TriangleTube PSRKIT25

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PRESTIGE Solo 60, 110, 175 and 250

HX Field Replacement

Kit

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

odel

PS 110 Natural Gas

Stainless Steel

Condensate Pan

PT 110 Natural Gas

Polypropylene

Condensate Pan

PS 60 (Nat. & LP)

/ PS 110 LP

Stainless Steel

Condensate Pan

PT 60 (Nat. & LP)

/ PT 110 LP

Polypropylene

Condensate Pan

PS 175 & PT 175

(Nat. & LP)

Both Condensate Pans

PS 250 & PT 250

(Nat. & LP)

Both Condensate Pans

1 PSRKIT01 Heat Exchanger Assembly X

1 PTRKIT124 Heat Exchanger Assembly X

1 PSRKIT76 Heat Exchanger Assembly X

1 PTRKIT125 Heat Exchanger Assembly X

1 PSRKIT25 Heat Exchanger Assembly X

1 PSRKIT26 Heat Exchanger 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

Need help?

Do you have a question about the TriangleTube PSRKIT25 and is the answer not in the manual?

The PRESTIGE Solo 60, 110, 175, and 250 HX Field Replacement Kit is designed for the maintenance and repair of Prestige boilers, specifically focusing on the heat exchanger (HX) component. This kit provides the necessary parts and instructions for replacing the heat exchanger, ensuring the continued efficient operation of the boiler system. The kit is tailored for various Prestige boiler models, including those running on natural gas or LP, and featuring stainless steel or polypropylene condensate pans.

Function Description

The primary function of this kit is to facilitate the replacement of a faulty or worn-out heat exchanger in Prestige Solo boilers. The heat exchanger is a critical component responsible for transferring heat from the combustion process to the boiler's water, which then circulates through the heating system. A properly functioning heat exchanger is essential for the boiler's efficiency, safety, and overall performance.

Each HX Replacement Kit comes with several pre-installed items on the heat exchanger itself, including combustion chamber insulation, a burner head and gasket, a sight glass assembly, and a burner mounting plate gasket. These pre-installed components streamline the replacement process and ensure that critical parts are correctly positioned and sealed from the outset.

In addition to the pre-installed items, the kit includes a separate "PARTS BOX" containing components that must be installed during the HX replacement. These include a vent outlet gasket, blower gasket, boiler piping gaskets, a long handle Phillips head screwdriver, a long handle T-20 Torx screwdriver, an igniter with its gasket and screws, and temperature sensors with harness adapters. These additional parts are crucial for completing the installation and ensuring all connections are properly sealed and functional.

The replacement process involves several key steps:

Preliminary Instructions: This includes verifying the correct kit for the boiler model, turning off electrical power and gas supply, draining the boiler, and removing the front jacket panel.
Removal of Vent Outlet Adapter: This step details how to safely detach the vent outlet adapter, which may be made of stainless steel or polypropylene depending on the boiler model. It involves removing mounting screws and disconnecting the flue temperature sensor.
Removal of Electrical Connections: This section provides instructions for disconnecting various electrical components, such as the ignition cable, blower connections, gas valve rectifier plug, display board ribbon cable, and temperature sensors. Different procedures are outlined for MCBA and TriMax control modules.
Removal of Gas Connection: This involves disconnecting the gas supply piping at the brass union below the gas valve.
Removal of Blower/Gas Valve/Venturi Assembly: This step guides the user through detaching the blower, gas valve, and venturi assembly from the burner plate, emphasizing the discarding of the old blower gasket.
Removal of Water Connections: This involves removing the condensate trap, cabinet gasket, and loosening brass union nuts on the internal return and supply connections of the heat exchanger.
Removal of Heat Exchanger: This is the core step, requiring two people to lift and carefully remove the old heat exchanger from the boiler cabinet.
Preparation of New Heat Exchanger: This involves unpacking the new heat exchanger, checking for damage, installing new temperature sensors, and installing the new igniter and gasket.
Installation of New Heat Exchanger: The new heat exchanger is carefully lifted into place, engaging its brackets with the boiler jacket panel.
Installation of Blower/Gas Valve/Venturi Assembly: The new blower/gas valve/venturi assembly is mounted using the new blower gasket and screws.
Installation of Water Connection: Boiler supply and return piping are reconnected using new gaskets and tightening brass union nuts.
Installation of Condensate Drain Assembly: The condensate drain assembly is installed, ensuring the metal washer and plastic seated ball are correctly in place.
Installation of Gas Connection: Gas piping is reconnected and tightened.
Installation of Vent Outlet Adapter: The vent outlet adapter is installed, ensuring the flue gasket is properly seated and applying clean water for ease of insertion.
Installation of Electrical Connections: All previously disconnected electrical connections are reconnected, following specific instructions for MCBA and TriMax systems, including the use of harness adapters for temperature sensors.
Installation of Vent Connection: The vent pipe is inserted into the adapter and secured.
Start-Up Procedures: This involves ensuring the pressure relief valve/air vent is piped correctly, filling the boiler with water, purging air, setting boiler pressure, turning on gas supply, and checking for leaks.
Combustion Test and Adjustments: This crucial final step requires a qualified installer/service technician to perform a complete combustion check at both high and low input firing rates, adjusting the throttle and offset screws as needed to meet recommended combustion settings.

Usage Features

The kit is designed for use by qualified installers and service technicians, emphasizing safety and precision throughout the replacement process. The detailed instructions, accompanied by diagrams, aim to guide technicians through each step, minimizing errors and ensuring a correct installation.

Key usage features include:

Comprehensive Parts: The kit provides all necessary components for a complete heat exchanger replacement, reducing the need to source individual parts.
Pre-installed Components: Critical items like insulation, burner head, and sight glass are pre-installed on the new heat exchanger, simplifying assembly.
Specialized Tools Included: The provision of specific screwdrivers (Phillips and Torx) in the parts box ensures technicians have the right tools for certain tasks.
Clear Safety Warnings: Prominent "WARNING" and "NOTICE" labels highlight potential hazards and important instructions, promoting safe practices. For example, warnings about electrical shock, scald hazards, flue gas leakage, and checking for gas leaks with an open flame are clearly stated.
Model-Specific Instructions: The manual differentiates between various Prestige Solo models and control modules (MCBA and TriMax) where procedures vary, ensuring applicability to the specific boiler being serviced.
Torque Specifications: A table of torque specifications for various assembly screws is provided, ensuring components are tightened correctly to prevent leaks or damage.
Combustion Adjustment Guidance: Detailed instructions for combustion testing and adjustments, including recommended O2 and CO2 levels for natural gas and propane, are provided to optimize boiler performance after replacement.

Maintenance Features

While primarily a replacement kit, certain aspects contribute to the maintainability of the boiler system:

Ensuring Proper Sealing: The kit emphasizes the use of new gaskets for all connections (vent outlet, blower, boiler piping, condensate drain) to prevent leaks, which is crucial for long-term boiler integrity and efficiency.
Checking for Damage and Corrosion: Instructions advise inspecting the old vent outlet adapter for deformation, damage, or corrosion, and replacing it if necessary. This proactive check helps prevent future issues.
Importance of Cleanliness: The manual stresses ensuring the adapter is clean of all debris before insertion, which is a good maintenance practice to prevent blockages or improper sealing.
Calibrated Combustion Analyzer Requirement: The recommendation of a calibrated combustion analyzer for post-installation adjustments highlights the importance of precise tuning for optimal and safe operation, contributing to the boiler's overall longevity and efficiency.
Return of Old Heat Exchanger: The instruction to retain the shipping box, foam packs, and HX Tracking Form for returning the old heat exchanger for warranty evaluation implies a system for tracking and potentially refurbishing or recycling components, which is a maintenance-related consideration.
Two-Wrench Method for Piping: The "two wrench method" for tightening piping connections is a best practice that prevents damage to boiler components, ensuring the integrity of the plumbing system.
Post-Installation Leak Checks: The requirement to test for water and gas leaks after installation is a critical maintenance check to ensure the system is safe and fully operational.

In summary, the PRESTIGE Solo HX Field Replacement Kit is a comprehensive solution designed to facilitate the safe and effective replacement of heat exchangers in Prestige boilers, ensuring their continued reliable and efficient operation through detailed instructions, necessary components, and emphasis on critical safety and performance checks.