TriangleTube PTRKIT304 Manual de usuario

Prestige Trimax Excellence

Ignition Kit - Installation Instructions

1.1. Applicability

Prestige boilers with “PT”-prexed serial number, as

indicated on data plate.

Kit Part Number Model

PTRKIT304 PT Excellence

Table 1 - PT Ignition Kit Numbers

1.2. Purpose

This kit (see Fig. 3 for details) replaces the existing TriMax

control module, the igniter and wiring, the internal

venting tube and the heat exchanger insulation.

1.3. Initial tasks

Conrm the replacement kit is appropriate for the boiler

to be worked on (see Table 1).

Write down all the appliance settings, including the

cascade settings (if the boiler is in a cascade) for reference

before bringing any change to the appliance. A reference

table is provided on the last page of this document.

1.4. Boiler preparation

1.4.1 Required Tools and Material

• Screwdriver, at head

• Screwdriver, cross head

• 10 mm socket/wrench

• Wrench, Torx 20

• Flue gas analyzer

1.4.2 Preparation Procedure

1. Turn the boiler o by pressing the on/o power

switch.

2. Allow boiler to cool down.

3. Disconnect electrical power at the external electric box

• Avoid electrical shock by disconnecting the

electrical supply prior to performing any operation

on the internal parts of the boiler.

DANGER

• Before any operation on the internal components

of the appliance, allow the appliance to cool

down to room temperature. Some components

can be very hot.

• Failure to comply will result in substantial property

damage, serious injury, or death.

4. Shut o the gas supply to the boiler at the main manual

shut o valve.

5. Remove boiler front panel as follows:

• Remove the thumb screw along the upper

edge of the unit.

• Lift the panel up and tilt back slightly to remove

the front panel.

6. Slide left and right tabs of control panel inward and

lower control panel. See Fig. 1.





Fig. 1 - Opening and Lowering the Control Panel

Retaining tabs

Fig. 2 - Opening the Retaining Tabs

Revision Date: 1/28/2020 2020-34 Prestige Trimax Excellence Ignition Kit

PRESTIGE IGNITION KIT - INSTALLATION INSTRUCTIONS

Bk. Black

Br. Brown

R. Red

V. Violet

W. White

Gr. Green

WBk

Fig. 3 - Prestige Solo & Excellence - Ignition Kit

Item Description Qty

Igniter 1

Screws, igniter 2

Gasket, igniter 1

Bracket, spark generator (not illustrated) 1

2 Spark generator 1

3 Wiring, spark generator 1

4Control Module, TriMax 1

Vent pipe, telescopic, for PT60 and 110 1

Clamp, vent pipe 1

Warning sticker, vent pipe 1

Burner insulation (not illustrated) 1

“PU”Sticker, S/N adaptation (not illustrated) 1

For PT Excellence

PRESTIGE IGNITION KIT - INSTALLATION INSTRUCTIONS

Before disconnecting any wire connections, mark

and label all connections and location of the

connections.

7. Pull the retaining tabs on top of the rear cover to

remove the rear control box cover. See Fig. 2.

8. Disconnect the ignition cable by grasping the igni-

tion terminal and pulling rmly upwards from the

back of the control module.

9. Remove all (8) Molex wiring connectors from the

Control Module.

10. Support TriMax Control Module with one hand

while removing individual Molex connectors,

pressing tabs on Molex plugs for quick release.

See Fig. 4 below.

Fig. 4 - Disconnecting and Removing the Control Panel

8 Molex

connectors

Screw

location

Screw

location

1.5. Burner Insulation and Igniter Replacement

1.5.1 Required Tools and Material

• Flat head screwdriver

• Extended Phillips/Torx head screwdriver

• Torx wrench

• Cord saw or similar tool to cut venting pipe

1.5.2 Venting Pipe Removal Procedure

(PT Excellence)

Before disconnecting any wire connections, mark

and label all connections and location of the

connections.

1. Disconnect the yellow wire leads/Molex plug from

the ue temperature sensor located on the pipe.

Use care when disconnecting the wire leads as not

to damage the sensor terminals or the wire leads.

2. Remove ue sensor and rubber seal from venting

NOTICE

pipe port. Retain for later reinstallation.

3. Cut the pipe (4) into two where practical. Remove

and discard both pieces and lower gasket accord-

ing to applicable local regulations.

When cutting the vent pipe, use care not to

damage other components (tubes, hoses,

wires, etc.). Failure to comply can result in

substantial property damage, serious injury,

or death.

To cut the vent pipe, it is recommended to

use a cord saw, so as to manage cutting the

in a restricted space, without damaging

components around.

1.5.3 Removal of Internal components

1. See Fig. 5 for reference. Remove air intake (3) from

venturi. Retain for reinstallation.

Before disconnecting any wire connections, mark

and label all connections and location of the

connections.

Fig. 5 - Boiler Components

WARNING

NOTICE

BEST PRACTICEBEST PRACTICE

1.5.5 Removing the Burner and Insulation

1. Remove heat exchanger bracket located at the back

of the heat exchanger. Discard bracket.

2. Remove burner plate nuts securing the burner mount-

ing plate to the heat exchanger using a socket wrench.

3. Remove burner plate/burner and blower by lifting

the assembly, using the clearance of the opening

at the top of the boiler, then rotating it to remove it

through the front of the boiler.

4. Remove insulation from burner. Discard according to

applicable local regulations.

5. Disconnect the igniter wiring from the igniter. Discard.

6. Using the Torx wrench, release two screws and

remove the igniter and gasket from the burner

mounting plate. Discard all.

If the gasket is stuck on the igniter support, use

a flat head tool and release it carefully from the

surface. Be careful not to scratch the surface.

7. Clean combustion chamber. Refer to the installation

manual of the appliance.

1.5.6 Checking the PT Excellence Burner.

1. On the PT Excellence burner, check the tube as fol-

lows:

• Natural gas: the appliance should be equipped

with a nit-free burner tube.

• Propane: the appliance should be equipped

with a nit burner tube.

• If not the case, install the required burner tube.

Refer to the appliance installation manual for

component reference.

1.5.7 Installation of new Insulation and Burner

1. Slide the newly supplied burner insulation over the

existing burner tube.

2. Install the new igniter (See Fig. 7), with its new gas-

ket, on the burner mounting plate support, paying

attention not to damage the new insulation.

NOTICE

PRESTIGE IGNITION KIT - INSTALLATION INSTRUCTIONS

2. Open top access panels by remove all screws secur-

ing the rear top jacket panel (1) from the side panels

and remove rear top panel. Retain all items for later re-

installation.

3. Disconnect all connectors from the blower and the

gas valve.

4. Using 2 wrenches, disconnect the gas supply pip-

ing (2) inside the boiler at the brass union located

just below the gas valve. The gas piping can remain

inside the boiler or be removed for additional clear-

ance / access.

5. Holding the gas valve/venturi assembly with one

hand, release the mounting screws that secure the

venturi to the blower.

6. Remove the gas valve/venturi assembly and hard-

ware from the blower. Retain for reinstallation.

1.5.4 Checking the Orifice Size

1. Remove 3 screws securing the gas valve to the ven-

turi and check the presence of an orice and its size,

if any.

2. Make sure that the correct orice (see Table 2), if any

is required, is installed on the boiler. Replace or in-

stall one as required.

3. Reassemble gas valve and venturi and set assembly

aside for later reinstallation.

Fig. 6 - PT 60-110 Orice location

Gasket

Orice

PT version NG LP

60 0.204” – 5.2mm 0.120” – 3.1mm

110 None Required 0.204” – 5.2mm

Table 2 - Orice Sizes

PRESTIGE IGNITION KIT - INSTALLATION INSTRUCTIONS

Fig. 7 - Prestige Trimax - New Igniter

3. Tighten 2 igniter screws by hand, then torque

screws between 13 and 18 lbf-in.

Do not exceed the recommended max. torque

value for the igniter attachment screws to

prevent the igniter stems from distorting.

4. Place burner/burner plate/insulation assembly care-

fully in position. Do not secure the assembly just yet.

5. If removed previously, reinstall the blower and gas-

ket.

6. Secure burner plate using the retained nuts. Torque

at 50 lbf-in.

7. Reinstall the venturi/gas valve assembly on blower

using retained screws.

8. Reconnect the gas pipe to the gas valve connec-

tion.

1.5.8 Installation of Spark Generator

1. Install spark generator on bracket using 2 screws.

2. Locate the spark generator with bracket (A) on the

blower (B). (See Fig. 10), and secure using 2 of the

venturi-to-blower screws.

3. Connect the spark generator cable with connector

1.5.9 Control Module Replacement

1. Remove the 2 screws securing the Control Module into

the enclosure and remove the Control Module. Retain

screws for new Control Module installation. See Fig. 4.

2. Discard Control Module according to applicable lo-

cal regulations.

NOTICE

3. Install new TriMax control module with 2 retained

screws.

4. Reinstall the rear cover of the control module.

1.5.10 Wiring Connection (See Fig. 13)

1. Reconnect all disconnected plugs to blower, gas

valve and sensors, as required.

2. Reconnect light green grounding cable (disconnect-

ed from old igniter) to the gas valve grounding tab.

3. Connect new brown cable to ignition transformer and

to control module grounding tab F01. See Fig. 13.

4. Connect new violet wire to igniter grounding tab

and to control module grounding tab F00.

5. Reconnect all disconnected Molex wiring connec-

tors to the Control module, except X02.

6. Connect spark generator wiring to the control

module and to unconnected Molex connector.

7. Connect new green grounding wire to one of the

left grounding tabs on the casing.

8. Connect green grounding cable that used to be

connected to F00 to the grounding tab on the new

violet cable connection.

1.5.11 Venting pipe installation (PT Excellence)

1. Install new venting pipe with telescopic section:

• Install new gasket into bottom ue connection

of condensate dish.

• Insert bottom of telescopic pipe into bottom con-

nection of condensate dish, as shown in Fig. 8.

• Then extend the pipe to t into upper adapter.

• Tighten the clamp to secure the pipe in position.

2. Reinstall ue temp sensor and rubber seal into port

of new telescopic venting pipe.

3. Connect wiring connector to ue sensor.

Fig. 8 - - Venting pipe with telescopic section

PRESTIGE IGNITION KIT - INSTALLATION INSTRUCTIONS

1.5.12 Checking the Combustion Settings

1. Turn boiler on.

2. Allow the appliance to stabilize and insert the gas an-

alyzer probe in the top vent adapter measuring port.

3. Check combustion values as follows (please refer-

ence the Installation Manual of the appliance for

more details on the controls):

• Press the round INSTALLER button.

• 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 conrm.

• Using the RIGHT button, highlight the Manual

Operation icon, then press the OK button.

• Press the OK button while the FAN icon is high-

lighted to manually re the burner and power

the CH circulator.

• Press the RIGHT button to adjust the ring rate

from 1% to 100%.

ENTER ACCESS CODE

05[4]

Manual Operation

FAN

CH1

CH2

DHW

Released

O

Fig. 9 - Accessing the Combustion Adjustment Interface

• If the CO2level during high re (100%) diers by

more than 0.4% from the recommended combus-

tion setting (See Table 3) adjust the throttle screw

(see Fig. 11) as follows:

• Counter-clockwise rotation of the throttle

screw at High Fire : O2decreases, CO2 increases

• Clockwise rotation of the throttle screw at

High Fire : O2increases, CO2decreases.

• Once the combustion level is set at high re

(100%), manually place the boiler into low re

(1%) mode by pressing the LEFT button to

adjust ring rate down.

Fig. 10 - Spark Generator and Bracket (PT Excellence)

Fig. 11 - Throttle and Oset Locations

NG LP

High Fire

CO29.5% 11.2%

O24.0% 4.0%

CO < 100 ppm <100 ppm

Low Fire

CO29.5% 11.2%

O24.0% 4.0%

Table 3 - Recommended Combustion Levels

• If the CO2 combustion level during low re (1%)

diers by more than 0.4% from the recommended

combustion setting (See Table 3), remove plastic

cover from Oset screw (See Fig. 11) and adjust as

follows:

Oset

Throttle

(Remove

plastic cover

to access

screw)

PRESTIGE IGNITION KIT - INSTALLATION INSTRUCTIONS

• Counter-clockwise adjustment of the oset screw at

Low Fire : O2 increases, CO2 decreases

• Clockwise adjustment of the oset screw at Low

Fire : O2 decreases, CO2 increases.

1.5.13 Return to Service

1. Reinstall the air intake on the venturi.

2. Close top access panel, as required.

3. Check that all wiring connections are secure.

4. Check that the gas connection is tight.

5. Supply power to the boiler through the external elec-

tric box.

6. Open gas supply.

7. Turn boiler on using the boiler On/O switch.

8. Perform any required conguration change in the Tri-

Max setup according to the initial settings indicated

in “Default Values and Adjustments” on page 9.

9. Reinstall the boiler front panel.

10. On the rating plate of the appliance, install the

sticker provided with the kit. This will indicate that

the boiler has been upgraded with the ignition kit,

for future reference.

Fig. 12 - Prestige Solo & Excellence - Rating Plate Correction

PU Stick here

Fig. 13 - Prestige Solo & Excellence - PCB Wiring - POSTMOD

WBk

F00

F01

To left side casing

grounding tabs

Connect to uncon-

nected Molex

connector in exist-

ing boiler wiring

DO NOT reconnect

original boiler

wiring Molex

connector here

Connect here

Bk. Black

Br. Brown

R. Red

V. Violet

W. White

Gr. Green

PRESTIGE TriMax Control

and/or Display Module Replacement

Table 1: TriMax Settings

Revised Date: 1/14/14 2011-55 Prestige_TriMax Control &/or Display Module Repl

DOMESTIC SETTING FACTORY DEFAULT MINIMUM SETTING MAXIMUM SETTING EXISTING SETTING

DHW Operation Enabled

Demand Switch

Boiler DHW Setpoint 186°F [86°C] 96°F [35°C] 188°F [87°C]

DHW Storage Setpoint 140°F [60°C] 68°F [20°C] 150°F [65°C]

DHW On Differential 6°F [3°C] 4°F [2°C] 18°F [10°C]

DHW Storage Adder 46°F [25°C] 0°F [0°C] 54°F [30°C]

DHW Post Pump Time 1 minute OFF 30 minutes

DHW Priority Timeout OFF OFF 120 minutes

DHW Priority Enabled

DHW Call Blocking 0 minute 0 minute 30 minutes

DHW to CH Call Blocking 1 minute 0 minute 30 minutes

Antilegionella Function Disabled

HEATING SETTING FACTORY DEFAULT MINIMUM SETTING MAXIMUM SETTING

EXISTING SETTING

Heating Operation Enabled

Demand Switch &

Outdoor Reset

Absolute Max CH Setpoint 188°F [87°C] 68°F [20°C] 188°F [87°C]

CH1 Maximum Setpoint 180°F [82°C] 68°F [20°C] 188°F [87°C]

CH1 Minimum Setpoint 120°F [49°C] 60°F [15°C] 188°F [87°C]

Reset Curve Coldest Day 0°F [-18°C] -30°F [-34°C] 50°F [10°C]

Reset Curve Warmest Day 64°F [18°C] 60°F [15°C] 78°F [25°C]

CH2 Circuit Enabled

CH2 Maximum Setpoint 140°F [60°C] 68°F [20°C] 188°F [87°C]

CH2 Minimum Setpoint 80°F [27°C] 60°F [15°C] 188°F [87°C]

Warm Weather Shutdown OFF OFF 78°F [25°C]

Pump Constant Circulation Disabled

CH Post Pump Time 1 minute OFF 20 minute

Freeze Protection Enabled

Frost Protection Setpoint -22°F [-30°C] -22°F [-30°C] 50°F [10°C]

Parallel Shift Value 0°F [0°C] 0°F [0°C] 144°F [80°C]

CH Call Blocking 1 minute 0 minute 30 minutes

System Pump CH1/CH2

CASCADE SETTING FACTORY DEFAULT MINIMUM SETTING MAXIMUM SETTING EXISTING SETTING

Stage Delay 60 seconds 0 second 255 seconds

Minimum Firing Rate 30% 0% 100%

Maximum Firing Rate 398 MBH [117kW] 0 MBH [0kW] 869 MBH [255kW]

CH / DHW Boilers 0 0 6

Automatic Rotation Enabled

CH Proportional Gain 7 1 255

CH Integral Gain 245 1 255

DHW Proportional Gain 7 1 255

DHW Integral Gain 245 1 255

BOILER SETTING FACTORY DEFAULT MINIMUM SETTING MAXIMUM SETTING EXISTING SETTING

Prestige Model Solo

Lockout Temperature 210°F [99°C]

Modbus Address 0=BCST 0 247

Prestige_TriMax_Control_Display_Module_DCR639 1/14/14 9:45 AM Page 6

1.6. Default Values and Adjustments

Tabla de contenidos

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