion Air Inlet4” Vent Outlet


Side View PRESTIGE Solo 399

78


OutputNote 4

157,500

94.1% 95.1%

Fuel CombustionEfficiency

InputNote 4

OutputNote 4Note 5

ThermalEfficiency

Net IBRRatingNote 2

ShippingWeight

Lbs / Kg

BoilerModel

225,500

379,000399,000 330,000 225 / 102NaturalSOLO 399

102,500 110,000 102,500Propane 87,000

FuelDOE

Heating CapacityNote 1 & 4

InputNote 4

DOE SeasonalEfficiency AFUE

Note 3

Net IBRRatingNote 2

60,000 95%

ShippingWeight

Lbs / Kg

95 / 43Natural

BoilerModel

SOLO 60 47,000

110,000 102,500 95% 95 / 43Propane 87,000

154,000

54,000

170,000 95% 131 / 60NaturalSOLO 175 134,000

102,500 102,500 95% 131 / 60Propane

Propane

87,000

223,000245,000 95% 142 / 65NaturalSOLO 250 194,000

102,500 110,000 102,500 95% 142 / 6587,000

Note 1: The heating capacity of the PRESTIGE Solo60/175/250 is based on the test requirementsof the U.S. Department of Energy.

Note 2: The IBR rating is based on a piping and pickup allowance of 1.15. This allowance shouldbe sufficient for the standard radiationrequirements for a building load.

Note 3: Based on the given AFUE the PRESTIGESolo 60/175/250 meets the energy efficiencyguidelines established by Energy Star.

Note 4: Input and output ratings are shown for sealevel applications. The PRESTIGE Soloautomatically derates the input at approxi-mately 2% for every 1,000 Ft. of altitude. Noalterations to the boiler or burner system isrequired.

Note 5: PRESTIGE Solo 399 output rating is basedoff of the thermal efficiency.

DOE

79


Graph 2: Pressure Loss Through Boiler-Grundfos Circulator

Pressure Drop Comparison -Grundfos

Note: Minimum allowable flow rate at full input:- 3 gpm SOLO 60

Graph 3: Pressure Loss Through Boiler-Taco Circulators

Pressure Drop Comparison -Taco

80


Graph 4: Pressure Loss Through Boiler - Grundfos Circulators

Note: Minimum allowable flow rate at full input:

- 8 gpm SOLO 175

- 12 gpm SOLO 250

Graph 5: Pressure Loss Through Boiler - Taco Circulators

81


Graph 6: Pressure Loss Through Boiler - Grundfos Circulators

Note: Minimum allowable flow rate at full input:

- 19 gpm SOLO 399

Graph 7: Pressure Loss Through Boiler - Taco Circulators

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