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

OPERATION PROCEDURES

Figure 22: Indicator Light Panel
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 boiler
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
1 Up MAN
2 Down CAL
2 UP OP
3 Down LO
3 Up HI
Figure 23: Electronic boiler control board
16
Automatic Boiler Operation
Manual Boiler Operation
Calibration Procedure
Blower Runs, Gas Valve
WILL NOT OPEN
Normal Boiler Operation
Low-Fire Operation
High-Fire Operation
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.
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 on a
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.
• 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
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 feed
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.