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INSTALLATION AND OPERATING INSTRUCTIONS
Contents
1. SLI 2 601 HLIM 38 LSNW 11 032 1434 LSNW JHL HLIM 31144056 SV 3 91 0 1 40 4 034100384 SY NOI LIFLONd AVOTYIAO SNYIW 123 02510 1 540123 02 Q3Z 1HY 10d 311 3114405 012 4 31144405 5 3 13 50 3 YIM qaim 131 4 3 19 1112019 QAVO NO 563 545 3719 143934 NO 9014 LdO MO 5 aaa 5 9 1100419 LVLSONU3HL WALSAS LVLSONY3HL GA is Se 1 Ss lt H LIMS MOTTAA 15 0 or dial 34055344 1 1123 2 HIH JOVLIOA 5 1 1 00 2990 6 8 4 9151 120 gt gt HOLW INDY 19 ea YOLON 831108 OV TE YOLIND 104 LNOO 9 394505 LOH 931 SLNN 341M LOH LOH LOH NANA Tg WaLnaN 1 193 30951 A 021 l l WYLNaN A 021 V L qnnowo 122
2. Check power wiring to electronic board hot wire to L1 neutral to L2 ground wire in junction box and to electronic board Check flame sensor current with microampmeter see How To Do It on page 24 Remove flame sensor from boiler see How To Do It on Page 24 Check for cracked wet ceramic insulator or bent burned coated kanthal rod If no pressure check for gas shutoff by utility If valve not opening replace valve Replacement must be same manufactur er and model Calibrate new valve as shown in Operation Procedures on page 16 If pressure reading is incorrect adjust gas valve as shown in Operation Procedures on page 16 If size not correct contact Slant Fin Tech nical Services Department Correct all wiring connections If reading is below 1 microamp continue with No Ignition troubleshooting If defective replace flame sensor Replacement must be same manufactur er model and length DIAGNOSTIC 3 FLASHES PRESSURE SWITCH PROBLEM Check wiring connections to pressure switch Wires go to Normally Open N O and Common C connections on switch Check for loose blocked tubing connections to pressure switch loose blower hose connection loose blower wheel Check for blocked air filter vent terminal or vent tubing Check blower calibration as shown in Operation Proce dures on page 16 Check pressure switch calibration see How To Do It on page 24 Check that
3. 02514 TWULNAN 17980 5 01123 02 01314 39 110 3 11 10H AVYOVIG 831108 3413 SVO 10 4010044 INVYSVIC QUENCE OF OPERATIO THERMOSTAT CALLS FOR HEAT WAIT FOR CONDITION TO CHANGE CLEAR FAULT CLEAR FAULT RE TRY OPERATION NO FURTHER ACTION RE TRY OPERATION FAULT DISPLAYED NO FAULT DISPLAYED DISPLAY FAULT YES HIGH LIMIT OPEN OVER 1 HOUR NO gt CIRCULATOR gt 5 NO BLOWER OFF gt CIRCULATOR CONTINUES To RUN gt _DISPLAY FAULT SWITCH OPEN COMPLETE CIRCULATOR CIRCULATOR AND BLOWER 3 TRIALS CONTINUES TO RUN CONTINUE TO RUN gt CHECK BLOWER OFF RPM DISPLAY FAULT CIRCULATOR CONTINUES TO RUN BLOWER OFF DISPLAY FAULT CIRCULATOR AND BLOWER CONTINUE TO RUN gt PRESSURE BLOWER PREPURGE 10 SEC HOT SURFACE IGNITOR ON IGNITOR WARM UP 10 SEC NO CIRCULATOR IGNITOR CURRENT CIRCULATOR AND BLOWER 3 TRIALS CONTINUES TO RUN CHECK CONTINUE RUN TO CHECK BLOWER OFF DISPLAY FAULT OK YES GAS VALVE OPEN 4 SEC IGNITOR OFF ma CIRCULATOR COMPLETE CONTINUES TO RUN 3 TRIALS TO DETECT FLAME FLAME DETECTED 2 BLOWER OFF DISPLAY FAULT THERMOSTAT SATISFIED GAS VALVE CLOSED CIRCULATOR OF
4. IMPORTANT READ ALL OF THE FOLLOWING WARN INGS AND STATEMENTS BEFORE READ ING THE INSTALLATION INSTRUCTIONS WARNING LIQUEFIED PETROLEUM L P PROPANE GAS FIRED BOILERS Installation location ONLY as permitted in paragraph entitled LIQUEFIED PETROLEUM L P PROPANE GASFIRED BOILER LOCATION on page 4 of this instruction book The above warning does not apply to NATURAL gas fired boilers The installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 latest edition or CAN CGA B149 1 M95 or latest edition for natural gas and CAN CGA B149 2 M95 or latest edition for propane The installation must also conform to the additional requirements in this Slant Fin Instruction Book In addition where required by the authority having juris diction the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers No CSD 1 or CAN CGA B149 1 M95 or latest edition for natural gas and CAN CGA B149 2 M95 or latest edition for propane If there is any conflict in the above requirements then the more stringent requirement will apply WARNING This boiler gas piping and accessories must be installed connected serviced and repaired by a trained experienced service technician familiar with all precautions required for gas fire
5. Pressure measurement gauge Magnehelic or Incline differential pressure gauge with 0 25 mm 0 1 0 w c range and 0 5 mm 0 02 increments recom mended Available from Slant Fin is a calibration gauge kit part number 665185 that has a gauge mounted stand with a toggling feature which allows the user to switch between the blower and gas valve calibration without moving the tubing connections Tubing and connectors for gauge Need 2 lengths of 5 mm 3 16 I D plastic tubing with female adapters which mate to the service fittings e Mount gauge securely within reach of all tubing Make sure it s level so the meter indicates zero or can be adjusted to do so HI LO sides marked on the gau ge Calibration also requires using boiler Operation Selector Switches and Blower Speed Adjustment Pots located on the Electronic Boiler Control Board see Figure 23 Figure 24 Locations of pressure measurement fittings GAS VALVE OUTLET VALVE ADJUSTMENT SCREW FITTING Basic Operating Principle The gas valve on the Prodigy 21 boiler is coupled to the combustion blower so that the gas flow is proportional to the air flow even under the most adverse conditions This insures a high level of safety and reliability when the fol lowing Operation Procedures are carefully followed Note that the proper input is obtained by adjusting the combus tion blower speed for a certain air flow which will fee
6. 2 The minimum quantity of venting for both models is one elbow plus the length required to pass through back wall to the termination 3 Up to 5 90 elbows may be used over the length of the vent system provided the proper pitch is maintained in the vent system to prevent conden sate accumulation When joining the various components of the vent sys tems listed on page 10 the manufacturers instruc tions should be closely followed to insure proper seal ing Use GE RTV106 or Dow Corning 732 sealant for sealing of pipe and fittings See Figure 4 for proper application of vent pipe sealant C All vent connections must be liquid and pressure tight VENT INSTALLATION A Follow the vent material manufacturer s instructions in conjunction with these instructions for venting system installation B Refer to Figures 4 and 14 which illustrate some of the requirements for venting in a typical installation C A condensate drain and drain trap MUST be installed on the flue tubing see Figure 14 The con densate drain should be installed close to the boiler as shown and must be equipped with a trap formed by attaching 10 mm 3 8 clear plastic tubing to the drain assembly making a loop approximately 102 mm 4 diameter and securing with cord or a tie wrap where the loop crosses over itself This loop should then be filled with water to form a liq uid filled trap DO NOT OPERATE THE BOILER WITHOUT INSTALLING THIS TRAP
7. Flue Connector 76 3 6 2 2 2 152 6 Provide 457 18 sides used for passage All minimum clearances shown above must This may result in increased values of some minimum clearances in order to maintain the minimum clear ances of others D Clearance from hot water pipes shall be 25 mm 1 At points where hot water pipes emerge from a floor wall or ceiling the clearance at the opening through the finished floor boards or wall or ceiling boards may not be less than 13 mm 1 2 Each such opening shall be covered with a plate of noncombustible material WALL MOUNTING BOILER Before installing the boiler on the wall review the fol TO INSTALL BOILER ON WALL lowing parameters and decide on a location which will 1 allow all of their requirements to be met Hold mounting panel on wall with the boiler mounting studs facing out in the location where boiler will be positioned and level wall panel If the 1 Boiler location requirements on page 3 wall is of frame construction locate wall studs for 2 Connections to electrical gas and water supply mounting 3 Venting application Direct Vent or Category IV 4 Direction which venting will exit boiler through rear 2 Mark the mounting bolt holes for wall panel on wall or to either side of jacket wall If the boiler is to be vented directly out the a For rear wall venting the wall passage cutout back of the wal
8. direct venting utilizing the following configurations 1 Vent and air intake piping vertically run up through a roof in close proximity a For a pitched roof installation refer to Figure 10 For a flat roof installation refer to Figure 11 When floor and ceiling passage is necessary refer to Figure 9 Adhere to all clearances and materials specified in these illustrations b The stainless exhaust vent pipe must pass through the roof vertically through a 178 mm 7 min diameter cutout and appropriate roof flash ing The pipe must exhaust straight up and termi nate with a screen terminator c The air intake pipe must pass through the roof vertically The cutout does not require any clear ance but must be sealed with a flashing or other means The air intake opening must face down by using a 180 elbow with a screen positioned at the opening The air intake opening must be at least 305 mm 1 foot below the vent opening Figure 9 Floor and ceiling venting passage All items shown below are REQUIRED All vent joints must be LIQUID and PRESSURE TIGHT FIRESTOP EXHAUST VENT AIR INTAKE TUBING 76 mm TUBING 3 1 0 76 mm 3 1 0 CLEARENCE 152 mm 6 MIN FOR 29 4C STAINLESS STEEL VENTING CLEARENCE 51 mm 2 MIN BETWEEN TUBING FIRESTOP AND SUPPORT Figure 10 Vent and air intake run through a pitched roof EXHAUST WITH SCREEN AIR INTAKE 3048 mm 10 180 ELBOW WITH OR LES
9. 9mm 3 8 FROM THE EDGE OF THE MALE END CARE MUST BE TAKEN TO ASSURE THAT ADHE SIVE DOES NOT BLOCK INSIDE OF PIPE DO NOT APPLY ADHESIVE INSIDE OF FEMALE FITTINGS IN ORDER TO PRE VENT BLOCKAGE OF INSIDE OF FITTINGS AND TUBING IF ANY ADHESIVE SHOULD GET INSIDE BE SURE TO WIPE IT OUT BEFORE ASSEMBLING Figure 14 Typical vent piping from boiler for Category IV CONTINUE WITH VENT PIPING AS SHOWN FOLLOWING FIGURES SLOPE UP 20 mm m 1 4 PER FT FILL TRAP WITH WATER TO DRAIN amen 83 BOILER Figure 15 Vertical Category IV venting through roof 3048 mm 10 FT OR LESS VENT TERMINATION WITH SCREEN 3048 mm 10 FT MAX 22222024 FIRE STOP SUPPORT 152 mm 6 MIN CLEARANCE NERA SS FIRE STOP ANO Aa VILL LLL LLL SRA AAA SA CONDENSATE TO DRAIN ORAIN ASSY VERTICAL CATEGORY IV VENTING All Prodigy 21 boiler models are certified for vertical Category IV venting through a roof provided the follow ing conditions are met 1 For roof passage of vent piping a UL listed roof flashing must be used 2 The vent piping must terminate with a screened tee elbow straight or cap termination at the minimum distance from the roof shown in Figure 15 Figure 17 Horizontal Category IV venting through outside wall VENT TERMINATION WITH SCREEN 4 MIN J VENT PIPE SLOPE UP
10. AND FILLING WITH WATER TO PREVENT FLUE GAS DIS CHARGE INTO SPACE Periodic inspection should be made of this assembly for deterioration of the tubing and to insure that the trap is filled with water but not plugged If it is plugged or appears to have excessive sediment in it it should be removed from the drain assembly straightened out to clear the obstruction reformed filled with water and rein stalled as before The drain must extend to a floor drain D The horizontal pipe must be sloped UPWARD from the boiler at a pitch of 20 mm m 1 4 per 1 foot of run so that the condensate from the vent system runs to the drain trap The horizontal portion must also be supported with 19 mm 3 4 pipe strap at intervals no greater than 1829 mm 6 feet E The vertical portion of the pipe must be supported in at least one location for each 9 m 30 feet of ver tical run A firestop is required for each wall ceiling and floor penetration F Use tabs on vent collar to secure stainless steel vent tubing to the boiler G Venting is approved for combustible wall passage through a 102 mm 4 minimum to 305 mm 12 maximum thick wall providing a thimble is used Figure 4 Vent sealing instructions Consult vent manufacturer s instructions VENT SEALING INSTRUCTIONS FOR HEAT FAB 29 4C STAIN LESS STEEL VENTING MATERIALS APPLY ADHESIVE BEAD 6mm 1 4 DIA MINI MUM AROUND OUTSIDE OF MALE END ONLY BETWEEN 6mm 1 4 AND
11. and air intake run horizontally out a vertical wall EXHAUST WITH SCREEN 10 FT OR LESS 305 mm 1 FT MIN 288 TOP PLATE AIR INTAKE 90 ELBOW WITH SCREEN FACE DOWN RUN AIR INTAKE PIPE THROUGH THE FOUNDATION OR AN EXTERIOR WALL SNOWL INE 305 mm 1 FT MIN GROUNDL INE AN SEAL CHIMNEY OPENING WITH_MORTAR OR COVER PLATE CONDENSATE DRAIN ASSY CATEGORY VENTING REQUIREMENTS BOILER ROOM AIR SUPPLY AND VENTILATION An ample supply of air is required for combustion and ventilation When buildings are insulated caulked and weather stripped now or later on direct openings to outside may be required and should be provided If the boiler is not near an outside wall air may be ducted to it from outside wall openings Provisions for combustion and ventilation air must be made in accordance with section 5 3 Air for Combus tion and Ventilation of the National Fuel Gas Code ANSI Z223 1 latest edition or CAN CGA B149 1 M95 or latest edition for natural gas and CAN CGA B149 2 M95 or latest edition for propane or applicable provi sions of the local building codes The following recom mendation applies to buildings of energy saving con struction fully caulked and weather stripped Provide one GRILLED opening near the floor and one near the ceiling on an outside wall near the boiler or duct from such openings to the boiler EACH opening to be a mini
12. boiler behind the boiler jacket right side cover The tab is stamped for the model of each boiler it is to be installed on IMPORTANT Reorificing for altitude change is NOT necessary on this Prodigy boiler 25 LIGHTING INSTRUCTIONS Reference For Labels 65 0645 FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage per sonal injury or loss of life A This appliance does not have a pilot It is equipped with an ignition device that automatically lights the burner DO NOT try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS DO NOT try to light any appliance DO NOT touch any electric switch DO NOT use phone in your building OPERATING INSTRUCTIONS STOP Read the safety information above on this label Set the thermostat to lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the burner DO NOT try to light the burner by hand Remove boiler front cover Depress and move gas control selector arm left to OFF position Note Arm cannot be turned to OFF unless arm is pushed in slightly DO NOT force Wait five 5 minutes to cl
13. close 18 STEP E SETUP BOILER FOR AUTOMATIC OPERATION Remove jumper from across T1 T2 terminals and reconnect wires to control board T1 T2 and A1 A2 ter minals properly Restore zone valves to automatic operation e Set thermostat s to call for heat e Set selector switches to AUTO OP and HI TEST COMMON VENTING SYSTEM IF REQUIRED If existing boiler was removed from a common venting system common venting system may be too large for proper venting of appliances remaining connected to it At the time of removal of existing boiler the following steps shall be followed with each appliance remaining connected to common venting system placed in opera tion while the other appliances remaining connected to the common venting system are not in operation 1 Seal any unused openings in common venting system 2 Visually inspect venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of build ing Turn on clothes dryer and any appliance not con nected to common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed DO N
14. high fire or LO for low fire in small increments clockwise to increase input or coun terclockwise to decrease input Allow for stabilization of operation between adjustments SYSTEM TESTING STEP D CHECK SYSTEM OPERATION Purge air one final time Let system water reach 160 Temperature pressure gage should be between 83 kPa and 172 kPa 12 and 25 psi e Bleed all air vents until water squirts out start on lowest floor with first air vent in the line of flow Check exhaust and air intake venting e Check for and reseal any vent tubing leaks Check for and remove any vent terminal obstruc tions Check gas valve operation with burner firing USE CAUTION LINE VOLTAGE PRESENT Disconnect flame sensor wire lead from flame sensor tab See Fig 25 for location Gas valve should close It is normal for boiler to re try for ignition times with wire removed from flame sensor but gas valve should only open for 4 seconds during each re try and be closed between trials Replace flame sensor wire lead on flame sensor tab If fault shown after trials complete cycle thermostat or power off on to clear Check high limit operation HIGH LIMIT CANNOT BE SET BELOW 82 C 180 F HIGHEST MAXIMUM ALLOWABLE SETTING IS 104 C 220 F e Set thermostat high enough for the water tempera ture to reach limit switch setting of 82 C 180 F e When reached limit switch should open and gas valve should
15. intake or separate from the combustion air intake means Category IV The air for combustion is taken from the ambient air surrounding the boiler The vent piping may be run horizontally or vertically to the outdoors The vent pressure is typically positive in this application The following venting installation requirements are divided into 2 sections each pertaining to the 2 differ ent applications described above Once the appropri ate venting application has been selected follow only the requirements specified under that section for vent ing the boiler These requirements must be carefully read and followed in order to avoid any hazardous conditions due to improper installation of the flue gas venting system DIRECT VENTING REQUIREMENTS VENT LOCATION Vent installations shall be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI 2223 1 CAN CGA B149 1 M95 or latest edi tion for natural gas and CAN CGA B149 2 M95 or latest edition for propane or applicable provisions of local building codes Vent termination must meet the following clearances Minimum of 305 mm 12 above grade and normal snow line to vent terminal bottom minimum of 305 mm 12 from any building opening minimum of 914 mm 3 feet above any forced air intake located within 3048 mm 10 feet minimum of 1219 mm 4 feet hori zontally from and in no case above or below unless 1219 mm 4 foot horizontal distanc
16. length requirements specified in this section also apply to the air intake piping C Seal all joints on air intake piping using appropriate sealants VENTING INSTALLATION A Follow the vent material manufacturer s instructions in conjunction with these instructions for venting system installation B Refer to Figures 4 5 and 9 which illustrate some of the requirements for venting in a typical installation C On all installations other than where the vent passes through the wall directly out the back of the boiler a condensate drain and drain trap MUST be installed on the flue tubing see Figure 5 The con densate drain should be installed close to the boiler as shown and must be equipped with a trap formed by attaching 10 mm 3 8 clear plastic tubing to the drain assembly making a loop approximately 102 mm 4 diameter and securing with cord or a tie wrap where the loop crosses over itself This loop should then be filled with water to form a liq uid filled DO NOT OPERATE THE BOILER WITHOUT INSTALLING THIS TRAP AND FILLING WITH WATER TO PREVENT FLUE GAS DIS CHARGE INTO SPACE Periodic inspection should be made of this assembly for deterioration of the tubing and to insure that the trap is filled with water but not plugged If it is plugged or appears to have excessive sediment in it it should be removed from the drain assembly straightened out to clear the obstruction reformed filled with water and rein
17. pressure switch contacts are open between N O and C when blower is OFF Correct all wiring connections Secure all loose connections Tighten blower wheel set screw Remove obstruc tions Replace or clean filter If pressure readings are incorrect adjust blower speed as shown in Operation Pro cedures on page 16 If switch is defective replace switch with same manufacturer model and calibration Observe orientation of clear tubing con nections when replacing Refer to Replacement Parts information on TROUBLESHOOTING POSSIBLE CAUSES AND SOLUTIONS page 27 when parts need to be replaced DIAGNOSTIC 4 FLASHES HOT SURFACE IGNITOR FAILURE CAUSE TEST Electrical Wiring Check wire connections from ignitor Hot Surface Ignitor Turn power OFF Carefully remove ignitor from boiler see Tip or Ceramic How To Do It on page 24 Check for cracks breakage Insulator Is Broken Hot Surface Ignitor Energize ignitor while outside of boiler BE CAREFUL OF Is Defective HOT TIP DO NOT allow hot tip to come in contact with your hand or any other objects Turn off gas valve to pre vent gas from exiting ignitor opening and igniting outside of boiler Observe glow on ignitor tip SOLUTION Tighten all wiring connections If defective replace ignitor Replacement must be same manufacturer model and length If tip does not glow quickly and strongly replace ignitor Replacement must be same manufacturer model and
18. stalled as before The drain must extend to a floor drain D The horizontal pipe must be sloped UPWARD from the boiler at a pitch of 20 mm m 1 4 per 1 foot of run so that the condensate from the vent system runs to the drain trap The horizontal portion must also be supported with 19 mm 3 4 pipe strap at intervals no greater than 1829 mm 6 feet E The vertical portion of the pipe must be supported in at least one location for each 9 m 30 feet of ver tical run A firestop is required for each wall ceiling and floor penetration F Use tabs on vent collar to secure stainless steel vent tubing to the boiler G Venting is approved for combustible wall passage through a 102 mm 4 minimum to 305 mm 12 maximum thick wall providing a thimble is used Figure 5 Typical direct vent side passage INDOOR WALL PLATE SLOPE UP 20 mm m 1 4 PER CONDENSATE DRAIN ASSY ON VENT HE TIGHT RADIUS 90 VENT ELBOW cur TO LENGTH gt a Pins B DIRECT VENTING WITH VENT TERMINAL All Prodigy 21 boiler models are certified for horizontal direct venting utilizing the vent terminal provided by Slant Fin only This vent terminal must be mounted on a vertical wall outside surface Terminal CANNOT be mounted on a roof or any horizontal surface Vent terminal is designed to deflect flue gases from outside building wall properly installed it will prevent flue gas degradation of normal building m
19. the vent system to prevent conden sate accumulation B When joining the various components of the above listed vent systems the manufacturers instructions should be closely followed to insure proper sealing Use GE RTV106 or Dow Corning 732 sealant for sealing of pipe and fittings See Figure 4 for proper application of vent pipe sealant C All vent connections must be liquid and pressure tight Figure 4 Vent sealing instructions Consult vent manufacturer s instructions VENT SEALING INSTRUCTIONS FOR HEAT FAB 29 4C STAIN LESS STEEL VENTING MATERIALS APPLY ADHESIVE BEAD 6mm 1 4 DIA MINI MUM AROUND OUTSIDE OF MALE END ONLY BETWEEN 6mm 1 4 AND 9mm 3 8 FROM THE EDGE OF THE MALE END CARE MUST BE TAKEN TO ASSURE THAT ADHE SIVE DOES NOT BLOCK INSIDE OF PIPE DO NOT APPLY ADHESIVE INSIDE OF FEMALE FITTINGS IN ORDER TO PRE VENT BLOCKAGE OF INSIDE OF FITTINGS AND TUBING IF ANY ADHESIVE SHOULD GET INSIDE BE SURE TO WIPE IT OUT BEFORE ASSEMBLING AIR INTAKE 76 mm 3 diameter PVC piping materials are ommended Sewer and drain type material or PVC Schedule 40 piping are best suited for connection to boiler and vent terminal Use 76 mm 3 PVC fit ting provided with vent kit to adapt PVC Schedule 40 air intake tubing to air filter box collar The fitting provided will fit onto the filter box collar and then a Schedule 40 76 mm 3 coupling will fit over that B The venting
20. time completion open all return shut off valves Standing cast iron radiation and systems with manual vents at high points Close all shut off valves drain valves and air vents e Open supply and return shut off valves If zoned with zone valves manually open all zone valves e Open fill line shut off valve Manually operate fill valve regulator Open pressure relief valve manual operator to fill boiler When water runs out of discharge pipe in a steady stream with no air bubbles close operator e Starting with nearest manual air vent open vent until water flows out close vent Repeat procedure work ing your way toward farthest air vent When finished e Place fill valve regulator and all zone valve operators in automatic position e Check that temperature pressure gage reads mini mum of 83 kPa 12 psi fill pressure cold If piping system rises more than 4 6 m 16 feet vertically above boiler higher fill pressures are required e Check for and repair any water leaks Length Gas Flow In Piping GAS PIPING of Pipe Pressure Drop 8mm 3 in water Specific Gravity 0 60 A Local installation codes apply The pipe joint com Iron Pipe Size Ips pound used on threads must be resistant to the fli fied 13mm 1 2 19mm 3 4 25mm 1 32 1 1 4 38mm 1 1 2 B saa or que lec petroleum gases cu ft hr m hr cu ft hr m hr cu ft hr m hr cu f
21. to the left or to the right of the flue exhaust tubing b If the air inlet tubing is going to be to the left of the flue exhaust viewed from outside of build ing then the vent terminal should be installed as supplied without alteration If the air inlet tubing is going to be to the right of the flue exhaust viewed from outside building then the air inlet cover plate must be removed and reinstalled over the alternate set of slots This alteration will insure that the air inlet slots face down when the vent terminal is installed 4 Vent terminal installation see Figure 8 a Center the vent terminal over the wall cutout The collar on the back of the vent terminal panel should clear the cutout edges by about 13 mm 1 2 Figure 8 Vent terminal installation AIR INTAKE TUBING WALL CUTOUT Shown from top view b Mark and drill out the location of the four screw holes in the wall for mounting vent terminal c Seal the vent collar adapter tube 76 mm 3 dia male end stainless into the collar on the back of the vent terminal box and slide the ring on the tube over the collar tabs then bend the tabs back over the ring This piece will allow easy connection of the flue exhaust tubing from inside the building On installations where vent passes through the wall directly out of the back of boiler measure the length of the tube needed to fit into the elbow on the boiler flue collar This piece can be cut to length a
22. 18 Water piping Note Orientation of piping drawn for clarity Observe relative location of components AUTOMATIC AIR VENT IEF VALVE EXPANSION TANK CONNECTOR TUBE ZONE VALES OR ALTERNATE PUMP LOCATION lt E SURE REDUCING VALVE s BACKFLOW PREVENTER IF REQUIRED Te VALVE on PIPE WATER PIPING Always follow good piping practices Observe minimum 25 mm 1 clearance to combustibles around all uninsu lated hot water pipes or when openings around pipes are not protected by noncombustible materials Factory installed low water cutoff will shut off boiler in the event water falls below the lowest safe water level Boiler must not be used in connection with a refrigera tion system If the boiler supplies hot water to heating coils in air handling units flow control valves or other devices must be installed to prevent gravity circulation of boiler water in the coils during the cooling cycle Expansion tank Install into water outlet manifold as shown in Figure 18 Piping systems with unusually large water volume may require the connection of a larger capacity expansion tank outside of the boiler s enclo sure Relief valve discharge piping Use same size or larger piping iron or copper than valve outlet Must terminate 152 mm 6 from floor or local codes with a plain no threads end DO NOT hard pipe to drain piping Make sure discharge is always visible Cold water fill Pres
23. 20 mm m 1 4 PER FT Figure 16 Vertical Category IV venting up an existing chimney VENT TERMINATION WITH SCREEN 305 mm 1 FT MIN 28 CHIMNEY TOP PLATE SLOPE UP 20 mm m 1 4 PER ee NI SEAL CHIMNEY OPENING WITH MORTAR OR COVER PLATE U N ASSY All Prodigy 21 boiler models are certified for vertical Category IV venting up an existing chimney provided the following conditions are met 1 To utilize an existing chimney as a chase the vent pipe must extend the total length of the chimney The top of the chimney must be sealed off around the protruding pipe with an appropriate plate or flashing 2 The vent piping must terminate with a screened tee elbow straight or cap termination at the minimum distance from the roof shown in Figure 16 3 Other appliances CANNOT be vented into the same chimney or vent pipe within the chimney HORIZONTAL CATEGORY IV VENTING All Prodigy 21 boiler models are certified for horizontal Category IV venting provided the following conditions are met 1 For combustible wall passage of vent piping a UL listed thimble must be used providing the wall thickness is 102 mm 4 minimum to 305 mm 12 maximum 2 The venting piping must terminate with a screened tee elbow or straight termination at the minimum distance from the outside wall shown in Figure 17 Figure
24. F GAS VALVE REMAINS CIRCULATOR CONTINUES TO RUN BLOWER RUNS AT HIGH OR LOW SPEED DEPENDING ON DIP SWITCH SETTING OR AUTOMATIC HEAT DEMAND BLOWER POST PURGE 5 SECONDS BLOWER OFF 20 TROUBLESHOOTING ilure Codes Continuous Flashing DIAGNOSTIC INDICATOR LIGHT RED Boiler Fa Carefully note red diagnostic indicator light When a system failure occurs indicator light will show a series 1 Flash of quick flashes with a short interval between the 2 Flashes series when indicator stops flashing Count the num 3 Flashes ber of flashes that occur after the short no flashing 5 interval Correct failure code for each number of flash es is shown in box 6 Flashes 7 Flashes If the diagnostic light is off when service technician arrives set thermostat to call for heat Boiler will attempt restart Boiler also attempts restart each hour during failure mode and after a power interruption If the boiler restarts the diagnostic light will stay off If the boiler does not restart the diagnostic light will return to either Steady On or the series of flashes Figure 25 Boiler components for troubleshooting SECONDARY WATER HI LIMIT OPTIONAL INDICATOR TEMPERATURE PRESSURE GAGE AIR_PRESSURE SWITCH HOT SURFACE 16 AND FLAME DETECTOR BURNER ENCLOSURE GAS VALVE Electronic control failure High limit open 1 hour No ignition Pressure switch problem Hot surface i
25. OCK OR DEATH CAN RESULT WARNING DO NOT USE BOILER TRANSFORMER TO POWER EXTER NAL ACCESSORIES I E ZONE VALVES RELAYS OVERLOADED BURNED OUT TRANSFORMER CAN RESULT Boiler must be electrically grounded in accordance with the requirements of the authority having jurisdic tion or in the absence of such requirements with the National Electrical Code ANSI NFPA 70 or the Cana dian Electrical Code CSA C22 1 Part 1 latest edi tion Power supply A separately fused circuit is recom mended Use a standard 15 amp fuse or breaker and 14 gauge conductors in BX cable or conduit Thermostat connections The boiler will run at high or low fire depending on space heating needs when the T1 and T2 terminals are closed Connect low voltage wiring from space heating zones to T1 and T2 termi nals on control board Wire connections to T1 and T2 terminal block must be from an isolated circuit DO NOT BRING VOLTAGE FROM AN EXTERNAL SOURCE HERE Wires should be only run from ther mostats zone valve end switches or circulator end switches 3 wire zone valves which do not have isolat ed end switches cannot be used unless a relay is added with the dry contacts wired to T1 and T2 Thermostat heat anticipator For zoned system set to match amp draw of zone valve or circulator relay For a non zoned system set to 3 amps Circulator relay on board DO NOT exceed 5 amp 120V max rating Power Connections Remove electrical junc
26. OT operate a summer exhaust fan Close fireplace dampers 4 Place in operation the appliance being inspected Fol low the lighting instructions Adjust thermostat so appliance will operate continuously 5 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from cigarette cigar pipe 6 After it has been determined that each appliance remaining connected to common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliances to their previous condition of use 7 Any improper operation of common venting system should be corrected so installation conforms with National Fuel Gas Code ANSI 2223 1 or CAN CGA B149 1 M95 or latest edition for natural gas and CAN CGA B149 2 M95 or latest edition for propane When resizing any portion of the common venting system common venting system should be resized to approach minimum size as determined using appropriate tables in Part II in National Fuel Gas Code ANSI 2223 1 or CAN CGA B149 1 M95 or latest edition for natural gas and CAN CGA B149 2 M95 or latest edition for propane 19 ONIOIAMAS NOILVYadO YadOYd 44143A 2 1790 49 NOI LVYadO 5 ANY 35 2 NYO STOYNLNOD ONIDIAYAS 01123 09510 OL XOl d SAMIM T1 138 1 2 0110 2
27. S SCREEN FACE DOWN 305 mm 1 610 mm 2 FT MIN MIN 914 mm MIN 8305 mm 1 FT SNOWLINE ROOFLINE 51 mm 2 MIN o ape 51 mm 2 MIN Figure 11 Vent and air intake run through a flat roof EXHAUST WITH SCREEN AIR INTAKE 180 ELBOW WITH SCREEN FACE DOWN 7 mm 1 FT MIN 305 mm 305mm 1 FT 1 FT MIN MIN 3048 10 OR LESS FLASHING 51 mm 2 MIN m 51 2 MIN 2 Vent piping run vertically up through a roof and air intake run horizontally out a vertical wall a See Figure 12 for general configuration For a pitched roof installation refer to vent pipe requirements shown in Figure 10 For a flat roof installation refer to the vent pipe requirements shown in Figure 11 When floor and ceiling pas sage is necessary refer to Figure 9 Adhere to all clearances and materials specified in these illustrations for installing the vent pipe only For installing the air intake pipe refer to the air intake requirements shown in Figure 12 b The stainless exhaust vent pipe must pass through the roof vertically through 178 mm 7 min diameter cutout and appropriate roof flash ing The pipe must exhaust straight up and termi nate with a screen terminator c The air intake pipe must pass through a vertical wall or foundation horizontally The cutout does not require any clearance but must be sealed with a flashing or by other mea
28. SURE NUTS LOCATION AIR AND GAS ORIFICES Figure 28 Convertible gas orifice installation BURNER AIR ORIFICE PLATE WITH GASKETS AIR ORIFICE 1 D BOILER MODEL ENCLOSURE MODEL PROPANE ORIFICE SCREWS STRAIGHT FLANGE Note These Prodigy boilers utilize the same air and gas orifices as the Slant Fin Concept 21 series boilers Therefore the model number shown on the orifice plates reflect the Concept boiler model numbers and correlate to the Prodigy boiler models as follows Prodigy 21 Model Use orifice plates with I D tab marked 45 S marked 90 S GAS ORIFICE PLATE ORIENTATION 1 The gas orifice plate contains both the natural gas orifice hole and the propane gas orifice hole to pro vide for a fast and simple conversion to either gas use 2 Each gas orifice hole on the plate has tab located adjacent to it The tab specifies the boiler model and type of gas for each orifice The larger hole in the plate is always the natural gas orifice hole and is adjacent to the 1 0 tab that is stamped NAT The smaller hole in the plate is always the propane gas orifice hole and is adja cent to the I D tab that is stamped PROP 3 When installed properly the tab that is stamped for the type of gas being utilized must face outward over the straight flange in the gas manifold so that it is clearly in view GAS ORIFICE PLATE CONVERSION 1 Turn of
29. Slant Fin PRODIGY LI models 50 and KC 100 Cast iron Gas fired Sealed combustion Hot water boiler e Direct vent or Category IV venting flexibility Wall mounted INSTALLATION AND OPERATING INSTRUCTIONS Contents eee Specifications Dimensions 2 Installation Requirements Location and Clearances 3 Wall Mounting 4 Direct Venting 5 9 Category IV 10 12 Water Piping 13 Gas Piping 14 Electrical 14 15 Operation Procedures 16 18 System 5 18 Wiring Diagram 19 Sequence of Operation 20 Troubleshooting 21 24 Air and Gas 5 25 Lighting Instructions 26 Boiler Jacket Installation Removal 26 Maintenance Procedures 27 Boiler Package Options 28 APPROVED This manual must be left with owner hung on or adjacent to the boiler Owner should retain manual for future reference Publication No P 40 A Part No 65 2101 Printed in Canada 0699 Heating Contractor Address Phone Number
30. ailable proceed to Step C to check input rate Always be sure to follow the Step E procedure to put boiler back in Automatic Operation after any setup of troubleshooting procedure is complete STEP CHECK BOILER INPUT RATE NOTICE DO NOT USE GAS VALVE TO ADJUST INPUT RATE FOLLOW DIRECTIONS BELOW e Consult gas supplier for heating value of gas usual ly 10 350 W m 1000 Btu cu ft for NG 25 875 W m 2500 Btu cu ft for LP Place the jumper across the T1 T2 terminals and allow the boiler to operate 10 minutes Shut off all other appliances served by gas meter during timing of input rate FOR HIGH FIRE OPERATION Set the Operation Selector Switches to MAN OP and HI At meter observe number of cubic feet of gas the boiler uses in 3 minutes Verify input using following formula minutes X heating value X 20 W hr input in minutes X heating value X 20 BTU hr input Example 0 1274 X 10 350 W m X 20 26 400 W hr input 4 5 cu ft 1000 BTU cu ft X 20 90 000 BTU hr input FOR LOW FIRE OPERATION Set Operation Selector Switch 3 to LO position Allow operation to stabilize At meter observe number of m cubic feet of gas boil er uses minutes Verify input using same formula Example 0 07 x 10 350 W m x 20 14 654 W hr Input 2 5 cu ft x 1000 x 20 50 000 Btu hr Input IF ADJUSTMENTS NECESSARY Turn Blower Speed Adjustment Pot HI for
31. and calibrated as specified in the Operation Procedures For replacement parts heating contractors should contact their Slant Fin boiler distributor 27 BOILER PACKAGE OPTIONS Boiler package includes mounted on boiler Standard vent kit for horizontal Full jacket enclosure direct venting included with boiler e Water manifold air scoop Vent terminal Relief valve Indoor wall plate e e Automatic air vent Wall passage thimble Circulator pump 305 mm 12 vent adapter tube Low water cutoff Tight radius 90 vent elbow 610 mm 24 PVC Schedule 40 pipe PVC Schedule 40 90 elbow PVC couplings for air in connection Tube of high temp RTV sealant Unmounted parts Expansion tank e Secondary water high limit optional e Service fitting adapters 2 Wall mounting lug screws 4 Venting kit options available e Vertical venting with roof termination Literature included Horizontal venting with separate vent and air intake Boiler Instruction Manual e Users Information Manual Refer to Prodigy 21 Replacement Parts List for details on e Replacement Parts List components and part numbers Slant Fin Corp 1999 Slant Fn SLANT FIN LTD LTEE 6450 Northam Drive Mississauga Ontario L4V 1H9 Phone 905 677 8400 905 677 1829 e mail slantcan aol com 28
32. aterials and reduce the possibility of air intake freeze up It is rec ommended to utilize this vent terminal on direct vent applications whenever the installation permits Figure 7 Vent terminal orientation EXHAUST TUBE AIR_INLET VER PLATE ERS TOP SET ors Shown with air inlet to the left of exhaust from outside view VENT TERMINAL INSTALLATION Warning The vent terminal provided is to be used for horizontal venting only DO NOT alter this part in any manner other then as shown in these instructions Only mount on a vertical surface DO NOT use when vertically venting through a roof or chimney 1 Wall cutout opening a On installations where vent passes through the wall directly out the back of boiler follow direc tions on page 4 b On installations where vent passes out through side of boiler jacket cut out a rectangular open ing 140 mm 5 high and 279 mm 11 wide in the appropriate location of an exterior wall Be sure that this location will allow for the connec tion of vent materials that come in fixed lengths or an adjustable connector will be needed 2 Vent terminal orientation see Figure 7 a The open slots for the air intake on the vent ter minal must face downward b The air inlet cover plate must face upward to insure that rain debris and flue gases do not enter the air inlet 3 Vent and air intake tubing orientation see Figure 7 a Air inlet tubing may be located
33. c power to the appliance if service is to be performed Remove boiler front cover Depress and move gas control selector arm left to OFF position Replace boiler front cover Gas Valve 7200 DERN BOILER JACKET INSTALLATION REMOVAL Note Follow these procedures in reverse to remove parts TO INSTALL BOILER ENCLOSURE On installations where venting extends out the side of the enclosure the appropriate panel located at top of jacket sides should be removed entirely to allow venting to pass out of enclosure e Place enclosure top over top flange of wall panel e Slide down until slots on the insides of enclosure are seated in support brackets on mounting panel Attach sheet metal enclosure to wall panel on both sides with screws 26 TO INSTALL FRONT COVER e Insert the slots in cover bottom over support clips on sheet metal enclosure bottom e Line up temperature pressure indicator through hole in front cover and push cover in until support clip at enclosure top snaps into slot on cover top e Locate 1 4 turn fastener next to indicator lights into receptacle behind front cover and turn in by rotating 1 4 turn only MAINTENANCE PROCEDURES This section must be brought to the owner s attention so the owner can make necessary arrangements with a trained and qualified service technician for periodic main tenance of this boiler Installer must also inform owner that the lack of proper
34. care and maintenance of this boil er may result in a hazardous condition Installer should discuss contents of the User s Information Manual with the owner KEEP THE BOILER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS BEFORE EACH HEATING SEASON A trained and qualified service technician should perform the inspections listed in these instructions at least once a year Air filter Located in sheet metal box in front area of boil er One quarter turn fasteners hold air filter box cover on Replace recommended or clean filter annually more often if conditions dictate Slant Fin replacement air filter part number 65 1306 must be used Can be cleaned with soap and water after drying spray with an adhesive type air filter spray which will attract hold airborne dust parti cles Vent termination Check for and remove obstructions Closet installations Check for and remove ventilation and or combustion air opening obstructions Vent tubing Check for and repair tubing separation leaks or sagging Vent tubing externally Check for corrosion of vent mate rial If corrosion is present replace and reseal tubing assembly Vent and air intake tubing internally Check for and remove obstructions To inspect remove tubing from boil er When finished reseal all removed tubing parts with manufacturer s specified sealant Heat exchanger In the unlikely event of boiler flue
35. d back to the gas valve and produce a proportionate gas flow See Step A DO NOT adjust the gas valve adjustment screw to set input rate only use this adjustment to set the differential pressure between the blower outlet and gas valve outlet to zero as shown in Step B STEP CALIBRATE BLOWER AIR FLOW Note This step will set the air flow required at the proper air gas ratio for the specified input rate e Connect tubing to differential pressure gage as fol lows 1 From Blower Outlet Pressure Fitting to GAGE HI side 2 From Burner Enclosure Pressure Fitting to GAGE LO side FOR HIGH FIRE OPERATION Set the Operation Selector Switches as follows Switch 1 left UP MAN Switch 2 center DOWN CAL Switch 3 right UP HI Turn power ON Red power light and amber full rate light will come on Blower will start Allow about 30 seconds for pressure to stabilize Read gage Reading should be 25 mm 1 00 w c e Adjust as necessary Using HI Blower Speed Adjust ment Pot turn in small increments clockwise to increase reading or counterclockwise to decrease the reading Allow to stabilize between adjustments FOR LOW FIRE OPERATION Set the Operation Selector Switch to DOWN LO position Amber light goes off green reduced rate light comes on Allow about 30 seconds for pressure to stabilize Read gage Pressure reading should be 6 35 mm 0 25 w c Adjust as necessary Using LO Blower Speed Adjus
36. d equipment and licensed otherwise qualified in compliance with the authority having jurisdiction Boiler Model Number Boiler Serial Number Installation Date SPECIFICATIONS AND DIMENSIONS Figure 1 Dimensions of boiler VENT 76 mm 3 DIAN lt lt 432 mm 17 AIR 64 mm 2 1 2 76 mm 3 m 38 GAS INLET 13 mm 1 2 219 mm 8 5 8 SUPPLY i 32 mm 1 1 4 32 mm 1 1 4 76 oy ie mm 2 3 4 DIMENSIONS Shipping Weight Boiler a Fire aon Fire No of Gas Model Btuh Btuh Sections Natural 14 500 50000 7500 26 000 Natural 89 3 5 KC 100 29 500 100 000 14 500 50 000 2 oa INSTALLATION REQUIREMENTS NOTICE INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED HEATING CONTRACTOR The installation must conform to the requirements of the National Fuel Gas Code ANSI 2223 1 or CAN CGA B149 1 M95 or latest edition for natural gas and CAN CGA B149 2 M95 or latest edition for propane and the requirements of the authority having jurisdiction as well as the requirements in this instruc tion manual In addition where required by the authori ty having jurisdiction installation must conform to the Standard for Controls and Safety Devices for Automat ically Fired Boilers ANSI ASME CSD 1 If there is any conflict in the above requirements then the mor
37. e accumulated propane gas causing an explo sion or fire Provide a level solid foundation for the boiler Location should be as near the chimney as pos sible so that the flue pipe from boiler to chimney is short and direct The UNIFORM MECHANICAL CODE may be in effect in your geographic area The following precautions are cited by the 1994 UNI FORM MECHANICAL CODE section 304 6 or CAN CGA B149 2 M95 or latest edition for propane LPG Appliances Liquefied petroleum gas burn ing appliances shall not be installed in a pit base ment or similar location where heavier than air gas might collect Appliances so fueled shall not be installed in an above grade under floor space or basement unless such location is provided with an approved means for removal of unburned gas Consult Chapter 5 of the 1994 UNIFORM MECHANI CAL CODE or CAN CGA B149 2 M95 or latest edi tion for propane for design criteria of the approved means for removal of unburned gas SAFETY KEEP THE BOILER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS MINIMUM CLEARANCES A Minimum clearances to the exterior surfaces of the boiler shall be as follows MINIMUM ALCOVE AND CLOSET CLEARANCE For Combustible Recommended Surface Construction for Service Front 152 mm 6 457 mm 18 Bottom 305 mm 12 305 mm Left Side 457 mm Right Side 457 51 51 76 3
38. e is maintained from electric or gas meters regulators and relief equipment Vent termination must not be located over any public walkway in any confined space i e window wells alcoves narrow alleys or under any overhang or deck Vent termination should not allow flue gas discharge towards neighbor s windows or where personal injury or property damage can occur DO NOT install the vent into a common venting system DO NOT install a vent damper or similar device in vent tubing or on the boiler VENT MATERIAL A DO NOT use galvanized or plastic vent system mate rials The vent system for direct vent applications must be CUL listed 76 mm 3 diameter corrosion resistant stainless steel The following manufacturers systems are approved for use within a specified minimum and maximum equivalent vent length for each model of boiler Refer to Slant Fin Parts List APPROVED VENT MANUFACTURERS SYSTEMS 76 mm 3 diameter vent system restrictions Equivalent length of each 90 elbow Heat Fab Saf T Vent 914 mm ft Protech Fas N Seal 1829 mm 6 ft Flex L Star 34 1829 mm 6 ft 1 The maximum equivalent length for both models is 30 5 m 100 feet includes elbows 2 The minimum quantity of venting for both models is one elbow plus the length required to pass through back wall to the termination 3 Up to 5 90 elbows may be used over the length of the vent system provided the proper pitch is maintained in
39. e strin gent requirement will apply BOILER LOCATION AND CLEARANCES BOILER LOCATION Boiler must be wall mounted and can be installed on a combustible wall The wall must be capable of support ing the weight of the boiler filled with water Structure through which venting will pass must be free and clear for opening i e no hidden conduit telephone cables or other obstructions Boiler location should be such that the gas ignition system components are protected from water drip ping spraying rain etc during appliance operation and service circulator replacement condensate trap control replacement etc Boiler can be installed above both combustible and noncombustible floors but must NOT be installed above carpeting For a closet installation ventilation openings must be provided through a door or wall to prevent excessive heat buildup Two openings one near the floor and one near the ceiling should be sized to assure sufficient air circulation in the closet minimum 64 500 mm 100 sq inches each WARNING LIQUEFIED PETROLEUM L P PROPANE GAS FIRED BOILER LOCATION REQUIRES SPECIAL ATTENTION Liquefied Petroleum L P propane gas is heavier than air Therefore propane boilers piping valves must NOT be installed in locations where propane leaking from defective equipment and piping will in a basement or other space below the leak A spark or flame from the boiler or other source may ignite th
40. ear out any gas Then smell for gas including near the floor If you smell gas STOP Fol low B in the safety information above on this label If you don t smell gas go to next step Depress and move gas control selector arm right to position Replace boiler front cover Turn on all electric power to the appliance Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boil er when the boiler underwent tests specified in ANSI 221 13 Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department C Use only your hand to depress and move the gas control selector arm NEVER use tools If the selector arm will not depress or move by hand DON T try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D DO NOT use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the con trol system and any gas control which has been under water TO TURN OFF GAS TO APPLIANCE e Set thermostat to lowest setting e Turn off all electri
41. ed It should be recognized that unless the build ing is kept above freezing temperature by some means the plumbing system is not protected Two types of anti freeze may be used ETHYLENE GLYCOL used in automobiles has desirable proper ties but is toxic Its use may be prohibited when sys tem water glycol solution is in contact with a potable water vessel as with a tankless heater PROPYLENE GLYCOL is used in the quick freeze food industry it is practically non toxic Its use may be permitted when tankless heaters are used When anti freeze must be used inhibited propylene glycol is recommended Useful information on the characteristics mixing pro portions etc of glycol in heating systems is given in Technical Topics No 2A available from the Hydronics Institute 34 Russo Place Berkeley Heights NJ 07922 Consult glycol manufacturers for sources of propylene glycol IF REPLACEMENT PARTS ARE NEEDED When parts are needed refer to boiler model and serial number shown on the boiler name rating plate Refer to Parts List for Replacement Part Numbers Whenever possible refer to the original order by number and date Control identification and replacement should not be attempted by unskilled personnel Relief Safety valves must be ASME rated for the pressure and gross output of the boiler This boiler is equipped with an unconventional gas con trol If this control is replaced it must be replaced with an identical gas control
42. er is running in high fire mode Light will come on when the boiler starts up will go off when boiler switches to low fire mode or shuts off Reduced Rate Indicator GREEN Steady ON means the boiler is running in low fire mode Light will come on when boiler automatically switches to low fire mode will go off when boiler returns to high fire mode or shuts off Note When the CAL OP selector switch is DOWN in the CAL position the amber and green lights indicate pressure switch closure at high and low blower speeds ELECTRONIC CONTROL BOARD Operation Selector Switches Switch Position Operation Description 1 Down AUTO Automatic Boiler Operation 1 Up MAN Manual Boiler Operation 2 Down CAL Calibration Procedure Blower Runs Gas Valve WILL NOT OPEN UP OP Normal Boiler Operation Low Fire Operation High Fire Operation LOHI 81 OC m gt 22202 Blower Speed Adjustment Pots Figure 23 Electronic boiler control board 16 CALIBRATION EQUIPMENT A differential pressure gauge is necessary to calibrate the blower speed and the gas valve to assure the proper air gas ratio when the boiler is operating Pressure measurement fittings There are 3 service fittings with caps provided on this boiler for convenient calibration of the air gas ratio and input in the field See Figure 24 for the location of each
43. er across the T1 and T2 terminals After about 20 seconds boiler will start Green reduced rate light on Allow about 30 seconds for pressure to stabilize Read gage Reading should be 0 mm 0 w c 0 25 mm 0 01 Adjust as necessary Remove round screw cap cov ering gas valve adjustment Position screwdriver into adjustment screw slot carefully Observe gage while adjusting and turn screw slowly Turn adjustment screw clockwise to decrease reading if over set point Turn adjustment screw counterclockwise to increase reading if under setpoint Note Remember that the gas pressure is on the low side of the gage Consequently decreasing the differ ential reading actually is INCREASING the gas pres sure reading since the blower outlet pressure is on the high side of the gage and not changing FOR HIGH FIRE OPERATION Set Operation Selector Switch 3 right to the UP HI position Green light goes off Amber full rate light comes on Allow about 30 seconds for pressure to stabilize Read gage Pressure reading should be about 0 mm 0 w c 1 25 mm 0 05 If reading slight ly off zero DO NOT re adjust gas valve This would alter the more critical low setting This step is done only to check boiler rate switching ability REPLACE SCREW COVER ON GAS VALVE ADJUSTMENT Double check gage reading with cover on Disconnect gage adapters and replace service fitting caps hand tight If gas meter is av
44. est edition 149 1 M95 or latest edition for nat ural gas B149 2 M95 or latest edi tion for propane C The boiler and its gas connection must be leak test ed before placing the boiler in operation Use liquid soap solution for all gas leak testing DO NOT use open flame This boiler and its individual shut off valve must be Gas flow 2 83 m hour Figure 20 Power and thermostat wiring disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 3 5 kPa 1 2 PSIG This boiler must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas sup ply piping system at test pressures equal to or less than 3 5 kPa 1 2 PSIG All gas piping used should be inspected thoroughly for cleanliness before makeup A sediment trap must be provided as illustrated in Figure 19 MIRE BLACK E The minimum and maximum gas supply pressure at the inlet of gas valve are shown on the boiler rating plate for the type of gas used Gas supply pressure should never be less than minimum or more than maximum pressure when the boiler or any other appliance is turned on or off SPACE HEAT ZONE ALARM SYSTEM ELECTRICAL WIRING DANGER BEFORE WIRING ALWAYS TURN OFF ELECTRIC POWER SUPPLY OTHERWISE SH
45. f power and gas supply to boiler 2 Remove boiler jacket front cover and enclosure see page 26 3 Remove the four nuts on the gas manifold angle flange KC 50 KC 100 AIR ORIFICE ADAPTER 4 Pull out the four screws on the gas manifold straight flange far enough to remove the gas orifice plate 5 Place the gas orifice plate in the position specified in the orientation instructions for the type of gas being utilized To convert from one type of gas to the other the plate should be rotated 180 The I D tab for the gas being utilized must face outward over the straight flange in the gas manifold so that it is clearly in view 6 Reposition the four screws through the flanges and orifice plate and tighten the four nuts onto the screws Make sure the nuts are tightened evenly and with sufficient force to prevent loosening or leakage 7 Replace boiler jacket enclosure and cover removed for this procedure 8 The appropriate self adhesive gas conversion label supplied with these instructions must be positioned adjacent to the boiler rating plate if the gas being utilized differs from the gas specified on the rating plate 9 Power and gas supply can be turned back on to operate boiler AIR ORIFICE PLATE 1 The air orifice plate for each boiler model is the same for both natural and propane gas no con version is necessary 2 Each model s air orifice plate has 1 0 tab which protrudes from the side of the
46. gnitor failure Blower RPM too low Low water cutoff open Improper flame signal Steady ON Loss of flame signal LIGHT PANEL ELECTRONIC CONTROL BOARD AIR FILTER 80X LOW WATER CUT OFF CONVERTIBLE GAS ORIFICE COMBUSTION BLOWER WATER HI LIMIT BLOWER OPTICAL BOARD Upper 120 Connector LED 2 Gas Valve Hot Surface ____ 15 Ignitor Combustion Blower Motor 7 LED 1 Blower RP 1 PE Flame Current Jack So o Figure 26 Electronic control board components for troubleshooting NOTICE ANY WIRES CUT WHILE SERVICING MUST BE ROUTED TO AND SPLICED INSIDE THE BOILER JUNCTION BOX OR SEPARATE JUNCTION BOX 21 TROUBLESHOOTING POSSIBLE CAUSES AND SOLUTIONS Refer to Replacement Parts information on page 27 when parts need to be replaced DIAGNOSTIC Continuous Flashing ELECTRONIC CONTROL FAILURE Electronic Control Is Defective CAUSE High Limit Is Defective Circulator Not Running Zone Valves Not Opening No Gas Supply To Gas Valve No Gas Supply To Burner Air Gas Ratio Is Not Proper Orifice Sizing Is Not Correct Electrical Connec tions Are Loose or Reversed Flame Sensor Current Is Weak Flame Sensor Is Defective Electrical Wiring No Pressure Signal To Pressure Switch Blower Speed Not Correct Pressure Switch Is Defective 22 Control board cannot be serviced Replacement must be same
47. hed Boiler continues to run normally but ONLY at high fire Improper Air Gas Check gas valve calibration at low fire Ratio Low Blower Speed Check blower calibration at low fire as shown in Operation Procedures on page 16 Bad Flame Sensor Check flame current at low fire Adjust gas valve at low fire Calibrate as shown in Operation Procedures on page 16 Adjust blower speed as shown in Operation Procedures on page 16 See No Ignition procedure regarding possible flame sensing problems 23 HOW TO DO PROCEDURES FOR TROUBLESHOOTING Flame Sensor Current For microampmeter with cable connector insert cable connector into flame current jack on electronic board see page 21 Turn power ON Once the gas valve opens and ignition occurs at the burner the microampmeter must read at least 1 microamp to keep the gas valve open Typically the reading is between 5 and 10 microamps If no reading polarity may be wrong reverse leads For microampmeter without cable connector Turn power OFF and remove lead from flame sensor Connect one microampmeter lead to the flame sen sor wire lead connect other microampmeter lead to the flame sensor Turn power ON Once the gas valve opens and igni tion occurs at the burner the microampmeter must read at least 1 microamp to keep the gas valve open Typically the reading is between 5 and 10 microamps If no reading polarity may be wrong reverse leads Fla
48. l use the cutout in the top of the should be made prior to mounting the boiler mounting panel to mark the rectangular vent b For venting out through the side of the boiler cutout on wall jacket the wall or roof cutout can be made 3 Drill mounting bolt holes for wall panel Cut the after mounting the boiler The boiler jacket has opening through rear wall if used and do alll fin removable panels on either side for vent piping ishing work passage 4 Secure the mounting panel see Figure 1 to wall using appropriate hardware 8 mm 5 16 lag Figure 2 Securing wall panel bolts provided for frame construction wall studs 8 mm 5 16 wall anchors or expansion plugs if construction is other type 5 Place hex nuts provided loosely on the ends of boiler mounting studs on mounting panel See Figure 2 Two keyhole shaped slots are provided on each side of the boiler rear which allow hex nuts on studs to pass through slots Lift the boiler and seat it on the mounting studs Tighten hex nuts securely Figure 3 Securing boiler APPROVED VENTING APPLICATIONS This Prodigy 21 boiler is approved to be vented using Direct vent or Category IV applications These applications are differentiated as follows Direct vent The air for combustion is piped directly to the air intake of the boiler from outdoors The vent piping may be run horizontally or vertically to the out doors to a common terminal with the combustion air
49. length DIAGNOSTIC 5 FLASHES BLOWER RPM TOO LOW Electrical Wiring Check wiring connections to motor particularly cable to RPM control on motor shaft Blower Wheel Check that wheel turns freely in housing Remove filter Restricted from filter box reach down through box to blower wheel Check for foreign material or misalignment Blower Motor Not Set boiler operation selector switch to CAL Motor should Running run Blower Optical Disconnect Blower Motor connector from control board Board Is Defective Spin the blower wheel by hand while observing Blower RPM Indicator LED on electronic board see page 21 Indicator should blink on and off with each wheel revolution Tighten all wiring connections If wheel not free or misaligned replace blower motor assembly Replacement must be same manufacturer and model If motor does not run replace blower mot or assembly Replacement must be same manufacturer and model If indicator does not blink replace board Replacement must be same manufactur er and model DIAGNOSTIC 6 FLASHES LOW WATER CUTOFF OPEN High Limit 15 Set high limit to lowest setting 82 C or 180 F run boiler to Defective get water temperature above 82 C 180 F Check for conti nuity across high limit contacts Boiler Water Level Check temperature pressure gage pressure reading Care Too Low fully snap open relief valve handle to determine if boiler is full of water If not fu
50. ll of water check for system leaks and check water pressure regulator operation Circulator Not With thermostat calling for heat check for power to circulator Running If no power check wiring connections to circulator Zone Valves Not With thermostat calling for heat check for power to each Opening valve If no power check wiring connections to valve If contacts remain closed when temperature exceeds 82 C 180 F replace high limit Replacement must be same manufacturer and model DO NOT set above 104 C 220 Repair any system leaks Adjust or replace water pressure regulator If power OK but circulator not running replace circulator If power OK but valve not opening replace valve DIAGNOSTIC 7 FLASHES IMPROPER FLAME SIGNAL Flame Signal Detected When Gas Valve Should Be Closed Gas Valve Is Turn gas valve knob to OFF and check that valve shuts off Defective gas flow Flame Detector Remove flame detector from boiler Check for coating on Shorted rod or material contacting rod inside ceramic or combus tion area If gas flow continues replace valve Replacement must be same manufactur er and model Calibrate new valve as shown in Operation Procedures on page 16 Clean or clear any foreign matter Replace flame detector if necessary with same manufacturer model and length DIAGNOSTIC Steady ON LOSS OF FLAME SIGNAL Flame Signal Lost After Proper Flame Signal Has Been Establis
51. manufacturer and model After replace ment calibrate blower speed as shown in Part 3 in manual DIAGNOSTIC 1 FLASH HIGH LIMIT OPEN 1 HOUR TEST Set high limit above boiler water temperature raise limit setting substantially as water temperature may be higher than gage reading when there is no water flow through boiler Check for continuity across high limit contacts With thermostat calling for heat check for power to circu lator If no power check wiring connections to circulator With thermostat calling for heat check for power to each valve If no power check wiring connections to valve SOLUTION If contacts remain open replace high limit Replacement must be same manu facturer and model DO NOT set above 104 C 220 F If power OK but circulator not running replace circulator If power OK but valve not opening replace valve DIAGNOSTIC 2 FLASHES NO IGNITION No Flame Signal After Trial For Ignition Check that manual gas shutoff is open Check for gas sup ply pressure to valve Check gas valve knob in ON position Check wiring and tubing connections to valve Check for power to gas valve Note gas valve LED on control board see page 21 Check valve outlet pressure to determine if valve is opening see How To Do It on page 24 Check gas valve calibration as shown in Operation Proce dures on page 16 Check gas and air orifice size see Orificing Identification on page 25
52. me sensor removal Turn power OFF and remove lead from flame sensor Remove flame sensor hold down bracket Carefully pull out flame sensor Hot surface ignitor removal Turn power OFF and remove ignitor hold down bracket e Carefully pull out ignitor handle with care fragile DO NOT CUT WIRES TO REMOVE IGNITOR Pressure switch calibration check Turn power OFF Remove wire leads from pressure switch terminals e Hookup resistance meter between Normally Open N O and Common C terminals e With blower off the switch should be open meter reading is infinity If not switch is defective e f switch is open check cutout pressure with blower running as described in following steps Hookup differential pressure gage in same manner as to set blower air flow high side to blower outlet low side to burner enclosure The switch and gage both read the same air flow differential pressure Turn on power and raise thermostat e Note pressure reading on gage when blower is run ning Reading should be higher than the pressure switch cutout pressure which is marked on the pressure switch label e lf the pressure switch terminals are still open with the blower running and the gage reading is at least 2 5 mm 10 higher than the pressure switch set ting the switch is defective 24 Ceramic burner Kanthal ground bar removal e Remove jacket enclosure around boiler and expan sion tank if nece
53. mum of 645 square inch per 293 W 1000 Btuh input to ALL APPLIANCES in the area For a total appliance input of 58 620 W 200 000 Btuh each opening will be 64 516 mm 100 square inches grilled opening 254 mm x 254 mm 10 X10 has 64 516 100 square inches of area If fly screen must be used over openings double the area and inspect and clean the screen frequently Openings must NEVER be reduced or closed If doors or windows are used for air supply they must be locked open Protect against closure of openings by snow and debris Inspect frequently No mechanical draft exhaust or supply fans are to be used in or near the boiler area The flow of combustion and ventilating air to the boiler must not be obstructed VENT LOCATION REQUIREMENTS Vent installations shall be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI 7223 1 or CAN CGA B149 1 M95 or latest edi tion for natural gas and CAN CGA B149 2 M95 or latest edition for propane or applicable provisions of local building codes This Prodigy 21 boiler is approved for pressure venting both horizontally and vertically The following require ments apply to both types of venting installation Vent termination must meet the following clearances Minimum of 305 mm 12 above grade and normal snow line to vent termination bottom minimum of 1219 mm 4 feet below or horizontally or 305 mm 1 foot above a
54. ns The air intake opening must face down by using 90 elbow with a screen positioned at the opening 3 Vent piping run vertically up an existing chimney and air intake run horizontally out a vertical wall a Refer to Figure 13 Adhere to all clearances and materials specified in this illustration b The stainless exhaust vent pipe must extend the total length of the chimney The pipe must exhaust straight up and terminate with a screen terminator The top of the chimney must be sealed off around the protruding pipe with an appropriate plate or flashing Other appliances CANNOT be vented into the same chimney or vent pipe within the chimney c The air intake pipe must pass through a vertical wall or foundation horizontally The cutout does not require any clearance but must be sealed with a flashing or by other means The air intake opening must face down by using a 90 elbow with a screen positioned at the opening Figure 12 Vent run through a roof and air intake run through a wall EXHAUST WITH SCREEN REFER TO VEN PIPE REQUIREMENTS p SHOWN PREVIOUS FIGURES FOR VENT AND AIR INTAKE RUN THROUGH A PITCHED OR FLAT ROOF REFER TO previous 4 FIGURE FOR FLOOR AND CEILING PASSAGE AIR INTAKE 90 ELBOW WITH SCREEN FACE DOWN RUN AIR INTAKE PIPE THROUGH THE FOUNDATION OR AN SNOWL I 305 mm 1 FT MIN CONDENSATE TO DRAIN DRAIN ASSY Figure 13 Vent piping run vertically up an existing chimney
55. ny building opening mini mum of 914 mm feet above any forced air intake located within 3048 mm 10 feet minimum of 1219 mm 4 feet horizontally from and in no case above or below unless 1219 mm 4 foot horizontal distance is maintained from electric or gas meters regulators and relief equipment Vent termination must not be located over any public walkway in any confined space i e window wells alcoves narrow alleys or under any overhang or deck Vent termination should not allow flue gas discharge towards neighbor s windows or where personal injury or property damage can occur DO NOT install the vent into a common venting system DO NOT install a vent damper or similar device in vent tubing or on the boiler VENT MATERIAL REQUIREMENTS A DO NOT use galvanized or plastic vent system materials The vent system for Category IV applica tions must be CUL listed 76 mm 3 diameter cor rosion resistant stainless steel The following manu facturers systems are approved for use within a specified minimum and maximum equivalent vent length for each model of boiler Refer to Slant Fin parts list APPROVED VENT MANUFACTURERS SYSTEMS Equivalent length of each 90 elbow Heat Fab Saf T Vent 914 mm ft Protech Fas N Seal 1829 mm 6 ft Flex L Star 34 1829 mm 6 ft 76 mm 3 diameter vent system restrictions 1 The maximum equivalent length for both models is 30 5 m 100 feet includes elbows
56. pas sage blockage service to remedy situation must be per formed only by an authorized Slant Fin representative Burner Annual service of the burner is not necessary Follow the burner removal procedure on page 24 when improper operation of the boiler necessitates inspection of this part System water Check if full of water and properly pressur ized Check for and correct radiation system air noise Water piping Check for and repair any leaks Gas piping Check for and repair any leaks Clear plastic tubing Located around burner enclosure area Check for cracked loose or blocked conditions Replace if necessary Safety shutdown controls Check operation as detailed on page 18 in this manual Blower This is a sealed component which does not require lubrication Check hose assembly on blower out let for air leakage Replace if necessary Circulator Some models require lubrication S A E 20 oil recommended WATER TREATMENT A good water treatment program will extend the useful life of the boiler and is especially recommended in areas where water quality is a problem A reputable water treat ment company should be consulted for determining the best overall treatment program for this equipment Providing protection from freezing Anti freeze is sometimes used in hydronic heating sys tems to protect against freeze up in the event of power failure or control shutdown when the building is unoc cupi
57. s required Insert the cut end into the elbow and secure with tabs and hose clamp after vent terminal is installed d Run a bead of silicone around the perimeter of wall panel and vent collar to prevent water and drafts from entering building Position the vent terminal on the wall as described in Step 2 and secure it to the wall e Interior wall panel installation a Cut the wall thimble 127 mm 5 diameter galv pipe about 13 mm 1 2 shorter than the wall thickness b Fit thimble onto the collar on the back of the vent terminal inside the wall c Hold the interior wall panel up to the wall cutout and fit the collar on this panel into the thimble Line up the air inlet holes and secure to wall Vent and air intake tubing installation to vent terminal a Finish tubing connections back to the boiler fol lowing the requirements in the venting installa tion instructions on pages 5 and 6 Exhaust tubing connects to the vent collar adapter tube Observe correct flow direction c Air intake tubing should slip into the air inlet opening in the back of the vent terminal Make sure the tubing extends into the vent terminal box as far as the tube stop inside the box allows 19 mm 3 4 approx Seal around the air intake tubing where it passes through the out side wall plate 2 DIRECT VENTING WITHOUT VENT TERMINAL Vertical venting configurations All Prodigy 21 boiler models are certified for vertical
58. ssary to access burner enclosure Disconnect wires to gas valve May be necessary to disconnect gas supply line to gas valve to move assembly slightly Disconnect air adapter from burner enclosure e Remove air filter box cover to access blower mount ing studs and nuts Remove the four nuts and drop blower down to move out of way Remove nuts around perimeter of burner enclosure drop down off of studs and remove enclosure Allow burner enclosure to drop down low enough to access burner bracket Remove and clear tubing if necessary but mark location of each tube for reassembly e While supporting underside of burner bracket to keep from falling undo knurled nuts at either end of burner Drop burner down off studs gently Pull down burner gasket with burner without ripping it e Ceramic burner is only attached to the burner bracket by the ground wire unscrew the wire tab to remove e Ground bar is held to burner with a weld stud through the burner remove the nuts and washers from the underside of the burner to disassemble e To reassemble follow this procedure in reverse carefully relocating all items removed in their proper location at tightness noted in removal Figure 27 Ceramic burner Kanthal ground bar removal BOTTOM OF BOILER BURNER SEAL KANTHAL GROUND BAR BURNER BRACKET CERAMIC BURNER GROUND WIRE BURNER MOUNTING SPRINGS BURNER ENCLOSURE ENCLO
59. sure reducing fill valve and shut off valve should be installed Supply and return For tapping sizes see dimensions on page 2 Recommend shut off valve in supply and shut off and drain valves in return on non zoned system Radiant floor and standing cast iron radiant systems A boiler by pass loop or equivalent will be required to avoid flue gas condensation on cast iron sections for low temperature application i e radiant floor systems Zone piping See page 15 for zoning with zone valves and domestic hot water installation WATER OUTLET MANIFOLD RELIEF VALVE SECONDARY WATER LIMIT OPTIONAL WATER HIGH LIMIT LOW WATER CUTOFF PURGE VALVE S SHUTOFF VALVES S 6 aa vy WATER SYSTEM FOR BOILER FILL AND PURGE HEATING SYSTEM Make sure flow direction arrows on components are facing in direction of flow Place bucket under pressure relief valve discharge Baseboard and radiant floor systems e Close all shut off valves drain valves and air vents e Open supply shut off valve and return drain valve on first zone or return drain valve on non zoned sys tem If zoned with zone valves manually open zone valve e Attach a hose from return drain valve to a drain Open fill line shut off valve Manually operate fill valve regu lator When water runs out of hose in a steady stream with no air bubbles close return drain valve Repeat procedure for additional zones one at a
60. t hr m hr cu ft hr The gas supply line to the boiler should be run 30 10 directly from the meter for natural gas or from the 61 20 fuel tank for L P propane gas See Figure 19 for 91 30 location of union and manual main shut off valve 122 40 that be specified locally ie Selecting pipe size for natural gas 213 70 1 Measure or estimate the length of piping from 243 80 the meter to the installation site 274 90 2 Consult gas supplier for heating value of gas ee W m BTU cu ft At pressure drop of 0 3 in water specific gravity 0 60 3 Divide boiler rated input by heating value to find gas flow in piping cu ft per hour Figure 19 Gas piping components location 4 Use table below to select proper pipe size Example Boiler model KC 100 is to be installed Distance from gas meter to the boiler is 12 1 40 ft Heating value of natural gas is 10 350 1000 BTU scu ft Select proper pipe size 29 310 W hour 10 350 W m Gas flow 100 ft hour LOCAL CODE At 12 1 m 40 ft length of pipe match required capacity from table above choose higher capacity in this case 3 7 m hour 130 ft per hour Required pipe size is 19 mm 3 4 Improper gas pipe sizing will result in insufficient heat and other installation difficulties For more information and also if other appliances are to be attached to the piping system see Appendix C of National Fuel Gas Code ANSI Z223 1 lat
61. tion box cover HOT CONNECTION LEAD IS BLACK NEUTRAL CONNECTION LEAD IS WHITE e Connect ground inside box DO NOT REVERSE POWER CONNECTIONS if reversed ignition control will not detect a flame and will go into safety shutdown OPTIONS AVAILABLE Domestic hot water installation The boiler will run at high fire mode for maximum recovery of the Storage Tank when the A1 and A2 terminals are closed Con nect zone valve end switch to A1 and A2 terminals on electronic boiler control board Water heater thermo stat operates zone valve DO NOT bring power from an external source to these terminals Note 3 wire zone valves which do not have isolated end switches cannot be used unless a relay is added with the dry contacts wired to T1 and T2 Alarm system A remote type alarm device may be connected to the boiler that will be activated if the boil er shuts down due to a malfunction FT1 and FT2 ter minals on electronic boiler control board are a dry con tact 5 amp 120 max that makes on a system fault or power outage Figure 21 Zone valves with indirect fired water heater piping and wiring Typical Zone Piping amp 24 Volt Wiring For Use With Packaged Boiler Equipped With Pre Piped amp Pre Wired Circulator Pump Thermostat Provide 120 volt power to 120 x 24 voli transformer with overcurrent protectior and disconnecting means as required Size transformer to number of zone valves Do not overload
62. tment Pot turn in small increments clockwise to increase reading or counterclockwise to decrease the reading Allow to stabilize between adjustments Notes on Input Rate 1 Refer to the Input Rate Specifications Charts on page 2 for the appropriate input rate setting on each model boiler 2 gas meter is available follow the Step proce dure to verify the specified input rate If a gas meter is not available the Step A procedure is ade quate for obtaining the specified input rate 3 For altitudes between 610 and 1372 m 2 000 and 4 500 ft derating is not necessary STEP B CALIBRATE GAS VALVE Note This step will set the air gas ratio for optimum combustion The purpose of this step is NOT to set input rate Follow Step A and or Step C to adjust input PURPOSE OF GAS VALVE CALIBRATION IS TO ADJUST AIR GAS RATIO ONLY NOT INPUT e Connect tubing to differential pressure gage as fol lows 1 From Blower Outlet Pressure Fitting to GAGE side 2 From Gas Valve Outlet Pressure Fitting to GAGE LO side e Disconnect any wires from T1 T2 and 1 2 termi nals and set up a jumper wire across T1 T2 termi nals to control operation at boiler Open zone valves FOR LOW FIRE OPERATION Set the Operation Selector Switches as follows Switch 1 left UP MAN Switch 2 center UP OP Switch 3 right DOWN LO Open manual main gas shutoff valve and turn boiler gas valve ON Place the jump
63. transformer Zone 2 Radiation Thermostat Supply To Additional Zones tT 120 x 24 Volt Transforr ier To Boiler Control Panel gt TERMINALS gt S 4 8 From Boiler Zone 1 Radiation 120 x 24 Volt Transformer Return To Boiler 4 WIRE ZONE VALVE WIRING 120 x 24 Volt Transformer ey 4 WIRE Thermostat Zone Valve on OTS Additional Zones gt TERMINALS IN BOILER CONTROL 4 WIRE Zone Water Heater Thermostat 3 WIRE ZONE VALVE WIRING 208 CONTROL RELAY 24v SPST N O CONTACTS VAI 2 OPERATION PROCEDURES Figure 22 Indicator Light Panel BOILER STATUS FUEL UTILIZATION RATE POWER DIAGNOSTIC FULL RECUCED LED indicator lights provide important information about boiler operation at a glance When the CAL OP selector switch see Fig 23 is UP in the OP position the lights indicate as follows Power Indicator RED Steady ON means there is electrical power to the boiler Light will come on when power is provided to boiler Diagnostic Indicator RED Steady ON or intermittent flashing indicates a system operation problem Full Rate Indicator AMBER Steady ON means boil
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