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Slant/Fin Prodigy 21 KC-50 Installation And Operating Instructions Manual

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See also: User's Information Manual , Installation Instructions and Operating Manual
• Cast-iron • Gas-fired • Sealed combustion • Hot water boiler
• Direct vent or Category IV venting flexibility • Wall mounted

INSTALLATION AND OPERATING INSTRUCTIONS

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page
Specifications and Dimensions . . . . . . . . . . . . . . . . . . .2
Location and Clearances . . . . . . . . . . . . . . . . . . . . .3
Wall Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Direct Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Category IV Venting . . . . . . . . . . . . . . . . . . . . . .10-12
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . .14-15
Operation Procedures . . . . . . . . . . . . . . . . . . . . . . .16-18
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . .20
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-24
Air and Gas Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Lighting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Boiler Jacket Installation/Removal . . . . . . . . . . . . . . . .26
Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . .27
Boiler Package/Options . . . . . . . . . . . . . . . . . . . . . . . .28
CANADIAN GAS ASSOCIATION
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
®
®
Models KC-50 and KC-100
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-fired equipment and licensed
otherwise qualified, in compliance with the authority
having jurisdiction.
Boiler Model Number
Boiler Serial Number
Installation Date

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Summary of Contents for Slant/Fin Prodigy 21 KC-50

  • Page 1: Table Of Contents

    The installation must also conform to the additional requirements in this Slant/Fin Boiler Package/Options ......28 Instruction Book.

  • Page 2: Specifications And Dimensions

    SPECIFICATIONS AND DIMENSIONS Figure 1. Dimensions of boiler DIMENSIONS Boiler Model KC-50 15-1/2 10-1/2 1-1/4 KC-100 18-1/2 13-1/2 3-1/2 Gas Supply Shipping Boiler Input Pressure Weight Water Boiler No. of High Fire Low Fire Volume Model Sections Type Btuh Btuh U.S.

  • Page 3: Installation Requirements

    INSTALLATION REQUIREMENTS WARNING NOTICE: INSTALLATION AND SERVICE MUST BE LIQUEFIED PETROLEUM (L.P.) PROPANE PERFORMED BY A QUALIFIED HEATING GAS-FIRED BOILER LOCATION CONTRACTOR REQUIRES SPECIAL ATTENTION The installation must conform to the requirements of Liquefied Petroleum (L.P.) propane gas is heavier than the National Fuel Gas Code ANSI Z223.1, or air .

  • Page 4: Wall Mounting

    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. Hold mounting panel on wall (with the boiler allow all of their requirements to be met: mounting studs facing out) in the location where boiler will be positioned and level wall panel.

  • Page 5: Direct Venting

    Refer to Slant/Fin Parts List. doors, to a common terminal with the combustion air intake or separate from the combustion air intake APPROVED VENT MANUFACTURERS’...
  • Page 6 19 mm (3/4”) pipe strap at direct venting utilizing the vent terminal provided by intervals no greater than 1829 mm (6 feet). Slant/Fin only. E. The vertical portion of the pipe must be supported This vent terminal must be mounted on a vertical wall in at least one location for each 9 m (30 feet) of ver- outside surface.
  • Page 7 Figure 7. Vent terminal orientation Figure 8. Vent terminal installation Shown with air inlet to the left of exhaust from outside view. Shown from top view. VENT TERMINAL INSTALLATION b) Mark and drill out the location of the four screw holes in the wall for mounting vent terminal.
  • Page 8 DIRECT VENTING WITHOUT VENT TERMINAL Figure 10. Vent and air intake run through a pitched roof Vertical venting configurations All Prodigy 21 boiler models are certified for vertical direct venting utilizing the following configurations. 1. Vent and air intake piping vertically run up through a roof in close proximity.
  • Page 9 Figure 12. Vent run through a roof and air intake run 2. Vent piping run vertically up through a roof and air through a wall 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.

  • Page 10: Category Iv Venting

    (100 square inches). A specified minimum and maximum equivalent vent grilled opening 254 mm x 254 mm (10"X10") has length for each model of boiler. Refer to Slant/Fin 64 516 mm (100 square inches) of area. If fly screen parts list.
  • Page 11 B. When joining the various components of the vent sys- Figure 4. Vent sealing instructions (Consult vent manufacturer’s instructions.) tems listed on page 10, the manufacturers’ instruc- tions should be closely followed to insure proper seal- VENT SEALING INSTRUCTIONS FOR HEAT-FAB 29-4C STAIN- ing.
  • Page 12 Figure 15. Vertical Category IV venting through a roof Figure 16. Vertical Category IV venting up an existing chimney 3048 mm (10 FT.) 3048 mm OR LESS (10 FT.) 305 mm (1 FT.) MIN. OR LESS 3048 mm 305 mm (10 FT.) MAX.

  • Page 13: Water Piping

    Figure 18. Water piping Note: Orientation of piping drawn for clarity. Observe relative location of components. FILL AND PURGE HEATING SYSTEM WATER PIPING • Make sure flow direction arrows on components are Always follow good piping practices. Observe minimum facing in direction of flow. 25 mm (1") clearance to combustibles around all uninsu- •...

  • Page 14: Gas Piping

    Gas Flow In Piping GAS PIPING Length Pressure Drop = 8mm (.3”) in water Specific Gravity = 0.60 of Pipe A. Local installation codes apply. The pipe joint com- Iron Pipe Size (Ips) pound used on threads must be resistant to the 13mm (1/2”) 19mm (3/4”) 25mm (1”)

  • Page 15: Electrical Wiring

    a non-zoned system, set to .3 amps. ELECTRICAL WIRING Circulator relay on board: DO NOT exceed 5 amp/120V max. rating. DANGER: BEFORE WIRING, ALWAYS TURN OFF ELECTRIC POWER SUPPLY. OTHERWISE, SHOCK OR DEATH CAN RESULT. WARNING: DO NOT USE BOILER TRANSFORMER TO POWER EXTER- NAL ACCESSORIES (I.E.

  • Page 16: Operation Procedures

    (see Fig. 23) is UP in the OP position, mended. the lights indicate as follows: Available from Slant/Fin is a calibration gauge kit (part Power Indicator (RED): Steady ON means there is number 665185) that has a gauge mounted on a electrical power to the boiler.
  • Page 17 STEP A: CALIBRATE BLOWER AIR FLOW STEP B: CALIBRATE GAS VALVE Note: This step will set the air flow required at the Note: This step will set the air/gas ratio for optimum proper air/gas ratio for the specified input rate. combustion.

  • Page 18: System Testing

    STEP C: CHECK BOILER INPUT RATE STEP E: SETUP BOILER FOR AUTOMATIC OPERATION NOTICE: DO NOT USE GAS VALVE TO ADJUST INPUT RATE. FOLLOW DIRECTIONS BELOW. • Remove jumper from across T1-T2 terminals and • Consult gas supplier for heating value of gas (usual- reconnect wires to control board T1-T2 and A1-A2 ter- ly 10 350 W/m (1000 Btu/cu.ft.) for NG;...

  • Page 20: Sequence Of Operation

    SEQUENCE OF OPERATION THERMOSTAT CALLS FOR HEAT WAIT FOR CONDITION TO CHANGE. WAIT 1 HOUR. CLEAR FAULT. CLEAR FAULT. RE-TRY OPERATION. RE-TRY OPERATION. WATER NO FURTHER ACTION. CUTOFF FAULT DISPLAYED. CLOSED? NO FAULT DISPLAYED CIRCULATOR ON DISPLAY FAULT HIGH HIGH LIMIT LIMIT CIRCULATOR...

  • Page 21: Troubleshooting

    TROUBLESHOOTING Boiler Failure Codes ......Page DIAGNOSTIC INDICATOR LIGHT (RED) Continuous Flashing Carefully note red diagnostic indicator light. When a ---------Electronic control failure .
  • Page 22 Operation Procedures dures on page 16. on page 16. Orifice Sizing Is Not If size not correct, contact Slant/Fin Tech- Check gas and air orifice size (see Orificing Identification Correct? nical Services Department. on page 25).
  • Page 23 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 SOLUTION Electrical Wiring? Check wire connections from ignitor. Tighten all wiring connections. Hot Surface Ignitor Turn power OFF.
  • Page 24 “HOW TO DO IT” PROCEDURES FOR TROUBLESHOOTING Flame Sensor Current Ceramic burner/Kanthal ground bar removal For microampmeter with cable connector, insert cable • Remove jacket enclosure around boiler and expan- connector into flame current jack on electronic board sion tank, if necessary, to access burner enclosure. (see page 21).

  • Page 25: Air And Gas Orifices

    Note: These Prodigy boilers utilize the same air and 4. Pull out the four screws on the gas manifold gas orifices as the Slant/Fin Concept 21 series boilers. straight flange far enough to remove the gas orifice Therefore, the model number shown on the orifice plate.

  • Page 26: Lighting Instructions

    LIGHTING INSTRUCTIONS Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boil- (Reference For Labels 65-0645) er when the boiler underwent tests specified in ANSI Z21.13. FOR YOUR SAFETY READ BEFORE OPERATING •...

  • Page 27: Maintenance Procedures

    Replace (recommended) or clean filter annually (more Two types of anti-freeze may be used: ETHYLENE often if conditions dictate). Slant/Fin replacement air filter, GLYCOL, used in automobiles, has desirable proper- part number 65-1306 must be used. Can be cleaned with ties, but is toxic.

  • Page 28: Boiler Package/Options

    Refer to Prodigy 21 Replacement Parts List for details on • Replacement Parts List components and part numbers. ©Slant/Fin Corp. 1999. SLANT/FIN LTD/LTEE, 6450 Northam Drive, Mississauga, Ontario L4V 1H9 • Phone: (905) 677-8400 / FAX: (905) 677-1829 e-mail: slantcan@aol.com ®...

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