14
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STEP 5: SETUP SYSTEM FOR AUTOMATIC OPERATION
FOR INITIAL START-UP ONLY
• Remove jumper from across T1-T2 terminals and
reconnect wires to control board T1-T2 and A1-A2
terminals properly.
• Restore zone valves to automatic operation.
• Set thermostat(s) to call for heat.
• Set selector switches to AUTO, OP and HI.
FOR NORMAL SYSTEM START-UP
• Set selector switches to AUTO, OP and HI.
• Follow lighting instructions attached to boiler.
See index on Page 20 for reference lighting instructions
and sequence of operation.
Safe lighting and other performance criteria were met
with the gas manifold and control assembly provided on
the boiler when the boiler underwent tests specified in
ANSI Z21.13.
STEP 7: 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 sys-
tem.
2. Visually inspect venting system for proper size and
horizontal pitch and determine there is no blockage
or restriction, leakage, corrosion and other deficien-
cies 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 NOT operate a summer exhaust fan. Close fire-
place dampers.
4. Place in operation the appliance being inspected.
Follow 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 or
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 Z223.1. When resizing
any portion of the common venting system, common
venting system should be resized to approach mini-
mum size as determined using appropriate tables in
Part II in National Fuel Gas Code ANSI Z223.1.
STEP 6: CHECK SYSTEM OPERATION
Purge Air One Final Time
• Let system water reach 160°. Temperature/pressure
gage should be between 12 and 25 psi.
• Bleed all air vents until water squirts out; start on low-
est floor with first air vent in the line of flow.
Check Exhaust and Air Intake Venting
• Check for and reseal any vent tubing leaks.
• Check for and remove any vent terminal obstructions.
Check Gas Valve Operation (With Burner Firing)
USE CAUTION - LINE VOLTAGE PRESENT.
• Disconnect flame sensor wire lead from flame sensor
tab. Gas valve should close.
• It is normal for boiler to re-try for ignition (3 times)
with wire removed from flame sensor, but gas valve
should only open for a few seconds during each re-try
and be closed between trials.
• Replace flame sensor wire lead on flame sensor tab.
Check High Limit Operation
HIGH LIMIT CANNOT BE SET BELOW 180°. HIGHEST
MAXIMUM ALLOWABLE SETTING IS 220°.
• Set thermostat high enough for the water temperature
to reach limit switch setting of 180°.
• When reached, limit switch should open and gas
valve should close.
Summary of Contents for Prodigy 21 KC-45
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