Prestige SOLO 110.pdf - Bloom Lake Farms

Table of ContentsPRODUCT AND SAFETY INFORMATIONDefinitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Product and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2SECTION I - PRE-INSTALLATION ITEMSCode Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Determining Product Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Boiler Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Recommended Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Residential Garage Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Boiler Freeze Protection Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4SECTION II - COMBUSTION AIR AND VENTINGCombustion 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. . . . . . . . . . 8-9Combustion Air and Vent Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Removal of an Existing Boiler from a Common Vent System . . . . . . . . . . 10Commonwealth of Massachusetts Installation . . . . . . . . . . . . . . . . . . . . . . . 11SECTION III - UNIT PREPARATIONSHandling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Wall Mounting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Wall Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Wall Bracket Installation - Stud Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13Wall Bracket Installation - Solid Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Boiler Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13SECTION IV - BOILER PIPINGGeneral Piping Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Low Water Cut Off Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Pressure Relief Valve and Boiler Drain Valve Installation. . . . . . . . . . . . . . 15Additional Limit Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16i

Table of ContentsBackflow Preventer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Boiler System Piping Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Expansion Tank and Makeup Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17Diaphragm Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Closed-Type Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24SECTION V - INSTALLING VENT / COMBUSTION AIR & CONDENSATE DRAINInstalling Vent and Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Installing Condensate Drain Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-26SECTION VI - GAS PIPINGGas Supply Piping Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Natural GasPipe Sizing -Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Natural Gas Supply Pressure Requirements. . . . . . . . . . . . . . . . . . . 28Propane GasPipe Sizing - Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Propane Gas Supply Pressure Requirements . . . . . . . . . . . . . . . . . . 29Gas Valve/Venturi Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30SECTION VII - INTERNAL WIRINGGeneral Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Control Module Circulator AMP Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . 31Wiring Tool Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Internal Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32ii

Table of ContentsAccessing Boiler InformationInformation Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Error (Hard Lockout) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49SECTION XI - OUTDOOR RESET CONTROLMounting the Outdoor Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Wiring the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Summer/Winter Switch at Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Adjusting Outdoor Reset CurveCH 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) . . . . . . . . . . . . . . . . 52Entering MCBA Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Changing a Parameter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Outdoor Reset Curve Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53SECTION XII - EXTERNAL MODULATING CONTROLWiring the Modulating Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Parameter Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Programming of External Modulating Control . . . . . . . . . . . . . . . . . . . . . . 54Factory Setting for Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55SECTION XIII - CHECK-OUT PROCEDURESCheck-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56SECTION XIV - INSTALLATION RECORDInstallation Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57SECTIONS XV - MAINTENANCE SCHEDULEService Technician - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Owner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58SECTION XVI - MAINTENANCE PROCEDURESMaintenance ProceduresReported Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59iv

Table of ContentsCheck Surrounding Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Inspect Burner Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Check System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Clean Condensate Drain Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 60Check Ventilation Air Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Inspect Vent and Combustion Air Piping . . . . . . . . . . . . . . . . . . . . . 60Check Boiler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Check Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Check Boiler Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Check Ignition Wiring and Ground Wiring . . . . . . . . . . . . . . . . . . . 61Check Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Check Control Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Perform Start-Up and Checkout Procedure . . . . . . . . . . . . . . . . . . . 62Check Burner Flame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Check Flame Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Check Combustion Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Check Flue Gas Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Clean Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-64Review with Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Handling Previously Fired Combustion Chamber Insulation . . . . . 64REPLACEMENT PARTSReplacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-68PRODUCT SPECIFICATIONSSpecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-72v

Product & Safety InformationDefinitionsThe following terms are used throughout this manual to bring attention to the presence ofpotential hazards or important information concerning the product.WARNINGIndicates the presence of a hazardoussituation which, if ignored, will result indeath, serious injury or substantialproperty damage.NOTICEIndicates special instructions on installation,operation or maintenance, whichare important to equipment but notrelated to personal injury hazards.WARNINGIndicates a potentially hazardous situationwhich, if ignored, can result indeath, serious injury or substantialproperty damage.BEST PRACTICEIndicates recommendations made byTriangle Tube for the installers whichwill help to ensure optimum operationand longevity of the equipmentCAUTIONIndicates a potentially hazardous situationwhich, if ignored, may result inminor injury or property damage.NOTICETriangle Tube reserves the right to modify the technical specifications and components ofits products without prior notice.1

Product & Safety InformationDANGERDo 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.WARNINGWHAT 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 supplier,call the fire department.Installation and service must be performedby a qualified installer, serviceagency or the gas supplier.WARNINGShould overheating occur or the gassupply fails to shut off, turn OFF themanual gas control valve external tothe appliance.WARNINGDO NOT add cold make up water whenthe boiler is hot. Thermal shock cancause potential cracks in the heatexchanger.CAUTIONWhen servicing the boiler:- Avoid electrical shock by disconnectingthe electrical supply prior toperforming maintenance.WARNINGQualified 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 guidelineswithin 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.NOTICEPlease reference the unit’s model numberand the serial number from the ratinglabel, on the back side of the controlpanel,when inquiring about service ortroubleshooting.NOTICETriangle Tube accepts no liability for anydamage resulting from incorrect installationor from the use of components orfittings not specified by Triangle Tube.2

Pre-Installation ItemsSECTION I - Pre-Installation ItemsCode ComplianceThis product must be installed in accordance tothe following:- All applicable local, state, national andprovincial codes, ordinances, regulationsand laws.- For installations in Massachusetts -code requires the boiler to be installedby a licensed plumber or gas fitter, andif antifreeze is utilized, the installationof a reduced pressure backflow preventerdevice is required in the boiler’s coldwater fill or make up water supply line.- For installation in Massachusetts alldirect vented appliances must complywith the guidelines as outlined onpage 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.NOTICEThe PRESTIGE Solo boiler gas manifoldand gas controls meet the safe lightingand other performance requirements asspecified in ANSI Z21.13 latest edition.Determining Product LocationBefore locating the PRESTIGE Solo check forconvenient locations to:- Heating system piping- Venting- Gas supply piping- Electrical serviceEnsure the boiler location allows the combustionair/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.WARNINGFailure 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 controls areprotected from dripping or spraying water duringnormal 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 ReplacementIf 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.3

Pre-Installation ItemsRecommended ClearancesThe PRESTIGE Solo is approved for zeroclearance to combustibles, excluding vent andboiler piping.- Boiler Piping - 1/4 inch from combustiblematerials.- Reference the appropriate vent supplementfor clearance requirements.BEST PRACTICETo provide serviceability to the unit it isrecommended that the following clearancesbe maintained:Top boiler jacket - 24 inches [610 mm].Front - 24 inches [610 mm].Bottom boiler piping - 24 inches[610 mm].Rear - 0 inchesSides - 6 inches [153 mm].WARNINGIf the clearances listed above cannot bemaintained or the enclosed in which theboiler is installed is less than 85 cubic feet,the space must be ventilated. See page 6for ventilation requirements.NOTICEWhen maintaining zero clearance or lessthan recommended clearances, someproduct labeling may become hiddenand unreadable.WARNINGWhen installing the PRESTIGE Solo ina confined space, sufficient air must beprovided for proper combustion andventing and to allow, under normal operatingconditions, proper air flow aroundthe product to maintain ambient temperatureswithin safe limits to comply withthe National Fuel Gas Code NFPA 54 -latest edition.4Residential Garage InstallationsWhen installing the PRESTIGE Solo in a residentialgarage, the following special precautionsper NFPA 54/ANSI Z223.1 must be taken:- Mount the unit with a minimum 18inches [458 mm] above the floor levelof the garage. Ensure the burner andignition devices / controls are no lessthan 18 inches [458 mm] above thefloor level.- Locate or protect the unit in a matterso it cannot be damaged by a movingvehicle.Boiler Freeze Protection FeatureThe boiler control has an freeze protection featurebuilt in. This feature monitors the boilertemperature and responds as follows when nocall for heat 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 minutesCAUTIONThe boiler freeze protection feature isdisabled during a hard lockout, howeverthe CH circulator will operate.CAUTIONThe boiler freeze protection feature isdesigned to protect the boiler. The boilershould be installed in a primary/secondarypiping arrangement if it isinstalled in an unheated space orexposed to water temperatures of 46ºF orless. See Section IV for primary/secondarypiping examples. See Section IXfor antifreeze guidelines

Combustion Air and VentingSECTION II - Combustion Air andVentingCombustion Air ContaminationWARNINGIf 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 location.Contaminated combustion air willdamage the unit and its burner system,resulting in possible severe personalinjury, death or substantial propertydamage.WARNINGDo not operate a PRESTIGE Solo if itscombustion air inlet is located near alaundry room or pool facility. Theseareas will always contain hazardous contaminants.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 corrosionof the heat exchanger, burnercomponents and vent system, causingserious damage and presenting a possiblethreat 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/fluorocarbons- Permanent Wave Solutions- Chlorinated wax- Chlorine - based swimming pool chemicals/ cleaners- Calcium Chloride used for thawing ice- Sodium Chloride used for water softening- Refrigerant leaks- Paint or varnish removers- Hydrochloric acid / muriatic acid- Cements and glues- Antistatic fabric softeners used inclothe dryers- Chlorine-type bleaches, detergents, andcleaning solvents found in householdlaundry rooms- Adhesives used to fasten building productsand other similar productsAreas likely to contain these products- Dry cleaning / laundry areas and establishments- 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 establishments- New building construction- Remodeling areas- Garages with workshops5

Combustion Air and VentingVentilation and Combustion AirRequirements - Direct VentA 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 ventilation.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 combustionequipment (gas or oil) the space mustbe provided with adequate air openings to provideventilation 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 installationsin Canada.WARNINGThe space must be provided with ventilation/ combustion air openings properlysized 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 openingsis not required. Failure to provideor properly size the openings couldresult in severe personal injury, death orsubstantial property damage.Ventilation and Combustion AirRequirements - Category IVA Category IV appliance utilizes uncontaminatedindoor or outdoor air (surrounding theappliance) for combustion.BEST PRACTICEIn 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 appliance.This practice also promotes highersystem efficiency by reducing heatedindoor air from being exhausted fromthe house and replaced by cold infiltrationair into the house.For installations in which the PRESTIGE Soloshares the space with air movers (exhaust fan,clothes dryers, fireplaces, etc.) and other combustionequipment (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.WARNINGThe space must be provided with ventilation/ combustion air openings properlysized for all make-up air requirements(exhaust fans, clothes dryers, fireplaces,etc.) and the total input of all appliancesincluding the PRESTIGE Solo whenlocated in the same space. Failure to provideor properly size the openings couldresult in severe personal injury, death orsubstantial property damage.6

Combustion Air and VentingMethods of Accessing Combustion Air Into ASpace - Category IVIndoor Combustion AirNOTICEThe methods listed in this section foraccessing Indoor Combustion Airassume that the infiltration rate is adequateand not less than .40 ACH. Forinfiltration rates less than .40 ACH, referencethe NFPA 54 National Fuel GasCode for additional guidance.Opening Size and LocationOpenings used to connect indoor spaces shallbe sized and located in accordance with thefollowing see Fig. 1:inches of the bottom of the enclosure.The minimum dimension of air openingsshall be not less than 3 inches.- Combining spaces in different stories.The volumes of spaces in different storiesshall be considered as communicatingspaces where such spaces are connectedby 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 AirBEST PRACTICEIsolating the combustion appliance roomfrom the rest of the building and bringingin uncontaminated outside air forcombustion and ventilation is alwayspreferred.Opening Size and LocationThe minimum dimension of air openings shallbe not less than 3 inchesOpenings used to supply combustion and ventilationair shall be sized and located in accordancewith the following:Fig. 1:All Combustion Air from AdjacentIndoor Spaces Through IndoorCombustion Openings- 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 commencewithin 12 inches of the top, andone opening shall commence within 12One Permanent Opening Method. See Fig. 2One 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 communicatewith the outdoors or shall communicatethrough a vertical or horizontal duct to the outdoorsor 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, and7

Combustion Air and Venting- Not less than the sum of the areas of allvent connectors in the space.Fig. 2:All Combustion Air from OutdoorsThrough One Permanent AirOpeningFig. 3:All Combustion Air from OutdoorsThrough Ventilated AtticTwo 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 communicatedirectly, or by ducts, with the outdoorsor spaces that freely communicate with the outdoors,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 ratingof all equipment in the enclosure.See Fig.3.- Where communicating with the outdoorsis through horizontal ducts, eachopening shall have a minimum freearea of not less than 1 sq.in./2000Btu/hr of total input rating of all equipmentin the enclosure. See Fig. 4.Fig. 4:All Combustion Air from Outdoorsthrough Horizontal DuctsCombination of Indoor and OutdoorCombustion AirIndoor Openings: Where used, openings connectingthe interior spaces shall comply withthe Indoor Combustion Air section on page 7.8

Combustion Air and VentingOutdoor Opening(s) Location. Outdoor opening(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 communicatingspaces divided by the requiredvolume.- The outdoor size reduction factor shallbe 1 minus the ratio of interior spaces.- The minimum size of outdoor opening(s)calculated in accordance with theabove outdoor air section multiplied bythe reduction factor. The minimumdimension of air openings shall not beless than 3 in.DANGERDo not install the PRESTIGE Solo into acommon vent with other gas or oil appliances.This may cause flue gas spillage orappliance malfunction, resulting in possiblesevere personal injury, death or substantialproperty damage.Combustion Air and Vent PipingThe PRESTIGE Solo requires a Category IVventing system, which is designed for pressurizedventing and condensate.BEST PRACTICEIn 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 appliance.This practice also promotes highersystem efficiency by reducing heatedindoor air from being exhausted fromthe house and replaced by cold infiltrationair into the house.NOTICEInstall combustion air and vent pipe asdetailed in the PRESTIGE Solo VentSupplement included in the boilerinstallation envelope. Refer to optionalvent kit instructions for additional ventinstallation instructions .DANGERVerify 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.The PRESTIGE Solo is certified per ANSIZ21.13 as a Category IV or Direct Vent (sealedcombustion) appliance. A Category IV applianceutilizes uncontamined indoor or outdoorair (surrounding the appliance) for combustion.A Direct Vent appliance utilizes uncontaminatedoutdoor air (piped directly to the appliance)for combustion.9

Combustion Air and VentingRemoval of an Existing Boiler from aCommon Vent SystemBEST PRACTICEWhen 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 followingsteps shall be followed with eachappliance remaining connected to the commonventing system placed in operation,while the other appliances remaining connectedto 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 determinethere 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 remainingconnected to the common venting systemare 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 reliedopening after 5 minutes of main burneroperation. Use the flame of a match or candle,or smoke from a cigarette, cigar or pipe.6. After it has been determined that eachappliance remaining connected to the commonventing system properly vents whentested as outlined above, return doors, windows,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 systemshould be resized to approach the minimumsize as determined using the appropriatetables in Part II of the National FuelGas Code ANSI Z223.1/NFPA 54 and/orCAN/CGA B149, Installation codes.DANGERDo not install the PRESTIGE Solo into acommon vent with other gas or oil appliances.This may cause flue gas spillage orappliance malfunction, resulting in possiblesevere personal injury, death or substantialproperty damage.10

Combustion Air and VentingCommonwealth of Massachusetts Installations OnlyFor direct-vent appliances, mechanicalventheating 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 bedroom(s),a carbon monoxide detectorand alarm shall be placed in the livingarea outside the bedroom(s). The carbonmonoxide detector shall complywith NFPA 720 (2005 Edition).2. A carbon monoxide detector shall belocated in the room that houses theappliance or equipment and shall:a. Be powered by the same electricalcircuit as the appliance or equipmentsuch 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); andd. 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 Productapprovedair 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”.NOTICEInstaller must provide tag identificationplate and ensure the lettering meetscode requirements.For direct-vent appliances, mechanicalventheating 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 bedroom(s),a carbon monoxide detectorand alarm shall be placed in the livingarea outside the bedroom(s). The carbonmonoxide 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; andc. Shall comply with NFPA 720 (2005Edition)3. A Product-approved vent terminal mustbe used, and if applicable, a Productapprovedair 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.11

Unit PreparationsSECTION III - Unit PreparationsHandling InstructionsThe PRESTIGE Solo is generally easier tohandle and maneuver once removed from theshipping carton and pallet.To remove the shipping carton and pallet:CAUTIONUse 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 InstallationThe PRESTIGE Solo should be wall mountedusing the bracket kit provided with the boiler.The PRESTIGE is not designed for floor installation.If floor installation is required anoptional floor stand is available throughTriangle Tube.WARNINGThe wall used for mounting the PRES-TIGE Solo must be vertically plumbedand capable of supporting a minimum130 pounds [59 Kg]. Failure to complywith these requirements could result inpersonal injury, death or substantialproperty damage.Wall Mounting Guidelines1. The wall-mounting bracket is designed forstud spacing of 12 inch or 16 inch on centers.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 lathewalls 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 singleperson to lift and attempt to mount; aminimum of 2 people is required formounting the boiler.WARNINGUse 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 damage,personal injury or death.Wall Bracket Installation - Stud Walls1. 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.12

Unit Preparations4. 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.Wall Bracket Installation - Solid Walls1. Locate the general area of the boiler placement.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 positionedin 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 Mounting1. 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 wallmountingbracket. Ensure the boiler isseated properly and is secure.13

Boiler PipingSECTION IV - Boiler PipingGeneral 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 components.- Install unions for easy removal of thePRESTIGE Solo from the system piping.WARNINGUse a two wrench method when tighteningpiping onto the boiler connections.Use one wrench to prevent the boilerpiping from turning / twisting. Failureto support the boiler piping and connectionsin this manner could cause damageto the boiler and its components.Pressure Relief Valve1. 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 surroundingarea or potential scalding hazarddue to the operation of the relief valve, thedischarge piping:- Must be connected to the discharge outletof 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.WARNINGFailure 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 factoryinstalled 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.NOTICEThe PRESTIGE Solo control system alsosenses the system water temperaturesentering and exiting the heat exchanger toprovide protection against low water conditionsWhere local codes and jurisdictiondo not accept a pressure device forlow water protection, the jurisdictionsmay accept these PRESTIGE Solo integralcontrol functions as a means of providinglow water protection.14

Boiler PipingPressure Relief Valve(Supplied with Boiler)3/4" Street ElbowAir VentDrain Piping Directedto a SuitablePlace of DrainageBoiler SupplyConnectionBoiler Return Connectionwith Tee Fitting andBoiler Drain ValveFig. 5:Pressure Relief Valve and Boiler Drain Valve Installation15

Boiler PipingAdditional Limit ControlIf a separate LWCO device is required by certainlocal jurisdictions or when the boiler isinstalled above the system piping, the followingguidelines must be followed:- The LWCO device must be designedfor water installations, electrode probetypeis 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 compliance.The limit should be installed as follows:- Install the limit in the boiler supply pipingbetween 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 ApplicationsBEST PRACTICEIt is recommended on all piping applicationsto utilize a primary/secondary pipingarrangement as a means to providefreeze protection of the boiler, which isan integral function of the boiler control.Maintain the minimum boiler flow rate,see Graph 2 on page 72. For other pipingarrangements, consult theEngineering Department at TriangleTube or consult other approved/recognizeddesign arrangements.BEST PRACTICEOn 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 WaterEnsure the expansion tank is properly sized forthe boiler volume (3 gallons [12 L] ) and thesystem volume and temperature.CAUTIONUndersized expansion tanks will causesystem water to be lost through the pressurerelief valve and cause additionalmakeup water to be added to the system.Eventual boiler heat exchanger failurecan result due to this excessive makeupwater addition.The expansion tank must be located as shownin Fig. 6 and Fig. 7 on page 18 or as per recognizeddesign methods. Refer, when using aprimary/secondary piping arrangement, to theexpansion tank manufacturer instructions foradditional installation details.16

Boiler PipingConnect the expansion tank to an air separatoronly if the air separator is located on the suctionside (inlet) of the system circulator.Always locate and install the system fill connectionat the same location as the expansiontank connection to the system.Diaphragm Expansion TankAlways install an automatic air vent on the topof the air separator to remove residual air fromthe system.Closed-Type Expansion TankIt is recommended to pitch any horizontal pipingupwards toward the expansion tank 1 inchper 5 feet of piping. Use 3/4” piping for theexpansion tank to allow air within the systemto rise.CAUTIONDO NOT install automatic air vents on aclosed-type expansion tank system. Airmust remain in the system and bereturned to the expansion tank to providean air cushion. An automatic airvent would cause air to be vented fromthe system resulting in a water-loggedexpansion tank.CirculatorThe PRESTIGE Solo is supplied with aCentral Heating (CH) circulator that is prewiredto allow for domestic hot water priorityand to provide circulation for the freeze protectionfeature of the boiler control. See Graph 2on page 72 for pressure drop and minimumflow rate through the boiler.Sizing Primary PipingSee Fig. 8 through 14, pages 20 - 24, for recommendedpiping arrangements based on variousapplications.Size the piping and system componentsrequired in the space heating system, using recognizeddesign methods.Domestic Hot Water System PipingThe PRESTIGE Solo is provided with a separateboiler connection for Domestic Hot Water(DHW) systems (1” NPT.). This connectionensures priority is given to the production andrecovery of the DHW.The piping for the DHW is separate from theboiler system piping and does not require a primary/ secondary piping configuration.See Fig. 8 , page 20 for recommended piping toa DHW system.NOTICEIf an indirect fired water heater is notutilized cap the (1” NPT) DHW connectionwith an adequate amount of pipedope to ensure a seal. See Fig. 5 on page15 for location of DHW connectionTo wire the DHW circulator to the boiler controlmodule reference Section VIII - ExternalWiring.System Piping - Zone CirculatorsConnect 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.NOTICETo ensure adequate flow rate throughthe PRESTIGE Solo, maintain a minimum1 inch diameter on the system pipingconnecting to the boiler.17

Boiler PipingSystemSupplySystemReturn12612"Max.67310ColdWater Fill645BoilerSupplyBoilerReturnFig. 6: Near Boiler Piping - Diaphragm Expansion Tank9SystemSupply184 6Minimum3/4" PipingColdWater Fill612"Max.6SystemReturn7310BoilerSupplyBoilerReturnNote: Pitch horizontal pipingupwards (1” of pitchper 5 ft of piping) towardsexpansion tank.Fig. 7 : Near Boiler Piping - Closed Type Expansion Tank1. System circulator2. Automatic air vent3. Air separator4. Automatic fill valve5. Diaphragm expansion tank6. Isolation valve7. Drain/purge valve8. Tank fitting9. Closed type expansion tank10. Primary/secondary connection18

Boiler PipingSystem Piping - Zone ValvesConnect the PRESTIGE Solo to the systempiping as shown in Fig. 10 page 21 when zoningwith zone valves. The primary / secondarypiping ensures that the boiler loop has sufficientflow.NOTICETo ensure adequate flow rate throughthe PRESTIGE Solo, maintain a minimum1 inch diameter on the system pipingconnecting to the boiler.System Piping - Through BoilerIn new or retrofit applications, in which primary/secondarypiping is not utilized and the systemis zoned with zone valves, a circulatorcould pump through the boiler and systemdirectly. When pumping through with morethan one zone, a pressure differential bypassvalve is required to avoid dead heading thepump through the post pump feature of thecontrol. Consult Fig. 11 and 12 page 22 forpiping diagrams and Graph 2 on page 72 forproper circulator sizing.System Piping - Radiant HeatingThe 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, eliminatingthe need for a mix system to achieve thedesired temperature.It is recommended for the installer to add ahigh temperature limit as shown in Fig. 13page 23. This will ensure that the primary supplytemperature does not exceed the maximumallowable temperature for the radiant tubing.BEST PRACTICEThe addition of the high temperaturelimit is important if the PRESTIGESolo is connected to a domestic hot watersystem, which requires a high primarysupply water temperature.Size the system piping and circulator to providethe flow needed for the radiant system.NOTICETo ensure adequate flow rate throughthe PRESTIGE Solo, maintain a minimum1 inch diameter on the system pipingconnecting to the boiler.System Piping - Special ApplicationIf 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 mediumfrom 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 InstallationUse a balanced manifold system as the primary/ secondary connection to the spaceheating piping 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 separatorand expansion tank.For the space heating piping refer to the applicationsmentioned in this manual or use recognizeddesign methods.19

Boiler Piping7SystemSupplySystemReturn15DomesticHotDomesticCold6362834Fig. 8: DHW Boiler Piping with a PRESTIGE Solo and SMART1. PRESTIGE Solo boiler2. SMART water heater3. Isolation valve4. DHW circulator5. CH circulator (provided)6. Flow/check valve7. Pressure relief valve8. Drain/purge valveNOTICEThe boiler system piping shown in Fig. 8must be a “closed” system to avoid anyoxygen contamination and potential failureof the outer tank of the Smart.20

Boiler Piping453AdditionalZone Load34453Zone Load3498412"Max.4764111012Fig. 9: CH System Piping - Zoning with Zone Circulators631. PRESTIGE Solo boiler2. CH circulator (provided)3. Flow/check valve4 Isolation valve5. Zone circulator6. Drain/purge valve7. Pressure relief valve8. Air separator9. Automatic air vent10. Diaphragm expansion tank11. Automatic fill valve45AdditionalZone Load445Zone Load41298412"Max.4761411102Fig. 10: CH System Piping - Zoning with Zone Valves631. PRESTIGE Solo boiler2. CH circulator (provided)3. Flow/check valve4 Isolation valve5. Zone valve6. Drain/purge valve7. Pressure relief valve8. Air separator9. Automatic air vent10. Diaphragm expansion tank11. Automatic fill valve12. System circulator21

Boiler PipingP1245AdditionalZone Load4457Zone Load1279446Note: Verify CH circulatoris properly sized toovercome the system pressuredrop and provide adequateflow through theboiler system.810 11 4Fig. 11: CH System Piping - Multiple Zone Valve with Single System/Boiler Circulator1. PRESTIGE Solo boiler2. CH circulator4 Isolation valve5. Zone valve6. Drain/purge valve7. Pressure relief valve8. Air separator9. Automatic air vent10. Diaphragm expansion tank11. Automatic fill valve12. Pressure differential valveSingleZone load71239846Note: Verify CH circulatoris properly sized toovercome the system pressuredrop and provide adequateflow through theboiler system.10 11 4Fig. 12: CH System Piping - Single Zone System with Single System/Boiler Circulator1. PRESTIGE Solo boiler2. CH circulator3. Flow check valve4 Isolation valve6. Drain/purge valve7. Pressure relief valve8. Air separator9. Automatic air vent10. Diaphragm expansion tank11. Automatic fill valve22

Boiler Piping45AdditionalRadiant Zone445Radiant Zone412139412"Max.46817411102Note: Manifold mounted valveactuators may be used in lieu ofzone valves.36Fig. 13: CH System Piping - Radiant/Low Temp. Heating1. PRESTIGE Solo boiler2. CH circulator (provided)3. Flow/check valve4 Isolation valve5. Zone valve6. Drain/purge valve7. Pressure relief valve8. Air separator9. Automatic air vent10. Diaphragm expansion tank11. Automatic fill valve12. System circulator13. High temperature limit control23

Boiler PipingTo theSystem12912"Max.From the System810 11 47771 1 11. PRESTIGE Solo boiler2. Boiler circulator3. Flow/check valve4. Isolation valve6. Drain/purge valve7. Pressure relief valve8. Air separator9 Automatic air vent10. Diaphragm expansion tank11. Automatic fill valve12. System circulator624 4 43 3 34 4462 26Fig. 14: Multiple Prestige Boiler Piping - Primary / Secondary / Piping using Balanced Manifold System24

Installing Vent/ Combustion Air & CondensateSECTION V - Installing Vent /Combustion Air & Condensate DrainInstalling Vent and Combustion AirDANGERThe 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 installationis completed, inspect the vent andcombustion air system thoroughly toensure systems are airtight and complywith the instructions given in the ventingsupplement and are within all requirementsof applicable codes. Failure tocomply with the installation requirementson the venting and combustion airpiping will cause severe personal injuryor death.Installing Condensate Drain Assembly1. Locate the condensate drain assembly andinstall as shown in Fig. 15 page 26.NOTICEThe installer may want to fill the condensatetrap with water prior to assemblingon 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!WARNINGEnsure 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 provided,slide the compression nut and rubberseal over the pipeNOTICEThe use of 3/4” PVC or CPVC pipe isalso acceptable. If 3/4” pipe is useddeburr and chamfer pipe to allow matingonto the drain assembly.5. Thread the rubber seal into the compressionnut to ease installation of the pipe tothe drain assembly.6. Seat the pipe onto the drain assembly andtighten the compression nut. Hand tightonly!NOTICEThe installer may opt to using 13/16" IDtubing in lieu of rigid piping.NOTICEThe drain line materials must be anapproved material by the authority havingjurisdiction. In absence of suchauthority, PVC and CPVC piping mustcomply with ASTM D1785 or D2845.The cement and primer used on the pipingmust comply with ASME D2564 orF493. For installations in Canada, useCSA or ULC certified PVC or CPVCpipe, fittings and cement/primer.25

Installing Vent/ Combustion Air & Condensate7. Continue the pipe from the drain assemblyto a floor drain or condensate pump.NOTICEWhen selecting and installing a condensatepump, ensure the pump is approvedfor use with condensing boilers and furnaces.The pump should be equippedwith an overflow switch to prevent propertydamage from potential condensatespillage.CAUTIONThe condensate drain must remain filledand unobstructed and allow unrestrictedflow of condensate. The condensateshould not be subject to conditionswhere freezing could occur. If the condensateis subjected to freezing orbecomes obstructed , it can leak, resultingin potential water damage to theboiler and surrounding area.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.Fill Plugwith VaccumBreak PortHeat ExchangerCondensateDrain NippleCompressionNut with Rubber SealRetaining Nutwith Rubber Seal(Hand Tight Only)Plastic BallFlexible Tubing(or 3/4 PVC/CPVC Pipingto Drain)CondensateDrain AssemblyFig. 15: Condensate Drain Assembly26

Gas PipingSECTION VI - Gas PipingGas Supply Piping ConnectionNOTICEThe gas supply piping must be installedin accordance to all applicable local,state and national codes and utilityrequirements.1. Install a 1/2” NPT pipe union at the factorysupplied gas nipple, for ease 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 thePRESTIGE Solo gas train as shown inFig. 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 andits gas valve from the gas supply pipingduring any pressure test greater than13”w.c..WARNINGDo not check for gas leaks with an openflame. Use a gas detection device or bubbletest. 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.WARNINGFailure to apply pipe dope as detailedabove can result in severe personalinjury, death or substantial propertydamage.WARNINGUse a two-wrench method of tighteninggas piping near the unit and its gas pipingconnection. Use one wrench to preventthe boiler gas line connection fromturning and the second to tighten adjacentpiping. Failure to support the boilergas piping connection could damagethe gas line components.External ManualGas Shut OffValve (Must BeWithin 6' of theBoiler)Tee FittingSedimentTrap Min.Length of 3"Gas FlowCapUnion FittingFig. 16: Recommended Gas Supply Piping27

Gas PipingNATURAL GASPipe Sizing - Natural GasRefer 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 specificgravity of 0.60 and a pressure dropthrough the gas piping of 0.30”w.c..- For additional gas piping sizing information,refer to ANSI Z223.1. For Canadianinstallations refer to B149.1 or B149.2.Natural Gas Supply Pressure Requirements1. 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 lockuppressure regulator for 13”w.c maximum.WARNINGDO NOT adjust or attempt to measuregas valve outlet pressure. The gas valveis factory-set for the correct outlet pressure.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.Table 1: Gas Piping Sizing - Natural Gas28

Gas PipingPROPANE GASPipe Sizing - Propane GasContact the local propane gas supplier for recommendedsizing of piping, tanks and 100%lockup gas regulator.Propane Gas Supply Pressure Requirements1. Adjust the propane supply regulator providedby the gas supplier for 13”w.c. maximumpressure2. Pressure required at the gas valve inlet supplypressure 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.NOTICEThe propane orifice requirement for thePRESTIGE Solo 110 is 0.204” (#52).WARNINGDO NOT adjust or attempt to measuregas valve outlet pressure. The gas valveis factory-set for the correct outlet pressure.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.WARNINGPrior to start up, ensure the unit is set tofire propane. Check the rating label forthe type of fuel. Check the gas valve forpropane conversion labels. If there is aconflict or doubt on the burner set up,remove the gas valve and check for thepropane orifice, see Fig. 17, page 30.Failure to ensure proper burner setupcould result in severe personal injury,death or substantial property damage.29

Gas PipingVenturiInlet SupplyPressure PortPropaneOrificeGas ValveGas ValveGasketGas ValvePipe FittingFig. 17: Gas Valve / Venturi Assembly30

Internal WiringSECTION VII - Internal WiringWARNINGELECTRICAL 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 personalinjury or death.CAUTIONPrior to servicing, label all wires prior todisconnection. 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 National ElectricalCode ANSI/NFPA 70 - latest edition and /or the Canadian Electrical Code Part 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 Instructions1. Locate the wiring tool on the PRESTIGESolo just below the 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.NOTICEThe 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 complete.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.Terminal BlockWiring ToolFig. 19: Using the wiring tool on theterminal blocksBEST PRACTICEWhen wiring the PRESTIGE Solo allowadditional length of wire for the accesspanel to swing open during servicing.31

Internal WiringHeating circulator (supplied on the PRESTIGE Solo 110 only)Gas ValvePRESTIGESolo 399 OnlyDHW Sensor or ThermostatDHW Sensor or ThermostatO-10v External Inputs (+)O-10v External Inputs (-)To properly connect wires to terminal block, use wiring tool included with Prestige. See wiring tool instructions, page 31.Fig. 20: PRESTIGE Solo Boiler Factory WiringNote:32

External WiringSECTION VIII- External WiringInstallation ComplianceAll 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.WARNINGELECTRICAL SHOCK HAZARD.Before making any electrical connectionsto the PRESTIGE Solo, disconnectelectrical power supply at the servicepanel. Failure to comply can causesevere personal injury or death.Line Voltage Connections1. Connect a 120 VAC/15A service to the120V terminal strip on the wiring panelbelow the PRESTIGE Solo control module,as shown in Fig. 20, page 32.2. Route the incoming 120 VAC power wirethrough the provided openings in the bottomjacket panel.3. The unit is provided with a service switchlocated on the front panel, check local coderequirements for compliance.NOTICEIf 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 Wiring1. 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 WiringNOTICEIsolate 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 the wiringpanel below the PRESTIGE Solo controlmodule, as shown in Fig. 20, page 32.2. For proper operation install the room thermostaton an inside wall away from influencesof heat and cold, i.e. water pipes, areasof draft, lighting fixtures and fireplaces.3. Set the thermostat anticipator (if applicable)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 manufacturers’specifications and the thermostatinstructions for additional informationon the anticipator setting.NOTICEWhen making low voltage connections tothe PRESTIGE, ensure no external voltageis present in the thermostat circuits.If external voltage is present, provide anisolated contact to prevent damage to theboiler control.33

External WiringCH and DHW Circulator1. The CH primary circulator is pre-wire tothe PRESTIGE Solo 120 V terminals 1,2and 3 as 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 ApplicationTo 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 asHonewell V8043 or equivalent.External Modulating ControlThe PRESTIGE Solo firing rate can be controlledby an external modulating boiler controller.See page 32 for wiring and Page 54 forcontrol module setup.Outdoor Reset Control1. The PRESTIGE Solo may operate with avariable boiler operating temperature usingthe Triangle Tube outdoor sensor, see pages49 through 51 for installation and setup.NOTICEIf the installer opts for a fixed operatingtemperature for the boiler system, theoutdoor sensor is not required andshould not be installed.Additional 24V Limit WiringThe 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.Room Thermostats24 VTransformerby OthersHoneywell V8043Zone Valvesor EquivalentH N120V R CG1 3 4 6Honeywell R8285DTransformer / Relayor Equivalent24V Low Voltage Wiring120V High Voltage Wiring78To Prestige24V Terminal StripSystem CirculatorFig. 21: Secondary System Circulator Wiring34

External Wiring4 Wire Zone ValveZone 1Transformer(Power)RoomThermostatH 120 NV.A.C. High Voltage24V.A.C.Zone ValveZone 2Additional zonesRoomThermostatZoneValveAdditional zones maybe added as shown above7 8To Prestige24V Terminal Strip3 Wire Zone ValveTransformer(Power)H 120 NV.A.C. High VoltageZone 1Zone 2Additional zonesRoomThermostatRoomThermostat24V.A.C.ZoneValveZone ValveAdditional zones maybe added as shown aboveNOTICE*Use isolation relay on3-wire zone valve withnon-isolated end switch.Transformer and the PrestigeMCBA control can burn outif isolation relay is not used.* Isolation relay78To Prestige24V Terminal StripFig. 22: Multiple Zone Field Wiring Using Zone Valves35

External WiringFig. 23: Field Wiring with Zone Circulators.HoneywellR845ARelayTTThermostatzone 1120HVACN2 1 4 3 56CirculatorZone 1Thermostatzone 2TT2 1 4 3 56CirculatorZone 2Additional zones may beadded as shown above7 8To Prestige24V Terminal StripFig. 24: Typical Zone Relay Panel WiringThermostatZone 1ThermostatZone 2ThermostatZone 3R C T1 T1 T2 T2 T3 T3L2ZCL1X1X2PRPRC1C1C2C2C3C3NH 7 8120VTo Prestige24V Terminal StripZone 1CirculatorZone 2CirculatorZone 3Circulator36

Start-Up PreparationSECTION IX - Start-Up PreparationCheck Boiler System Water ChemistryWARNINGDo not use petroleum-base cleaning orsealing compounds in the boiler system.Damage to seals and gaskets in the systemcomponents could occur, resulting insubstantial property damage.NOTICESystem 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 8.0Maintain 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 GrainsFor areas with unusually hard water (hardnessabove 7 grains) consult a water treatmentcompany.Flush Boiler and Domestic System toRemove SedimentThe 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 boiler 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 AntifreezeFor boiler systems containing antifreeze solutions,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.NOTICESystem water including additives must bepractically non-toxic, having a toxicityrating or Class of 1, as listed in ClinicalToxicology of Commercial Products.Chlorinated WaterDo not use the PRESTIGE Solo to heat aswimming pool or spa directly.Maintain the chlorine level of the water at levelsconsidered safe for drinking.37

Start-Up PreparationUse of Antifreeze in the Boiler SystemWARNINGNEVER use automotive or ethylene glycolantifreeze 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). Remember toinclude the volume of the expansion tank.Check with local codes requirements for theinstallation of backflow preventers or actualdisconnect from the boiler’s cold water fill ormake up water supply line.NOTICEMassachusetts Code requires a pressurereducer backflow preventer if antifreezeis used.Ensure the concentration of antifreeze to waterdoes not exceed a 50/50 ratio.NOTICESystem water, including additives, mustbe practically non-toxic, having a toxicityrating or Class of 1, as listed in ClinicalToxicology of Commercial Products.Filling the Boiler System1. Close the boiler drain valve located on thebottom of the unit and any manual or automaticair vent in the system.2. Open all system isolation valves.3. Fill the boiler system to correct systempressure. Correct pressure will vary witheach application.NOTICETypical 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.WARNINGUnrepaired system leaks will cause continualmakeup water to be added to theboiler. Continual makeup water couldcause mineral buildup within the heatexchanger, reducing the heat transfer,causing possible heat buildup and eventualheat exchanger failure.Check Low Water Cut-Off Device- The PRESTIGE Solo is provided with afactory installed LWCO device that measuressystem 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 5, on Fig. 27 page 66.38

Start-Up PreparationCheck For Gas LeaksWARNINGPrior to start-up and during initial operation,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.WARNINGPropane 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 periodicallyafter 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.NOTICEIn systems using 3-wire zone valves,backfeed of voltage to the unit is a commonproblem. 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 Assembly1. 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 condensate drainassembly and fill the trap with fresh water.NOTICEThe condensate drain assembly must befilled with water when the PRESTIGESolo is in operation. The condensatedrain assembly prevents flue gas emissionsfrom 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 assembly.39

Start-Up ProceduresSECTION X - Start-Up ProceduresFinal Checks Before Start-UpcccccccRead page 45 through 48 regarding theoperation of the PRESTIGE Solo control.Verify the PRESTIGE Solo and the boilersystem is full of water and all system componentsare correctly set for operation,including the minimum flow rate throughthe boiler, see page 72.Verify Start-up Preparation items outlined onpages 37 thru 39 have been completed.Verify all electrical connections are correctand securely fastened.Inspect vent piping and combustion air inletpiping for signs of deterioration from corrosion,physical damage or sagging. Verifycombustion air piping and vent piping areintact and correctly installed and supported.Reference the PRESTIGE Solo VentSupplement.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 configuration,remove the gas valve and checkfor proper propane orifice size 0.204”(#52). Refer to Fig. 17, page 30 forlocation of the propane orifice.Ensure the Condensate Drain Assembly isfilled with water.PRESTIGE Solo Start-Up1. Turn the ON-OFF switch located on thefront control panel to the OFF position.Turn the electrical supply or any serviceswitch to the unit in the ON position.2. Read and follow the Operating Instructionsoutlined on page 42.If PRESTIGE Solo Does Not Start Correctly1. Verify DHW (parameter 2) and CH (parameter3) Systems are turned ON or set to“01”. Read the Boiler Display Standby andParameter Section of the manual startingon page 45 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 66.4. 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 appliancesoperating ON or OFF.7. Are the heating thermostats set below roomtemperature?If none of these steps correct the problem, referto the PRESTIGE Solo Trouble-ShootingGuide or contact Triangle Tube Tech Service.Check the PRESTIGE Solo and Systemc Check Boiler Piping.Check Boiler system piping and componentsfor 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.cCheck Vent Piping and Combustion AirPiping.Check for gas-tight seal at every connectionand seam of the venting andcombustion air inlet piping.40

Start-Up ProceduresccWARNINGVenting system must be sealed gas-tightto prevent flue gas spillage and potentialcarbon monoxide emissions, which willresult in severe personal injury or death.Check Gas PipingCheck around the unit for gas odor followingthe procedure outlined in thismanual on Page 39.WARNINGIf 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 substantialproperty damage.Verify Flame Pattern and CombustionCheck 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.WARNINGThe combustion testing and adjustmentsmust be performed by a qualifiedinstaller, service agency or the gas supplier.All combustion measurements must beperform 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 reading shouldbe within the range listed in Table 2.The CO level should not exceed 100ppm when combustion is correct.WARNINGThe combustion levels should be measuredat high firing rate, refer to page 45of the PRESTIGE Solo control sectionon how to set the firing rate. If the combustionlevels 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.Table 2: Recommended Combustion LevelsO2 Min.O2 Max.CO2 Min.CO2 Max.CO MaxNatural Gas2.30%5.30%8.80%10.50%100 ppmPropane2.70%4.70%10.70%12.00%100 ppmc Measure Input - Natural Gas Only1. 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 building,except the PRESTIGE Solo.4. At the gas meter, record the time requiredto use one cubic foot of gas.5. Calculate Natural gas input using the followingequation: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.41

Start-Up ProceduresFOR YOUR SAFETY READ BEFORE LIGHTINGWARNINGIf you do not follow these instructions exactly, a fire or explosion mayresult causing property damage, personal injury or loss of life.A. This appliance does not have a pilot. It isequipped with an ignition device which automaticallylights 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.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 perpendicularto gas piping).3. Turn the service switch on the PRESTIGE controlpanel OFF.4. Remove the front jacket panel on the unit.5. Turn the external manual gas valve handlecounter clockwise to “OPEN” gas supply(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 informationabove. If you don’t smell gas, go to thenext step.1. Set the room thermostat to lowest setting.2. Turn the service switch on the PRESTIGE controlpanel to “OFF”OPERATING INSTRUCTIONSTO TURN OFF GAS TO APPLIANCE427. Turn the service switch on the PRESTIGE controlpanel “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.3. Turn the external manual gas valve handle clockwiseto “CLOSE”.

Start-Up ProceduresSet Boiler CH Target Temperature1. 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 outlet watertemperature setting (high limit).3. Press the "+" or "-" button to change thesetting of the outlet temperature (highlimit).NOTICEIf an outdoor sensor is used, then the settingof the Boiler CH Target temperatureis the target temperature when the outdoortemperature is at or below 0ºF.When the outdoor temperature is higherthan 0ºF the PRESTIGE Solo control willcalculate the target temperature betweenthe minimum and maximum temperaturesettings.4. Press the "STORE" button to save the setting.Operation Verification - Space HeatingNOTICEDigits and characters shown as [0000],in the following outline, represent thecontrol panel display. The last three digitson the display is the measured boilerwater temperature and may differ fromwhat is shown in the manual.1. Disconnect the DHW (Domestic HotWater) thermostat wiring from the PRES-TIGE Solo or turn down DHW tank aquastat(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 heat5. 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 momentarilyprior to the prepurge cycle.[1140] This is the prepurge cycle. Theboiler blower and the CH (Central Heating)circulator become energized. The blowerhas a 10 second prepurge cycle.[2140] This is the ignition cycle. The controlmodule will energize and open the gasvalve and begin the spark for ignition.- If the burner flame proves the burnerwill continue to fire at an 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 5 attempts the control will lockoutand 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.[3140] This is the normal operation cycle.After the flame is proven and stabilizedthe 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.43

Start-Up Procedures6. 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 thermostatis 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 continuefor 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 repeatingthe operational sequence several times.9. Return the room thermostat to a desired setting.Reconnect the DHW wiring or returnthe DHW aquastat to desired setting, placingthe 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 operationthe display should show:[5140] This is a fan / air flow check. Theburner blower will be energized momentarilyprior to the prepurge cycle.[1180] The prepurge cycle. The boilerblower and DHW circulator become energizedand the 10 second pre-purge cyclebegins.[2180] The boiler will begin the ignitionsequence. The same sequence of establishingflame, 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 modulatingits input based on the length of demandby the DHW aquastat. The burner will notgo into the low input rate for the 1 minuteflame stabilization period that occurs in CHmode.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 will continue for a 30second post pump cycle. If another DHWcall for heat is initiated the boiler ignitionsequence will begin immediately.[0180] Boiler is in standby MODE waitingfor a CH or DHW call for heat.4. Verify the DHW operation of the boiler byrepeating the outline operation sequenceseveral times.5. Return the DHW aquastat and room thermostatto the desired setting.44

Start-Up ProceduresBoiler Control DisplayStandby ModeStbYThis 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 display)the current status of the boiler dependingon the condition of both the boiler and theburner. The last 3 characters indicate the starttemperature.If the burner is blocked due to a “soft” lockout,the display alternates between a 9 followed bythe boiler outlet 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 “+”button simultaneously until the first digit flashes“H”.While in the test mode:- high limit will function- boiler CH circulator will function- domestic DHW circulator will not function- the test mode will time out in approximately10 minutesTO DEACTIVATE THE HIGH OR LOWFIRE TEST MODE:press and hold the “+”and “-” button simultaneously to deactivate thehigh or low fire test mode. While in the“StbY” mode.DisplayH180L180NOTICEBoiler functionTest function: Burner on, high fire modeTest function: Burner on, low fire modeIf 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 systemback ON, the display will show “c”followed by CH set point. If the “-” buttonis 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 domesticset point temperature.TO TEMPORARILY PLACE THE BURN-ER INTO LOW FIRE TEST MODE: pressthe MODE button until “StbY” is displayed.Then press and hold both the mode and “-” buttonsimultaneously until the first digit flashes“L”.45

Start-Up ProceduresStandby Mode DisplayDisplay0180118021803180418051806180718081809180b 18b 19b 24b 25b 26b28b 29b 30b 33b 35b 38b 40b 52b 65b 116b 118Boiler functionSTANDBY, no demand for heatFan prepurge or post purge cycleIgnition sequenceBurner ON for space heating (CH)Burner ON for domestic hot water (DHW)Pre-check for air flow prior to prepurge cycleBurner OFF due to reaching temperature setpointSpace Heating (CH) post pump cycleDomestic hot water (DHW) post pump cycleBurner blocked:Supply temperature too high (202 F) . Burnerwill remain OFF until temperature dropsbelow 200 FReturn temperature too high (202 F). Burnerwill remain OFF until temperature dropsbelow 200 FReturn temperature is higher thansupply 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 1minute for a max. 15 minutesFactory supplied LWCO device orexternal limit (terminals 15 & 16) is OPEN.Burner off for 150 seconds, auto reset.No blower signalBlower signal present with no demand, Burnerwill remain OFF until condition terminatesTemperature difference between the supply andreturn is more than 72 F. Burner will remain OFFfor 150 seconds. Burner will recycle increasingwating period 1 minute for a max. 20 cycle.Indirect water heater temperature sensor isshort-circuited. Burner OFF until corrected.Flue temperature sensor is short-circuited.Burner OFF until correctedIndirect water heater temperature sensor is“open” or disconnected. Burner OFF untilcorrected.Flue temperature senor is “open” Burner OFFuntil corrected.Flue temperature greater than 240 F but lessthan 250 F. Burner off for 150 secondsWait for the blower to startPower frequency deviationFlame current signal lost46

Start-Up ProceduresSetting The Boiler ParametersParameter modePARATo access PARAMETER mode when the systemis in STANDBY mode, press the MODEbutton once.Key:MODEDisplayPARAPressing MODE onceTo scroll through the list of parameters, simplypress the “STEP” button. To modify a parametervalue, use the + or - keys. Then press“STORE” to save the value you just changed.The display flashes once to confirm the datahas been stored.To activate the parameters you changed, pressMODE once more (which brings you intoINFORMATION mode). However, if you donot press a key, the system returns to STAND-BY mode after 20 minutes and automaticallystores 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 performanceof the DHW will be affected and canbecome unreliable.Key: Display Description of parametersSTEPSTEPSTEPSTEP1. . 1402.013.014.186Domestic Hot Water Setting (See Note 1)DHW Application Selection (See Note 2)CH Application Selection (See Note 3)CH Maximum Boiler Operating SetpointNote 3: This parameter should not be changedfrom the factory setting of 01. The performanceof the CH (Central/Space Heating) willbe affected and can become unreliable.47

Start-Up ProceduresAccessing Boiler InformationInformation modeTo switch from STANDBY mode to INFOR-MATION mode, press MODE twice.Key:MODEMODEDisplayPARAINFOINFOPressing MODE oncePressing MODE twicePress STEP until the system displays the informationyou need. The first digit is the informationitem number followed by the items value.The decimal point located behind the first positionflashes to indicate that the boiler is inINFO mode.NOTICEThe 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.NOTICEJ 12.34.56In the INFO Mode a temperature readingof -22 typically indicates an “open”circuit. A temperature reading of 240typically indicates a short-circuit.Information Mode ItemsDisplay DigitSegments48

Start-Up ProceduresError (Hard Lockout) ModeIf a system fault occurs while the boiler is running,the system goes into lockout and the displaystarts to flash with the first digit as an Eand the next two digits give the code for thisfault.For a detailed description of the error codes, referencethe PRESTIGE Solo TroubleshootingGuide.CAUTIONThe boiler freeze protection feature isdisabled during a Hard Lockout, howeverthe CH circulator will operate.CAUTIONDuring a hard lockout or low water conditionthe boiler will not re-start withoutservice. If the heating system is left unattendedin cold weather appropriate safeguardsor alarms should be installed toprevent property damage.DisplayHard LockoutE 00 Flame detected prior to burner startupE 02Failed ignition after 5 attemptsE 03E 04E 05 Electrical InterferenceE 06Internal control failureE 07Internal control failureE 08Internal control failureE 09Internal control failureE 11Internal control failureE 12E 13Internal control failureE 14E 15Internal control failureE 16Internal control failureE 17 Internal control failureE 18 Supply Temperature exceeds 212 FE 19Return Temperature exceeds 212 FE 24E 25E 28 No blower signal presentE 29 Blower signal does not reset to zeroE 31E 32E 35E 36 Supply Temperature sensor is OPENE 37 Return Temperature sensor is OPENE 40 Flue Temperature sensor is OPENE 44 Gas Valve Circuit failureE 52 Flue Temperature exceeds 250 FE 60E 61 Internal control failureE 65 Inadequate power supply to the fanE113Invalid power frequencyE115Internal control failureE122E123Supply or Return Temperature failureE124Gas valve harness not properly connectedPower supply lost after lockout occuredExternal limit (terminals 13 & 14) is OPENLow voltage internal short or voltage backfeedReturn temperature is higher than supplytemperatureSupply Temperature increased too rapidlySupply Temperature sensor is short circuitedReturn Temperature sensor is short circuitedFlue Temperature sensor is short circuitInternal control error - failure to read parametersSupply or Return Temperature sensor driftSupply or Return Temperature not changing49

Outdoor Reset ControlSECTION XI - Outdoor Reset ControlThe boiler setpoint for a heating call can befixed or vary with the outdoor temperature. Ifthe application requires a constant supply temperaturefrom the boiler, the outdoor temperaturesensor should not be connected to the boiler.If an outdoor temperature sensor is connectedto the boiler, the outdoor reset functionis automatically enabled and will vary the CHsetpoint with the change in outdoor temperature.The outdoor reset function has no affecton the DHW setpoint during a domestic call.Fig. 25: Sensor Enclosure and ComponentsMounting the Outdoor Sensor1. 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 temperaturesensing.4. Mount the sensor enclosure at an elevationon the exterior wall to prevent accidentaldamage or tampering.5. Avoid mounting the enclosure in areas subjectedto 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 Sensor1. Remove the sealing nut and sealing gasketfrom the sensor enclosure.2. Route two 18 gauge wires through the sealingnut 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.NOTICEIf 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 sensorterminals on the 24V terminal strip locatedinside the boiler enclosure (see boilerwiring diagram, Fig. 20 page 32).50

Outdoor Reset ControlSummer / Winter Switch at BoilerIf required the CH (Central Heating) system canbe turned off at the boiler, similar to manualsummer / winter switch by press/hold the “+”button while in the “StbY” mode, the displaywill show “cOFF”. Press/hold the “+” button toturn the CH system back on, the display willshow “c” followed by CH set point temperature(Parameter 4) or CH target temperature.WARNINGIf 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 settingsor appropriately revised for theapplication prior to commissioning theboiler. Failure to comply could result inerratic or unreliable operation of thePrestige boiler.NOTICEOnce 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 continuepressing 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.CH Maximum Boiler Operating Setpoint(Parameter 4)If an outdoor temperature sensor is not connectedto the boiler, the boiler setpoint for aheating call will be set to the CH MaximumBoiler Operating Setpoint. If an outdoor temperaturesensor 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)Adjusting Outdoor Reset CurveParameters 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.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.51

Outdoor Reset ControlCH 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 CodeThe 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 buttonstogether for 2 to 3 seconds until thedisplay shows CODE.3. Press the STEP button once and the displaywill show C_XX where XX represents arandom 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 pressingthe MODE button until the display showsPARA. Once the display shows PARA, pressthe STEP button to reach the appropriate parameter.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_11Etc......After Parameter 4, the display will show P followedby the parameter number. Once a particularparameter is reached, the display willchange to show the current setting of that parameter.NOTICEThe actual parameter values displayedon the display may vary depending onthe application, but the sequence willalways occur in the order shown.Changing a Parameter Setting1. Use the “+” or “–“ button to change theparameter setting.2. Press the STORE button to save thechange. The display should flash to indicatethat the change was saved.3. Press the RESET button to leave the AccessCode mode.52

Outdoor Reset Control180Boiler Temperature ( F)140100866020Parameter 10Set PointParameter 12 SettingParameter 4 Set PointParameter 11 Setting90706450 30 10 0 -10Outdoor Air Temperature ( F)Graph 1: Outdoor Air Temperature Reset Curve (Example)Table 3: Outdoor Air Temperature Reset (Example)Graph 1 illustrates Parameter 4 adjusted to 140ºF target temperature at 0ºF outdoorair temperature.Note: Factory setting of Parameter 4 is 186ºF.53

External Modulating ControlSECTION XII - External ModulatingControlThe boiler can directly accept an analog 0-10VDC signal to control the firing rate from anexternal modulating boiler controller.Wiring the Modulating ControllerRun 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 boiler.No wiring is required at the thermostat (T-T) terminals 7 and 8 of the boiler.NOTICEEnsure that Parameter 4 is set above thehighest setpoint of the external modulatingcontrol. Paramater 4 is a boiler hightemperature limit when using an externalmodulating controller.Programming of External ModulatingControlThe external modulating control must be programmedto 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 burnerto stabilize before modulating the boiler.NOTICEEnsure that the polarity of the connectionsfrom the external modulating boilercontroller to the boiler is correct.Reversed polarity could lead to erraticand/or no response from the boiler controller.Parameter AdjustmentThe 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 02.54

Factory Setting ParametersFactory Setting Parameters1 140ºF DHW Setting2 01 DHW Application Selection3 01 CH Application Selection4 186ºF CH Maximum Boiler Operating Setpoint10 86ºF CH Minimum Boiler Operating Setpoint11 00ºF CH Reset Curve Coldest Day12 64ºF CH Reset Curve Warmest Day13 -22ºF Frost Protection Setpoint18 32ºF CH Block Temperature Setting19 00 Minutes Boost Feature Setting20 00ºF Parallel Shift Value21 46ºF Setpoint Value Addition for DHW32 01 Minutes CH Circulator Post Pump Time Period33 03 x 10.2 Sec. DHW Circulator Post Pump Time Period38 02ºF DHW On Differential39 06ºF DHW Off Differential40 03 x 10.2 Sec. CH Call Blocking Time41 00 x 10.2 Sec. DHW Call Blocking Time42 00 x 10.2 Sec. DHW to CH Call Blocking Time43 00 Minutes DHW Priority Timeout45 00 CH Operating Signal Selection46 02 DHW Operating Signal Selection55

Check-Out ProceduresSECTION XIII- Check-Out ProceduresPerform the following check-out proceduresas outlined and check off items ascompleted. When procedures are completed,the installer should complete theinstallation record on page 53.Check-out Proceduresc Boiler system water chemistry checked andverified as outlined on page 37.ccccccccccNOTICEThe boiler air vent and any automatic airvents placed within the system are openone full turn.Air is purged from the heating zones andboiler system piping.If applicable confirm that the burner hasbeen properly configured for Propaneapplication, as outlined on page 29 (Ifapplicable).Thermostat circuit wiring checked and verifiedthat no voltage is present to the lowvoltage terminals as outlined on page 39.Operating Instructions on page 42 were followedduring start-up.Combustion levels and flame pattern verifiedas outlined on page 41.Measured the rate of input on Natural Gasas outlined on page 41.Checked the incoming gas pressure to thePRESTIGE to ensure a minimum pressureof 5”w.c during flow conditions to all gasappliances and a maximum pressure of13”w.c during non-flow conditions forNatural and Propane.Adjusted balancing valves and system limitcontrols to provide design temperatures tothe primary space heating system.In multiple zone applications, adjusted forcorrect flow of boiler water to each zone.ccccccChecked and verified room thermostat(s)function properly and the thermostat(s)heat anticipator (if used) was properly set.Observed several operating cycles forproper operation of the PRESTIGE Soloand the system.Set the room thermostat(s) to the desiredroom temperature.Reviewed all instructions shipped with thePRESTIGE Solo with the homeowner ormaintenance personnel.Completed the Installation Record on page57.Ensure all manuals and other documentationare returned to the Installation envelope andgiven to the owner for safekeeping.56

Installation RecordSECTION XIV - Installation RecordPRESTIGE Model Number:Serial Number:Date of Installation:Fuel: Natural Gas PropaneMeasured Rate of Input:Btu/hrCombustion Readings:CO2%O2%COppmThe following items were completed during installation:Installation instructions have been followed and completedCheck-out procedures have been followed and completedInformation regarding the unit and installation received and left with owner /maintenance personnel.Installer Information(Company) ____________________________________________________________________(Address) ____________________________________________________________________(Address) ____________________________________________________________________(Phone Number) _________________________________________________________________57

Maintenance ScheduleSECTION XV - Maintenance ScheduleService TechnicianAt least on an annual basis the following maintenanceshould be performed by a qualified servicetechnician: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 condensate.- 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 uniform)and flame.Additional items if combustion or performanceis poor:- Clean heat exchanger and flue ways.- Remove burner assembly and clean burnerhead using compressed air only.Owner MaintenancePeriodically:- Check the area around the unit.- Check and remove any blockage from thecombustion air inlet and ventilation openings.- Check the temperature/pressure gauge.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.WARNINGFollow 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.Once the maintenance items are completed,review the service with the owner.58

Maintenance ProceduresSECTION XVI - MaintenanceProceduresMaintenance ProceduresWARNINGThe PRESTIGE Solo should be inspectedand serviced annually, preferably atthe start of the heating season, by a qualifiedservice technician. In addition, themaintenance and care of the unit as outlinedon page 54 and further explainedon pages 55 through 60 should be performedto assure maximum efficiencyand reliability of the unit. Failure to serviceand maintain the PRESTIGE Soloand the system components could resultin equipment failure, causing possiblesevere personal injury, death or substantialproperty damage.NOTICEThe following information providesdetailed instruction for completing themaintenance items outline in the maintenanceschedule on page 54. In additionto this maintenance, the PRESTIGESolo should be serviced at the beginningof the heating season by a qualified servicetechnician.materials listed on page 5 of this manual. Ifany of these products are in the area fromwhich the unit takes its combustion air, theymust be removed immediately or the combustionair intake must be relocated to anotherarea.Inspect Burner AreaRemove the boiler front jacket panel and venturiinlet elbow.Vacuum any dirt or debris from theburner/blower components.Re-install venturi inlet elbow and front jacketpanel when completed.WARNINGDo not use solvents to clean any of theburner components. The componentscould be damaged, resulting in unreliableor unsafe operation.Check System PipingInspect 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.Reported ProblemsAny problems reported by the owner should bechecked, verified and corrected before proceedingwith any maintenance procedures.Check Surrounding AreaVerify that the area surrounding the PRES-TIGE Solo is free of combustible / flammablematerials or flammable vapors or liquids.Remove immediately if found.WARNINGEliminate 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 surroundingarea. Inspect the gas supplypiping using the procedure outlined onPage 41.Verify that combustion air inlet area is free ofany contaminates. Refer to the list of potential59

Maintenance ProceduresClean Condensate Drain Assembly1. Loosen the slip ring nut from the condensatedrain assembly disconnecting theassembly from the boiler.2. Empty any water from the trap and drainassembly. Flush with fresh water as necessaryto 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 slip ringnut 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 OpeningsVerify 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 PipingVisually inspect the venting system and combustionair piping for blockage, deteriorationor leakage. Repair any deficiencies.Verify that the combustion air inlet piping isconnected, sealed and properly supported.WARNINGFailure to inspect the vent system andcombustion air inlet piping and to haveany conditions repaired, can result insevere personal injury or death.Check Boiler SystemVerify all system components are correctlyinstalled and operating correctly.Check the cold fill pressure for the system, typicalcold 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 indicatesexpansion tank sizing is incorrect or systemperformance problems.Inspect air vent and air separators in the system.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.60

Maintenance ProceduresCheck Expansion TankRefer to Section IV - Boiler Piping for recommendedlocation of the expansion tankand air eliminators.Close -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 airsaturatedtank water back into the system.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 residentialapplications 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 ValveInspect the relief valve and lift the lever to verifyflow at least annually or as recommendedon the warning tag of the valve.WARNINGBefore manually operating the pressurerelief valve, ensure the discharge piping isdirected to a suitable place of disposal toavoid a potential scald hazard. The dischargepiping must be full size withoutrestriction and installed to permit completedrainage 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 systemover-pressurization caused by an expansiontank that is waterlogged or undersized.Inspection of Ignition ElectrodeRemove 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 WiringInspect the burner wiring from the burner controlmodule to the ground terminal behind thecontrol panel.Ensure wiring is in good condition and securelyconnected.Check ground continuity of the wiring to theboiler jacket or piping using a continuity meter.Replace and correct ground wire if ground continuityis not completed and satisfactory.61

Maintenance ProceduresCheck Control WiringInspect all control wiring. Ensure wiring is ingood condition and properly connected.Check Control Settings1. 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 ProceduresStart the unit and perform the start-up procedureas 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 referencedin this manual.Check Burner FlameInspect the burner flame through the observationport 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. Remove the blower from the unit.combustion 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 gasketif 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 assemblyonto the heat exchanger. Ensure the burnerplate gasket and combustion chamber insulationis in place and not damaged, replace gasketand insulation if necessary. See WARNINGon page 64.Re-assemble the blower onto the burnermounting plate and reconnect the wiring harnessconnectors.Re-assemble the gas supply connection andrectifier to gas valve. Open the external manualgas valve. Check gas piping for any leaks asoutlined on page 41 and repair if necessary.Place the unit back into service.Remove the mounting nuts securing the burnermounting plate to the heat exchanger and setaside.Carefully remove the burner mounting plateassembly from the heat exchanger. Ensure62

Maintenance ProceduresCheck Flame SignalThe flame signal 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 conditionsare satisfactory.Check Combustion LevelsRefer to page 41 of this manual for measuringcombustion levels and burner adjustments.Check Flue Gas Temperature1. 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 higherthan the measured supply water temperature.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 followthe procedures listed below to cleanthe heat exchanger.Clean Heat Exchanger1. Shut down the boiler:- Follow the instructions on Page 42 "ToTurn Off Gas to Appliance"- Do not drain the boiler unless the boilerwill be subject to freezing conditions.- Do not drain the boiler if freeze protectionfluid is used in the system.2. Allow the boiler to cool down to room temperaturebefore 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. Remove the blower fromthe unit.5. Remove the mounting nuts securing theburner mounting plate to the heat exchangerand 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 insulationonto 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 damaged,replace gasket and insulation if necessary.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 necessary.13. Close isolation valves on the boiler waterpiping to isolate the boiler from the heatingsystem.14. Attach a hose to the boiler drain valve andflush the boiler thoroughly with fresh63

Maintenance Procedureswater by using the purge valves to allowwater to enter through the make-up waterline to the boiler.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 56.Review With OwnerEnsure the owner understands the importanceto perform the maintenance schedulespecified in this manual.Remind the owner of the importance to calla licensed contractor should the unit or systemexhibit any unusual behavior.Handling of Previously Fired Combustion Chamber InsulationWARNINGThe combustion chamber insulationcontains ceramic fibers, which areclassified as a possible human carcinogen.When exposed to extremely hightemperatures, the ceramic fibers,which contain crystalline silica, can beconverted into cristobalite.Avoid Breathing and Contact with Skinand EyesWhen removing or repairing the combustionchamber insulation follow these precautionmeasures:1. Use a NIOSH approved respirator whichmeets OSHA requirements for cristobalitedust, similar to N95. ContactNIOSH at 1-800-356-4676 or on theweb at www.cdc.gov/niosh for latest recommendations.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 air64

Replacement Parts7659253Fig. 26: PRESTIGE Jacket Components1865

Replacement PartsFig. 27: PRESTIGE Internal Components66

Replacement PartsFig. 28: PRESTIGE Burner Components67

Replacement PartsFig. 29: PRESTIGE Electronic Components68

Product Specifications15.43” [392 mm]9.87” [251 mm]3” Vent Outlet3” Combustion Air InletNPSC Pressure Relief Valve3”[76 mm]3/4” NPSC Pressure ReliefValve ConnectionFront View19.75” [502 mm]7.31” [186 mm]9.87” [251 mm]2.2”1” NPT CH and DHW Supply[56 mm]1” NPT Boiler Return1/2” NPT Gas Connection69

Product Specifications15.60” [396 mm]12.04” [306 mm]11.66” [296 mm]3/4” NPSC Pressure Relief3” Combustion Air Inlet3” Vent Outlet35.53”[902 mm]1.89” [ 48 mm] 1” NPT Boiler Return2.28” [ 58 mm] 1/2” NPT Gas Connection1” NPT DHW SupplySide View9.53” [242 mm]1” NPT CH Supply70

Products SpecificationsBoilerModelFuelDOEHeating CapacityNote 1 & 4InputNote 4Net IBRRatingNote 2DOE SeasonalEfficiency AFUENote 3ShippingWeightLbs/KgSOLO 110 Natural 99,000 110,000 86,00095%106/48SOLO 110 Propane 87,000 97,000 76,00095% 106/48Note 1:The heating capacity of the PRESTIGE Solo110 is based on the test requirements of theU.S. Department of Energy.Note 3:Based on the given AFUE the PRESTIGESolo 110 meets the energy efficiency guidelinesestablished by Energy Star.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 4:Input and output ratings are shown for sealevel applications. The PRESTIGE Soloautomatically derates the input at approximately2% for every 1,000 Ft. of altitude. Noalterations to the boiler or burner system isrequired.DOE71

Product SpecificationsGraph 2: Pressure Drop Comparison Solo 110 vs Grundfos UPS 15-58F-FCNote:Minimum allowable flow rate at full input: 5 gpm72

Additional Quality Water Heating Equipment Availablefrom Triangle TubeMAXI-FLO Heat Exchangers- Construction of high quality corrosion resistantstainless steel (AISI 316) or titanium- Specially designed built-in flow restrictor to assuremaximum heat exchange- Compact and light weight- Available in 5 sizes that can accommodate any sizepool or spaSMART Indirect Fired Water Heaters- Exclusive Tank-in-Tank design- Stainless steel construction- Available in 7 sizes- Limited LIFETIME residential warranty- 15 year limited commercial warranty- Self cleaning/self descaling designTTP Brazed Plate Heat Exchangers- For domestic water, snow melting, radiant floor,refrigeration- Plates made of stainless steel, with a 99.9 % copperand brazed, ensuring a high resistance to corrosion- Self cleaning and self descaling- Computerized sizing available from TriangleTube/Phase III- Available in capacities from 25,000 BTU/hr to5,000,000 BTU/hrFreeway Center - 1 Triangle Lane - Blackwood, NJ 08012Tel: (856) 228 8881 - Fax: (856) 228 3584http://www.triangle tube.comE-mail: Info@triangle tube.comMember ofGroup