TriangleTube PTRKIT111 Use and care manual

Prestige
Gas Valve Replacement
1
WARNING
!
Indicates a potentially hazardous situation which,
if ignored, can result in serious injury or substan-
tial property damage.
NOTICE
Indicates special instructions on installation, operation
or maintenance, which are important to equipment
but not related to personal injury hazards.
WARNING
!
For your safety, turn off electrical power supply
at service panel and allow unit to cool before pro-
ceeding to avoid possible electrical shock and
scald hazard. Failure to do so can cause severe
personal injury or death.
WARNING
!
Failure to follow instructions below can result in
severe personal injury or damage if ignored.
• Instructions are for a qualified installer/ ser-
vice technician only.
• Read all instructions before proceeding.
• Follow instructions in proper order.
Each Kit Includes:
• Gas Valve
• Gas Valve Gasket
• Venturi/Blower Gasket
• Gas Valve Screws
Recommended Tools:
• Adjustable Wrench
• Torx Screwdriver
• Phillips Head Screwdriver
Kit Part Number Description Model
PTRKIT111 Gas Valve Replacement Prestige 250
TCRKIT18 Gas Valve Replacement Prestige 299/399
2020-17 Prestige CTRLMax Gas Valve Replacement
Revised 1/10/2020

Prestige
Gas Valve Replacement
2
1. Preliminary Instructions:
1. Verify that the Gas Valve replacement kit is correct
for the model of boiler. See table on page 1.
2. Carefully open and unpack the PARTS BOX from its
shipping carton.
3. Carefully remove and check for any damage.
NOTICE
Do not proceed with installation and contact Triangle Tube
right away if the gas valve is damaged in any way.
4. Turn o the electrical power supply to the boiler.
5. Close the manual gas shut o valve to the unit.
2. Gas Valve Removal Instructions:
1. Remove the front jacket panel.
2. Disconnect the Molex plugs to the gas valve.
3. Remove the screws/nut securing the gas valve
from the gas valve piping below. Discard the gas
valve gasket as a replacement is included in the kit.
4a. (Prestige 250) Remove the three screws securing
the gas valve from the venturi. Discard the gas
valve gasket as a replacement is included in the
kit. Do NOT discard the Orice or gasket as it will
be reused.
4b. (Prestige 299/399) Remove the four screws secur-
ing the gas valve from the piping to the venturi.
Discard the gas valve gasket as a replacement is
included in the kit.
5. Remove the old gas valve from the unit.
Fig. 1: Prestige 250
Fig. 2: Prestige 299-399

Prestige
Gas Valve Replacement
3
3. Gas Valve Installation Instructions:
1a. (Prestige 250) Install the orice and orice gasket
between the gas valve and venturi. Tighten the
three screws securing the gas valve to the venturi.
WARNING
!
Ensure the orifice is installed with the gasket as pre-
viously installed. Installing the orifice incorrectly can
result improper combustion and can result in substan-
tial property damage, serious injury, or death.
1b. (Prestige 299/399) Insert a new o-ring between
the gas valve and gas piping. Tighten the four
screws securing the gas valve to the venturi.
2. Tighten the screws to secure the gas valve to 31-35
in-lbs of torque.
3. Insert a new gasket between the gas valve and gas
piping. Tighten the screws/nut securing the gas
valve from the gas valve piping below.
NOTICE
For the reassembly process do not use adhesive on any gas-
ket surface.
WARNING
!
Ensure the o-ring/gasket are in place before reassem-
bly. Failure to do so can result in death, serious injury
or substantial property damage.
WARNING
!
Ensure the gas valve is properly sealed in order to pre-
vent a gas leak. Gas leaks can result in death, serious
injury or substantial property damage.
4. Reconnect the Molex plug to the gas valve.
5. Open the main shuto valve to the gas supply
piping. Before placing the boiler back into service
check and test all gas piping connections for leaks.
Repair leaks if found.
WARNING
!
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 Combustion Test and Adjustments
4. Combustion Test and Adjustments
NOTICE
The installer MUST perform a complete combustion check
to ensure the following combustion levels are met at high
and low input ring rates and the burner is operating at op-
timum conditions.
Table 1: Recommended Combustion Settings
NG
All Modes
Propane
250/299
Propane
399
High Fire
CO2Range 8.8 to
10.5%
10.7 to
12.0%
10.4 to
11.4%
CO2Target 9.2% 11.0%
O2Range 2.3 to
5.3%
2.7 to
4.7%
3.7 to
5.2%
O2Target 4.6% 4.2%
CO Max 100 ppm 150 ppm
Low Fire
CO2Range 0.5 to 0.6% Lower than or equal to
High Fire CO2level
O2Range 0.8 to 0.9% Higher than or equal to
High Fire CO2level
WARNING
!
The combustion testing and adjustments must be per-
formed by a qualified installer, service agency or the
gas supplier. All combustion measurements must be
performed with calibrated equipment to ensure prop-
er readings and accuracy.

Prestige
Gas Valve Replacement
4
WARNING
!
Failure to perform a complete combustion test at both
high and low input rates may result in incomplete
combustion and the production of carbon monoxide,
which can cause severe personal injury, death or sub-
stantial property damage.
1. Press the round INSTALLER button.
DHW Demand
Target = 186°F
Installer Button
Fig. 3: Navigation Buttons
2. Enter the installer access code “054” by using the
LEFT and RIGHT buttons to select a digit and the UP
and DOWN buttons to change the digit. Press the
OK button to enter the access code.
3. Press the RIGHT button to highlight the Manual
Operation icon then press the OK button.
4. Press the OK button while the FAN icon is high-
lighted to manually re the burner and power the
CH1 circulator (see Fig. 6)
Manual Operation
Released
O
O
O
CH1
FAN
DHW
CH2
Manual Operation
Released
O
O
O
CH1
FAN
DHW
CH2
Manual Operation
Released
O
O
O
CH2
FAN
DHW
CH1
Manual Operation
Released
O
O
O
DHW
FAN
CH1
CH2
Fig. 4: Manual Operation
NOTICE
An adequate CH load must be present to dissipate the heat
generated during the combustion test. If an adequate CH
load is not available an indirect water heater can be used to
dissipate the heat by creating a DHW call which will enable
the DHW circulator.
5. Press the RIGHT button to adjust the ring rate to
100% (high re). Hold down the RIGHT button to
rapidly increase the ring rate.
6. If the combustion levels during high re are outside
the recommended combustion settings adjust the
THROTTLE SCREW using a at-blade screwdriver as
follows:
Counter-clockwise adjustment of the THROTTLE SCREW
at High Fire (100% ring rate):
O2 decreases and CO2 increases
Clockwise adjustment of the THROTTLE SCREW at High
Fire (100% ring rate):
O2 increases and CO2 decreases
7. Once the combustion level is set at high re, manu-
ally place the boiler into low re mode by pressing
the LEFT button to adjust ring rate down to 1%
(low re) to verify low re combustion settings.
8. If the combustion levels (O2& CO2) during low re
are outside the recommended combustion set-
tings in Tables 2, contact Triangle Tube Technical
Support Department for assistance.
9. Press the OK button while the fan icon is highlight-
ed to shutdown the burner.
10. 11. Press the LEFT or RIGHT button to highlight the
home screen icon to exit the service mode.
11. Replace the front jacket panel and secure with
screws.
12. Turn on the electrical power supply to the Prestige
boiler and return the unit back to service.