TriangleTube PSRKIT11 Instructions

for PRESTIGE 60 through 250 1 Kit Part Numbers: PSRKIT11 - Prestige 60 Natural or Propane Gas PSRKIT11 - Prestige 110 Propane Gas PSRKIT10 - Prestige 110 Natural Gas PSRKIT31 - Prestige 175/250 Natural Gas /Propane Gas Parts List 1. Burner Head 2. Burner Head Gasket 3. Stainless Steel Phillips Screws. (For attaching the new burner head to the burner mounting plate.) Recommended tools: A. Pipe Wrench. B. Phillips Screw Driver. C. 10 mm Socket and/or 10 mm Open Ended Wrench and/or Adjustable Wrench. D. Flat Blade Putty Knife. Indicates a potentially hazardous situation which, if ignored, can result in serious injury or substantial property damage. For your safety, turn off electrical power supply at service panel and allow unit to cool before proceeding. Failure to do so can cause severe personal injury or death. Indicates special instructions on installa- tion, operation or maintenance, which are important to equipment but not related to personal injury hazards. 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. WARNING NOTICE WARNING WARNING

for PRESTIGE 60 through 250 Instructions: 1. Turn power to the unit “OFF” and allow unit to cool. 2. Shut off gas supply to the inlet of the unit at the main manual shutoff valve to the unit. 3. Remove front door and disconnect the gas supply piping to the PRESTIGE at the brass union near the gas valve. 4. Disconnect the gas valve rectifier plug from the gas valve 5. Disconnect the ignition cable and remove the ground wire at the igniter. To ease the removal of the burner assembly, remove the top jacket access panel. 6. Remove the 10 mm mounting nuts and remove the burner assembly from the HEAT EXCHANGER body. Use care in removing the burner assembly not to crack or damage the combustion chamber insulation. See warning on page 4. 7. Remove the Phillips head screws attaching the burner head to the burner mounting plate. Remove and discard the old burner head and burner head gasket. If the gasket “sticks” to the burner mounting plate use a flat blade putty knife to remove any gasket material. Ensure not to scratch or score the mating surface. For the reassembly process do not use adhe- sives on ANY gasket surface. 8. With the new gasket in place attach the new burner head to the burner mounting plate, using the screws supplied in the kit, as shown in Fig. 2. 9. Re-insert the burner assembly onto the heat exchanger body. Carefully align the burner assembly and igniter with the combustion chamber insulation to avoid insulation damage, as shown in Fig. 2. 10. Hand tighten the 10 mm nuts to hold the burner assembly in place. 11. Using a wrench tighten each nut approxi- mately 2 additional full turns past hand tight. NOTICE NOTICE NOTICE NOTICE 2 Burner Head Burner Mounting Plate Burner Head Gasket Gas Piping Union Connection Combustion Chamber Insulation 10 mm Mounting Nuts Ignition Cable Fig. 1: Burner Assembly Fig. 2: Burner Head and Gasket Assembly

for PRESTIGE 60 through 250 3 Do not over tighten. Pinching or tearing of the burner plate gasket may occur causing the possible escape of combustion gases from the combustion chamber resulting in death, seri- ous injury or substantial property damage. 12. Re-attach the ignition cable and the ground wire to the ignitor. 13. Reconnect the gas valve rectifier plug. 14. Reconnect and tighten the brass gas pipe union before placing the PRESTIGE unit back into operation. 15. Turn on gas supply to the inlet of the unit at the main manual shutoff valve to the unit. Check and test all gas connections for leaks. Repair leaks if found. 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. 16. Turn power to the unit “ON”. The unit is now ready to be placed back into service. 17. It is recommended that the installer per- forms a complete combustion test to ensure the combustion levels, in table 1 on page 4. are met at high input and the burner is oper- ating at optimum conditions. 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 high input rate may result in incom- plete combustion and the production of car- bon monoxide, which can cause severe per- sonal injury, death or substantial property damage. 18. Manually place the boiler into high fire mode by pressing the MODE button with “+” button simultaneously on the control panel display while in the standby (STBY) mode. The control panel will display an H followed by the current boiler temperature when placed into high fire test mode. If the combustion levels during high fire is outside the recommended combustion settings adjust the THROTTLE SCREW (see Fig. 3) as follows: Counter-clockwise adjustment of the throttle screw at high fire: O2 decreases and C02 increases Clockwise adjustment of the throttle screw at high fire: O2 increases and CO2 decreases 19. Reinstall Top jacket panel and front door. WARNING NOTICE WARNING WARNING WARNING Throttle Screw Fig. 3: Combustion Adjustment - Prestige Burner

for PRESTIGE 60 through 250 4 The combustion chamber insulation contains ceramic fibers, which are classified as a pos- sible human carcinogen. When exposed to extremely high temperatures, the ceramic fibers, which contain crystalline silica, can be converted into cristobalite. Avoid Breathing and Contact with Skin and Eyes When removing or repairing the combustion cham- ber insulation follow these precaution measures: 1. Use a NIOSH approved respirator which meets OSHA requirements for cristobalite dust, simi- lar to N95. Contact NIOSH at 1-800-356-4676 or on the web at www.cdc.gov/niosh for latest recommendations. 2. Wear long sleeved, loose fitting clothing, gloves and eyes protection. 3. Assure adequate ventilation. 4. Wash with soap and water after contact. 5. Wash potentially contaminated clothes sepa- rately from other laundry and rinse washing machine thoroughly. 6. Discard used insulation in an air tight plastic bag. Niosh Stated First Aid: Eye/Skin: Immediately irrigate Breathing: Clean fresh air WARNING Handling of Previously Fired Combustion Chamber Insulation Revised 3/23/11 2008-15 Burner Head Replacement Kit Prestige 60 THRU 250 Table 1: Recommended Combustion Levels