Prestige Trimax Cascade Manual
Contents
1. 90 100 110 T Lj o QU te y 3 LA un q k aL Flow GPM Pressure Loss Through CRR1200 Pressure Drop feet of W C Flow GPM Graph 3 Pressure Loss Through CRR 1000 and CRR 1600 Product Specifications TriangleTube CRR2000 Pressure Drop Curve q L o a o a 2 um Va i x BL Pressure Drop feet of W C Flow GPM Graph 5 Pressure Loss Through Optional Strainer Product Specifications 4 TriangleTube Hydronic Junction System Pressure Drop Curve J va o ex q q o o Q q os 5 q S Q 100 Flow GPM Graph 6 Pressure Loss Through Hydronic Junction System Piping Notes 0 TriangleTube Additional quality water heating equipment available from Triangle Tube PRESTIGE CONDENSING WALL MOUNTED BOILER 4 TriangleTube 95 AFUE Fully modulating Natural gas or propane Stainless Steel Construction Direct vent with standard schedule 40 PVC Outdoor Reset Exclusive tank in tank design Stainless steel construction Available in 8 sizes and 2 models Limited LIFETIME residential warranty 15 year limited commercial warranty Self cleaning self descaling design For domestic water snow melting radiant floor refriger ation Plates made of stainless steel with a 99 9 copper and brazed ensuring a high resistance to corrosion Self cleaning a2. 5 16 18 x 34 1 1 2 NPT Union 1 1 2 NPT x 4 Nipple 10 1 1 2 NPT x 1 1 4 NPT 90 Reducing Elbow 11 1 1 2 NPT x 13 Flexible Hose Union Assembly 12 1 1 4 NPT x 4 Nipple 13 1 1 2 NPT 90 Street Elbow 14 1 1 4 NPT x 13 Pipe 2 Heavy Duty Concrete Anchors with Washer amp Nut 4 Concrete Drill Bit 1 1 1 4 NPT Union 4 15 16 17 18 1 1 4 NPT x 1 2 NPT x 1 1 4 NPT Inline Reducing Tee 19 1 2 NPT Plug 2 BEST PRACTICE It s recommended to install Reverse Return with Valves to allow for isolation of an individual boiler for servicing 0I 9Seq AQEL IS UIA Y JJO MUS SALA YIM SUN 092 9195 103 sjusuoduro Wy jeuondo 214 01 ebed 6 ainbi4 6 I 99S 0 abed g aunbi4 ses ZI 4 TriangleTube Installation Items Pre Pre Installation Items 0 TriangleTube Supplied in Standard d Reverse Return Kits CRR Supplied in 21 Reverse Return Kits CRR Fig 9 Optional Kit Components for Solo 250 Boilers R R with Valves Return Piping See Table 3 Table 3 Optional Kit Components for Solo 250 Boilers R R with Valves See Figures 7 9 Pages 9 amp 10 Kit Components PSCAS31 1 Boiler Quantity 1 2 NPT Union Shut Off Valve Assembly 1 2 NPT Close Nipple 1 4 NPT Union Drain Shut Off Valve Assembly 1 4 NPT x 16 Pipe T 9884 FP ALL 99S S d
3. TO WI LIA OTUP H p pv ruL ions CPS for Solo 399 Boilers 0 C E EE O 0002 542 SET e K 0091 542 AI 2 9 0021 SAD 0 Ee um E 008 542 m E A o CAD s i e 3 o Q 4 TriangleTube gil El LO YN A k 2 e e 2 un 5 CS m z O Q 919119 AOH NOE 9 2 9 000 HHO TO CUT L UMA S 0091 HH suer popeolu Ze T 0021 HHO ra o 008 HHO E a Y en 9 um Product Specifications Product Specifications Cascade Kit P N C PS or RR C PS or RR 500 800 C PS or RR 1000 C PS or RR 1200 C PS or RR 1600 C PS or RR 2000 Component Prestige 250 Prestige 399 2 Boiler Manifold 3 Boiler Manifold Hydronic Junction of Manifolds Individual Water Content Gal Total Net IBR Rating MBH Note 3 of Solo 250 or 399 Boilers Total Input MBH Note 1 Total Output MBH Note 1 amp 2 446 758 892 1 138 1 518 1 897 65 490 112 798 65 980 112 1 197 112 1 596 112 1 095 Total VVater Content Gal Individual Shipping Weight Lbs Cascade Kit P N CPS 500 CPS 800 CPS 1000 CPS 1200 CPS 1600 CPS 2000 Total EDR VVater Ft 2 Note 4 2 588 4 396 5 176 6 603 8 804 11 006 Total Shipping Weight Lbs TriangieTube Total Output Boiler Horse Power Minimum Minimum Recommended Recommended System ron Natural Gas Pipe S
4. 4 TriangleTube Cascade Multiple Boiler Distribution Manifold and Hydronic Junction for PRESTIGE Solo 250 or PRESTIGE Solo 399 Boilers Aw ARNING This document is intended to be used by a qualified heating contractor or service technician Read all instructions within this document the PRESTIGE Boiler Installation and Maintenance Manual and Prestige Vent Supplement before proceed ing with the installation It is recommended to follow the procedures in the steps given skipping or missing procedural steps could result in severe personal injury death or substantial property damage NOTICE Installation of boilers must comply with local requirements and codes and with the National Fuel Gas Code NFPA 54 ANSI Z223 1 for installations within the U S For installations in Canada the installation must comply with CAN CSA B149 1 Revised 3 25 13 2011 40 Prestige Cascade Manual Table of Contents TriangleTube PRODUCT amp SAFETY INFORMATION RE EEN 1 Product and Safety Information 1 SECTION I PRE INSTALLATION ITEMS Code Compliance sea iii 2 Determine Location aqua sss sasaqa saa dar PELA 2 Recommended Clearances 2 Cascade KIUMA III xama ga apiu DS bi A A dA 2 Operai Restricciones uox rw duod cy Sa 3E le 2 Kit Component Diagrams and Tables 3 19 SECTION II COMBUSTION AIR AND VENTING
5. Bolt 8 Nut Circulator ear 23 1 1 2 NPT Circulator Flange Shut Off Valve Assembly 2 Heavy Duty Concrete Anchors with Washer 4 Nut Concrete Drill Bit O N O O 24 N 25 00 O TriangleTube Pre Installation Items 9 3384 ALL S Y Y uanjos ISIIAIN 66 OJOS 10 Sjuouoduiro JM IPRISBO ET SIT 0900 VOD Pre Installation Items TriangieTube D Fig 14 Cascade Kit Components for Solo 399 Boilers Reverse Return Supply Piping See Table 5 Page 16 Fig 15 Cascade Kit Components for Solo 399 Boilers Reverse Return Return Piping See Table 5 Page 16 Pre Installation Items 4 TriangleTube Table 5 Cascade Kit Components for Solo 399 Boilers Reverse Return R R See Figs 13 15 Pages 14 amp 15 CRHSOO CRR1200 CRR1600 CRR2000 T uantity 2 Boiler Manifold a po 2 1 3 Boiler Manifold o 13 0 3 ase asss T e 2 a range ansie sim e oe 2 2 s sassa Flared Bolt amp Nut Flange 5 8 11 x 3 2 Bolt Washer amp Nut Boiler Mounting Bracket 5 16 18 x 34 8 i 1 2 NPT Union 1 1 2 NPT x 4 Nipple 10 11 1 2 NPT 90 Elbow it Z NPT File Hose Union Assemby L 4 12 11 1 2 NPT x Close Nipple 13 11 1 2 NPT 90 Street Elbow 4 14 Pi 2 15 1 1 2 NPT x 1 2 NPT x 1 1 2 NPT Inline Reducing Tee 2 3 4 7 pay Day Concrete Anchor
6. PSHOSO os NPTx 13 Flexible Hose Union Assembly Replacement Parts TriangleTube Fig 39 Cascade Kit Components for Solo 399 Boilers Reverse Return with Valves Return Piping l l s m PSNIPO7 has NPT x 10 Pipe RR with Valves RZ z NPT x 13 1 2 Pipe RR Replacement Parts 4 TriangleTube Fig 40 Cascade Kit Components for Solo 399 Boilers Primary Secondary Supply Piping Cm me Femme 1112 NPT Union Shut Off Valve Assembly 1 1 2 NPT x 15 Flexible Hose Union Assembly 8 PSTEEM os NPT x 1 2 NPT x 1 1 2 NPT Inline Reducing Tee Replacement Parts TriangleTube Fig 41 Cascade Kit Components for Solo 399 Boilers Primary Secondary Return Piping Cm er n 83 PSvLVIO 1 2 NPT Circulator Flange Shut Off Valve Assembly 4 PSHOSOT os NPTx 15 Flexible Hose Union Assembly 4 TriangleTube Product Specifications 0001 54 00S 542 umy ur s 919119 AOH WO 9 TO 1 LUNA 93UB J POPeoIUL Dimensions CPS for Solo 250 Boilers Fig 42 uinjow UISAS TriangleTube AOH WOT 9 TO c T L QI esue 4 E 0001 HU 00S HHO DDD a 3 UGALI a S Le Fig 43 Dimensions CRR for Solo 250 Boilers Product Specifications 4 TriangleTube ummy ulojs g 919119 AOH HO 9
7. Arepuo g AIVUILIg Syoproq 66 OJOS 10y sJu uodutoO JM DB SU 01 SH cl abed 21 ni s 21 obed LL eJnBig ees O 4 TriangleTube QOS TO Pre Installation Items Pre Installation Items 0 TriangleTube Fig 11 Cascade Kit Components for Solo 399 Boilers Primary Secondary Supply Piping See Table 4 Page 13 Fig 12 Cascade Kit Components for Solo 399 Boilers Primary Secondary Return Piping See Table 4 Page 13 Pre Installation Items 4 TriangleTube Table 4 Cascade Kit Components for Solo 399 Boilers Primary Secondary P S See Figs 10 12 Pages 11 amp 12 CPS800 CPS1200 CPS1600 Kit Components Quantity Prestige Solo 399 Boiler CPS2000 1 Hydronic Junction with Insulation amp Air Vent 1 1 4 NPT 90 Elbow 1 1 4 NPT x 4 Nipple Flange ANSI to 3 NPSC 7 Flange ANSI to Blind Aa s NS Flared Bolt amp Nut Flange 5 8 11 x 3 Bolt Washer 4 Nut Boiler Mounting Bracket 5 16 18 x 34 40 6 1 1 2 NPT Union Shut Off Valve Assembly 1 1 2 NPT 90 Street Elbow 40 6 13_ 1 112 reg Hose Union Assemby 4 6 EM E EN 1 1 2 NPT Union 1 1 2 NPT Drain Shut Off Valve Circulator Flange 2 3 Assembly VE NPT 907 Elbow 5 uz NPT Pu EN on B N o N C2 N N r NI 20 Circulator Grundfos UPS 26 99FC 21 Gasket Circulator 22
8. Combustion Air and Venting 20 21 SECTION III INSTALLATION Distribution Manifold 22 Multiple Distribution Manifolds 22 UIONE JON CHON xou euo en e 71071 2 QUEI O SERRE a ra a xa RW ANS 23 Boiler ek 544403 107 7007777777174 7 24 SECTION TV BOILER PIPING E 002 07 25 SECTION V CSD 1 PIPING CONTROL INSTALLATION P S or R R with Valves Kit PSCASI7 26 Reverse Retum R R 26 SECTION VI SYSTEM PIPING Multiple Distribution Manifolds 21 Pit e 27 28 High Pressure Systems or Involving Fluid Separation 29 System Piping Diagrams 30 35 SECTION VII GAS PIPING Natural Gas Pipe Sizing 36 Propane Gas Pipe SIAN BSD ba ER 36 Table of Contents TriangleTube SECTION VIII WIRING POWCE susam deena ease li 37 Multiple Boiler Control 37 CSD 1 P S or R R with Valves Kit 37 CIRR EE Tn KC e ds 77 37 Feld Within Disc dis qb nao ap RS ey eee eee Ode ee Red ue 38 40 SECTION IX SYSTEM START UP Check System W
9. Te m TEE sasa Pos is 2 ANSI Flanges Machined 26 27 26 29 3 32 ca esje 2e uy bul Cho Pos T l mril mE si cat 2 3 52 Menea ozlozloslosloslo l Pro cs TT 04 05 Machined 94 04 os 5s os 07 C T Tos o T Table 10 Equivalent Length of Straight Pipe System Piping High Pressure Systems or nvolving Fluid Separation A heat exchanger 1s required between the Cascade and the system piping as shown in Figure 33 page 35 when operating under the following conditions Standard 30 PSI Cascade System operating pressure greater than 30 PSI High Pressure HP 80 PSI Cascade System operating pressure greater than 80 psi Any Cascade requiring fluid separation glycol from water 4 TriangleTube NOTICE For applications involving multiple Cascade configu ration as shown in Figure 33 page 35 in conjunction with a system heat exchanger contact Triangle Tube Technical Support for assistance in sizing heat exchanger and piping recommendations System Piping circulator vv isolation flanges circulator w internal check valve amp isolation flanges central air separator ball valve hose bib drain valve backflow preventer pressure reducing valve strainer primary secondary fitting w trim SMART Indirect
10. the area around the unit Check the temperature and pressure gauges Monthly Check the pressure relief valve TriangleTube Every 6 months Check piping for corrosion or potential signs of leakage Operate the pressure relief valve A WARNING Follow the maintenance procedures given throughout this manual Failure to perform the service and maintenance or follow the directions in this manual could result in damage to the Cascade or in system components resulting in severe personal injury death or substantial prop erty damage Maintenance Procedures SECTION XI MAINTENANCE PROCEDURES Maintenance Procedures A WARNING The Cascade should be inspected and serviced annually preferably at the start of the heating season by a qualified service technician In addi tion the maintenance as further explained should be performed to assure reliability NOTICE The following information provides detailed instruction for completing the maintenance items outline in the maintenance schedule In addition to this maintenance the Cascade should be serv iced at the beginning of the heating season by a qualified service technician Reported Problems Any problems reported by the owner should be checked verified and corrected before proceeding with any main tenance procedures Check Surrounding Area Verify that the area surrounding the Cascade is free of combustible flammable ma
11. water cut off and manual high limit will be required in the system supply piping before the system supply shut off valve The low water cut off must be installed in the system piping above the boilers The low water cut off with probe and manual high limit and dry well can be field supplied or ordered separately see page 45 for part number CSD 1 Piping 6 Control Installation SECTION VI SYSTEM PIPING Multiple Distribution Manifolds The maximum number of boilers that can be piped in series 1s five If installing more than five boilers you will need to install the boilers in banks of no more than 5 boil ers per bank The multiple banks should only consist of Primary Secondary Cascade Kits to ensure adequate flow through boilers The system piping between these boiler banks should be piped in parallel see Figure 29 page 31 The parallel system piping between banks may require a balancing valve s if installing an uneven number of boil ers per bank 1 e 4 boiler bank with a 2 boiler bank see Figure 30 page 32 System Piping NOTICE The system piping must be a closed system to avoid any oxygen contamination and potential fail ure of the Cascade 1 The minimum recommended system iron pipe size is listed in Table 9 This table provides the individual boiler and system flow rates at various system tem perature differences This table also lists system pip ing pressure drops per 100 feet of system piping 2 T
12. 15161 7118192021722 2324252627282930818283343586873883940 eje Red E Black amp Shielding gt 5 ED _ E 95 Bis 3 LL 2 o 5 CH2 SYS go o 33 o Os a o oN 26 5 5 a Bo i Note1 Domestic Circulator controlled N o 59 o by external circulator relay I 0 as O A 13 s ip O gt Dry Contact Red Input Relay Included with Common Vent Sep 9 5 x m 2 g is Cascade Cable Slave Prestige Boiler WI 4 4 j oltage te a p 2 Sys Aux Boiler DHW Pump CH1 Pump Power Alarm CH1 CH2 Outdoor DHW Manual Auto 5 System Cascade Modbus Pump Pump Divert Valve Diverter Valve Supply Contact Cascade T stat T stat Sensor Sta SensReset lImtReset Im Sensor Master A B G L G N L G N L G N L G N Lic IN m cca 112314 516 71819 101 112131415161 7118192021722 23242526272829308318283343586837383940 eee 13 S 13 O gt Dry Contact Red Input Relay Included with Common Vent 9 5 x m 2 g is B NO Low Water Cut Off C HO Common Vent Pressure Switch High Temp Limit NOTES Common Vent Only 1 This drawing shows system wiring concept only 2 Installer is responsible for all equipment amp detailing required by local codes 3 All wiring shall be in conformance with the latest edition of the National Electrical Code 4 Do not run sensor wiring in same conduit or raceway as line voltage wiring 5 Use 18 AWG copper twisted pair wiring for all s
13. INIL GIN LI GIN 1 2 31456 7 8 910111213141516171819202122 23 262728293081323384 38 000 1 OS OOO OOO OOO S OI GS 120 VAC Coil 9 SPST Relay Os a Low Water Cut Off c HO This drawing shows system wiring concept only Installer is responsible for all equipment amp detailing required by local codes High Temp Limit All wiring shall be in conformance with the latest edition of the National Electrical Code Do not run sensor wiring in same conduit or raceway as line voltage wiring Use 18 AWG copper twisted pair wiring for all sensor wiring NOTICE See Fig 32 page 34 for System Piping Fig 35A Wiring Diagram One LWCO amp High Limit Per Cascade without Common Vent System Start Up SECTION IX SYSTEM START UP Check System VVater Chemistry A WARNING Do not use petroleum base cleaning or sealing compounds in the boiler system Damage to seals and gaskets in the system components could occur resulting in substantial property damage NOTICE System vvater including additives must be practi cally non toxic having a toxicity rating or Class of 1 as listed in Clinical Toxicology of Commercial Products VVater pH Level 6 0 to 8 0 Maintain the water pH between 6 0 and 8 0 Check using litmus paper or contact a water treatment company for a chemi
14. ade Modbus uda ud Ke Cascadel T stat T stat Sensor Stat SensReset Imt Reset Imt 5 Sensor Master IA B G LIGINILIGINILIGIN LIGINILIGIN 11121314 516 7 8 9 10111213141516171819202122 1232425262728293031323384353637383940 eee High Temp Limit AUX Os NO Low Water Cut Off HO S Yellow Dry Contact 6 Red Input Relay Common Vent Only Black o lla s g 2 Common Vent Pressure Switch Common Vent Only NOTES 1 This drawing shows system wiring concept only 2 Installer is responsible for all equipment amp detailing required by local codes NOTICE 3 All wiring shall be in conformance with the latest edition of the National Electrical Code 4 Do not run sensor wiring in same conduit or raceway as line voltage wiring 5 Use 18 AWG copper twisted pair wiring for all sensor wiring See Fig 31 page 33 for System Fig 34 Wiring Diagram Individual LWCO amp High Limit Per Boiler Piping VViring TriangleTube NGL Master Prestige Boiler WI 4 4 oltage te a D CH2 Sys Aux Boiler DHW Pump CH1 Pump Power Alarm CH1 CH2 Outdoor DHW Manual Auto 7 System Cascade Modbus Pump e EN Contact Cascade T stat T stat Sensor Stat SensReset Imt Reset Imt Sensor Master A B G IGN LG E SR SEN eee 112314 516 71819 101 1121314
15. ater Chemistry 41 Water pH Level OOTO SO ausa ee 7 41 Water Hardness Less Than 7 Grains 41 Chlorindted AA e ee cei 41 Flush System to Remove Sediment 41 Use of Antifreeze in he SYSTEM 0000007077 7 h asas aqa 41 Check aud ISANGE ei titadi ag Eaa Kaa kaaa 42 SECTION X MAINTENANCE SCHEDULE Service Technician General 43 Owner Maintenance 43 SECTION XI MAINTENANCE PROCEDURES Maintenance Procedures 44 Reported Problems s beens yas e aia its ened 44 Check Surrounding ATEA xo dd aes es enti dea 44 Check Systemi PIPINS IIIA dee ER e 44 Check Boiler Cascade System 44 Check Expansion Tank pirata 7 7 44 Check Boiler Relef YA IIIA petad da kawasakiana 45 REPLACEMENT PARTS Replacement Parts 46 51 PRODUCT SPECIFICATIONS S GO C ils axd a d r ax eae stan eee ete sates I A das 52 59 4 TriangleTube Product amp Safety Information Definitions The following terms are used to bring attention to the presence of potential hazards or important information concerning the product A WARNING ndicates a hazardous situation which i
16. cal analysis If the pH does not meet this requirement do not operate the Cascade or leave the system filled until the condition Is corrected Water Hardness Less Than 7 Grains For areas with unusually hard water hardness above 7 grains consult a water treatment company Chlorinated Water Do not use the Cascade to heat a swimming pool or spa directly Maintain the chlorine level of the water at levels consid ered safe for drinking TriangleTube Flush System to Remove Sediment The installer must flush the system to remove any sedi ment to allow proper operation Flush the systems until the water runs clean and is free of sediment For zoned systems each zone should be flushed through a purge valve Purge valves and isolation valves should be installed on each zone to allow proper flushing of the system Use of Antifreeze in the System A WARNING NEVER use automotive or ethylene glycol antifreeze or undiluted antifreeze in the primary system as freeze protection This can cause severe personal injury death or substantial prop erty damage if ignored Determine the antifreeze fluid quantity using the system water content volume and following the antifreeze man ufacturer instructions Consult product specifications page 56 for the Cascade water volume Check with local codes requirements for the installation of backflow preventers or actual disconnection from the boiler s cold water fil
17. e TriMax Control Supplement for more information CSD 1 P S or R R with Valve Kit 1 A high limit control and a low water cut off are required for each boiler and should be wired to ter minals 9 amp 10 of the boiler terminal strip see Figure 34 page 38 2 Ensure wiring to terminals 9 amp 10 utilize a dry set of contacts with no power 24V or 120V being brought back or taken from the terminals on the boiler 3 When wiring to terminals 9 amp 10 an open set of contacts will result in an E87 External Limit Open hard lock out for that individual boiler 4 While in a hard lock out condition the auxiliary boiler pump amp CH 1 pump wired to the boiler will be energized 5 Toreset the boiler the condition will need to be cor rected and then the boiler will need to be reset 4 TriangleTube CSD 1 R R A single high limit control and low water cut off control for the Cascade system can be wired to each boiler through an isolation relay A dry contact input relay is included with the common vent system and can be used for all external limits See Fig 35 page 39 If the common vent system is not being utilized each boiler will require a 120 VAC coil relay with a normally open contact See Fig 35A page 40 Ensure wiring to terminals 9 amp 10 utilize a dry set of contacts with no power 24V or 120V being brought back or taken from the terminals on the boiler When wiring to terminal 9 amp 10 an open set o
18. e cause of the relief valve to weep is the valve itself not due to system over pressurization caused by an expansion tank that is waterlogged or undersized TriangleTube Replacement Parts TriangleTube PSLWCO1 Low Water Cut Off with Probe 3 4 NPT x 2 Long Insertion PSFLGOS Flange ANSI to 3 NPSC PSFLG02 Flange ANSI to Blind PSGK24 Gasket ANSI PSNUTO3 5 16 18 Nut Flanged PSBLTO3 5 16 18 x 3 Bolt Flanged PSCONO7 Manual High Limit 200 F PSVVELO1 1 2 NPT x 1 1 2 Diy vvell for High Limit PSCOMO1 Heat Conductive Compound for High Limit Fig 36 Cascade Kit Components for Solo 250 Boilers Reverse Return with Valves Return Piping e oe ko PSNIPHM Du NPT x 16 Pipe RR with Valves o HEI NPT x 18 Pipe RR 8 rengem tue NPT x 13 Flexible Hose Union Assembly 4 PSELBO9 tue NPT x 1 1 4 NPT 90 Reducing Elbow Replacement Parts 4 TriangleTube Fig 37 Cascade Kit Components for Solo 250 Boilers Primary Secondary Supply Piping l l m 1 1 2 NPT x 13 Flexible Hose Union Assembly 8 PSEBO os NPT x 1 1 4 NPT 90 Reducing Elbow 4 PSTEEOS ka NPT x 1 2 NPT x 1 1 4 Inline Reducing Tee Replacement Parts TriangleTube Fig 38 Cascade Kit Components for Solo 250 Boilers Primary Secondary Return Piping ml vv rem 0 1 1 4 NPT Drain Shut Off Valve Circulator Flange Assembly 4
19. e does not exceed the max imum pressure rating of the boiler Connect the supply piping and return piping from the dis tribution manifold to each boiler If necessary to align the supply and return pipes you can slide the boiler s on the boiler mounting bracket s NOTICE Use a high quality sealant for sealing all threaded con nections similar to Loctite 577 Assemble and tighten pipes in the proper orientation within the sealants working cure time Pipe individual boilers as shown in the appropriate figures 1 through 18 pages 3 18 CSD 1 Piping amp Control Installation SECTION V CSD 1 INSTALLATION If local codes require the installation to comply with CSD 1 the addition of high limit control s and low water cut off con trol s are required The quantity and location of the controls vary depending on the installation P S or R R with Valves Kit PSCAS17 In these installations the boilers can be individually iso lated and therefore both a high limit control and a low water cut off control are required for each boiler An optional kit PSCAS17 is required for each boiler see Table 7 page 19 for a breakdown of kit components 1 The high limit control will need to be installed in the supply piping directly below the boiler Remove 1 2 NPT plug in supply piping and install drywell from PSCAS17 kit 2 Install sensing bulb of the high limit control with heat conductive compound into the drywell both the limi
20. e min 6 max 8 NOTICE Any water conditioning system must be installed and maintained in accordance with manufacturer s specifications NOTICE Do not install the Cascade on any application if the system piping contains non oxygen barrier tubing or if the system is considered an open system Exposing the Cascade to oxygen contamination will lead to premature failure and denial of the warranty 39384 I ALL S S d Azepuo s JBUITIJ SIAJ QST OJOS 10 spuouoduro 9 JM IPLISEO 1 sia 8 UN y obed e anbiy ees y Bed z eJnDi ees 4 oe 4 TriangleTube 0066 6 X8X9X Pre Installation Items Pre Installation Items 4 TriangleTube 03 23 Fig 2 Cascade Kit Components for Solo 250 Boilers Primary Secondary Supply Piping See Table 1 Page 5 Pre Installation Items TriangleTube Table 1 Cascade Kit Components for Solo 250 Boilers Primary Secondary P S See Figs 1 3 Pages 3 amp 4 CPS 500 Quantity 8 2Boilermanito fm 2 yuna a 1 4 NPT 90 Elbow 3 E 1 1 4 NPT x 4 Nipple EM Flange ANSI to 3 NPSC o 2 2 7 Jrene ansioBina 2 2 8 GeketANS lr 8 NE Flared Bolt amp Nut Flange 5 8 11 x 3 mo s EM Bolt Washer amp Nut Boiler Mounting Bracket 5 16 18 x 34 40 8 1 1 2 NPT Union Shut Off Valve Assembly 1 1 2 NPT 90 Street E
21. egulator 2 1 2 1580 3050 4860 8580 726 1090 2090 3340 5900 583 499 1060 Table 11 Gas Piping Sizing Natural Gas 57 _ jJ DO E 1 5 5 o mo lim m 0 l m 0 Y r T_T se Not applicable for multiple Solo 399 Boilers VViring SECTION VIII WIRING Power Supply A dedicated 120 VAC 15A minimum service must be used to power the boilers in the Cascade System Multiple boilers in the Cascade System can be placed on the same electrical circuit Each boiler can draw a maxi mum of 8 amps Multiple Boiler Control The TriMax Boiler Management System includes a cas cade function which allows up to six Prestige boilers to operate together in a single heating system Consult the Prestige TriMax Control Supplement for more informa tion on the built in cascade function If necessary to con trol more than six boilers Triangle Tube s Optima SCC4 PSCONO3 and SCC4 Extension Modules PSCON04 can be used to control up to sixteen boilers Contact Triangle Tube Technical Support for more information regarding Triangle Tube s Optima Series of Multiple Boiler Controls The TriMax Boiler Management System includes the abil ity to communicate with building management systems BMS through a Modbus interface Building management system gateways are also available for BACnet and LonWorks systems Consult the Prestig
22. ensor wiring NOTICE See Fig 32 page 34 for System Piping Fig 35 Wiring Diagram One LWCO amp High Limit Per Cascade with Common Vent i E E 7 VViring NOTES o AON gt TriangleTube Master Prestige Boiler TriangleTube TriMax Control Line voltage terminal strip Low voltage terminal strip Aux Boiler DHW Pump CH1Pump Power Alarm Modulation Pump Pump Divert Valve Diverter Valve Supply Contact Signal Cascade um L G N L G NL G N L G N Slave 1213 262728293081823384 38 00 CS GO O m S S SIS Red Black amp K Shielding N CQ GOO S S S S S SS S S gt ED ES OD oc o o LO D 82 2 m SIN o x E D tQ 2 26 cO 2 e gt O N o Sx D Note1 DC1 Circulator controlled AS by external circulator relay 120 VAC Coil 9 SPST Relay ST Cascade Cable PTCAB01 Slave Prestige Boiler lt 4 TriangleTube TriMax Control Line voltage terminal strip Low voltage terminal strip Aux Boiler DHW Pump CH1 Pump Alarm CH2 Outdoor DHW Manual System Cascade deL AR id d Se Cascadell T stat T stat Sensor Stat Sens Reset mtReset lmt Sensor Master A B G LIG
23. ent Air Side Wall Kit PSVKTT03 Solo 399 Boilers Only Combustion Air and Venting TriangieTube Fig 21 Optional Common Venting of 2 or 3 PRESTIGE Solo 399 Bollers Not Available for Solo 250 Boilers For instructions or information regarding Common Venting of 2 or 3 PRESTIGE Solo 399 Boilers as shown in Fig 21 contact Triangle Tube Technical Support Installation SECTION III INSTALLATION Distribution Manifold 1 Place the distribution manifold in the location to be installed If a Hydronic Junction is utilized consider ation must be made in determining location 2 Level distribution manifold 3 Secure manifold to floor To secure the manifold to the floor drill and install anchors supplied with Cascade in floor through the holes in the legs of the distribution manifold one per leg BEST PRACTICE For optimum support of the weight of the Cascade it is recommended to secure the distribution manifold to the floor especially when utilizing multiple distri bution manifolds 4 Install blind flange seal plate on the distribution manifold with gasket and hardware supplied see Figure 22 For primary secondary applications this flange should be installed on the distribution mani fold on the end opposite to the hydronic junction For reverse return applications the top blind flange should be installed opposite of the system supply piping Install the bottom blind flange opposite of
24. f con tacts will result in an ES7 External Limit Open hard lock out To reset the boilers the condition will need to be cor rected and then each boiler will need to be reset e VViring TriangleTube Master Prestige Boiler CH2 Sys Aux Boiler DHW Pump CH1 Pump Power Alarm CH1 CH2 Outdoor DHW Manual Auto Moduaion system Cascade Modbus Pump Pump DivertValve Diverter Vave Supply Contact Cascade T stat T stat Sensor Stat SensReset Imt Reset Imt M Sensor Master A B G LIGINILIGINILIGINILIGINILIGIN Sas 11112 13 41516 7 8 9 1011121314151617181191202122 232425262728293081323384353637388940 DOO Red Black amp Shielding gt amp ET Ec o oc O o ce 2586 o e D o CH2 SYS AUX ke o O o o o E E DIN 5 o gt Bo D Note1 Domestic Circulator controlled N o 52 o by external circulator relay nu Q A High Temp Limit NE NO Low Water Cut Off Oc HO S Yellow Dry Contact Red nput Relay Common Vent Only Black White Red White Blue Cascade Cable Slave Prestige Boiler mi 4 4 2 p CH2 Sys Aux Boiler DHW Pump CH1 Pump Power Alarm CH1 CH2 outdoor DHW Manual Auto tito system Casc
25. f not avoided could result in death serious injury or substantial property damage NOTICE ndicates special instructions on installation operation or maintenance which are important to equipment but not related to personal injury Product amp Safety Information NOTICE This supplement is intended for the installation of a Cascade Multiple Boiler Distribution Manifold and Optional Hydronic Junction with Prestige Solo 250 or Solo 399 Boilers The Cascade is not intended for installation with any other Prestige Boilers The installation of the Prestige Solo 250 or Solo 399 boilers in the Cascade configuration must be in accordance with the Prestige Solo 250 or Solo 399 Installation and Maintenance Manual and other corresponding supplements including venting BEST PRACTICE Indicates recommendations made by Triangle Tube for the installers which will help to ensure optimum operation and longevity of the equipment A CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury or property damage NOTICE Please reference the Cascade Distribution Manifold serial number on the inclined section of left leg when inquiring about service or trou bleshooting of the manifold NOTICE Please reference the Prestige Boiler serial num ber when inquiring about service or trou bleshooting of the boiler NOTICE Triangle Tube reserves the right to modify the technical specificatio
26. he return temperature of the system is equal to the return temperature of the boiler Cascade NOTICE The installation of the hydronic junction only applies when the Cascade system is configured in a primary secondary arrangement The maximum number of boilers that can be piped up to a single hydronic junc tion is five The hydronic junction can be installed on either the right or left side of the distribution mani fold The hydronic junction can be rotated 180 degrees about its height or vertical axis 1 Place the hydronic junction in the location to be installed The distribution manifold must be consid ered in determining location 2 Connect the hydronic junction to the distribution manifold using the gaskets and hardware provided 3 Level distribution manifold and hydronic junction 4 TriangleTube 4 Install air vent and drain valve in the Hydronic Junction see Figure 23 The air vent should be installed in the top tappings as shown The drain valve 1 1 4 NPT shut off valve should be installed horizontally using a 1 1 4 NPT 90 elbow and 1 1 4 NPT x 4 nipple in the tapping located at the bottom The handle on the shut off valve will need to be in the horizontal position when the valve is closed Remove handle and install accordingly System Return Fig 23 Hydronic Junction Insulation BEST PRACTICE It s recommended to install insulation to minimize standby losses Position and secu
27. ize Header Size Note 5 Note 6 Total Shipping Weight Lbs Total Water Content Gal Cascade Kit P N CRR 500 CRR 800 CRR 1000 CRR 1200 CRR 1600 CRR 2000 Note1 Input and output ratings are shown for sea level applications The PRESTIGE Solo automatically derates the input at approxi mately 2 for every 1 000 feet of altitude No alteration to the boiler or burner system is required Note 2 PRESTIGE Solo 399 output ratings are based off a thermal efficiency of 95 1 Prestige Solo 250 output rating is based on DOE heating capacity Note 3 The IBR rating is based on piping and pick up allowance of 1 15 This allowance should be sufficient for the standard radiation requirements for a building load Note 4 Equivalent Direct Radiation EDR is based on 150 Btu h per square foot EDR at 170 F average supply temperature and total net IBR rating Note 5 Minimum recommended system iron pipe size is based on temperature differential of 20 F Note 6 Minimum recommended natural gas header size is based on using schedule 40 metallic pipe 0 30 w c pressure drop and 100 feet of total equivalent length at a gas inlet pressure of less than 2 psi Consult National Fuel Gas Code for alternate sizing Product Specifications 4 TriangleTube CRR 500 and CRR 800 Pressure Drop Curve Pressure Drop feet of W C Flow GPM Graph 1 Pressure Loss Through CRR 500 and CRR 800 o _
28. l or make up water supply line NOTICE Massachusetts Code requires the installation of a backflow preventer if antifreeze is used Ensure the concentration of antifreeze to water does not exceed a 50 50 ratio NOTICE System water including additives must be practi cally non toxic having a toxicity rating or Class of 1 as listed in Clinical Toxicology of Commercial Products System Start Up Check and Test Antifreeze For systems containing antifreeze solutions follow the antifreeze manufacturer s instructions in verifying the inhibitor level and to ensure the fluid characteristics are within specification requirements Due to the degradation of inhibitors over time antifreeze fluids must be periodically replaced Refer to the man ufacturer of the antifreeze for additional instructions NOTICE System water including additives must be practi cally non toxic having a toxicity rating or Class of 1 as listed in Clinical Toxicology of Commercial Products 4 TriangleTube Maintenance Schedule SECTION X MAINTENANCE SCHEDULE Service Technician At least on an annual basis the following maintenance should be performed by a qualified service technician General Attend to any reported problems Check for leaks water Check water pressure piping and expansion tank Once the maintenance items are completed review the service with the owner Owner Maintenance Periodically Check
29. lbow EN 1 1 2 NPT x 13 Flexible Hose Union Assembly 40 8 neem E TA NPT Union A u 1 1 4 NPT Drain Shut Off Valve Circulator Flange Assembly Circulator Grundfos UPS 15 58 20 1 2 NPT Circulator Flange Shut Off Valve Assembly 2 NEN NN mm 0 O T _ 1 1 2 NPT amp 1 1 4 NPT 90 Reducing Elbow 2 214 1 4 NPT x 1 2 NPT x 1 1 4 NPT Inline Reducing Tee wF Item Kit Components 8 2384 7 ALL S Y Y UIMIY ST A I SIOE QSZ OJOS 10 sJu uodutoO JM IPLISBO p SI Z ebed g aunbi4 ses 1 eDeg 9 ni ses 900 4 TriangleTube my SXSXeX2 Pre Installation Items Pre Installation Items 4 TriangleTube 1 Fig 5 Cascade Kit Components for Solo 250 Boilers Reverse Return Supply Piping See Table 2 Page 8 Fig 6 Cascade Kit Components for Solo 250 Boilers Reverse Return Return Piping See Table 2 Page 8 Pre Installation Items 4 TriangleTube Table 2 Cascade Kit Components for Solo 250 Boilers Reverse Return R R See Figs 4 6 Pages 6 amp 7 CRR500 CRR1000 Item Kit Components Quantity Prestige Solo 250 Boiler 2 Boiler Manifold 3 Flange ANSI to 3 NPSC Flange ANSI to Blind Gasket ANSI Flared Bolt amp Nut Flange 5 8 11 x 3 1 2 1 2 2 4 1 2 4 3 O NO N Bolt Washer amp Nut Boiler Mounting Bracket
30. nd self descaling Computerized sizing available from Triangle Tube Phase III Available in capacities from 25 000 BTU hr to 5 000 000 BTU hr Freeway Center 1 Triangle Lane Blackwood NJ 08012 and Tel 856 228 8881 Fax 856 228 3584 E mail sales triangletube com
31. ns and components of its products without prior notice MEN Pre installation Items SECTION I PRE INSTALLATION ITEMS Code Compliance Installation of the Cascade must comply with local codes and requirements and with the latest edition of National Fuel Gas Code NFPA 54 ANSI Z223 1 for installations in the U S For Installations in Canada the installations must comply with latest edition of CAN CSA B149 1 The installation of the Cascade must be installed in accordance with the Standards for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 CSD 1 when required The Cascade must be fully constructed using ONLY the components from Triangle Tube Determine Location Consider the following piping venting gas electric and drain when selecting a location for the Cascade Recommended Clearances The PRESTIGE Solo 250 or Solo 399 is approved for zero clearances to combustibles excluding vent and boiler piping Vent amp Boiler Piping 4 from combustible materials BEST PRACTICE To provide serviceability it is recommended that the fol lowing clearances be maintained from the Cascade Top boiler jackets 24 inches Front boiler jackets 24 inches Bottom boiler jackets 24 inches Rear of boiler jacket 13 inches Left side of outer left boiler jacket 9 inches Right side of outer right boiler jacket 9 inches A WARNING If the clearances lis
32. o determine the system pressure drop calculate the total equivalent length T E L of pipe for each valve and fitting in the system piping in the appro priate pipe size using Table 10 page 28 Add the T E L to the actual straight length of system pipe of the same size 3 Once you have calculated the T E L of system pipe based on a specific pipe size multiply it by the pressure Size Individual Boiler or Cascade Kit Total Output MBH 38 45 76 PS or RR 1600 PS or RR 2000 4 TriangleTube drop 100 feet listed for the pipe size to establish the total circuit pressure drop for that pipe size If using various pipe sizes in the system you will need to do this calcula tion for each pipe size separately and add the total pres sure drops of all sizes to get a total system pressure drop NOTICE When sizing the system piping and components it s recommended to use a minimum flow rate of 11 gpm per Solo 250 boiler or 19 gpm per Solo 399 boiler in the cascade to limit the flow velocity to 4 feet second and the friction loss pressure drop to 4 2 feet 100 feet of pipe Size system piping and components using approved recognized design methods if necessary con tact Triangle Tube Technical Support for assistance BEST PRACTICE It is recommended to utilize a primary secondary Cascade when the total system flow rate is greater than 22 gpm per Solo 250 boiler or 38 gpm per Solo 399 boiler or less than 11 gpm per Solo 250 b
33. oiler or 19 gpm per Solo 399 boiler A primary secondary Cascade is also recommended when the system flow rate and pressure drop are unknown See Figure 31 page 33 for P S Cascade system piping See Figure 32 page 34 for R R Cascade system piping NOTICE To avoid potential contamination of the boiler piping and heat exchangers Install optional strainer kit PSCAS24 on the system return piping to boilers in any R R Cascade application with or without boiler valves System Temperature Difference F AP 100 Feet Table 9 Minimum Recommended System Iron Pipe Size and Pressure Drop 100 Feet of Pipe ee a System Piping 4 TriangleTube iu dd mae man amar SETE Machined 66 74 85 93 r 18 cs aia xx os aspas 72 meus Meier sz aa Tas E 90 Elbow Pos 33137 Long Radius Machined 20 23 27 29 84 42 s 57 9 ce zs 34 47 Pe ae SEE 1S ca EES ER av Fango ester ra ay e pe fas fas Tas 9 ca ai Tas ERE E Tee Line ca T II IZ IE EA AA sed ce T l l ar Machined 87 99 12 19 17 2 Tee Branch Los Tivi s Luet em einer aa 52 Tas 75 e a Ts Ts ca 77 0 5 Machined 37 42 54 62 79 39 MEN Gsl 6 ee Pos Z
34. omponents CSD 1 for P S amp R R with Valves Kit Components PSCAS17 1 Boiler Brass 34 NPT 90 Degree Elbow Brass 34 NPT Shoulder Nipple Brass 34 NPT Tee Brass 34 Close Nipple Drywell 4 NPT with 1 5 Long Well Wire Splice NOTICE CSD 1 for R R The LWCO with probe High Limit Drywell and heat conductive compound can be ordered separetely see page 46 for part numbers Table 8 Optional Kit Components R R Strainer PSCAS24 Kit Components 1 Cascade Quantity 1 Wye Strainer with 3 ANSI Flanges 8 Bolt amp Nut 5 8 11 x 3 Flanged Combustion Air and Venting SECTION II COMBUSTION AIR AND VENTING A WARNING For detailed instructions regarding the installation of the combustion air and venting reference the PRES TIGE Installation and Maintenance Manual PRES TIGE Vent Supplement and or the various optional vent kit instructions Both the PRESTIGE Solo Installation and Maintenance Manual and PRESTIGE Vent Supplement is included in each boilers installation envelope For instructions or information regarding the optional side wall vent air kits shown below in Figs 19 amp 20 contact Triangle Tube Technical Support Each boiler must be individually vented and supplied with combustion air 4 TriangleTube Fig 20 Optional Vent Air Side Wall Termination Kit PSVKITO1 for Solo 250 PSVKTT02 for Solo 399 Fig 19 Optional Concentric V
35. pesa HT Tp Ajddns Jayem poz peo dus JaAO 01 HOI Ajgpuo2as doot Auewud b Ba peo dual Jayy o3 noq A EA Yayo ZP 2 2 Qi Josuag lesi dorin ul qsAs ELULIC 22 API 1 3SP N SULIIM ISISIIG 107 6c 9SBd SE 011 99S JOILON EE Cascade R R iping System P Fig 32 System Piping 4 TriangleTube E D 82 E en Cp de E 22 gh gii ce ez lE 1 S E T and gt ae 2 53 Haer 1 Ea gu EE sera E ad ME E 5 SE D i x LE E E B E 23 wr b m D I primary circulator Fig 33 System Piping High Pressure Systems or Involving Fluid Separation asa Gas Piping SECTION VII GAS PIPING Natural Gas Pipe Sizing Refer to Table 11 for Schedule 40 metallic pipe length and diameter requirements for natural gas based on the total of all PRESTIGE Solo Boiler inputs divided by 1 000 to obtain cubic feet per hour required Table 11 is based on Natural Gas with a specific gravity of 0 60 and a pressure drop through the gas piping of 0 30 w c 1 1 4 1 1 2 4 TriangleTube For additional gas piping sizing information refer to ANSI Z223 1 For Canadian installations refer to CAN CSA B149 1 Propane Gas Pipe Sizing Contact the local propane gas supplier for recommended sizing of piping tanks and 10096 lockup gas r
36. r leaving an air gap as a cushion Refer to the manufac turer s instruction for proper fill level Ensure the tank is fitted with a device that reduces gravity circulation of air saturated tank water back into the system This device pre vents air from bubbling up through the water as it returns from the system Ensure no automatic air vents are used in the system This will allow air to escape from the system instead of returning to the tank Diaphragm Tank Ensure the system contains a minimum of one automatic air vent Recommended location of the air vent should be atop an air elimination devices Remove the tank from the system and check the charge pressure The charge pressure is typical ly 12 psig If tank does not hold a charge pres sure then the membrane is damaged and the tank should be replaced rr Maintenance Procedures Check Boiler Relief Valve Inspect the relief valve and lift the lever to verify flow at least annually or as recommended on the warning tag of the valve A WARNING Before manually operating the pressure relief valve ensure the discharge piping is directed to a suitable place of disposal to avoid a potential scald hazard The discharge piping must be full size without restriction and installed to permit com plete drainage of both the valve and line If after closing the valve the valve fails to seat properly or continually weeps replace the relief valve Ensure th
37. re insulation to hydronic junction as shown in Fig 23 rr Installation Boiler Mounting l Attach the boiler mounting brackets shipped with the boilers to the top front of the distribution mani fold using the hardware supplied see Figure 24 Ensure brackets are level Prestige Wall Bracket Supplied with Boiler 8 Fig 24 Prestige Wall Bracket Installations Remove the front doors from the boilers and care fully lift boilers by internal supply and return pipes Obtain assistance in lifting the boilers onto the boil er mounting brackets Make sure the boiler mount ing lip located along the upper edge of the rear boil er jacket panel engages the boiler mounting bracket Ensure each boiler is seated properly and is secure 4 TriangleTube NOTICE Remove the front door from all boilers before mount ing boilers on brackets Carefully lift boilers using the supply return pipes in the boilers onto the mounting brackets A WARNING Use extreme care not to drop the boiler or cause bod ily injury while lifting or mounting the boiler onto the bracket Once mounted verify that the boiler is securely attached to the bracket Failure to comply with the above guidelines could result in property damage personal injury or death Boiler Piping 4 TriangleTube SECTION IV BOILER PIPING General NOTICE Ensure that the maximum boiler and distribution manifold working pressur
38. s wih Weshera Nu a e e T concrete DST Te e BEST PRACTICE It s recommended to install Reverse Return with Valves to allow for isolation of an individual boiler for servicing 2 1 1 4 IN 4 0 5 5 Lo MT MT N O O A 81 3384 9 AQEL IS uruq Y JJO MUS UNA H A SIMOJ 66 OJOS 103 Wy euondo 97 214 g abed g aniy ses 4 TriangleTube 8 abed Z ainbi4 ees Pre Installation items Pre Installation items 4 TriangleTube Supplied in Standard Reverse Return Kits CRR Fig 17 Optional Kit Components for Solo 399 Boilers R R with Valves Supply Piping See Table 6 Supplied in Standard Reverse Return Kits CRR Fig 18 Optional Kit Components for Solo 399 Boilers R R with Valves Return Piping See Table 6 Table 6 Optional Kit Components for Solo 399 R R with Valves See Figures 16 18 Pages 17 amp 18 Item Kit Components PSCAS32 1 Boiler Quantity Pre Installation Items TriangleTube BEST PRACTICE The CRR models Reverse Return R R and the optional R R with Valves kit do not include any balancing valve s It is recommended to balance the flow through the individual R R boilers This balancing can be accomplished by installing a balancing valve on the return pipe of each boiler Table 7 Optional Kit C
39. t and heat conductive compound are supplied in the kit 3 Secure limit to well using clamp supplied with limit 4 Low water cut off control for each boiler will need to be positioned above the boiler combustion chamber 5 The standard field installed air vent and pressure relief valve configuration will need to be reposi tioned see Figure 27 Install Probe and Low Water Cut Off Control Fiping Assembly supplied with the Boiler Fig 27 Low Water Cut Off Installation TriangleTube 6 A 2 NPT brass tee will need to be installed at the top of each boiler utilizing 4 NPT brass close nip ple both supplied in kit Install tee with the branch portion facing horizontally 7 Low water cut off control and probe supplied in the kit should be installed vertically in the top flow through portion of tee 8 A 4 NPT brass nipple should be installed in the branch portion of the tee along with a brass 34 NPT 90 degree elbow both supplied in kit 9 The standard field installed air vent and pressure relief valve configuration supplied with the boiler should be installed in the top of elbow see Figure 27 Reverse Return R R In this installation a shut off valve will need to be installed on both the system supply and return connec tions A drain should also be installed before the system return shut off valve In this configuration the boilers cannot be individually isolated therefore a single low
40. ted above cannot be maintained for the Cascade or the enclosure in which the Cascade is installed is less than 85 cubic feet per Prestige Boiler the space must be ventilated see Prestige Installation and Maintenance Manual for ventilation requirements 4 TriangleTube Consult local codes for any additional clearance requirements Cascade Kit Components Prior to installation check to ensure all parts required for the completion of the Cascade are present See Figures 1 6 and Tables 1 and 2 pages 3 8 for complete break down of Solo 250 boiler cascade kit components See Figures 7 9 and Table 3 pages 9 10 for optional Solo 250 boiler reverse return with valve kit and kit compo nents See Figures 10 15 and Tables 4 and 5 pages 11 16 for complete breakdown of Solo 399 boiler cascade kit components See Figures 16 18 and Table 6 pages 17 18 for optional Solo 399 boiler reverse return with valve kit and kit components See page 19 for optional kits and kit components for both Solo 250 amp 399 boilers Operating Restrictions e Maximum water temperature 15 200 F e Maximum working pressure for PRESTIGE Solo 250 Boilers is 30 psig e Maximum working pressure for PRESTIGE Solo 399 Boilers is 30 psig Maximum working pressure for PRESTIGE Solo 399HP is 80 psig Maximum working pressure for Cascade Manifold is 80 psig e and chloride limits for water heaters are chloride less than 150 mg l ppm pH valu
41. terials or flammable vapors or liquids Remove immediately if found Check System Piping Inspect water piping on the Cascade system for leaks and verify that the piping 1s leak free and properly sup ported Inspect the fittings and components on the unit and ver ify they are leak free A WARNING Eliminate all boiler water system leaks Continual fresh make up water will reduce the heat exchang er life causing boiler failure Leaking water may also cause severe property damage to the sur rounding area 4 TriangleTube Check Boiler Cascade System Verify all system components are correctly installed and operating properly Check the cold fill pressure for the system typical cold water fill pressure is 12 psig Verify the system pressure as the unit operates at high temperature to ensure the pressure does not exceed 25 psig Standard Cascade or 75 psig High Pressure HP Cascade Excessive pressure reading indicates expan sion tank sizing is incorrect or system performance prob lems Inspect air vent and air separators in the system Remove the caps on automatic air vents and briefly depress the valve stem to flush vent Replace the cap when complet ed Ensure vents do not leak replace any leaking vents Check Expansion Tank Refer to Section VI System Piping for recommended location of the expansion tank and air elimination devices Closed Type Tank Ensure tank is partially filled with wate
42. the system return piping which is also opposite the top blind flange Blind Flange Fig 22 Blind Flange Manifold Installation 4 TriangleTube 5 Install ANSI to 3 NPSC connection flanges to the system supply top and system return bottom con nections utilizing the gasket and hardware supplied Multiple Distribution Manifolds The maximum number of boilers that can be piped using multiple Cascade Distribution Manifolds is five When connecting multiple manifold a 2 Boiler Distribution Manifold with another 2 Boiler Distribution Manifold or with a 3 Boiler Distribution Manifold utilize the gas kets and hardware supplied in kits to join the two mani folds Installation Hydronic Junction The hydronic junction serves as a low loss header provid ing hydraulic separation dirt separation and air elimination NOTICE When utilizing a hydronic junction the mixed system supply temperature can be calculated as follows Boiler Supply Temp x Boiler Flow Rate System Supply en O o System Flow Rate 525 System Flow Rate Boiler Flow Rate Flow Rate When the boiler Cascade flow rate does not equal the system flow rate the total heat output of the boil ers Cascade will be absorbed by the system when the following conditions are met The boiler Cascade supply temperature is greater than the system supply temperature The boiler Cascade flow rate is less than the system flow rate T
43. water heater Fig 28 System Piping Component Symbols 3 way thermostatic mixing valve union float type air vent swing check valve spring loaded check valve purging valve pressure gauge metered balancing valve pressure relief valve temperature pressure relief valve TriangleTube diaphragm type expansion tank brazed plate heat exchanger System Piping lt q TriangleTube Flovv System A Return Fig 29 System Piping Cascade P S with Banks of Equal Number of Boilers System Piping 0 TriangleTube Flow System Check Supply Valves System Return Balancing t Valve Fig 30 System Piping Cascade P S with Banks of Uneven Number of Boilers 4 TriangleTube iping System P SAJEA p jeos Hue rr Ru Aiddns sayem you puondo Lee PS dal Te LE E Ajddns Jayem pjos peo diay JaMo 03 n ree m 17 SAJEA T EE doo fuewuud SAS ZH2 T d ji Tm un Wi Tei Josuas 222 o 1018 N3 119 Wajs s Agewud df peoj dua Jayo o3 HIE KAEpuo2 s SULIIA 98198914 103 g ased pe 014 IIS APIS Ja Se Cascade P S iping System Pi Fig 31 TriangleTube iping System P pjgas nue E 5 Ajddns sayem yoy T guondo UONE DE
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