TriangleTube PTRKIT111 User manual

Gas Valve Replacement Kit
1
Kit Part Number: PTRKIT111
Parts List
1. Honeywell Gas Valve VK4115V (120V)
2. Gas Valve/Orifice Gasket
3. Torex Screws (3 pcs)
4. Venturi/Blower Housing Gasket
5. # 25 Torex Wrench.
Recommended tools:
A. Pipe Wrench.
B. Phillips Screw Driver.
C. Flat Blade Putty Knife.
D. # 25 Torex Wrench. (Furnished in Kit.)
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.
Failure to do so can cause severe personal
injury or death.
This kit is designed for gas valve replace-
ment on the Prestige TriMax 60, 110, 175,
250 and Prestige TriMax Excellence prod-
ucts. Boiler serial number must start with
PT.
This kit M ST NOT be used on Prestige
Boilers equipped with MCBA Controls.
These boilers have a serial number starting
with PS.
NOTICE
WARNING
WARNING
NOTICE
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 injury hazards.
NOTICE
WARNING
5
3
1
2
4

Gas Valve Replacement Kit
2
PRESTIGE BOILER INSTR CTIONS:
1. Turn power to the unit “OFF”.
2. Shut off the gas supply to the boiler at the main
manual shutoff valve.
3. Remove the front jacket panel.
4. Remove the air inlet elbow from the venturi.
5. Remove the olex plug from the gas valve.
6. Disconnect the gas supply piping inside the
PRESTIGE at the brass union located just
before the gas valve.
7. Remove and save the two Torex screws attach-
ing the venturi / gas valve assembly from the
blower housing. See Fig.1. Remove the venturi
/ gas valve assembly from the blower housing.
Use the Torex wrench supplied in the kit to
remove screws.
There is a gasket between the venturi and blow-
er housing. If gasket “sticks” to the blower
housing use a flat blade putty knife to remove
any gasket material. Make sure not to scratch or
score the mating surface on the blower housing.
8. Remove the three screws attaching the gas
valve to the venturi. Use Torex wrench sup-
plied in kit to remove screws. Note orientation
of the venturi to the old gas valve for reassem-
bly of the venturi on the new gas valve.
9. Reassemble the new gas valve, gas valve/orifice
gasket and the three Torex screws from the kit
and reassemble the gas valve to the venturi. See
Fig. 2.
Ensure the gas valve/orifice gasket is in place
before reassembling the gas valve and venturi.
Failure to do so can result in death, serious
injury or substantial property damage.
NOTICE
WARNING
1. Gas Valve
2. Venturi
3. Gas Valve Fitting
4. Venturi ounting screws.
Attaching Gas Valve/Venturi to Blower
Housing
Fig. 1: Prestige Burner Assembly

Gas Valve Replacement Kit
For propane installations a brass orifice is locat-
ed inside the gas valve/orifice gasket. This ori-
fice must be placed inside of the new gas
valve/orifice gasket before reassembly.
Failure to insert the propane brass orifice, on
propane installations, before reassembling the
gas valve and venturi can result in the produc-
tion of carbon monoxide due to incomplete com-
bustion and may result in death, serious injury
or substantial property damage.
10. With the venturi to blower gasket in place,
reassemble the venturi / gas valve to the blower
housing using the two mounting screws from
step 7.
For the reassembly process do not use adhesive
on any gasket surface.
11. Reconnect the olex plug to the gas valve elec-
trical connection.
12. Reconnect the brass gas piping union connec-
tion. Open the main manual gas shutoff valve
before placing the PRESTIGE unit back into
operation check and test all gas connections for
leaks. Repair leaks if found.
Do not check for gas leaks with an open flame.
se a bubble test. Failure to check for gas leaks
can cause severe personal injury, death or sub-
stantial property damage.
13. Reattach the air inlet elbow to the venturi.
14. Reattach the front jacket panel.
15. Turn the electrical power “ON” to the PRES-
TIGE to return the unit back into service.
NOTICE
WARNING
WARNING
NOTICE
3
Venturi
Orifice
Gas Valve
Gasket
Gas Valve
Fig. 2: Gas Valve / Venturi Assembly - PRESTIGE Solo 60/110/175/250

Gas Valve Replacement Kit
4
COMB STION TEST
1. The installer UST 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.
Table 1: Combustion Settings
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.
Failure to 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. Test for CO2 or O2 and for CO during high fir-
ing rate. The combustion readings should be
within the range listed in Table 1. The CO level
should not exceed 100 ppm when combustion
is correct. Perform the following procedure to
manually place the burner into high fire.
a. Press the round INSTALLER button. See
Fig. 3.
b. Enter the installer access code “054” by
using the LEFT and RIGHT buttons to
select a digit and the P and DOWN but-
tons to change the digit. Press the OK but-
ton to enter the access code.
c. Press the RIGHT button to highlight the
anual Operation icon then press the
OK button.
d. Press the OK button while the FAN icon is
highlighted to manually fire the burner and
power the CH circulator.
An adequate CH load must be present to dis-
sipate the heat generated during the combus-
tion test. If an adequate CH load is not avail-
able, an indirect water heater can be used to
dissipate the heat by creating a DHW call
which will enable the DHW circulator.
e. Press the LEFT and RIGHT buttons to
adjust the firing rate from 0% to 100%.
Hold down the LEFT or RIGHT button to
rapidly increase or decrease the firing rate.
WARNING
WARNING
NOTICE
Natural Gas Propane
O2 Min. 2.30% 2.70%
O2 Max. 5.30% 4.70%
CO2 Min. 8.80% 10.70%
CO2 Max. 10.50% 12.00%
CO Max. 100 ppm 100 ppm
Manual Operation
Released
O
O
O
CH
CH1
FAN
DHW
SYS
CH2
Installer
Button
Fig. 3: Trimax Navigation Buttons

Gas Valve Replacement Kit
5
f. Press the OK button while the FAN icon is
highlighted to shutdown the burner.
g. Cycle power to the Prestige once combus-
tion testing is complete to return to normal
operation.
The combustion levels should be measured at
high firing rate. If the combustion levels are
not within the range given in Table 1 for the
firing rate, shut the boiler down and contact
Triangle Tube Engineering Department.
Failure to comply with this requirement
could result in severe personal injury, death
or substantial property damage.
If the combustion levels during high fire is outside
the recommended combustion settings adjust the
THROTTLE SCREW (see Fig. 4) 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 LEFT button to adjust firing rate
down.
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. 4) 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
WARNING
Offset Pressure
Cover Screw
Throttle
Screw
Fig. 4: Combustion Adjustment - Prestige Burner
2011-53 PrestigeGas Valve Repl. Kit_Tri ax
Date: 12/8/11