TriangleTube PSRKIT41 User manual

Gas Valve Replacement Kit
Prestige Solo 399
1
Kit Part Number: PSRKIT41
Parts List (Fig. 1)
1. Honeywell Gas Valve VR8615VB
2. Gas Valve/Supply Pipe O-ring
3. Gas Valve/Outlet Pipe O-ring
4. (8) - M5 Phillips Head Screws.
Recommended Tools:
1. Adjustable Wrench.
2. Phillips Head Screwdriver
3. Small Flat Head Screwdriver
Failure to follow instructions below can result
in severe personal injury or damage if ignored.
•Instructions are for a qualified installer/ser-
vice technician.
• Read all instructions before proceeding.
•Follow instructions in proper order.
For your safety, turn off electrical power
supply at service panel before proceeding to
avoid possible electrical shock hazard.
Failureto do so can cause severepersonal
injury or death.
This kit is designed for gas valve replace-
ment on the Prestige Solo 399 only.
NOTICE
WARNING
WARNING
Indicates a potentially hazardous situation
which, if ignored, can result in serious
injury or substantial property damage.
Indicates special instructions on installa-
tion, operation or maintenance, which are
important to equipment but not related to
personal injuryhazards.
NOTICEWARNING
23
4
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Fig. 1: Gas Valve Kit

Gas Valve Replacement Kit
Prestige Solo 399
2
PRESTIGE 399 BOILER INSTRUCTIONS:
1. Turn power to the unit “OFF”
2. Shut off the gas supply to the boiler at the main
manual shut off valve.
3. Remove the front jacket panel and swing away
the control module panel.
4. Remove the wires to the gas valve.
5. Disconnect the gas supply piping inside the
PRESTIGE at the union located just before the
gas valve.
6. Remove the 4 screws on the top of the gas
valve, securing the gas valve outlet extension
pipe to the valve, see Fig. 2.
7. Remove the gas valve from the PRESTIGE
unit.
8. Remove the 4 screws securing the gas valve sup-
ply piping adapter to the gas valve, see Fig. 2.
9. Remove the O-rings in the gas valve supply pip-
ing adapter and gas valve outlet extension pipe.
10. Install the gas valve supply piping adapter and
O-Ring gasket on the new gas valve using 4
screws supplies in kit. Ensure screws are tight.
11. Install the new gas valve and O-Ring gasket to
the gas valve extension using the 4 screws sup-
plies in kit. Ensure screws are tight.
12. Reconnect the gas supply piping using two
wrenches. Open the manual gas shut offvalve
to check and test all gas connections for leaks
before placing the PRESTIGE unit back into
operation. Repair leaks if found.
Do not check for gas leaks with an open
flame. Use a bubble test. Failure to check for
gas leaks can cause severe personal injury,
death or substantial property damage
13. Reconnect the wires to the gas valve, see Fig. 3.
14. Reposition the control module panel and reat-
tached the front jacket panel.
15. Turn the electrical power “ON” to the PRES-
TIGE to return the unit back into service.
WARNING
2
1
3
Fig. 2: Prestige 399 Gas Valve Assembly
1. Gas Valve
2. Gas Valve Supply Piping Adapter
3. Gas Valve Outlet Extension Pipe

3
COMBUSTION TEST
1. The installer MUST perform a complete com-
bustion check to ensure the following combus-
tion levels are met at high and low input firing
rates and the burner is operating at optimum
conditions.
The combustion testing and adjustments
must be performed by a qualified installer,
service agency or the gas supplier.All com-
bustion measurements must be perform with
calibrated equipment to ensure proper read-
ings and accuracy.
Failureto perform a complete combustion
test at both high and low input rates may
result in incomplete combustion and the pro-
duction of carbon monoxide, which can
cause severe personal injury, death or sub-
stantial property damage.
2. Manually place the boiler into high fire mode
by pressing the MODE button with “+” button
simultaneously on the control panel display
while in the standby (STBY) mode.
The control panel will display an H followed
by the current boiler temperature when
placed into high fire test mode.
If the combustion levels during high fire is outside
the recommended combustion settings adjust the
THROTTLE SCREW (see Fig. 3) as follows:
Counter-clockwise adjustment of the throttle
screw at high fire:
O2decreases and C02increases
Clockwise adjustment of the throttle screw at
high fire:
O2increases and CO2decreases
4. Once the combustion level is set at high fire,
manually place the boiler into low fire mode by
pressing the MODE button with “-” button
simultaneously on the control display while in
the standby (STBY) mode.
NOTICE
WARNING
WARNING
Natural Gas Propane
O2Min. 2.30% 3.70%
O2Max. 5.30% 5.20%
CO2Min. 8.80% 10.00%
CO2Max. 10.50% 11.00%
CO Max. 100 ppm 100 ppm
Gas Valve Replacement Kit
Prestige Solo 399
1. Brown Wire
2. Blue Wire
3. Throttle Screw
4. Offset Screw
5. Inlet Pressure Tap Gas Valve
Fig. 3: Gas Valve Wiring &
Combustion Adjustment

Gas Valve Replacement Kit
Prestige Solo 399
42007-22 Solo 399 Gas Valve Repl. Kit
5/14/08
The control panel will display a L followed
by the current boiler temperature when
placed into low fire test mode.
5. If the combustion level during low fire is not
within +/-0.2% of the combustion level mea-
sured at high fire, adjust the metal offset screw
inside the brass fitting on the top right of the gas
valve (see Fig. 3) as follows.
Counter-clockwise adjustment of offset screw at
low fire:
O2increases and O2decreases
Clockwise adjustment of offset screw at low fire:
O2decreases and CO2increases
NOTICE