A06_Big_Stone_Prestige_Solo_399_Owners_Manual.pdf

BOILER

prestige_- Fullq Condensing Water Bailer c(i)us , .. .., Engineering Submittal Da~

ASME Boiler Certification - ASME "H" Stamp Unit complies with ANSI Z21.13 and CSA 4.9 Boiler Standards Fnlly condensing - 95.1 % thermal efficiency Full modulation capability from 25% to rated input Modulation allows fewer and longer cycles leading to lower operating cost and longer component life Low pressure drop heat exchanger Control interface and logic for indirect hot water storage tank with priority Approved for zero clearance to comhnstibles (excluding vent and boiler piping) Autpinatic boiler free:ze protection Anti.-:freeze allowed when used per manufacturer's spec-ili.cations.

• Superiorgradestainlesssteelheatexchangerconstruction

- 439 Grade

• Self cleaning flue ·ways in heat exchanger

• Low NOx operation exceeding SCAQMD 2012 regula tions

O TraangleTi Engineering Submittal

Solo 399

Digital display conti:ol panel .

Use of 4" PVC, CPVC; PPS or•AL29-4C pipe for vent and air up to 100 equiv.dent feet each (total length and :fit tings - each 90" elbow equals 5 feet and each 45° elbow equals 3 feet) Limited 10 year·warranty Boost feature low temperature startup Solid wall mounted or optional ,vall and floor stand Standard equipment:

ASME 30 psi pressure relief valve pressure and temperature gauge high limit temperature safety control ootdoor temperature reset control air vent 24 volt terminal strip Vlith removable jumpers for manual.reset or automatic reset automatic low water cutoff feature variable speed blower

Mi.ct:oprocessor electronic gas and air controller Stainless steel preµrix, burner Reliable spaik: ignition Unique geometry - 3 consecutive baffles guide water flow through the heat excha.n.ger and around the combus tion chamber High water content - stable temperature control and less sensitive to water flow and quality Electronic controls Vlith easy to read menus, perlonnance and trouble sboofuig codes, Swing out control panel for easy access and servicing Attractive appliance design for installation in high visi bility areas.

Boiler water supply temperature can be maintained by the Prestige, eliminating the need for a mix system to achieve the desired temperature with high limit protection

Project/ Location: _____ ____ __________ _ Date: ______ _

Consulting Engineer I Architect: _________ _________________ _

Mechanical Contractor: _______________ ______________ _

Notes: ______________________________ _

D>tr 215/09 1 2007-17 PR:stige Snb<mllal 399

All program correspondence will be handled directly with Cornerstone, the Plan Adrninistrat~r.

Contact CornerStone as shown below:

Cornerstone United Eastway Plaza 1899 Tate Boulevard, SE- Suite 2110 Hickory, NC 28602

Phone: 800-824-5090 Fax: 828-345-1918

• All necessary forms are available from ComerStone or from Triangle Tube.

• Contractors will send the registration form and their remittance directly to ComerStone.

• Homeowners will receive a congratulations letter welcoming them to the program containing the contract information directly from ComerStone.

If you have any questions regarding the Triangle Tube Homeowner Protection Plan, contact your Triangle Tube Sales Representative or ComerStone directly.

Thank you.

S:\Smcwilliams\Tmining\Print for Training (Don)\Protection Plan-use: letter head-Cornerstone-May.doc

J

THIS WARRANTY JS VOID AND SHALL I.fOT APPIXIF:

I. The PJeslige CondepsmgBoilec ii DOI inscilled in occordllnbewith Triangle Tobe Phase Ill's installation and operating manual by an -~ and qu:illfie11 biutiog mechanic skilled in the installa:

lion of Triangle Tube Phase.ID. equipment; or

2. The failure or malfunction results from improper-ormgligent opa-ation. accident, abuse. freezing, misuse, unauthorized alteration or improper repair or maintenance; or

3. 1be failwe or malfunction results from failure to lceep the boiler full of water, free to circulale al all time and with the boiler free of damJlging wm,,r sediment or sc.ile deposiis; or-

4. The Prestige Condensing B0tler is used for noirpotable applica tions such as pool or process heatio~ or

5. The unit is osed outside the Uniled Stales, its territories or posses sions, or Canada: or

6. 1be failore or malfunction occurs on a component, control, air vent or component pait not solely manufactnred by Triangle Tube/Phase m.

4- SHIPPING-~LY - INSTALLATION

Any and :ill costs required to disassemble, remove, ship, _reassemble and reinslall a Prestige Condensing Boiler or part ~ of ARENOT COV ERE) under thiswarraniy and sb:ill be borne by original user. Deliveries under th.is warranty way ~ cootiDgeDt opon T~ Tube/Pbase m receiving shipments of equipment from outside the United States and Triansie Tubell'hase Ill shall not be liable for any failure or delay in deliv ery due to any cause beyond its conti-ol

5- GENERAL PROVISIONS

For prompt waminty service. notify the installer who, in lum., will notify the TrillD.gle Tube distributor from whom be pwt:hased I.be Prestige Coode:nsing Boiler. Ii this action does not result in w.munty service. coo Ill.ct WANGLE TUBEJPHASE IIl, Freeway Cmtec, Biackwood. NJ 08012, wilh details in support of the warranty claim. This nolification must inchJde tire user's lll!JllC, address aod lhe serial number of the Prestige Condensing Boiler and proof of pun:h:J.se.. If me original user cannot provide proof of purchase, die warranty shall begin from the date of manufacture as indicated by serial number.

Prestige Condensing Boiler Warranty

ALL:TIIE WARRAN~-JMPDED BYS'L\TELAW, INCLlJD IJS'G 1llE ThiPi:.nm wAR'RANriEs 'or Mriiamrr A1IIU'iY AND FITNESS FOiU.P.AKIICULAR l'ORPOSE; ARE BEKEBl' EXPRESSU LIMITED ro THE J>ORA.TJoN OF 1BE DMil'BD ONE n:AR. AND_ FIRS'l' 'YEAR WARIW:'ITY . SET .FORTH ABOv.E. Some siat.es do pot aBo.w limitations on how Jong an implied warranty lasts; i;o the ahem, limitations may not apply toyou..

A) In order to gain CU>oert,ge under this ..amznl)' die conns,,er is rrquiml to fill Oil/ and mail _Ilse mrache:d ~ regi.r.mJlion H-ilhin lhi,ty (30) days qfpun:JJtJH. (For first oa:upanrs C/[ a new lwme. the date of dosing shculd be deemed the date of p~)

THIS~ WARRANTY JS MADE IN LIEU OF ALL OTHER

WARRAN~ WHETHER EXPRESSED OR IMPIJED. GUAR

ANTEES, AGREEMENTS, AND SIMILAR OBLIGATION OF

'MANUFACTURER WITH RESPECT TO THE REPAIR OR

REPU.~EMENT OF ANY SAME OR SIMILAR PRODUCT. TRI

ANGLE TUBF.IPHASE m~ NEITBER ASSUMFS N:OR AUTHO

IUZE'>ANY OTHER PERSON TO ASSUME FOR IT ANY OTHER

LIABILn'Y IN CONNECTION WITH THE SALE OF ITS PROO.

UC£ ·Any and all descr.ipliom;, i;pecificatiomi, _inslroctions, dn'llings, samph. ur JDod.ck famished to the orlgina] user do not am.mtnte a,pnss wamu:fils.

T1i.s is: 011T e,rlus/,.., writtm ~ Ir gi.~s >"" sp<c/jic kll"I Tight., buJ }""' l1IOJI also l,m-,, oiher rightr whidi vary fa,m J:la1e 10 state.

Rovi...S 8f!O'll6 .2f.r:M-4.6~W~

IMPORTANT: Registration required for complete warranty protection, fill and mail this canf immediately.

Name: ________________ _ Model No.:-----

.Street! ___________ _ Serial No.:, ____ _

City: ______ _ State: ____ _ Zip:---

Date Installation:------ Installed by._• _______ _ (NameofFnm)

Table of Contents °"' TraangleTube

INTRODUCTION Page 1-2

SERVICING TIPS AND INSTRUCTIONS Page3-4

CONTROL MODULE DISPLAY - GENERAL Page5-9

PRESTIGE CONTROL MODULE DISPLAY Page 10-11

SOFT LOCKOUT ERROR CODE Page 12-17

HARD LOCKOUT ERROR CODE Page 18-26

COMBUSTION TEST I SETTINGS PaQe27-2B

INTERNAL WIRING/ ELECTRICAL Page29-31

REPLACEMENT PARTS Page32-42

TORQUE SPECIACATIONS Page43

Introduction --i, Tr1angleTube

Introduction

This guide is to be used in conjunction with the Triangle Tube PRESTIGE Boiler Installation and Maintenance Manual.

Good Troubleshooting Practices

Before leaving for the job site:

Check your parts and tools

Test equipment and tools you will need:

Electrical meter that tests both voltage (AC/DC), continuity (0Q), resistance ( Q,ohms), and frequency (Hi) Temperature gauge- or metering device Manometer Calibrated Combustion Analyzer Standard tools of the trade (wrenches, screwdrivers ... )

Parts to solve most problems Control module Transfo,:mer with surge protection Blower with gasket PS 399 Parts Case - PSRKIT102 PS 60-250 Parts Case - PSRKIT103

Review all appropriate manuals before leaving for the job site

At the job site:

Clarify problem

Have the PRESTIGE manual and any other wiring, zone control or piping diagrams, or installation guides readily available.

REMEMBER

Follow the Troubleshooting Guide step by step, always double checking your results. Skipping steps or not complet ing steps can lead to wrong conclusions. repeated visits to the job site, unhappy customers and unnecessary warran ty claims.

Servicing Tips and Instructions ~ TrtangleTube

8. Reconnecfthe external power supply to the boiler and perform the verification of operation steps as outline in the Prestige Installation Manual.

After completing any servicing of the boiler verify proper operation of the boiler. Steps to verify proper oper ation are outlined in the Start-Up Procedures in the PRESTIGE Boiler Installation and Maintenance Manual.

Failure to comply could result in severe personal injury, death or substantial property damage.

Control Module

120V-High Voltage

Bectrical Quick Conmict

Q,------------\-----,0

□ F1fut.::¥

S-AMP/250V

FastActi.ng

D ~,= D Slow Acting for 24V-l.Dw Voltage

C7

D

0------------~o

Fig. 1 Control ModuJe Fuse Locations (Housing Cover Removed}

Control Module Display - General .-,, Tr1angleTube

Standby Mode Display Display Boiler 11,lnction a,ga l:J ... l:il STANDBY, no demand

L1·ac. Fan prepurge or post pu19e cycle e 1s::, Ignition S4lqUance

J,l~C Burner ON for space healing (CH)

1'IIBC' Burner ON for domestic rot waler (DHW)

5JB,:- Pte-ched< for air flow prior to. prepu1ge cycle

,5-, 8- 0

- , .L · f:I Bu mer OFF due to reaching lemperaltire setpcint

!JlSn, Space Heating (CH) post pump cycle

8 , ·ga ..l ,.,, Domestic hot water (DHW) post pump cycle

91BC Burner blocked:

'b 1.8· S141ply temperature too high (202°F) . Burner will remain OFF until temperature drops below 200'F

1, 19 Rahim temperature too ligh (202°F). Burner will remain OFF until temperature drops belcm200'F

'I, ?&/ Return temperature is higher than supply temperature. Sumer wiU remain OFF until corrected.

2_5 Supply temperature increased too ~ickly.

b BumerwillremainOFFfora 10 mi!Elepericx:I.

Burner will recycle, increasing waiting period 1 minute for a max. 15 minutes

'b-_ l"6 F.ictory :;upplied LWCO device or external limit (terminals 15 & 16) is OPEN.

Burner off for 150 seconds, aulo reset.

h cB No blower signal

& c9 Blower signal present wi1h no demand, Burner wiU remain OFF until concfrtia, IBrminates b JC i"rernpera!ure difference .between the supply an:l return is more than 72'F. Bllmer wil remain OFF for t 50 seconds. Burner wiD recy:le incre~g waling period 1 minute for a lllalt 20 cycle.

'b 11 Indirect water heater temperature sensor is short--cil'Cl,Jited. Burner OFF urrlil c;Qrrected.

b 15" Aue temperature sensor is short-cirruited.

Burner OFF until COffected

·1, 1'8 looirect water heater temperature sensor is "open· or disconnected. Burner OFF mtil corrected.

_b '{::

Flue temperature senor is "open• Burner OFF Until corrected.

1, Aue temperature greater than 240"F but less 5l than 25Cf'F.. Burnel' off for 150 seoonds bJ5: Wait for the blower to start b.[lE PONer frequency daviation bllrfl Raine current signal lost

1b). lg_ Fa:tory SLppied I.WOO d!Mce or exlemal limit (tenninals 15 &16) is OPEN, wtile burneri$firad.

Control Module Display - General

Accessing Boiler rnformation

Information mode : ':ffF'{J

Key: Display

[i] 'f'JliJB· Pressing MODE once

Ii] [ ~'1.PfJ Pressing MODE twice

BOILER

~ Tr1angleTube

~OTIC'E

The ignition counters and burner hours are split into three two digit numbers.

For example:

rJ 11e , . I :&/1

•• 5'fi To switch from STANDBY mode to Information mode, press MODE twice. Write the numbers down from left to right to arrive at 123,456 CH ignitions.

Press STEP until the system displays the information you need. The decimal point located behind.the first position flashes to indicate that the boiler is in INFO mode. NOTICE

·/En5

Display Digit Segments

.Item l A B C D E F G H I

Se_g. c Seg. .c

J Seg. e Se~ C

L Seg,. e .Seg. c

N SCI!. e Scg:. c

In the INFO Mode a temperature reading of "'.2.2 typically indicates an "open" circuit. A temperature reading of 240 typically indicates a short-circnit.

Information Mode Items

Value Supply Water Temperature •p Return 'Water Tcmp<:rnture "F DRW Water Temperture "F (Optional) Outdoor Tcmperture "F (Optional) Flue Temperature "F Boiler Sclpoint 0 f Rate oflncrcase of Supply Wau:rTcmpcralurc "F/Scc.

Rafe of Increase of Rctum Water Temperature "F/Scc.

Rate oflncreasc of DHW Water Tcrilpcrature uF/SC!C.

Not Used Not Used 'Not Used Not Used Ionization Cwrent in micro-ampere Analo~ Input Volta!!.c NotUsed MCBA Internal Temporture "F CR Ignition Counter·(! 00 thousands/ 10 thousands) CH J~nition Counter (thousands I hundreds") CH fanition Counter (ten l ones} CH fanition Hours ( I 00 thousands / 10 thousanos) CH.I l!llition Hours ((housands / hundreds) CH Jgnition Hows (ten/ ones) DBW Jiroitii>n Cowncr (100 thousands/ 10 thousands) DHW Ienition Colllltcr (thousands /hundreds) DHWJ~rion Counter (ten/ ones) DRW13umer Co.unter ( I 00 thousands / IO thousands) DH.W Burner Counter {thousands/ hundreds) DHW Burner Counter {ten I ones)

Prestige Control Module Display ~ Tnan.gleTube

Boiler control display is blarik

Check for 120 volts at terminals Land N of the 120V terminal strip

If no power is measured check the external power supply, external fuse or breaker.

Check the internal fuse F1 by locating the control module and removing the black housing. The internal fuse F1 is located in the right comer of the control module near the 120V high voltage electrical connector on the control as shown in Fig. 1, page 4. See Servicing Tips and Instructions, page 3, for accessing the internal fuses of the con trol module.

Disconnect electrical supply power to the boiler and remove the F1 fuse from the MCBA. Check continuity across the fuse. If continuity is not present, the fuse has blown, replace the fuse with a 5 amp/250V fast acting fuse. Check the wiring for possible causes for the fuse to blow.(shorted wiring to circulator}

Check external wiring at 120V terminal strip and boiler internal wiring, ensure all wiring is properly connected, in good condition and all control module and boiler connections are secure.

Correct/replace any mis-wiring or wiring components if needed. If problem continues replace the control module.

Boiler display shows Ul.25 or Ul.22

Check transfonner connections

Check the internal fuse F3 by locating the control module and removing the black housing. The internal fuse F3 is located in the center of the control module as shown in Fig. 1 page 4. See servicing tips and instructions, page 3, for accessing the internal fuses of the control module.

Disconnect electrical supply power to the boiler and remove the F3 fuse from the MCBA.

Check continuity across the fuse. If continuity is not present, the fuse has blown.

If fuse F3 has blown, replace the fuse with a 4-amp/250V slow acting fuse_ Check external boiler wiring for exteral source of 24V backteed.

Boiler display shows a O for the first digit on the left followed by 2 or 3 digits (boiler tem perature)

Check to see if room and DHW thermostats are satisfied.

If the thermostats are satisfied the boiler is off due to no call for heat. Turn up a thermostat and the boiler should begin ignition sequence.

If the room thermostat or DHW thermostat is calling for heat and the boiler is not firing and the boiler is below the maximum operating temperature_

Check and verify Parameters 2 and 3 are correct as outlined on page 7. Both parameters should be set as "01 ", which turns DHW and CH modes ON.

Temporarily jump low voltage terminals 7 and 8 on the 24V terminal strip. It boiler operates check the room thermostat wiring and thermostat contrciL Replace as needed. Remove jumper when completed .

. • Temporarily jump low voltage terminals 11 and 12 on the 24V terminal strip. If boiler operates check the DHW thermostat wiring and thermostat control. Replace as needed. Remove jumper when completed.

Disconnect power to the boiler. Check all wiring and wiring connections and compare to the wiring diagram.

Ensure all wiring and wiring connection are in good condition and secure. If necessary, replace complete wiring harness.

Check for 24 volts across the control module internal fuse F3, which is located toward the middle of the con trol see Fig. 1 page 4. If necessruy replace the fuse. See Serving Tips and Instructions, page 3, for accessing the internal fuses of the control module.

Check Item 6 in the INFO mode. If Item 6 shows a reading of 32, remove the air inlet tube from venturi on the Blower/Burner Assembly. Looking into the inlet of the venturi, check for any rotation of the blower impeller. If the blower impeller is rotating, replace the blower.

Soft Lockout Error Code .,_ TraangleTube

The boiler will display Soft Lockouts with a flashing "9", then "b" as the first digit on the left of the display followed by a s~ady two digit code. The boiler will automatically reset a Soft Lockout once the condition has been corrected and returned to standard operating condition.

Code Error Condition b-18 High Temperature Limit, Boiler Supply

Correcting Error Condition

If the primary boiler supply water temperature exceeds 200°F, the burrier will shut down until the supply temperature drops below 200"F. The boiler circula tor will continue operating.

This problem should only occur if the heat load demand is less than the low input-firing rate of the boiler, typicalty found on small single heat zones and where there is a potential flow issue.

- Verify the boiler and heating sys.tern are filled with water and the LWCO is operating property.

- Ensure the boiler and heating system have been properly purged and there is no entrapped air.

- Inspect and vetify heating system piping and its components.

Ensure piping is per the recommendations given in the Prestige fnstallation Manual or per other approved/recognized designed configurations~

Ensure system and/or zone circulators are operating properly

Use a temperature-metering device to measure the supply water tem perature leaving the boiler. Compare this measured temperature with the display temperature (INFO Mode display, «1" is the first digit on the left followed by the temperature.)

- Replace the supply temperature sensor if the temperature com parison is largely varied by more than 1C>°F.

b- 19 High Temperature Limit, If the primary boiler return water temperature exceeds 200°F, the burner will Boiler Return shut down until the return temperature drops below 200°F. The boiler circula-tor will continue operating.

This problem rarely occurs unless the boiler experiences an Error Code 18 and the system is charged with a water temperature in excess of 200°F

- Verify the boiler and heating system are filled with water and the LWCO is operating property.

- Ensure the boiler and heating system have been properly purged and there is no entrapped air.

- fnspect and verify heating system piping and its components.

Ensure piping is per the recommendations given in the Prestige installation Manual or per other approved/recognized designed configurations.

- Ensure the boiler piping is correct and the water flow is not reversed or pipes are cross connected.

Use a temperature-metering device to measure the return water tem perature entering the boiler. Compare this measured temperature with the display temperature (INFO Mode display, "2n is the first digit on the left followed by the temperature.)

- Replace the return temperature sensor if the temperature com parison is largely varied by more than 1 D°F

Soft Lockout. Error Code ,,_ TraangleTube

Code Error Condition Correcting Error Condition b- 25 J:figh Temperature Li,nit, - Check and verify 120V at the 120V terminal smp along tenninals Boiler Supply (continued) 1 and 2 inside the boiler enclosure. Check circulator wire harness from the boiler to the circulator if necessary.

. Verify and ensure the external DHW circulator is operating property .

- Check and verify 120V at the circulator wiring in the circulator junction box. If no voltage is measured, check circulator wiring and connections.

- Check and verify 120V at the 120V te1minal smp, terminals 4 and 5 inside the boiler enclosure. Check circulator wire harness from ·the boiler to the circulator if necessary.

b- 26 LWCODevice If the LWCO device is determined to be open by the control module the boil-er will remain in a shut down mode until the condition is corrected. Once the condition is corrected the boiler will remain in the shut down mode for an additional 150 seconds before startup.

- Check the pressure gauge on the boiler and ensure the system is at minimum 10 psig.

- Ensure proper operation of the boiler make up system and fill valve.

. Check continuity across the LWCO terminals for closed contacts if the boiler system pressure gauge reads 10 psig or greater.

- Replace the LWCO device if the continuity shows an open circuit and the system pressure is 10 psig or greater.

- Check the wiring and contacts from the LWCO to the control mod-ule terminals if the continuity check shows a close circuit b- 28 Blower Assembly Will occur if during the ignition sequence the blower does not start. The boiler display will indicate a status code of 5 during the ignition sequence.

. Disconnect the connector at the blower. Restart the boiler sequence and check for 35Vdc at the connector between the black and white wires (pin 1 & 5).

- If 35Vdc is present at the connector, reconnect the wire harness to the blower and ensure a secure connection. Replace the blow-er assembly if problem is not resolved.

- If 35Vdc is not present at the connector, inspect the wiring har-ness. Replace the wire harness, if there is any damage visible

. Contact Triangle Tube Technical Support if problem is not resolved .

b- 29 Blower Assembly The control module is detecting the blower in operation when it should not be.

. Check and verify the wiring from the blower to the control module is correct as shown in the appliance wiring schematic, page 29 and 30.

. Contact Triangle Tube Technical Support if problem is not resolved .

Pffl\s . .c 29

Soft Lockout Error Code ~ TraangleTube

Code Error Condition Correcting Error Condition b- 38 Indirect Water Heater The control module detects the indirect water heate( temperature sensor as Temperature Sensor "open" which is typically an improper or missing connection of the sensor.

- Review parameter setting for DHW operating signal selection.

Reference Prestige Control Supplement for proper selection.

. Inspect the DHW temperature sensor and wiring, ensure rt is secure and in good condition.

- Replace the sensor if problem persists.

b- 40 Rue Temperature Sensor The. control module detects the flue temperature sensor as "open", which is typically an improper or missing connection at the sensor.

. Inspect the flue temperature sensor and wiring, ensure it is secure and in good condition.

- Replace the sensor if problem persists.

b-52 Rue Temperature Sensor The control module detects the flue temperature greater than 241 °F, less than 250"F. Burner off for 150 seconds.

. This is an indication the heat exchanger flue ways may need cleaning .

Reference the Maintenance section of the installation manual for pro-cedures on cleaning the flue side of the heat exchanger.

. Isolate the boiler from the boiler system piping and drain the boiler heat exchanger. Flush the boiler heat exchanger several times, check-ing the discharge water for signs of scale or sediment

. Inspect the flue temperature sensor and wiring, ensure it is secure and in good condition, replace as needed.

- Replace the sensor if problem persists.

b-65 Blowe.r Assembly The control module does not detect proper blower operation during a call for heat.

. Disconnect the 35Vdc connector at the blower. Restart the boiler sequence and check for 35Vdc at the connector between the black and white wires (pin 1 & 5).

- If 35Vdc is present at the connector, reconnect the wire harness to the blower and ensure a secure connection. Replace the blow-er assembly if problem is not resolved.

- If 35Vdc is not present at the connector, inspect the wiring har-ness. Replace the wire harness rt the inspection reveals any signs of damage.

- Contact Triangle Tube Technical Support if problem is not resolved b-116 Incoming Voltage The oontrol module requires an incoming voltage of 120V and a frequency of 60 Hz.

Frequency . If the incoming voltage is being supplied by a generator or alternative source, check the frequency supplied and adjust accordingly.

b-118 Aame Current Signal Lost - Contact Triangle Tube Technical Support for further assistance.

BOILER.

Hard Lockout Error Code ...,_ TnangleTube

The boiler will display a Hard Lockout with an E as the first digit on the left of display followed by an error code. The boiler must be manually reset by pressing the RESET button on the display once the condition has been corrected_ A Hard Lockout will occur when boiler conditions, that are considered critical in terms of safety, are not met or exceeded_

Code Error Condition

E:... 00 Flame Detection Error

E- 02 Failed Ignition Error r=r...c:

Correcting Error Condition

This error will occur if the control module detect a burner flame (flame signal) prior to the ignition sequence_

This problem maybe related to the burner operating too hot due to poor combustion_ The flame pattern and combustion should be tested at both high fire and low fire inputs. Reference page 5 regarding high and low fire input procedures. Reference page 27 for combustion requirements_

- If the application is propane, check and verify the propane orifice for proper size (reference page 27 for orifice sizes)_ Ensure the propane orifice is properly seated in the gas valve gasket.

Inspect the burner head through the burner sight port during shut down sequence of the boiler.

- If the flame remains after the shut down sequence, the gas valve maybe leaking. Check and verify the gas pressure is less than 13 inches w.c. If the gas pressure is less than 13 inches w.c., replace the gas valve.

This error will occur if the boiler has failed to establish flame detection during the ignition sequence. The lockout will occur after 5 tries.

If no ignjtjon spark occurs during the ignition sequence:

- Check the ignition electrode cable, the electrode boot connector and all connections, ensure all are in good condition and tightly secure. Replace cable if damaged.

- Inspect the insulation of the electrode cable and the electrode igniter; ensure there is no damage. Replace cable or igniter as needed.

- Check. the ground lead for a secure connection from the control module ground to the burner mounting plate. Use a ground con tinuity check to verify a good ground.

If there is an ignition spark during the ignition sequence, but no flame:

- Verify the manual shutoff valve on the gas supply piping is in the

OPEN position.

Check and verify the gas pressure at the inlet of the valve during ignition sequence_ Ensure the gas pressure maintains a minimum 5 inches w_c during ignition sequence. Note: All gas appliances within the building ·should be operating during this measurement Check and verify all gas piping is free of obstructions and has been purged of all air.

Check the gas meter for indications of gas flow during the ignition sequence.

- Remove the ignition electrode to inspect for damage. Clean any white oxides off the electrode if necessary. Replace the electrode if damaged or will not clean.

- Replace the gas valve rectifier cable.

- Remove and inspect the gas valve and venturi gas ports. Ensure ports are free of obstructions.

- If the above items have been completed and verified, Triangle

Tube Technical Support for additional assistance.

Cqde Error Conditio,n

E- 05 Electrical Interference

E- 06 Internal Failure

E- 07 Internal Failure

E- 08 Internal Failure

E- 09 Internal Failure

E-11 Internal Failure

E-12 External Limit Lockout

E-13 Internal Failure

BOILER

_,, Tr•angleTube

Correcting Error Condition

This error may occur due to a short in either the ignition cable or display panel.

Check flat ribbon cable to display for short.

Check for moisture at display and repair cause of moisture, dry and/or replace display.

Inspect ignition cable replace if necessary.

Reset the boiler control module and retry ignition sequence and boiler operation.

If problem continues, contact Triangle Tube Technical Support for additional assistance.

Reset the boiler control module and retry ignition sequence and boiler opera tion. If problem continues, contact Triangle Tube Technical Support for ~ddi tional assistance.

Reset the boiler control module and retry ignition sequence and boiler opera tion. If problem continues, contact Triangle Tube Technical Support for addi tional assistance.

Reset the boiler control module and retry ignition sequence and boiler opera tion. If problem continues, contact Triangle Tube Technical Support for addi tional assistance.

Reset the boiler control module and retry ignition sequence and boiler opera tion. If problem continues, contact Triangle Tube Technical Support for addi tional assistance.

Reset the boiler control module and retry ignition sequence and boil.er opera tion. If problem continues, contact Triangle Tube Technical Support for addi tional assistance.

• An external limit control connected at the 24V terminal strip, between terminals 13 and 14 is open, breaking the circuit. Detennine reason for the limit to be open and correct condition.

- If no external limit is used, then check and verify connection of the factory applied jumper across terminals 13 and 14.

- If the external limit is closed, then check the boiler internal wiring connections and repair or replace if necessary. Remove the exter nal limit and apply a temporary jumper across terminals 13 and 14 and verify operation.

Reset the boiler control module and retry ignition sequence and boiler opera tion. If problem continues, contact Triangle Tube Technical Support for addi tional assistance.

E-14 Low Voltage Internal Short This error may be due to a short or voltage feedback in the 24V circuit.

or Voltage Backfeed

Check the wiring of the outdoor sensor

- Ensure the wiring is not located near high voltage wiring. Relocate the wiring or use shielded cable.

• Check for backfeed of voltage to terminals 7 and 8, terminals 11 and 12 and terminals 17 and 18 in the boiler enclosure.

Code Error Condition

E- 18 High Temperature Limit, Supply Temperature

(continued)

Ec. 19 High Temperature Limit, Return Temperature

E- 24 High Temperature Limit, Boiler Supply

BOILER

.-,, Tr1angleTube

Correcting Error Condition the display temperature {iNFO Mode display, "1" is the first digit fol lowed by the temperature.)

- Replace the supply temperature sensor if the temperature com parison is largely varied by more than 1D°F.

This error will occur if the boiler return water temperature exceeds 212°F.

This problem rarely occurs unless the boiler experiences an Error Code 18 and the system is charged with a water temperature in excess of 212°F. The following items should be checked:

- Verify the boiler and heating system are filled with water and the LWCO is operating properly.

- Ensure the boiler and heating system have been properly purged and there is no entrapped air.

- Inspect and verify heating system piping and its components.

Ensure piping is per the recommendations given in the Installation Manual or per other approved/recognized designed configurations.

- Ensure the boiler piping is correct and the water flow is not reversed or pipes are cross-connected.

Use a temperature-metering device to measure the return water tem perature leaving the boiler. Compare this measured temperature with the display temperature (INFO Mode display, "2" is the first digit fol lowed by the temperature.)

- Replace the return temperature sensor if the temperature com parison is largely varied by more than 1 O"F.

If the primary boiler return water temperature exceeds the boiler supply temper ature, the burner will shut down until the boiler return temperature drops below the boiler supply temperature. The boiler circulator will continue operating.

The following items should be checked:.

- Verify the boiler and heating system are filled with water and the

LWCO is operating properly.

- Ensure the boiler and heating system have been properly purged and there is no entrapped air.

- Inspect and verify heating system piping and its components.

Ensure piping is per the recommendations given in the Prestige lnstaflation Manual or per other approved/recognized designed configurations.

;.. Ensure the boiler piping is correct and the water flow is not reversed or pipes are cross connected.

Use a temperature-metering device to measure the supply water tem perature leaving the boiler. Compare this measured temperature with the display temperature (INFO Mode display, a1 n is the first digit fol lowed by the temperature.)

- Replace the supply temperature sensor if the temperature com-parison is largely varied by more than 1 D°F.

Use a temperature-metering device to measure the return water tem perature entering the boiler. Compare this measured temperature with the display temperature (INFO Mode display, "2n is the first digit followed by the temperature.)

- Replace the return temperature sensor if the temperature com parison is largely varied by more than 10°F.

Hard Lockout Error Code ~ TraangleTube

Gode Error Co.ndition Correcting Error Condition

E- 29 Blower Assembly The control module is detecting the blower in op~ration when it should not be.

. Check and verify the wiring from the blower to the control module is correct as shown in the appliance wiring schematic, pages 29-30.

- Replace the blower if the wiring harness is verified to be good. If problem is not resolved, contact Triangle Tube Technical Support for additional assistance.

E- 31 Boiler Supply The control module detects a short or jumped out condition of the boiler supply Temperature Sensor (outlet) temperature sensor.

. Inspect the boiler supply temperature sensor and wiring, ensure it is secure and in good condition, replace as needed.

- Replace the sensor and wiring if problem persists.

E- 32 Boiler Return The control module detects a short or jumped out CQndition of the boiler return Temperature Sensor (inlet) temperature sensor_

. Inspect the boiler return temperature sensor and wiring, ensure it is secure and in good condition, replace as needed.

- Replace the sensor and wiring if problem persists.

E- 35 Aue Temperature Sensor The control module detects a short or jumped out condition of flue temperature sensor.

. Inspect the flue temperature sensor and wiring, ensure it is secure and in good condition.

- Replace the sensor and wiring if problem persists.

E- 36 Boiler Supply The control module detects the boiler supply (outlet) temperature sensor as an Temperature Sensor open circuit.

. Inspect the boiler supply temperature sensor and wiring, ensure it is secure and in good condition, replace as needed.

E- 37 Boiler Return The control module detects the boiler return {inlet) temperature sensor as an Temperature sensor open circuit.

. Inspect the boiler return temperature sensor and wiring, ensure it is secure and in good condition, replace as needed.

E- 40 Aue Temperature Sensor The control module detects the flue temperature sensor as "open", which is typ-ically an improper or missing connexion at the sensor.

. Inspect the flue temperature sensor and wiring, ensure it is secure and in good condition.

- Replace the sensor if problem persists.

E- 44 Gas Valve Circuit The control module detects a short circuit in the gas valve or gas valve wiring harness.

. Inspect the gas valve wiring harness and gas valve for a short circuit

- Repair short circuit

Reset the boiler cont{ol module and retry ignition sequence and boiler opera-tion. If problem continues, contact Triangle Tube Technical support for addi-tional assistance.

Z4

Code Error Condition

E- 123 Supply or Return Temperature Sensor Failure

E- 124 Supply or Return Temperature not changing

BOILER

.-, Tr1angleTube

Correcting Error Condition

The control module has defected a defective supply or reb.Jm temperature sensor.

Inspect the boiler supply and return temperature sensors and wiring, ensure they are secure and in good condition, replace as needed.

- Replace the temperature sensors if problem persists.

The contror module has not detected a 1emperature change of the supply or return temperature sensors.

If the control module (MCBA54) is Rev.4, the control needs to be updated to a Rev. 5.

Inspect the boiler supply and return temperature sensors and wiring, ensure they are secure and in good condition, replace as needed.

- Replace the temperature sensors if problem persists.

Combustion Test/ Settings -i, TrtangleTube

Combustion Adjustment

To perform the following procedure it is essential the service technician reads and follows the procedures closely. After any adjustments are completed it is essential to perform a combustion check before proceeding with further steps. Failure to comply with these procedures can result in personal injury, death or substantial property damage.

If the O2 level measured during the combustion test is below 2.3% for natural or 2.7% for propane:

OR

If the CO2 level measured during the combustion test is above 10.5% for natural or 12.0% for propane:

Adjust the gas valve throttle screw, a~ shown in figure 2A or in Fugre 28 as follows:

1s Ensure the PRESTIGE is OFF and no "calls for heat" are initiated.

2. Using a flat head screwdriver, tum the throttle screw clockwise (inward}. It is important to note the initial start point of the screw prior to any adjustments.

3. Place the PRESTIGE back into service and conduct a combustion test.

4. If necessary, repeat the adjustment steps until the desired combustion level is met.

Adjusting the throttle screw in Figure 2A clockwise (inward) decreases the volume of gas injected into the burner.. Adjustments beyond 1 full tum clockwise will greatly affect the operation of the burner and result in unstable combustion conditions.

W.-\Rc '\ING

DO NOT adjust the throttle screw in Agure 2A counter-clockwise beyond the initial factory set point and DO NOT make any throttle screw adjustment in Figure 2B without the use of proper equipment (manometer, com bustion analyzer .. ) and/or the consultation with the Tech Services at Triangle Tube. AdJustments counter-clock wise beyond the factory set point will increase the volume of gas inJected into the bumer, resulting in possi ble unstable combustion conditions and potential dangerous levels of CO.

Throttle Screw

Inlet Gas --Pressure

Test Port

Fig. 2A Gas Valve/Ventnri Assembly for Prestige 60, 110,175 and 250 and Excellence 110 Fig. 28 Gas Valve tor Prestige 399

Valve (Throttle) Adjustment

Inlet Gas Pressure Test Port

.i,,..

CJl

':I a 8· to t.'!:1 ij j'

WI,,. Color Coda Kay BK • Black W • White G • Graen

BL • BIU!'I

R • Red o • Oronge V • Violet Y • Yellow BR • Brown

12DV Wlr& Termlnal Key L • Incoming Supply L N • lncomln11 Supply N G - Incoming Supply G 1 • Circulator L 2 - Circul11tor N 3 • Circulator G 4 - ValveCH 6 - Valve N 6 , VolveDHW

24V Wire T1rmln1I Key 7 • Thermoslal (T • T) B • Thennoalat (T•T) 9 - Outdoor sensor 10 • Outdoor Se'1901' 11 • OHW Thermostat 12 • DHW Thermostat 13 • Exlarnal limit- Manual Rll!lat 14 • Eltt11rnal l.lmit • Manuel Reaal 15 • Exlernel llmll-Auto Reeel 16 • Eltlernal Llmii • AUto Reeet 17 • 0-10v EKternollnput(+) 18 • 0-1 Ov External Input(<) 19 • Flame Signal

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.. ~ H .. lng : ~ C•rul•lot

Vatv, Tormlnal 8 • VALVE OPEN V~l•t nrmlMI i. VI\I..Vls N Vnll/D Terminal 3 ~ VALVE CLOSED u§X10-3 . X10-1

X10-11 X10•7

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X1-I X1-S x,-e

: 11 i=P' " 120VCtrcull _i:::-, OliW Min, 14g•Wirll w ·•-t::..J NT¢3

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§ a., ,- - - Val Yo 11111: ---+----- .... -=---

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J<.1-3 x+~ X4-I :[]Flu. .!JI •---- NTCS l(!-4 --tt--- -------------10--- --------' xw )(!-2

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Replacement Parts ~ Tr1angleTube

Fig. 7: Jacket Components -

PRESTIGE SOLO '@

Item Part# Part# Part# Description

PRESTIGE PRESTIGE PRESTIGE

SoloW/110 Solo 175/250 Solo399

I PSCSOI Display/Control Panel

IA - - PSCS02 (Left) Di~play/Contml Panel Extensions (Not Shown)

PSCSOJ (Right)

2 PSJKTUIB PSJKT03B PSJKT04l3 l3ase Panel

3 PSJKTOIF PSJKT02F Front Jacker Panel

5 PSJKT02S PSJKTI}3S Side Jacket Panel (Left and Right)

6 PSJKTOIT PSJKTOJT PSJK'JUSf Top Jacket P'.mel

7 PSJKT02T PSJKT04T PSJKT06T Top Jacket Access Panel

8 PSJKJU3 PSJKT04 C<,ntrol C<,ver Panel

9 PSRKIT21 Wail MOUDting Bracket with Hardware

Replacement Parts .-, Tr1angleTube

Fig. 9: Domestic Components - PRESTIGE EXCELLENCE

Item Part No. Description

I P3DW05 Drywell

2 PSRKI.T63 NTC 3 DHW Water

3 P3WKITDTOI Dip Tube

Replacement Parts 0 Tr1angleTube

Fig. 11: Internal Components - PRESTIGE 110

Hem Part No. Description PRESTIGE 1 l 0 l PSRKITOJ Heal Exchanger Body

2 PSRKIT02 V enl Outlet Adapter

3 PSRKIT03 Combustion Air Inlet Adapter

4 PSRKf1'04 NTC Sensor (!•ffCJ, t,ffC2 and NTD")

5 PGRKIT20 LWcp Pressure Device

6 PSRKJT05 Condensalc Drain Assembly

7 PSRKI'f06 Boiler Piping- Return Assembly

8 PSRKIT07 Boiler Piping - Supply Short Assembly

9 PSRKJT08 Boiler Piping - Supply Long Assembly

10 HMCIR0J Circulator

11 PSRK1Tl7 Pressure Gauge and Fitting

""" IC

Replacement Parts ~ Tr1ang·1eTube

Fig. 13: Internal Components - PRESTIGE 399

Item Pan No. Description PRES'llGE399

'1 PSRKIT44 I Jcat fachangcr- Body

2 PSRKIT45 Vent Outlet Adapter-

3 PSRKIT46 Combuslio11 Air- Inlet Adapter

4 PSR.KIT47 Supply & Return !\'TC Serisor (NTCl, NTC2)

5 PSRKIT34 Aue NTC Sensor (NTCS)

6 PGRKIT20 LWCO Pressure Device

1 PSRKIT05 Cooc;lcnsaic Drain Assembly

8 PSRKI.T48 Boiler Pipini - Rclllm Assembly

9 PSRKIT49 Boiler Piping- Supply A.,;sembly

10 PSRKIT17 Pn=un:Gaugcand Fitting

BOILER.

Replacement Parts ~ TrtangleTube

Fig. IS: Bomer Components - l'RESTIGE 60/110/175/250 and EXCELLENCE

Item Part No. Description

PSRKIT09 Combustion Chamber Insulation - PRESTIGE 601!00/EXCELLENCE I

PSRKJT30 Combustion Chamber Insulation • PRESTIGE 1751250

PSRKITIO Burner Head with Gaskei - Natural - PRESTIGE 110 and EXCELLENCE

2 PSRKITII Burner Head with Ga.<;J,:cr • Propane· PRESTiGE I JO EXCELLENCE,.

PRESfJGE 60 (all Fuds·i

PSRK.IT31 Burner Head with Gasket - PRESTIGE I 75/250 ~All Fuels)

PSRKIT12 Burner Plate - PRESTIGE 60/110/EXCELLENCE

PSRKIT32 Burner Plate - PRESTIGE 175/250

PSRKITI3 Blower with Gasket - PRESTIGE 1751250

PSRKIT55 Blower with Gasket - PRESTJGE 60/1 I 0/EXCELLENCE

5 PGRKlTOJ Gas Valve

6 - Venturi - 055 (PRESTIGE 60) - 052 (PRESTIGE 175) - 051

{PRESTIGE 250) - 001 (PRESTIGE I IO/EXCELLENCE)

7 PSRKIT14 Ignition Cable

8 P§.RKIT15 )z:niter witb Gasket

9 PSRKIT16 Sight Gl~-s Assembly (Glass. Gasket and Brackc:t)

10 - Propane Orifice - Not Shown n - Bomer Plate Gasket - Not Shown u PGRKITI5 03$ Vil!v,: Rl'Ctifil'r Plllg - Not Sb()Wll

Replacement Parts ~ Tr1angleTube

Fig.17: Electronic Components - PRESTIGE

Item Part No. Description

PSRKIT50 Prestige Control Module

PSRKIT58 EXCELLENCE C.OUtrol Module

2 PSRKIT19 Transformer with Sl!Jlle Protection

3 PSRKIT20 Prestige Control Module Display

-· ... •--a..a11C11i.

Addilional qualitY water heating equipment available from· Triangle Tobe

Brazed Plate Heat Exchangers

For domestic water, snow melting, radiant floor, refrigeration

Plates made of stainless steel, with a 99.9 % copper and brazed, ensuring a high resistance to corrosion

Self cleaning and self descaling

Computerized sizing available from Triangle Tube

Available in capacities from 25,000 BTU/hr to 5,000,000 BTU/hr

SMART Indirect Fired Water Heaters

Exclusive "tank-in-tank" design

Stainless steel construction

- Available in 8 sizes

Limited LIFETIME residential warranty

15 year limited commercial warranty

Self cleaning/sett descaling design

Maxi-flo Pool and Spa Heat Exchangers

- Constructed of high quality corrosion resistant stainless steel

(AISI 316)

Specially designed built-in flow restrictor to assure maximum heat exchange

Compact and light weight

Also available in titanium for salt water clorinated pools

~ Tr1angleTube Freeway Center - 1 Triangle Lane Blackwood, NJ 08012 Tel: (856) 228 8881- Fax: (856) 228

.Memberof

• Group

BOILER'

Replacement Parts ..,_ Tr1angleTube

PRESTIGE Solo 399 Internal Components

Item Part No. Description

PRESTIGE 399

1 PSRKIT44 Heat Exchanger Body

2 PSRKIT45 Vent Outlet AdapLCr

3 PSRKIT46 C-ombustiOll Air JnletAdapter

4 PSRKIT47 SUpply & Return NTC Sensor (Jl,.'TCI. l\ ... l''C2)

5 PSRKIT34 flue !':"TC Sensor (NTc5)

6 PGRKIT20 LWCO Press~ Device

1 PSRKIT05 Condensate Drain Assembly

8 PSRKIT48 Boiler Piping-Return Assembly

9 PSRK1T49 Boiler Piping- Supply Assembly

IO PSRKIT17 Pres.sure Gauge and Filling

,SICl...c: