TriangleTube PRESTIGE Excellence Series User manual

PRESTIGE Excellence
HX Field Replacement Kit
1
Each Heat Exchanger (HX) Replacement Kit includes
the following items already installed on the heat
exchanger:
- Combustion chamber insulation
- Burner head and gasket
- Sight glass assembly
- Burner mounting plate gasket
The following items are shipped in a PARTS BOX and
must be installed as part of the HX replacement:
- Vent outlet gasket
- Blower gasket
- Boiler piping gaskets
- Long handle phillips head screwdriver
- Long handle T-20 Torx screwdriver
- Igniter, igniter gasket, screws
- Temperature sensors and harness adapters
Recommended tools:
A. Pipe wrenches
B. Phillips and flat head screw drivers
C. 10 mm socket and/or 10 mm wrench
D. Adjustable wrench
E. Needle nose pliers
F. Diagonal cutting pliers
G. Calibrated combustion analyzer
Quantity Kit Part
Number
Description Model
PE 110 N tur l G s
St inless Steel
Condens te P n
PT 110 N tur l G s
Polypropylene
Condens te P n
PE 110 LP
St inless Steel
Condens te P n
PT 110 LP
Polypropylene
Condens te P n
1 PSRKIT01 He t Exch nger Assembly X
1 PTRKIT124 He t Exch nger Assembly X
1 PSRKIT76 He t Exch nger Assembly X
1 PTRKIT125 He t Exch nger Assembly X
Indicates a potentially hazardous situation
which, if ignored, can result in serious injury
or substantial property damage.
Indicates special instructions on installation,
operation or maintenance, which are impor-
tant to equipment but not related to personal
injury hazards.
NOTICE
WARNING
For your safety, turn off electrical power sup-
ply at service panel and allow unit to cool
before proceeding to avoid possible electrical
shock and scald hazard. Failure to do so can
cause severe personal injury or death.
Use a two wrench method when tightening piping
onto the boiler piping connections. Use one
wrench to prevent the boiler piping from turning /
twisting. Failure to support the boiler piping and
connections in this manner could cause damage to
the boiler and its components.
Failure to follow instructions below can result
in severe personal injury or damage if ignored.
• Instructions are for a qualified installer/
service technician only.
• Read all instructions before proceeding.
• Follow instructions in proper order.
WARNING
WARNING
WARNING

Preliminary Instructions
1. Verify that the heat exchanger kit is correct for
the model of boiler. See table on page 1.
2. Turn off power to the unit at the main service
panel and allow the unit to cool.
ELECTRICAL SHOCK HAZARD!
Ensure power to the boiler has been switched off
prior to servicing the unit.
3. Remove the front jacket panel of the boiler by
removing the thumbscrew located on the upper
edge of the unit. Lift the panel up and pull for-
ward to remove the front panel from the unit.
4. Using a voltmeter verify there is no electrical
power to the boiler by checking for power on
the boiler’s power supply terminals L and N
5. Shut off gas supply to the inlet of the unit at the
external main manual shutoff valve.
6. Close external system isolation valves to the
boiler supply and return piping and on the sys-
tem make up / fill piping.
7. Attach a hose to external boiler drain. Place
other end of this hose to a suitable drain.
8. Open external boiler drain valve and begin
draining the boiler.
To assist in the draining of the boiler, remove the
air vent at the top of the unit or manually lift
open the pressure relief valve.
Removal of Venting Connection
1. Use a flat head screw driver to loosen the banding
clamp located on the vent outlet adapter. (Fig. 2).
2. Remove vent piping from vent outlet adapter as
the internal flue tube / vent outlet adapter must be
removed.
3. Disconnect the yellow wire leads/ olex plug
from the flue temperature sensor (shown as
Item 1 in Fig. 1). The flue temperature sensor
may be located in the vent pipe or the conden-
sate pan depending on the model. Use care
when disconnecting the wire leads as not to
damage the sensor terminals or the wire leads.
Before disconnecting any wire connections mark and
label all connections and location of the connections.
NOTICE
WARNING
NOTICE
PRESTIGE Excellence
HX Field Replacement Kit
2
4
5
3
2
1
Fig. 1: Prestige Excellence

Stainless Steel Vent Outlet Adapter Removal
1. Dismount the vent outlet adapter from top of boil-
er cabinet by removing the 4 mounting screws.
Do not discard the mounting screws and vent out-
let adapter as they will be reused. (Fig. 2)
2. Remove entire vent outlet adapter by lifting ver-
tically upward and out of the boiler cabinet
using a twisting / rocking motion (Fig. 3).
3. In case of insufficient space above the boiler,
remove combustion air inlet piping and boiler
relief valve / air vent assembly from the top of
the boiler. Close the DHW cold water supply
isolation valve and open a hot water faucet to
relieve water pressure in the water heater.
Remove all DHW piping including T&P relief
valve from the DHW connections on the top of
the boiler. Remove all screws securing the top
jacket panel from the side panels and remove
vent outlet adapter and top jacket panel togeth-
er from the boiler cabinet. Put all items in a safe
place as they will all be reused.
4. Once the vent outlet adapter is removed from the
boiler, it should be inspected for deformation
damage or corrosion.
If there are any signs of deformation, damage or
corrosion on the vent outlet adapter, replace it
immediately. Check condition of flue sensor
mounting, replace vent outlet adapter if necessary.
Failure to comply could result in flue gas leakage
resulting in severe personal injury or death.
Polypropylene Vent Outlet Adapter Removal
1. Dismount the vent outlet adapter from top of boil-
er cabinet by twisting the vent outlet adapter
counter clockwise to disengage the retaining tabs.
Remove the vent outlet adapter by lifting verti-
cally to disengage it from the internal vent pipe.
2. Remove the internal vent pipe from the unit by
lifting vertically upward and out of the boiler
cabinet using a twisting / rocking motion.
Removal of Electrical Connections (MCBA)
Before disconnecting any wire connections mark and
label all connections and location of the connections.
WARNING
NOTICE
PRESTIGE Excellence
HX Field Replacement Kit
3
Vent Outlet
Adapter
Test
Port
Banding
Clamp
Mounting
Screws
(4) Each
Fig. 2: Vent Outlet Adapter Mounting
Flue Gasket
Heat Exchanger
Flue Adapter
Vent Outlet
Pipe
Fig. 3: Removal of Vent Outlet Adapter

PRESTIGE Excellence
HX Field Replacement Kit
4
1. Remove both top access panels located above
the heat exchanger and water heater on the top
jacket panel.
2. Remove ignition cable and green ground wire
from the igniter. (Fig. 4).
3. Disconnect the ignition cable from the CBA
control module and remove air intake pipe from
venturi. (Shown as item 2 in Fig 1). Place the
intake pipe and ignition cable aside, DO NOT
discard as they will be re-used.
4. Disconnect the electrical connection(s) for the
blower at the blower housing.
5. Remove the mounting screw and disconnect the
black rectifier plug from the gas valve.
6. Disconnect the grey flat ribbon cable from the
display board at the CBA control module.
7. Disconnect the orange low voltage and high volt-
age wiring terminal strips by unplugging the bot-
tom strips from the upper portion.
8. Remove the retaining screw for control mount-
ing panel and swing open the control mounting
panel. The high voltage and low voltage termi-
nals should pass through the lower cutouts of
the panel to allow movement of the panel.
9. Disconnect the red wire leads from supply tem-
perature sensor (Shown as item 3 in Fig. 1)
located at the top of the heat exchanger.
10. Disconnect the blue wire leads from return tem-
perature sensor (Shown as item 4 in Fig. 1)
located at the bottom of the heat exchanger.
11. Disconnect the orange wire leads from the Low
Water Cut-Off (LWCO) pressure switch
(Shown as item 5 in Fig. 1). Use care when dis-
connecting the wire leads as not to damage the
LWCO terminals or the wire leads.
Removal of Electrical Connections (TriMax)
Before disconnecting any wire connections mark and
label all connections and locations of the connections.
1. Remove both top access panels located above
the heat exchanger and water heater on the top
jacket panel.
2. Slide left and right tabs of control panel inward
and lower control panel.
3. Pull the retaining tabs on top of the rear cover to
remove the rear control box cover.
4. Remove green ground wire from the igniter and the
ignition cable from the Tri ax control module.
5. Remove air intake pipe (Shown as item 2 in Fig.
1) from venturi. Place the intake pipe aside, DO
NOT discard as it will be re-used.
6. Disconnect the electrical connection(s) for the
blower at the blower housing.
7. Disconnect the olex plug from the gas valve.
8. Disconnect the olex plug from supply tem-
perature sensor (Shown as item 3 in Fig. 1)
located at the top of the heat exchanger.
NOTICE
Ignition
Cable
Igniter
Venturi
Fig. 4: Top of Heat Exchanger

PRESTIGE Excellence
HX Field Replacement Kit
5
9. Disconnect the olex plug from return temper-
ature sensor (Shown as item 4 in Figs. 1-3)
located at the bottom of the heat exchanger.
10. Disconnect the orange wire leads from the Low
Water Cut-Off (LWCO) pressure switch
(Shown as item 5 in Fig. 1). Use care when dis-
connecting the wire leads as not to damage the
LWCO terminals or the wire leads.
Removal of Gas Connection
1. Disconnect the gas supply piping inside the
boiler at the brass union located just below the
gas valve using two wrenches.
2. The gas piping can remain inside the boiler or
be removed for additional clearance / access.
Removal of Blower/Gas Valve/Venturi Assembly
1. Remove 4 blower mounting screws from the
burner plate using the extended Phillips/Torx
head screw driver provided in the kit and remove
the blower/gas valve/venturi. Gas valve and ven-
turi assembly can remain connected to the blower
housing. Discard old blower gasket. (Fig. 5).
Removal of Water Connections
1. Remove condensate trap and cabinet gasket
from the boiler. Do not discard, as they will be
reused. Cut serrated washer on polypropylene
condensate pan to remove retaining nut.
2. Remove electrical wiring from the internal cir-
culator. ark and label all wires. Disconnect
the olex plug from the diverter valve actuator.
3. Using a pipe or adjustable wrench, disconnect
the brass union on the boiler piping at the top of
the DHW tank. (Fig. 6)
4. Loosen brass union nuts located above and
below the diverter valve body. (Fig. 7)
Venturi/Gas Valve
Assembly
Blower
Blower
Gasket
Burner
Plate
Fig. 5 Blower/Gas Valve and Venturi Assembly
Brass
Union
Brass
Union
Diverter
Valve
Fig. 7: Excellence Front View
Brass Union
Fig. 6: Excellence Top View