Kenmore 229.960340, 229.960360, 229.960370, 229.960380, 229.960390 Owner's Manual

Owner'sManual

CONTINUOUSPILOT

MODELNO.

229.960330

229.960340

229.960360

229.960360

229.960370

229.960380

229.960390

ELECTRONIC

INTERMITTENTIGNITION

MODELNO.

220.960230

229.960240

229.960260

229.960260

229.960270

229.960280

229.960290

Theseinstructionsmustbeaffixed

onor adjacenttotheboiler.

CAUTION

Readall instructionscarefully

beforestartingtheinstallation.

Save this manual

for future reference.

®

Gas-Fired

CastIron

STEAM

BOILER

• Installation

• Operation

• RepairParts

WARNING: Improper installation, adjustment, alteration, service or

maintenance can cause injury or property damage. Refer to this manual.
For assistance or additional information consult a qualified installer,

service agency or the gas supplier. Natural gas boilers are not to be
converted to Propane gas.

PRINTED IN U.S.A. FOAM e37-_00-02_02-6"7949

Warranty .................................................... 2

Rules for Safe Installation and Operation .................. 3

Boiler Ratings and Capacities ............................. 4

Before You Start ............................................ 5

Locating the Boiler ......................................... 5

Fresh Air for Combustion .................................. 6

Installation - System Piping ............ : ................... 7

Chimney and Vent Pipe Connection ....................... 10

Vent Damper Operation .................................... ! 1

Gas Supply Piping ......................................... 12

Electrical Wiring ............................................ !3

Controls and Accessories - What They Do ............... 19

For Your Safety - Read Before Operating ................. 20

Operating Your Boiler ...................................... 22

Checking and Adjusting ................................... 23

Cleaning Your Boiler ....................................... 24

Maintaining Your Boiler ...................................... 25

Service Hints ............................................... 26

Repair Parts ................................................ 27

E_ AIRS

KENNMORE CAST IRON BOILERS

FULLONEYEARWARRANTYON HOTWATERAND GAS STEAMCASTIRONBOILERS

For one {1) year from the date of installation,when this boiler is installed and maintained in accordance

with our instructions. Searswill repair defects in material orworkmanship inthe boiler,free of charge.

LIMITED 12 YEAR WARRANTY ON STEAM CAST IRON BOILERS

After one {1)yearand through twelve (12} yearsfrom the date of installation,Searswillfurnish a replacement

heatexchanger, ifthe heat exchanger in the boiler is defective. YOU PAY FOR LABOR.

LIMITED 20 YEAR WARRANTY ON HOT WATER CAST IRON BOILERS

After one (1)yearand through twenty (20) years from the date of installation,Searswill furnish areplacement

heat exchanger ifthe heat exchanger inthe boiler isdefective. YOU PAY FOR LABOR.

SEARS INSTALLATION WARRANTY

Inaddition to any warranty extended to you on the Sears merchandise involved, which warranty becomes
effective the date the merchandise is installed,should the workmanship of any Sears arranged installation
prove faulty within one year, Sears will, upon notice from you, cause such faults to be corrected at
no additional cost to you.

FOR WARRANTY SERVICE, SIMPLY CONTACT THE NEAREST SEARS STORE OR SERVICE
CENTER THROUGHOUT THE UNITED STATES. This warranty gives you specific legal rights, and

you mayalso haveother rights which vary from state to state.

IMPORTANT

The following are the responsibilities of the user and are

not covered by the Warranty

1. Filter cleaning or replacement.

2. Damage to unit or unsatisfactory operation due to improper
cleaning or use of unit in corrosive atmosphere.

3. Damage to unit or unsatisfactory operation due to blown
fuses or inadequate or interrupted electricaI protective

devices.

4. Damage to unit caused by the use of components or other
accessories not compatible with the unit.

5. If the unit is removed from the place it was originally
installed, this Warranty becomes void.

6. Damage tothe unit caused by accident, abuse, negligence,
misuse, riot, fire, flood, or acts of God.

SEARS ROEBUCKAND COMPANY

D/817WA

Hoffman Estates, IL 60179

®,_E 2

1. Read the Owner's Manual carefully Failure to fallow the
rules for safe operation and the instructions can cause

a malfunction of the boiler and result in death, serious
bodily injury, and/or property damage.

2. Check your local codes and utility requirements before
installation, The installation must be in accordance with

their directives,

3. Before servicing, allow boiler to cool. Always shut off any
electricity and gas to boiler when working on it. This will

prevent any electrical shocks or burns.

4. Never test for gas leaks with an open flame. Use soap
and check all connections. This will avoid any possibility
of fire or explosion.

5. Be certain your new boiler will be using the correct gas.
Overfiring will result in premature failure of the boiler

sections and cause dangerous operation.

6. Never vent this boiler into an enclosed space. Always vent
to the outside. Never vent to another room or inside a

building.

7. Be sure there is adequate air supply for complete
combustion.

8. Follow a regular service and maintenance schedule for
efficient and safe operation.

TOOLS

Pipe Wrench
Screwdrivers

Tin Snips

6 foot tape or folding rule
Hack Saw

LP Torch, if you have copper piping

Pipe cutter and threading tools

(for iron pipe systems)

MATERIALS

Pipe joint compound suitable for natural and propane gas.
Iron or copper pipe for the water lines,

Black pipe for the gas lines.
Miscellaneous fittings.

Solder and flux if you have copper piping.

The following booklets will help you in making the installation:

Electrical Wiring - Available at Sears from the Plumbing, Heating or Electrical Departments at nominal cost.

American National Standards, Installation of Gas Appliances and Gas Piping, ANSI Z223.1-1atest revision.

©btain from American Gas Association, 1515 Wilson Boulevard, Arlington (Roslyn), VA 22209

e07_3,_

VENT

DAMPER

ASME

POP

SAFETY
VALVE

, ; J i

: 2'/2" NPT _ ",

\ :

29" ; \ :

; LEFT SIDE

I

i

J I I

I iL

PRESSURE

GAUGE

SPILL '_

/ SWITCI-€

WATER

LiNE -- __ --

PROBE

ROLLOUT 36_e"

-SWITCH

_ -, _o _ _

GAS

A ...._ UNE

43/,=. 261/="

RESSURE

LIMIT

ONTROL

_$8 6 CUT'OFF

GAS

FRONT RIGHT SIDE

24"

DESIGN
CERTIFIED FOR
NATURAL GAS

GAS-FIRED STEAM BOILERS

BOILER MODEL NUMBER DgMENSlO_

INTERMrr_NT s'rANOING NO.OF (_)

IGNITION PLOT SECTIONS

FLUE "A"

Wr_l VIg_IT I_MPER WiTH vl_rr DAMPER DIAMErE_ WlEI].I

229960230
22996024O
229960250
229960260

229.960270

229.960280

229.960290

229.960330

229.960340

229.960350
229960360

229.960370

229.960380

229.960390

3
4
5
6
7
8
9

"[h_TURALG/_

NET N_ _B_

AGA HEATING _B-R RARN6

INPUT CAPAQ'rY

"MW'I *MOH RA'J_NG SO.

°MBH PJ_4ATIQ#

75 62 47 196 5 111_

112 91 68 283 6 14V_
150 122 92 383 6 !7¾

187 153 115 479 7 21

225 183 137 571 7 24%
262 214 161 67! 7 2_/_
299 245 184 767 7 303/4

* MBH = 1,000 8tuh. Btuh = British Tnermat Unit Per Hour
**Add 5Vz"to height for Vent Damper
1"For altitudes above 2,000 ft rabngs should be reduced a[ the rate of 4% fc_ each 1,000 ft above sea level

Heating Capacity is based on DOE. (Department of Energy) test prc_edure

The Ratings marked "Net I=B=R Ratings" indicate the amount
of equivalent direct cast iron radiation each boiler will take

care of under normal conditions and thermostatic control.
The Net I=B=R Steam Ratings shown are based on an

allowance of 1.333 in accordance with the factors shown

in the I=B=R Code as published by The Hydronics Institute.

Selection of boiler size should be based upon "Net I--E_R

Rating" being equal to or greater than installed radiation in

square feet. Consult manufacturer before selecting a boiler
for installations having unusual piping and pickup requirements,

Specifications and dimensions are subject to change without
notice.

These Gas-Fired Steam Boilers are low pressure, sectional

cast iron boilers Design Certified by A.G.A. (American Gas
Association} for use with Natural Gas. They are constructed
and hydrostatically tested for a maximum working pressure

of 15 psi (pounds per square inch) in accordance with A.S.M.E.
(American Society of Mechanical Engineers) Boiler and

Pressure Vessel Code Section IV Standards for cast iron
heating boilers.

BOILERS FOR USE AT HIGH ALTITUDE

This boiler is factory equipped for use at altitudes of 0-2,000

feet above sea level. For use at altitudes above 2,000 feet
above sea level, the input ratings are reduced by a change

in main burner orifice size.
For altitudes above 2,000 feet above sea level, input ratings

should be reduced at the rate of 4% for each 1,000 feet
above sea level. Consult the National Fuel Gas Code

(NFPA54/ANSl Z223.1 -latest edition}, or the manufacturer for
correct orifice sizing information. High altitude orifices are

available from the boiler manufacturer.

r_7_c 4

Checktobesureyouhavetherightsizeboilerbeforestartingtheinstallation.

Seeratingand capacitytableon previouspage.Alsobe surethe new
boiler is for the type of gas youare using.Checkthe ratingplate on
therightsideof theboiler.

Youmustsee that the boiler is suppliedwith the correcttype of gas,
fresh air for combustion,anda suitableelectricalsupplyAlso,the boiler

mustbe connectedto a suitablechimneyandanadequatepipingsystem.

Finallya thermostat,properlylocated,is neededfor controlof theheating
system.If you haveany doubtsas to the variousrequirements,check

with local authoritiesandobtain professionalhetp whereneeded.Take

the time to completeall of the stepsfor SAFEandPROPERoperation

oftheheatingsystem.

Theseboilersare designedfor use in closedheatingsystemswhereall

of the steam is returnedto the boileras condensateandthe amount

of make-upwaterrequiredis minimal.Theseboilers are not designed

for or intendedfor use in opensystemsor processapplicationsusing

I

100%make-upwater.Damageto theboilerresultingfromsuchuseshall
notbecoveredunderthewarranty

Whererequiredby theauthorityhavingjurisdiction,the installationmust
conformto AmericanSocietyof MechanicalEngineersSafetyCodefor
ControlsandSafetyDevicesforAutomaticallyFiredBoilers,No.CSD-1.

Theinstallationmus_conformto therequirementsof theauthorityhaving
jurisdictionor,in theabsenceof suchrequirements,to the NationalFuel

GasCode,ANSIZ223.1-1atestrevision.
Thefollowingstepsareallnecessaryforproperinstallationandsafeoperation

ol yourboiler.

1. LOCATINGTHEBOILER 5. GASSUPPLYPIPING

2. FRESHAIRFORCOMBUSTION 6. ELECTRICALWIRING

3. INSTALLATION- SYSTEMPIPING 7. CHECKING&ADJUSTING

4. CHIMNEY& VENTPIPECONNECTION

KEEP BOILER AREA CLEAN AND FREE FROM COMBUSTIBLE MATERIALS,

GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS

1. Selectlevellocationas centralizedwith pipingsystem,and as near
chimney,aspossible.

2. Placecratedboilerat selectedlocation,removecrateby pullingcrate

sidesfromtop and bottom boards.Combustiblefloors:Whenboiler
is to be installedon a combustiblefloor,a SpecialBasePlatemust

beused- 146-14-031(3-6Section}or 146-14-032(7-9 Section}.
Thisboilermustnotbeinstalledoncarpeting.

3. If this boileris equippedwith cast iron burners,it is alsoequipped

with stainlesssteel wire ties to hold the backend of the cast iron
burnersin placeduringshipping.In orderto removetheburnersfor

cleaningor inspection,the wireties mustbe cut andremoved.The
wire ties are accessedthroughthe combustionair openingon the
backside of the boiler at the bottomof the rearjacketpanel,and
maybe cut with anywire cuttingpliers. I1the boileris installedat
its minimumclearancesit maybe difficultto reachthewireties after

the boileris installed,and lhe wireties shouldbe cutnow.Thewire
tiesareonlyneededduringshipping,anddo notneedtobereplaced.

Boilersequippedwithstainlesssteelburnersdonothavewire
ties andthis informationdoesnotapply.

4. Boiler is to be level.Metalshimsmaybe used underbaselegs for

finalleveling.

5. Accessibility clearances must take precedence over fire
protectionclearances.18"clearanceshouldbemaintainedat a side
wherepassageis requiredto accessto anothersidefor cleaningor

servicing,inspection,or replacementof any partsthat normallymay

requiresuchattention.18" clearanceis recommendedon thecontrol
sidefor servicing.

Figure2showsminimumclearancesto combustibleconstruction.Rooms
thatare largein comparisonwith the size of the boiler are defined

as rooms havinga volumeequal to or greaterthan16 times the
volumeof the boiler. Wherethe actualceilingheightof a room is

greaterthan8', the volumeof a roomshaftbe figuredon the basis
of a ceilingheighto18'. Determinationof roomsizeshouldbebased
on thetotal volumeof air gas fired equipmentinstalledin the room.

Consuttsection 6.3.1 of the NationalFuel Gas Code for further
information,includingapprovedmethodsfor reducingclearancesin

largerooms.

6. Equipmentshallbe installedin a locationin which the facilitiesfor

ventilationpermitsatisfactorycombustionof gas,properventing,and

maintenanceof ambienttemperatureat safe limits under normal

conditionsof use.Equipmentshall be locatedso as notto interfere

withpropercirculationofair.Whennormalinfiltrationdoesnotprovide
thenecessaryair,outsideairshallbeintroduced(SeePage6- "Fresh
Airfor Combustion").

7. Adviseownerto keepair passagesfree of obstructions.Ventilating
andcombustionairmustenterboilerroomwithoutrestrictions.

8. Theboilershallbeinstalledsuchthattheautomaticgasignitionsystem
componentsare protectedfrom water(dripping,spraying,rain,etc.)
during applianceoperationand service (condensatetrap, control
replacement,etc.).

Top
Rear

Control Side
Opposite Side

Front
Flue/Vent Connecto_

Near Boiler Piping

BoilerVolume

(Cu.Ft.)

63

8!
99

11.7

13.5
153

17.2

BoilerSize

3 sect.
4 sect.
5 sect.
6 sect.
7 sect.
8 sect.
9 sect.

Alcove,orRoomNMLarge

InComparisonWithBoiler

6'
6' 6*
7' 6*
6' 6'

18" 18'

6" 6"

1" 1"

MinimumRoomVolumeRequiredToBe

LargeRoom(Cu.Ft.)*

100.4

129.4

158.4

187.4
216,4

245.4
274,5

RoomLargeIn

ComparisonWithBoiler

6'

* FORROOMWITHSINGLEBOILERONLY

THIS UNIT MUST BE SET ON A CONCRETE OR OTHER

NON-COMBUSTIBLE MATERIAL BASE OR FLOOR.

Provision for combustion and ventilation air must be in accordancewith Section 5.3, Air for Combustionand

Ventilation, of the National Fuel Gas Code,ANSI Z223.1-1atest revision, or applicable provisionsof the local buildingcodes.

WARNING

Besure to provideenough fresh air for combustion.
Enoughair insuresproper combustionand assuresthat

nohazardwilldevelopdueto the lackofoxygen.

You must provide for enough fresh air to assure proper
combustion. The fire in the boiler uses oxygen. It must have
a continuous supply. The air in a house contains only enough

oxygen to supply the burner for a short time. Outside air
must enter the house to replace that used by the burner.

Study following examples 1 and 2 to determine your fresh

air requirements,

EXAMPLE 1: Boiler Located in Unconfined Space

If your boiler is in an open area (unpartitioned basement)
in a conventional house, the air that leaks through the cracks
around doors and windows will usually be adequate to provide
air for combustion. The doors should not fit tightly. Do not

caulk the cracks around the windows,

An unconfined space is defined as a space whose volume

is not less than 50 cubic feet per 1,000 Btu per hour of

the total input rating of all appliances installed in that space.

EXAMPLE 2: Boiler Located in Confined Space

A. All Air from Inside the Building: The confined space

shall be provided with two permanent openings
communicating directly with an additional room(s) of
sufficient volume sothat thecombined volume of all spaces

meets the criteria foran unconfined space. The total input
of all gas utilization equipment installed in the combined

space shall be considered in making this determination.
Each opening shall have a minimum free area of one

square inch per 1,000 Btu per hour of thetotal input rating
of all gas utilization equipment in the confined space, but

not less than 100 square inches. One opening shall be
within 12 inches of the top and one within 12 inches of

the bottom of the enclosure,

B, All Air from Outdoors: The confined space shall be

provided with two permanent openings, one commencing
within 12 inches of the top and one commencing within

12 inches of the bottom of the enclosure. The openings

shall communicate directly, or by ducts, with the outdoors
or spaces (crawl or attic) that freely communicate with

the outdoors.

1. When directly communicating with the outdoors, each
opening shall have a minimum free area of one square
inch per 4,000 Btu per hour of total input rating of alt
equipment in the enclosure.

NOTE

If you use a fireplace or a kitchen or bathroom exhaust

fan, you should install an outside air intake.These devices
will rob the boiler and water heater of combustion air.

2. When communicating with the outdoorsthrough vertical
ducts, each opening shall have a minimum free area
of one square inch per 4,000 Btu per hour of total
input rating of all equipment in the enclosure.

3. When communicating with the outdoors through
horizontal ducts, each opening shall have a minimum

free area of one square inch per 2,000 Btu per hour
of total input rating of all equipment inthe enclosure.

4. When ducts are used, they shall be of the same cross-
sectional area as the free area of the openings to which
they connect. The minimum dimension of rectangular

air ducts shall be not less than three inches.

Fresh Air Duct Capacities for Ducts Supplying Fresh Air to
boiler in tightly constructed houses. British Thermal Units per

hour Input (Btuh)*.

Fresh Air 1/,-Mesh Wood Metal

Duct Screen Louvers Louvers
Size Btuh Btuh Btuh

3' x 12' 144,000 36,000 108,000
8" x 8' 256,000 64,000 192,000

8' x 12" 384,000 96,000 288,000

8V2' x 16' 512,000 128,000 384,000

*Basedon opening covered by V4"meshscreen,woodIouvers,ormetallouvers.

FRESH AIR DUCT
FOR TIGHTLY
SEALED HOUSE

FRESH

AIR
DUCT

,_,* 6

The near boiler piping, that is the piping around the boiler,

must be considered as part of the boiler for proper water
level control, and to produce dry steam. Correct near boiler

piping is crucial to the proper operation of the boiler and

the heating system. Follow these recommendations carefully

1 Place boiler in selected location, as near chimney as

possible.

2. Install the pop safety valve, using the furnished 3/4"
coupling, into the 3/4' pipe nipple on the top of the boiler.
Make a discharge pipe, using 3/4' pipe (not furnished}

to carry the water or steam to a nearby drain. Do not

connect the discharge pipe directly to a drain but leave
an air gap. The downstream end of the discharge pipe

must be unthreaded. No shutoff of any description shall
be placed between the pop safety valve and the boiler,

,

4.

or on discharge pipes between such safety valves and

the atmosphere. Installation of the pop safety valve shall

conform to the requirements of the ANSI/ASME Boiler and
Pressure Vessel Code, Section IMThe manufacturer is not

responsible for any water damage

This boiler is equipped with two 2V2' supply connections
and two 2V2" return connections, one each on both the

left and right sides of the boiler. Unused connections must
be plugged with the 2V2" plugs (furnished}

Recommended near boiler piping for gravity return
systems is shown in Figure 5. This configuration uses one
supply and one return tapping. This setup can be used
on any size boiler in this series. The supply and return
connections may be piped both into the same side (either

left or right} or one into each side of the boiler.

PiPEFULLSIZESAME

ASBOILERTAPPING

(2

POPSAFETYVALVE

FLUE

2 1/2" TEEWITH
PLUGFOR

24"

JFEED

STEAMMAINS

- REDUCINGELLPOINTING

DOWN

6" TO 10"

1 1/2" MIN

PIPESIZE

15" MIN.

28' MIN - DIMENSIONA

NIPPLE

)RD LOOP

WETRETURN

-GATE VALVE(NOT FURNISHED)

_" DRAINVALVE(FURNISHED)

FOR FLUSHINGSYSTEM

I 1/2" FULL PORT BALL VALVE

FOR BOTTOMBLOWDOWN
AND DRAINING BOILER
& SYSTEM(NOT FURNISHED)

MAINVENT

DRYRETURN
MAIN

7,_

5. For installers choosing to use both supply tappings, Figure
6A shows the correct way to pipe this system. Figure

6B shows the wrong way to pipe a header with two risers.

• Headers must be fitted with header offsets or swing joints,

or be equipped with expansion joints, so that thermal
expansion and contraction of the header will not damage

the boiler. Headers shall not be welded.

• System takeoffs from the header must be between the

equalizer and the riser to the header nearest the
equalizer. System takeoffs must never be between two

risers.

6. System takeoffs from the header must never be bul-
lheaded. If the steam main goes in two directions, there

must be two takeoffs from the header, one for each main.

7. All boilers in gravity return systems must be equipped
with a Hartford Loop as shown in Figures 5 and 6A.

8. When piping the vertical risers from the boiler to the
header, the bottom of the header must be a minimum

of 24 inches above the water level line on the right side
of the boiler.

9. Steam riser(s) and header shall be 2V2"pipe size.

10. Equalizer line shall be minimum iV2" pipe size.

11. The near boiler piping shall include a 21/2, tee with a
plug located on the supply line as shown for skimming
{i.e. surface blowdown).

PIPEFULLSIZESAN_E

AS BOILERTAPPING

(2 1/2"

POP SAFETY VALVE

CONNECTRISERTO BOILERWITH
2 I/2"ELBOWAND NIPPLE

(NOTSHOWN)

FLUE

COLLAR

MIN

2 1/2" TEEWITH
PLUGFOR

@ 24"

W_AfERFEED

STEAM MAINS

ELLPOINTING

DOWN

1 1/2" MIN.

PIPESIZE

NIPPLE

6" TO 10"

MAINVENT

DRY RETURN
MAIN

1S"MIN.

28" MIN DIMENSIONA

HARTFORD LOOP

RETURN

-GATEVALVE(NOTFURNISHED)

_ORAIN VALVE(FURNISHED)

FOR FLUSHINGSYSTEM

I I/2"FULLPORT BALLVALVE

FOR BOTFOMBLOW DOWN
AND DRAININGBOILER

& SYSTEM(NOTFURNISHED)

WRONG WAY

DO NOT BULLHEAD,USE

TWO TAKEOFFS

THIS PIPING CONFIGURATION

IS INCORRECTTO SHOW

COMMONMISTANES

WRONG WAY

TAKE OFFS MUST BE BETWEEN RISER & EQUALIZER

WRONG WAY

SWING JOINTS ARE MISSING

)NG WAY

MISSING TEE
FOR SKIMMING

12. The near boiler piping shall include a 1V2" ball valve
in the return piping as shown for bottom blowdown and

draining.

13. For gravity return systems, the bottom of the lowest steam
carrying pipe, be it a dry return, or the end of the steam

main, must be at least 28' above the normal water level
line on the right side of the boiler. This is known as

"Dimension A."

14. For pumped return systems, follow the condensate pump
or boiler feed pump manufacturer's instructions for proper
installation and hookup.

15. In connecting the cold water supply to the water inlet
valve, make sure that a clean water supply is available.

When the water supply is from a well or pump, a sand
strainer should be installed at the pump.

FOR USE WITH COOLING UNITS

A. This boiler, when used in connection with chilled water

systems, must be installed so that the chilled water is piped

in parallel with the heating boiler. Appropriate valves must
be used to prevent the chilled water from entering the

heating boiler (Fig. 7).

B. When this boiler is connected to heating coils located

in air handling units where they may be exposed to
refrigerated air circulation, the piping system shall be

equipped with flow control valves or other automatic means
to prevent gravity circulation of the boiler water during
the cooling cycle.

VALVES A & B
OPEN FOR HEATING;

CLOSE FOR COOLING

VALVES C & D
CLOSE FOR HEATING:

OPEN FOR COOLING

TO SYSTEM t

C

O

CHILLER

_4_o7

I For boilers for connection to gas vents or chimneys, vent installations shall be I

In accordance with Part 7, VenUng of Equipment, of the National Fuel Gas Code,

IANSI Z223.1-1atest revision and applicable provisions of the local building codes.

CHECK YOUR CHIMNEY

This is a very important part of your heating system. It must

be clean, the right size, properly constructed and in GOOD
CONDITION. No boiler can function properly with a bad chim-

ney Inspect the chimney and verify that the construction and
size of the chimney meets all applicable provisions of the
National Fuel Gas Code and local building codes. Fig. 8
gives you an idea how a boiler might be vented to a chimney.
Note that the height (HT) is measured from the vent pipe
to the top.

CHIMNEY SIZING

Chimney sizing and all other aspects of the vent installation

must be in accordance with Part 7 of the National Fuel Gas
Code, ANSI Z223.1-latest revision, and applicable provisions

of the local building codes.

CONNECTING THE VENT DAMPER
AND VENT CONNECTOR

Refer to Fig. 1 flue diagram for the size and location of the
vent (flue opening). Use a 28 gauge (minimum) galvanized
pipe to connect to the chimney

IMPORTANT - The damper blade on the furnished vent
damper has a 1/2square inch hole (approximately 3A,diame-
ter). On boilers equipped with standing pilot, the hole must

be left open. On boilers equipped with intermittent ignition,
the hole should be plugged by using the plug supplied with
the vent damper.

1. Position furnished vent damper on top of flue outlet collar,
Fasten damper securely to flue outlet collar with sheet

metal screws. Make sure damper blade has clearance
to operate inside of diverter.

As An Option

The damper may be installed in any horizontal or vertical

position, closer to the flue outlet collar preferred. Follow

the diagrams - Figures 9, 10 and 11.

2. Install the vent damper to service only the single boiler
for which it is intended. The damper position indicator

shall be in a visible location following installation. Locate

the damper so that it is accessible for servicing.

3. The damper must be inthe open position when appliance
main burners are operating.

4. The boiler is equipped with a factory wired harness that
plugs into the vent damper. The thermostat must be

connected to the black wires marked 24 volt thermostat
on the boiler.

5. Vent pipe must be same size as the flue outlet collar.

6. Slope pipe up from boiler to chimney not less than V4'
per foot.

7. Run pipe as directly as possible with as few elbows as
possible.

8. Do not connect to fireplace flue.

9. End of vent pipe must be flush with inside face of chimney
flue. Use a sealed-in thimble for the chimney connection.

10. Horizontal run should not be longer than 3Athe chimney
height (HT) (Fig. 8).

The sections of vent pipe should be fastened with sheet metal
screws to make the piping rigid. Horizontal portions of the

vent system must be supported to prevent sagging. Use
stovepipe wires every 5' to support the pipe from above.

If the vent pipe must go through a crawl space, double wall
vent pipe should be used. Where vent pipe passes through
a combustible wall or partition, use a ventilated metal thimble,
The thimble should be 4 inches larger in diameter than the
vent pipe.

MINIMUM VENT PIPE CLEARANCE

Wood and other combustible materials must not be closer

than 6' from any surface of single wall metal vent pipe. Listed

Type B vent pipe or other listed venting systems shall be

installed in accordance with their listing.

REMOVING EXISTING BOILER FROM

COMMON VENTING SYSTEM

When an existing boiler is removed from a common venting

system, the common venting system is likely to be too large

for proper venting of the appliances remaining connected

to it.

At the time of removal of an existing boiler, the following

steps shall be followed with each appliance remaining
connected tothe common venting system placed in operation,

while the other appliances remaining connected to the
common venting system are not in operation.

1,

2.

Seal any unused openings in the common venting system.
Visually inspect the 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.

,

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 the building. Turn on clothes

dryers and any appliance not connected to the 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 fireplace dampers.

,,_ 10

4 Placeinoperationtheappliancebeinginspected.Follow

thelightinginstructions.Adjustthermostatsoappliance
willoperatecontinuousl_z

5.Testforspillageatthedrafthoodreliefopeningafter5
minutesofmainburneroperation.Usetheflameofamatch

orcandle,orsmokefromacigarette,cigarorpipe

6.Afterithasbeendeterminedthateachapplianceremain-
ingconnectedto thecommonventingsystemproperly

ventswhentestedas outlinedabove,returndoors,
windows,exhaustfans,fireplacedampersandanyother
gas-burningappliancetotheirpreviousconditionsofuse

7 Any_mproperoperationof thecommonventingsystem

shouldbecorrectedsotheinstallationconformswiththe
NationalFuelGasCode,ANSIZ223.1-latestrevision.When

resizinganyportionof thecommonventingsystem,the
commonventingsystemshouldbe resizedtoapproach

them_n_mumsizeasdeterminedusingtheappropriate

tablesin Part11 in the NationalFuelGasCode,ANSI
Z223.1-latestrewsion.

For boilers for connection to gas vents or chimneys,
vent installations shall be in accordance with Part 7,

Venting of Equipment, of the National Fuel Gas Code,

ANSI Z223.1-1atest revision and applicable provisions
of the local building codes,

Vent connectors serving appliances vented by natural
draft shall not be connected into any portion of mech-

anical draft systems operating under positive pressure.

ROOF
RIDGE

3/4 HT MAXIMUM

HT

MUST SLOPE UP
AT LEAST 1/4 INCH

PER FOOT OF
HORIZONTAL RUN

HORIZONTAL INSTALLATION

TO FURNACE VENT TO CHIMNEY

OR BOILER DAMPER INSTALL VENT DAMPER WITH

ACTUATOR TO SIDES OF

VENT ONLY, DO NOT MOUNT

ABOVE OR BELOW VENT.

VERTICAL INSTALLATION

TO CHIMNEY [_

FLOW VENT

DAMPER

ACTUATOR MAY BE

TO FURNACE N INSTALLED IN ANY POSITION

OR BOILER

U

TYPICAL INSTALLATION FOR VENT DAMPER

NOTE CAUTION AND FOOTNOTES

1. Install the vent damper to service only the single appliance for
which it is intended,ff improperlyinstalled,a hazardous condition,
such as an explosion or carbon monoxide poisoning, could result.

2. Do not install the vent damper on vent pipe curve.

3. DO not run wiras near high temperature surfaces. Use stand-off
brackets itnecessary

For safe, efficient operation, the vent damper and all flue
product carrying areas of the appliance must be checked
annually by you, with particular attention given to deterioration
from corrosion or other sources. Ifyou see corrosion or other
deterioration, contact your heating contractor for repairs.
Check vent damper operation as follows:

1. When the boiler is off, check that the vent damper position
indicator points to the closed position, Fig. 11.

2. Turn the thermostat or controller up to call for heat and
check that the vent damper indicator points to the open

position, Fig. 11.

3. Turn the thermostat or controller down again and check
that the vent damper position indicator returns to the closed

position.

4. If you have central air conditioning, set the thermostat to
COOL and turn it down to call for cooling. Cooling system
should operate.

5. Return thermostat to desired position.

The vent damper must be Inspected st least once a
year by a trained, experienced service technician, The

name of the person who originally installed your vent

damper is shown on the installation label.

MANUAL OPERATION OF THE VENT DAMPER

The Effikal vent damper may be placed in the open position
to permit burner operation by using the "HOLD DAMPER

OPEN" switch, located on the damper controller. The

thermostat will control the burner firing as before, while the
damper will remain open. DO NOT turn damper open manu-

ally or motor damage will result. Set switch to "AUTOMATIC
OPERATION" to close vent damper during burner off cycle.

For further information, and for a vent damper troubleshooting
guide, refer to the Effikal manual that was packaged with

the vent damper.

iI

DAMPER CLOSED DAMPER OPEN

SHOWING OPEN AND CLOSED POSITION

CHECK GAS SUPPLY

The gas pipe to your boiler must be the correct size for the
length of the run and for the BTU per hour input of all gas
utilization equipment connected to it. See Fig. 12 for the
proper size. Be sure your gas line complies with local codes
and gas company requirements.

The boiler and its individual shutoff valve must be
disconnected from the gas supply piping system during any

pressure testing of that system at test pressures in excess
of V2psig (3.5 kPa).

The boiler must be isolated from the gas supply piping system

by closing its individual manual shutoff valve during any
pressure testing of the gas supply piping system at test
pressures equal to or less than V2psig (3.5 kPa).

CONNECTING THE GAS PIPING

Refer to Fig. 13 for the general layout at the boiler. It shows

the basic fittings you will need. The gas line enters the boiler
from the right side.

The following rules apply:

1. Use only those piping materials and joining methods
listed as acceptable by the authority having jurisdiction,

or in the absence of such requirements, by the National
Fuel Gas Code, ANSI Z223.1-latest revision.

2. Use pipe joint compound suitable for LP gas on male
threads only.

3. Use ground joint unions.

4. Install a sediment trap upstream of gas controls.

5. Use two pipe wrenches when making the connection
to the gas valve to keep it from turning.

6. Install a manual shut-off valve in vertical pipe about 5
feet above floor.

7. Tighten all joints securely

CHECKING THE GAS PIPING

Upon completion of piping, check immediately for gas leaks.

Open the manual shut-off valve. Test for leaks by applying
soap suds (or a liquid detergent) to each joint. Bubbles
forming indicate a leak. CORRECT EVEN THE SMALLEST

LEAK AT ONCE.

WARNING 1Never use a match or open flame to test for leaks.

.... 12

NATURAL GAS

Pipe Capactty- BTUPer Hourlnput

Length of Includes Fittings

Pipe - Ft.

½" ¾" 1" 1%"

20 92,000 190,000 350,000 625,000

40 63,000 130,000 245,000 445,000

60 50,000 ! 05,000 195,000 365,000

MANUAL
SHUT-OFF

VALVE

AUTOMATIC

VALVE

GROUND
JOINT

MANIFOLD UNION

S OI.ENTTRAP p l

FLOOR
LINE _u

ELECTRIC POWER SUPPLY

All electrical work must conform to local codes, as well as

the National Electrical Code, ANSI/NFPA-70, latest revision.

Run a separate 120 volt circuit from a separate overcurrent
protective device in your electrical service entrance panel.
This should be a 15 ampere circuit. Locate a shut-off switch
at the boiler. It must be turned off during any maintenance.
Connect 120 volt electrical supply to the primary leads on
the 24 volt transformer. Solder and tape or securely fasten

these connections with wire nuts.
The boiler, when installed, must be electrically grounded in

accordance with the requirements of the authority having

jurisdiction or, in the absence of such requirements, with the

National Electrical Code, ANSI/NFPA No. 70-latest revision.

Run a 14 gauge or heavier copper wire from the boiler to

a grounded connection in the service panel or a properly

driven and electrically grounded ground rod.

]

WARNING

Turn off electric power at fuse box before making any
line voltage connections. Follow local electrical codes.

I

INSTALL YOUR THERMOSTAT

The thermostat location has an important effect on the

operation of your boiler system. BE SURE TO FOLLOW THE
INSTRUCTIONS INCLUDED WITH YOUR THERMOSTAT.

Locate the thermostat about five feet above the floor on an
inside wall. It may be mounted directly on the wall or on

a vertically mounted outlet box. Itshould be sensing average
room temperature, so avoid the following:

DEAD SPOTS:

Behind doors
Corners and alcoves

HOT SPOTS:

Concealed pipes
Fireplace

TV sets
Radios
Lamps

Direct sunlight
Kitchens

COLD SPOTS:

Concealed pipes or ducts
Stairwells - drafts

Doors - drafts

Unheated rooms on other side of wall
Set heat anticipator at 0.4 amps for boilers equipped with
standing pilot, and at 0.6 amps for boilers equipped with

intermittent ignition. The 24 volt thermostat leads shall be
connected to the two wires tagged "24 volt thermostat" on
the boiler. For boilers with 67D-1 float type low water cut-
off, the two wires are black. One wire is located on the
secondary of the 24 volt transformer, the second wire is

located on the pressure limit control. For boilers with PS-
802 probe type low water cut-off, one wire is green and

is located on terminal B of the PS-802, the second wire is
black and located on the pressure limit control.

ELECTRONIC THERMOSTATS

Certain types ofelectronic therrnostats may lose their memory
or shut down. With 67D-! float type low water cut offs,
this may occur each time the thermostat calls for heat,
due to the internal circuit in the vent damper. With PS-802

probetypelowwatercutotis,thismayoccureachtimethe
lowwatercutoffdetectsa lowwaterconditionIfthisisthe

case,anisolationrelayisrequiredforthethermostatcircuit
A24voltsinglepolesinglethrow(SPST)normallyopen(N.O.)
relay _srequired,such as the HoneywellR8222Aor
equivalent.WireasshowninFig.14AorFig.14B.

VENT DAMPER

The boiler is equipped with a factory wired harness with 4

pin molex plug, that plugs into the 4 pin molex receptacle
inside the vent damper operator.

The vent damper must be connected for the boiler to operate.

Wiring diagrams follow for the various different models.

CAUTION

Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation, Verify proper
operation after servicing.

24 VOLT

TRANSFORMER

VENT DAMPER

4 PLN

MOLEX PLUG

TO LWCO AND

IGNITION SYSTEM

-ISOLATION RELAY 24V.

SPST N+O. HONEYWELL

Y I R8222A OR EQUIVALENT

' !O

,_-----t----IBK

]_,_? i PRESSURE LIMIT

L........ p.J

.... .+tJ

%\

ELECTRONIC

THERMOSTAT

.... FIELD WLRING

VENT DAMPER

4 PIN

MOLEX PLUG

BK

24 VOLT r_

TRANSFORMER L_

7

TO LWCO AND

IGNITION SYSTEM

_y _-ISpOs[TATI?o ' REoLNAYyW22E VL

R8222A OR EQUIVALENT

°

+ ++ __±,,",PRES_ LIMIT

L -," TERMINAL++

-o"o--- G OF LWCO
_- ELECTRONIC

THERMOSTAT

--- FIELD WLRING

..... 14

_ -- WIRE NUT

COLOR CODE

8K-BIJ_CK

BR-BROWN

0 -ORA_C£

y -_AA_OW

R -RED
BT-BIJ_CN WITH TRACER

W -11_41rE

G -GRE[]_

8 -BLUE

EFFIKAL RVGP VENT OA,_PER
MOLEX PLUG

I15V/BOHZ/I f L_

pOWER B_X

SUPPLY

r-l_ \/

j\®/.....

L_ _____.j'--"

OP_ONAL WF-2U-2_.

WATi_
_"l{EOER

NOTE:

T_¼1N_. N0 ] APpFJ_R$ ONLy

ON WATER FEEC_R MODELS WITH
tJXNL_I. _£0 PUSH 8U_'ON.

INTERMITTENT IGNITION

) _

iiii

_LWC 0 pRoBEWt_RMRTF'NT pIL'OT CONTRCt

R TO PrLOT

SAP_ SHUTOFF

AI_V[

VR8204A / VR8304M

IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED,

IT MUST BE REPLACED WITH TYPE 105° C THERMOPLASTIC WIRE OR ITS EQUIVALENT.

15 7411_

_--WIRE NUT

HeVI_OHZllm i (

pOW_ 8K

SUpPLy

.T

_SO3NNECT _

A

',IQ-÷ .......

I_@-4

L_X=/___J- .....

COLOR CODE

8X-B_

BR-E_ROWN
0 -ORANGE OPI1ONAL _-2U--:14

y -YELLOW W_TER

R -RED REED_
BT-B_ VCh'H TRACER NOTE:
W -WHITE

G -GREEN TERMIteS. NO, 3 APpF_S C_NLY
8 -BLUE ON WATER F_ER MOC_'LS

MANUAL BEF.,D PUSH t_,rrTON

STANDING PILOT

EFFIKAL RVGP V_NT DAMPER
MOLEX PLUG

)@(

Y

r......

J

PRESSURE UMIT

I
I

I

RVGP-KS-BKF VENT OA._PER

OOUBL_ POLE, DOUBLE THROW RELAy

II 4 POLE CONNECrOR

/-;

NC

C

N.C.

I I

12_._?I

i 7J-_6 I

15_15 I

.... _2 J

A.C. TO D.C POWER

). CONVERSION CIRCUIT

,3-

MOTOR

_2 4 VAC

50/60 HZ

N'O

N.C,

N,C, C

®..o.__-___J

PI_osTAT

LIMI T LWCO

1_ 24 V.

_1-0411yll

FLA_E ROLLOUT

SHUTOFF

_ N[UT_ L

BLOCKED _NT HOT
S_E_ O_RCURRENT
SHUTOFF PROTECT[D

GAS DISCONNECT
VAL_

i1_V/BOHZ/I_

NOTE:

SlA AND SlB ARE THE AUTOk_T_C Op[RATJON / HOLD BAMPER OPEN SWITCH
SWITCH SHOWN tN AUTOMATICPOSLTION.

$2, $3. AND S4 ARE CAXt ACTUATEDSNAP SV_TCHES

IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED,

IT MUST BE REPLACED WITH TYPE 105° C THERMOPLASTIC WIRE OR ITS EQUIVALENT.

I_-- WIRE NUT

INTERMITTENT IGNITION

24 VOLT
TRANSFORMER

115V/BOHZ/I_ %

POWER SUPPLY

.oT-_Jo-._

0V£RCURRENT PROTECTED

DISCONNECT

W

NEUT

\ )

\(_ .....

OPTIONAL WF-2U-24

WAFER FEEDER

NOTE:

TERMINAL NO. 3
APPEARS ONLY ON

WATER FEEDER MODELS
WITH MANUAL FEED PUSH BUTTON

EFFIKAL RVGP VENT DAMPER

MOLEX PLUG

pR_SSURC LIMIT

FLAME ROLLOUI T

GAS VALVE

RVCp-KS-BKF V,ENT O_IpzR

" i _ ZNr DAtaPER C_.81E

I 7 I I r

_ _6 I --

is i ...... 'p._L"o,1 r.ER'_OS,^T

Kt r r _ Ll_Ir

°," ,'

-- i Y BK _

o D ,°'-°",1I

S2j'a-_

( _°,fv°_ _--i L# I ;2_;, I.

50/60 HZ. 8K N_UIRAL

LWC0 _ _HO T 115'V/60HZ/ II_

NC N0 Nj

.-% .o1o

kOTD

SlA A_O SIB _g THE AUT0_TIC
OPg_TrON / HIN_ _I_R OPEN NTCH
S,N_TCH SHNH IN _OMATIC POSmI_.

_FFPr

5NUIOFF

BLOCKED _T
SV_"ET_

SHUTOFF

cAs

VRB204A / VR8304M

OV£RCURRENI PROT[CTED

DISCORNECT

S8600(F,M) INI[RUlTT[N_ PILOI CONTROL

>>>Z _" N _.

1234 S 6 g

T TO pILOt BURN£R

IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED,

IT MUST BE REPLACED WITH TYPE 105° C THERMOPLASTIC WIRE OR ITS EQUIVALENT.

1 7 741_3

EFFIKAL RVGP VENT DAMPER STANDING PILOT

MOLEX PLUG

NOTE:

I_ -- WIRE NUT

24 VOLT
TRANSFORMER

IIBV/6OHZ/I¢

POWER SUPPLY

HOT ._----_--_

OVERCURRENT PROTECTED

DISCONNECT

W

NEUT

OPTIONAL WF-2U-24
WATER FEEDER

TERMINAL NO. 3 APPEARS ONLY
ON WATER FEEDER MODELS WITH

MANUAL FEED PUSH BUTTON.

PRESSURE LIMIT

BT I

I

J y

BK

FLAME ROLLOUT
SAFETY SHUTOFF

LOW WATER

CUT OFF

_ VALVE

TR T_ TH

B K

BLOCKED VENT
SAFETY SHUTOFF

RVCp-KS-BKF V_NT OA._pER

TO OC. POWER

CONVERSION CIRCUIT

NC

C

IP1-03

NOTE:

S1A AND SIB ARE THEAUTO,TIC OPERATION / HOL0 DAMPER OPEN SWITCH¸
SWITCH SHOWN IN AUrO_:ATICPOSITION¸
$2. $3. Nq0 $4 ARE CAM ACTUATEDSN_o SWITCHES.

IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED,

IT MUST BE REPLACED WITH TYPE 105 ° C THERMOPLASTIC WIRE OR ITS EQUIVALENT.

..... 18

POP SAFETY VALVE

The pop safety valve should open automatically if the boiler
steam pressure exceeds the pressure rating of the valve (15

psig). Should it ever fail to open under this condition, shut
down your boiler. If valve discharge occurs, or valve fails
to open as described above, contact an authorized contractor

or qualified service technician to replace the pop safety valve
and inspect the heating system to determine the cause, as
this may indicate an equipment malfunction.

Run a p_pe from the safety valve outlet (pipe must be same
size as outlet and open end must not be threaded) to an

open drain, tub or sink, or other suitable drainage point not

subject to freezing. Failure to do so may cause Water damage

or injury should relief valve release Do not cap off the drain

line from this valve!

STEAM PRESSURE GAUGE

Every system should have a pressure gauge installed in the

boiler. This gauge enables you to monitor the pressure in

the system. If the safety devices fail to shut off your boiler

at the proper settings, notify your serviceman immediately

WATER LEVEL GAUGE

The water level in the boiler can be seen through the glass

tube in the water level gauge at side of boiler. Correct cold

boiler water revel is stamped on side jacket panel. The water

level should be checked regularly for the proper level.

On the right side jacket panel of the boiler, there are three

holes for the glass water level gauge. The top hole is common

for both types of low water cut off, and is used for the upper

gauge glass fitting. The middle hole, 9" down from the top

hole, is used for the bottom gauge glass fitting for the Model
67D-1 and 47-2 float type low water cut off. The lowest hole,

12V4"down from the top hole, is used for the bottom gauge
glass fitting for the Model PS-802 probe type low water cut

off. The hole that is not being used is covered with a sheet
metal knockout.

STEAM PRESSURE CONTROL

The steam pressure limit control {pressuretrol) shuts off the
gas to the main burners when the steam pressure in the

boiler reaches the cut-off setpoint (i.e. the sum of the cut-
in and the differential setpoints). Burners retire when the steam

pressure drops to the cut-in setpoint. System pressure
requirements are based on the size and condition of the

pipes, and the load.

LOW WATER CUT-OFF

1 Model 67D-1

This is a float operated switch which shuts down the gas
burner if water falls below the visible bottom of the gauge

glass.

2. Model PS-802
This is an electronic probe type LWCO. The probe is

located inside the boiler. The LWCO will shut down the
burners if the water loses contact with the probe for a

period of 10 seconds.

Refer to manufacturer's instructions {enclosed) for more

information.

WATER FEEDER (Optional)

The Model WF-2U-24 water feeder may be used with either
of the available low water cut-offs. The water feeder's job

is to maintain a safe minimum water level It's used to
keep the boiler running by compensating for minor

evaporative steam leaks, and to prevent freeze-ups if the
homeowners are away and a return line should spring

a leak.
McDonnell and Miller Model 101 water feeders may be

used, however the water feed rates are too high and need
to be regulated or throttled, and wiring will have to be
revised. Consult the boiler manufacturer before using these

or any other non-standard types of controls.
The automatic water feeder is a safety device, not a

convenience item. It is not designed to maintain a "normal"
water line. The water feeder does not take the place of

a responsible person monitoring and maintaining the
normal water line. Steam boilers require personal attention.

VENT DAMPER

This is an automatic, motorized stack damper that has

been developed to increase the efficiency of heating

systems by reducing standby losses from the boiler end
the conditioned air space. The damper closes the chimney

vent when the burner is off and fully opens it when
combustion is required.

ROLLOUT SWITCH

(FLAME ROLLOUT SAFETY SHUTOFF)

The rollout switch is a temperature-sensitive fuse link

device. It is located on the boiler base just outside the

fire box. In the event of heat exchanger flueway blockage

causing flame to roll out of the fire box, the fuse will blow,
shutting down the flow of gas to the main burners. The

fuse does not change in appearance when blown.
If the rollout switch blows, it must be replaced with an

exact replacement. Check heat exchanger flueways for
blockage when restoring system to operating condition.

Do not operate system without a rollout switch.

SPILL SWITCH

(BLOCKED VENT SAFETY SHUTOFF)

The spill switch is a manual reset disc thermostat with
a fixed setpoint (280 ° F), and normally closed contacts.

It is located at the relief opening of the draft diverter. In
the event of chimney or venting system blockage causing

products of combustion to spill out of the relief opemng,

the spill switch disc heats up and the spill switch contacts
will open, shutting down the flow of gas to the main burners

by removing power to the gas valve.
In the event that the spill switch contacts open, the reset

button on the back of the switch will pop up. The spill
switch must be reset manually, after the switch has cooled

off, by pushing the reset button down. Check the venting
system and chimney for blockage when restoring the

system to operating condition. DO NOT operate the boiler
without a spill switch.

1 9 7_ISH

WARNING: If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury or loss of life.

A. Some boilers are equipped with an intermittent ignition

device which automatically lights the pilot. Do not try to
light the pilot by hand.

Some boilers are equipped with a continuous pilot and
must be manually lighted. (See lighting instructions on page

17.)A match holder is included in the parts bag.

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 any phone
in your building.

C.

E_

• 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.

Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or turn

by hand, don't try to repair it, call a qualified service
technician. Force or attempted repair may result in a fire
or explosion.

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 control
system and any gas control which has been under water.

1. STOP! Read the safety information on this page.

2. Set the thermostat to lowest setting.

3. Turn off al! electric power to the appliance.

4. This appliance is equipped with an ignition device which
automatically lights the pilot. Do not try to light the pilot
by hand.

GAS

INLET |

GAS CONTROL KNOB

SHOWN IN "ON" POSITION

5. Remove lower front panel.

6. Rotate the gas control knob clockwise _ to "OFE"

7. Wait five (5) minutes to clear out any gas. Then smell
for gas, including near the floor. If you smell gas, STOP!

Follow "B" in the safety information on this page. If you
don't smell gas, go to next step.

8. Rotate the gas control knob counterclockwise I# to "ON."

9. Replace lower front panel.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the instructions
"To Turn Off Gas To Appliance" and call your service

technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is
to be performed.

3. Push in gas control knob slightly and turn clockwise

to "OFE" Do not force.

..... 20

1.STOP!Readthesafetyinformationonpage16.

2. Setthethermostattolowestsetting.

3.Turnoffallelectricpowertotheappliance.

4. Removelowerfrontpanel.

5. Rotategas controlknobslightlyandturn clockwise
to

GAS CONTROL KNOB

[-SHOWN IN "ON" POSITION

/

GAS

INLET

• O

RESET BUTTON

6. Wait five (5) minutes to clear out any gas. Then smell
for gas, including near the floor. Ifyou smell gas, STOP!

Follow "B" in the safety information on page 16. If you
don't smell gas, go to next step.

7. Find pilot - follow metal tube from gas control. The pilot

is between two burner tubes as shown in Fig. 15.

8. Turn knob on gas control counterclockwise _ to

"PILOT"

9 Rotate the gas control knob counterclockwise _, to

"PILOT" Push down and hold the red reset button while
you light pilot burner with a match.
After about one minute, re[ease reset button. Pilot should
remain lit If it goes out, turn gas control knob clockwise

to OFE To relight, repeat steps 5-9.

• If button does not pop up when released, stop and
immediately call your service technician or gas supplier.

• If the pilot will not stay lit after several tries, turn the

gas control knob to "OFF" and call your service
technician or gas supplier.

10. After pilot remains lit when red reset button is released,
turn gas control knob counterclockwise _ to "ON."

1!. Replace lower front panel.

12. Turn on all electric power to the appliance.

13 Set thermostat to desired setting.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is
to be performed.

3. Push in gas control knob slightly and turn clockwise
_i to "OFE" Do not force.

MATCH HOLDER

P_ESSUR( R£GULATOR CONVENIENCE WIRING
ADJUSTMENT TERMINAl{2} TERMINAL3 (2)

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CONNECTION . 'RREEN \GA S (UNDER CAP SCREW)

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A_JUSTMENT

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PRESSURETA_

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OUTLETPRESSUR£
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.: , ;:LOTOUTL'T

OTADJ_STM_NT

{UNOERCAPSCREW)

_GA$

CONTROL
KNOE

21 7_0t 7H

HOW A STEAM SYSTEM OPERATES

The water in the boiler is heated until it reaches the boiling
point. As the water boils it turns into steam. The steam rises
from the top of the water through the supply main to the

radiation units. As it passes through the radiators it releases
its heat and condenses into water. The water returns to the

boiler through the return main. Most residential systems

operate at less than 1 pound steam pressure.

FILLING SYSTEM WITH WATER

©n steam heating systems the boiler is partially filled with

water. It is very important to the proper operation of the entire

system thatyour boiler befilled to the proper level. The correct

water level is about halfway up the glass water level gauge

as marked on the boiler jacket. To fill:

1. Close the boiler drain valve.

2. Open the valves at the top and bottom of the glass water
level gauge. Also open the drain valve at the bottom of

the gauge.

3. Open the fill valve and allow water to run into the boiler.

J WARNING - Never run water into a hot empty boiler, J

4. Allow boiler to fill until water runs out the gauge drain
valve. Then close the gauge drain valve.

5. Continue to fill boiler until water reaches the indicated water
line. This is about halfway up the glass tube.

THERMOSTAT

Keep it set at a desired room temperature. If windows are

to be opened or heat is not needed, move thermostat pointer
to a lower setting.

NOTE

In the event of failure of any component, the system

will not operate or will go into safety lockout. The system

iscompletely self-checking On every call for heat, each

component must be functioning properly to permit
operation. On safety lockout the system has to be reset

by turning the thermostat to the lowest setting for one
minute, then back to the normal setting.

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

- latest revision.

WATER LEVEL

The normal water level is shown on the right side of the
boiler and is 24' above the floor. The normal water level

is determined when the boiler is off and cold, i.e. when all
of the water in the system is inside the boiler and the return
piping below the water line, and everything above the water

line is air, no steam. When the boiler is making steam, the
water level win drop two to three inches below the normal
water line.

AUTOMATIC GAS VALVE

The Automatic Gas Valve opens or closes according to the

heat requirements of the thermostat and temperature limit

control. It closes if the pilot goes out. Each individual control

must be operating correctly before any gas can pass to the
burners. Any one control can hold the gas supply from burner

regardless of the demand of any other control.

..... 22

ADJUST PILOT BURNER

Pilot flame should surround 3/8' to 1/2" of the pilot sensor.
Refer to Fig. 19. If flame needs adjusting, do it as follows:

1. Remove screw cover over pilot adjusting screw.

2. Insert small screwdriver and adjust flame as needed. Turn
screw counterclockwise to increase flame, clockwise to
decrease.

3. Replace screw cover over pilot adjusting screw.

MAIN BURNER AIR ADJUSTMENT

The primary air shutters on the cast iron main burners should

be adjusted so the flame forms a sharp blue cone with no

yellow. Refer to Fig. 18.

li_[_ll i1I:]

0000@@0@0000 °°'''°°''

I_ARKIER BLUE

INNER CONE

t ) .Lo.

GAS VALVE SAFETY SHUTDOWN TEST

1. For boilers equipped with continuous pilot, with main
burners firing, disconnect the thermocouple from the gas
valve. The gas valve should immediately shut off the main
burners and the pilot.

2. For boilers equipped with intermittent ignition, with main
burners firing, disconnect the ignition cable from the
intermittent pilot control box. The gas valve should shut

off the main burners. TURN OFF ELECTRIC POWER to
boiler before reconnecting ignition cable, to prevent

electric shock.

ADJUST STEAM PRESSURE CONTROL

The steam pressure limit control (pressuretrol) shuts off the
gas to the main burners when the steam pressure in the

boiler reaches the cut-off setpoint (i.e. the sum of the cut-
in and the differential setpoints). Burners retire when the steam
pressure drops to the cut-in setpoint. System pressure
requirements are based on the size and condition of the
pipes, and the load.

For 'good system operation, the cut-in setting of the
pressuretrol should never be less than twice the system

pressure drop. In a typical single family residence with a

clean one pipe heating system and cast iron radiation, this

means that the cut-in will usually be set atthe minimum setting,
i.e. 1/2psi.

Steam radiation is usually sized based on square feet of
equivalent direct radiation (EDR). This is based on a steam
pressure in the radiator of just less than 1 psi. Therefore,
in our example system from above, we would set the

differential adjustment at 1 psi, i.e. the steam pressure
required in the radiators. This will give us a cut-off setpoint

of 11/2psi.
The above is an example of a typical one pipe system. For

larger systems or other types of systems such as two pipe
systems, or systems with convectors or fan coil units, the
pressuretrol settings will need to be determined on a system-

by-system basis.

The cut-in setpoint is determined by the system pressure

drop tothe furthest radiator or terminal unit. Double the system
pressure drop as a safety factor, resulting in the rule that

the cut-in setting should never be less than twice the system

pressure drop.

The differential setpoint is the steam pressure required at
the terminal heating units.

Now your boiler will operate in the correct pressure range.
It will maintain enough steam pressure to send the steam

out to the furthest radiator, and not go over the optimum

steam pressure that is required at the radiators.

CHECKING CONTROLS

To check the Low Water Cut-Off, turn off power to the boiler
or turn the thermostat down to the lowest setting. Drain water
to below the visible bottom of the water gauge glass. Turn
power on and turn the thermostat to call for heat. When the
boiler is equipped with the float type LWCO, the gas valve
should not open on a call for heat when the water is low.
When the boiler is equipped with a probe type LWCO, the
gas control should be powered for approximately 10 seconds
(the time delay on the probe type LWCO), then the gas valve

will close and the red indicator will illuminate on the LWCQ
If your boiler is equipped with the optional WF-2U-24 water

feeder, continue to keep the thermostat calling for heat after
the low water cut off recognizes the low water condition. After

a one minute time delay, the water feeder should start feeding
water to the boiler, The feeder should feed for one minute,

and then go into another one minute waiting period. This
cycle of alternately waiting and feeding should repeat until:

1. For Model 67D-1 float type low water cut offs - as the
water leve! raises the float above the burner cut off switch

level, the burners should ignite. The water feeder remains
powered until the water level raises the float to the water
feeder switch level, satisfying the water feeder,

2. For Model PS-802 probe type tow water cut offs - the
water level wil! rise until water in the boiler makes contact

with the probe, satisfying the water feeder, and igniting
the burners

In either case, there should be between one and two inches
of water visible in the gauge glass when both the water feeder

is satisfied, and the burners are allowed to ignite.
The time delays in the feed cycles are designed to prevent

the boiler from flooding due to slow return lines.
To check the pressure limit, run the boiler until the pressure

reaches system demand. Then turn the pressure screw and

3 _21A

drop the pressure setting until the boiler shuts down. This
will show that the pressure limit is operating properly

Refer to control manufacturer's instructions (enclosed} for
more information.

Check thermostat operation. When set above temperature
indicated on the thermometer, boiler should ignite. Make

certain the thermostat turns off the boiler when room
temperature reaches the selected setting and starts the boiler

operating when room temperature falls a few degrees.
Finally, set the thermostat for the desired temperature. Special

conditions in your home and the location of the thermostat
will govern this setting.

It is very important to clean a new steam boiler after it has

3/8" to 1/2"

been installed and put into continuous operation. This must
be done to remove any accumulation of oil, grease, sludge,
etc., that may have been present in the system. These
substances may cause the boiler water to foam and surge,
thus producing a very unsteady water line, throwing water
into the steam header, and possibly preventing steam
generation. Follow these steps in order to remove these

contaminants.

SKIMMING AND BLOWDOWN

New boilers must be skimmed at the time of installation to
remove threading oil and other impurities that float on the

surface of the water.

1. Remove the plug from the skimmer tapping and pipe to
a floor drain or bucket.

2. Raise the water level to the skimmer tapping.

3. Fire the boiler to maintain a water temperature of 180-
200 degrees.

4. Feed water to the boiler to maintain the water level. Adjust

the water feed rate to keep water continuously flowing

out of the skimmer tapping without the water level going
above or falling below the tapping. Cycle the burners to

prevent boiling.

5. Continue skimming until the water runs clear. This may
take several hours.

6. Float type low water cut offs must be blown down after
skimming. The float chamber of the low water cut off must

be flushed clean and maintained clear of sediment to allow

free movement of the float: This must be done frequently

during initial operation of the boiler, and at least once

a week thereafter. Follow the instructions on the tag
attached to the control.

Probe type low water cut offs require no maintenance

at this time.

7. After blowing down the low water cut off and before
blowing down the boiler, fill the boiler to the water line.

Fire the burners and allow normal steam pressure to build
up. Run a connection from the boiler blowdown valve to

a nearby sewer or floor drain or to a safe discharge point
outside. Shut off the gas burners, open the blowdown

valve, and allow all of the water in the boiler to drain out.

Close the b!owdown valve. Allow the boiler to cool

thoroughly and then slowly refill the boiler to the water

line. Repeat this step as many times as necessary until
the blowdown water is clear.

.

Following the final blow down, allow the boiler to thoroughly
cool, and then add fresh water slowly up to the normal

water line. Start the burners and maintain at least 180
degrees for 15 minutes to remove dissolved gasses from

the fresh water. Shut off burners.

Now, let the boiler steam for a few days, to give the majority
of the system dirt a chance to work its way back to the boiler.

Then check the water in the gauge glass. The gauge glass
should be dry above the water line. The water line should

not bounce more than one inch when the boiler is steaming.
If you see water droplets carrying over from the top of the

gauge glass, or excessive bouncing of the water line, the
boiler needs further cleaning. Take a water sample and boil

it on the stove, to see if it foams. If it does, this also indicates

the boiler needs to be cleaned.

If cleaning is necessary, repeat the skimming and blow down
procedure from above. Usually a long skim will be all you

need to clean the boiler.

In more troublesome cases it may be desirable to flush the

system as well. This is accomplished by closing the gate
valve in the Hartford Loop, and opening the drain(s) at the

end of the wet return(s). Run a hose from the drain valve
on the wet return to a nearby floor drain or bucket. Run

the boiler at two pounds of steam pressure. Feed just enough

water to compensate for the waste condensate going down
the drain, and to keep the boiler from going off on low water

cut off. Run the boiler until all waste condensate runs clear.

NOTE

Boiler cleaners and chemical cleaning additives are not
recommended. If used and not rinsed properly, they

will do more harm than good. The cleaning procedures

laid out above will clean out the typical oilsand impurities

found in new boilers and in residential heating systems.
The best thing for your boiler and heating system is
clean water with no additives.

In very extreme cases it may be necessary to chemically
clean and flush the heating system. Consult the boiler manu-

facturer before introducing any chemicals into the boiler.

,,+_ 24

Checkthewaterleveleverydayortwo.Verifythewaterlineshownby

operatingthedrainvalveonthegauge.BESURETOPANDBOTTOM

VALVESONGAUGEAREALWAYSOPENSOTHATACTUALWATERLEVEL
WILLBESHOWNATALLTIMES,

Thegaugeglassshouldbedryabovethewaterline.Thewaterlineshould
notbouncemorethanaboutoneinchwhentheboilerissteaming.If

youseewaterdropletscarryingoverthroughthetopofthegaugeglass,
orexcessivebouncingofthewaterline,theboilerneedsto becleaned.

Followtheinstructionsunder"CleaningYourBoiler."

POP SAFETY VALVE

This valveshouldopenautomaticallywhenthe steampressureexceeds
the safe limit (per instructionspackagedwith valve).Shouldit ever fail

to openundertheseconditions,shutdownyour system.Havethe valve
replacedimmediately

LOW WATER CUT-OFF

TheLowWaterCut-Offwill interruptthe electricalcurrentto theburner

whenthewaterlineintheboilerdropsto a lowlevel.

On float type low watercut-offs,it is very importantto keep the float
chamberfree from sediment,a conditionessenlialto dependabilityTo

keepanyaccumulationfrominterferingwithfloatactionisto"BLOWDOWN"
or flush out thecontrol regularly.This mustbe donetwo to threetimes

duringthe first weekafter installationand oncea weekthereafterduring
theheatingseason.Do it whiletheboileris inoperation.Firstnotewater

level in gaugeglass.Open blow-offvalve at bottomof control;water
will pour out, flushingawaysediment.Drain untilwater is clear,about

a pailful,then close valve, g waterlevel in gaugeglass hasdropped,
addwatertoboilerto restorelevel.Consultlowwatercut-offmanufacturer's

instructionsincludedwithboiler.
NOTE: Openingblow-off valvechecks cut-off operationtoo. As float

dropswithfallingwaterlevel,burnerswill shutoff. Aftervalveis closed
andnormaloperatingconditionsarerestored,burnerswillresumefiring.

Forprobetype LowWaterCut-Offs,checkactionof the LowWaterCut-
Offmonthlytomakesureitisprovidingtheproperprotection.See"Checking

and Adjusting"on page23. Low WaterCut-0ff remoteprobesmustbe

removedfor periodicinspectionandcleaning,preferablyatthe beginning
ofeachheatingseason.Morefrequentcleaningmaybe requiredonboilers

requiringconstantorveryfrequentadditionsof makeupwater.

BURNERS

A visualcheckof the pilot and mainburnerflamesshouldbe madeat
leastonceeachyear,preferablyat thebeginningof the heatingseason.

Seepage23.

BOILER FLUE PASSAGES

Undernorma]operatingconditions,with the burnersproperlyadjusted,
it shouldnotbe necessaryto cleantheboilerfluegaspassages.However,
to assuretrouble-freeoperation,we recommendthat you havethe flue

passages,burneradjustment,andoperationof the controlscheckedonce

eachyearbya competentServiceTechnician.
Beforethestartof eachseason(or wheneversystemhasbeenshutdown

for sometime)recheckthe wholesystemfor leaks... andrecheckthe
boilerandventpipefor leaks.

VENT PIPE

Theventingof thisunitis veryimportantandthepipingshouldbechecked
at leastonce a season.If the vent piping showsany sign of leaking,

replaceit immediately

CLEANING YOUR BOILER FLUE PASSAGES
AND BURNERS

FluePassagesbetweensectionsshouldbe examinedyearlyandcleaned,
if necessaryToclean,removeburners,pilot,andvenl pipe,Removetop

andfrontjacketpanels.Removethetwoscrewsattachingtheintermediate
front pand 1o lhe left andrighl side jacketpanels.Removethe draft

diverlerandintermediatefrontpanelasa unit.Carefullyremovethecerafeg
gasketstrips.Cleanpassagewaysbetweensectionswitha flexiblehandle

wirebrush.Removedirt from botlomof boilerandfrombetweenseclions

by vacuuming,Makesureall flameports in burnersare openand clear.

Shakeout or blow out all loosedirt in burners.Resealseamsbetween
adjacentsectionsasnecessarywith400FRTVsiliconesealant.Reassemble
all parts.Be sureto checktightnessof pilot connectionsand condftion

of burnerflamesafterreassemNy(seeFigures18 and19).Besurevent

pipeconnectionstochimneyaresecureandnoobslructionsarepresent.

FOAMING, PRIMING OR SURGING

Theseterms areusedto describea fluctuatingwaterline- whenwater

leavestheboilerwiththesteam.

It iscausedbyanycombinationofthefollowing:

1. Threadingoil andorganicmatterin the boiler water,(Mineraloil, or
coresanddoesnotcausesurging.)Followinstructionsunder"Cleaning

YourBoiler."

2. Faultyquick ventsthat do not releaseair unlil a sizeablepressure
is builtup - if old style, reptace it dirty cleanso you caneasily
blowthroughvalve.

3. Improperheaderdesign- whensteamflowsin oppositedirection
of equalizerlineon "HartfordLoop."Generallya 15" horizontalrun
betweenriser andmaintakeoffwill allowentrainedwaterto fall out

of the steamvapor so it can returnto boiler. (SeeFigures5, 6A

&6Bonpages7,8and9).

4. Adjustmentofsteamlimitcontroltoawidedifferentialincreasesdifficulty
if quickventsareold style,slow-releasingtype or dirty Alwaysset

steamlimitcontroldifferentialaslow aspossible.

5. Soapanddetergentsin theboilerwatercauseextremesurging.Boiler
cleanersandchemicalcleaningadditivesarenotrecommended.If used

andnotrinsedproperlytheywill demoreharmthangood.Thecleaning
procedureslaid out in these instructionswill cleanout the typical

oilsandimpuritiesfoundinnewboilersandinresidentialheatingsystems.
Thebestthingfor yourboilerandheatingsystemis cleanwaterwith

noadditives.

CAUTION ]

Never refill a hot boiler with cold water - the danger
of thermal shock may crack a section.

BOILER WATER TREATMENT (Other Than Cleaners)
In steamsystemswherethe systemis tight, free from leaks,andall

the steamis returnedto the boiler as condensate,the amountof make
upwaterissmall,Watertreatmentis generallynotrequired.

In steamsystemswith less than90% of the steam beingreturnedas
condensate,or wilh veryhardor corrosivemakeup water,treatmentmay
bedesirable.Followtherecommendationsof'yourlocalboilerwatertreatment

speciafisl.

BETWEEN HEATING SEASONS

Boilersshouldnotbedrainedbetweenheatingseasons.Steamboilersshould

beentiretyfilledwithwaterduringthesummermonthsto excludeair.

5 _1_

You may avoid inconvenience and service calls by checking these points before you call for service.

FOR YOUR SAFETY

WHAT TO DO IF YOU SMELL GAS

1. Do Not try to light any appliance.

2. Do not touch any electric switch, do not use the phone.

3. Leave the building immediately, then call your gas supplier.

4. If you cannot reach the gas supplier, call the fire department.

Possible Cause

Thermostat is not set correctly
Burner is not operating properly

No electric power to boiler

Controls out of adjustment
Radiators not heating

Poor electrical contact
Rollout switch blown

Chimney flue is blocked

Vent damper not operating

Possible Cause
Gas input amount is incorrect

Possible Cause
Not enough ventilation

Chimney flue is blocked

Possible Cause
Air in system

Possible Cause
Dirt on seat

What to do

Reset thermostat above room temperature.
Check flame. If it is yellow, the burner is not getting enough air. Or, if flame

is blue and noisy and seems to lift off the burner, the burner is getting too
much air. Contact your service technician.

Check overcurrent protection. Check to be sure electric power supply circuit
is "ON."

Reset according to instructions.
Steam air vents are not operating properly. Check flow control valve (if used).

It may be in closed position.
Check all control terminals and wire joints.

Have your service technician check heat exchanger for blockage. Replace rollout
switch with exact replacement.

Spill switch contacts open, requiring manual reset of spill switch. Have your
service technician check and correct chimney problem.

Consult troubleshooting guide in Effikal manual, packaged with vent damper,

What to do

Contact your service technician.

What to do

Contact your service technician.
Have your service technician check and correct, if necessary

What to do

Refer to "Radiators Not Heating Properly" above

HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT.

..... 26

GAS-FIRED STEAM BOILERS

-- IMPORTANT --

READ THESE INSTRUCTIONS BEFORE ORDERING

All parts listed in the following Parts List may be ordered
through your nearest supplier.

When ordering parts, first obtain the Model Number from

the data plate on your boiler, then determine the Part No.

(not the Key No.} and the Description of each part from the

following illustrations and list. Be sure to give us all this

information:

The Part No, - The Part Description - The Boiler Model No.

15\ 16.

10

18

. _ 19 20

4 6 7

0

/

"1

JACKET - SECTION AND BASE PARTS

THIS IS A REPAIR PARTS LIST - NOT A PACKING LIST

KEY

NO.

1
2
3
4

5
6

7
8

DESCRIPTION

Jacket, Right Side Panel
:#10 x 1/2 Sheet Metal Screw

Rating Plate

Base Insulation - Base Sides (2)

3 SECTION

Part No.

425-00-802
146-95-074
146-80-001
146-14-130

4 SECTION

Part No.

425-00-802
146-95-074
I46-80-001
146-14-130

5 SECTION

Part No.

425-00-802
146-95-074

146-80-001

146-14-130

6SECTION

Part No.

425-00-602

146-95-074
146-80-001

146-14-130

7 SECTION

Part No,

425-00-802

146-95-074
146-80-001

146-!4-130

8 SECTION

Part No,

425-00-802
146-95-074
146-80-001
146-!4-130

-Base Front
Base Rear

Base Baffle
Base

JacketTie Bar
Push Nipple
Jacket,Left Side Panel

Knob,Service Door (Pair}

146-14-113
146-14-123
425-00-643
425-00-663
425-00-653
433-00-976
425-00-801
137-02-153

146-14-114
146-14-124

425-00-644
425-00-664

425-00-654
433-00-976
425-00-801
137-02-153

146-!4-115
146-14-125

425-00-645
425-00-665
425-00 655

433-00-976
425-00-801

137-02-153

146-14-116

146-14-126
425-00-646
425-00-666
425-00-656
433-00-976
425-00-801
137-02-153

146-14-1!7
146-14-127
425-00-647
425-00-667
425-00-657
433-00-976
425-00-801
t37-02-153

146-14-118
146-14-128
425-00-648

425-00-668
425-00-658

433-00-976
425-00-801

137-02-153

9

10
! ! Jacket, Service Door

12 Jacket, Int'd Panel
13 Jacket, Front Panel
14 1/4" Tie Rod, Nut

15 Boiler Section, Left
16 Boiler Section, Middle
17 Jacket, Top Panel

18 Draft Diverter
19 Boiler Section, Right

20 ! Jacket, Back Panel

:I: Jacket Complete
:l: Block Assembly (19, 16, 15, 14, 8)

qt: Combustible Floor Plate
:i: Cerafelt Gasket

21 Vent Damper

:i: Base Assembly (6, 5, 4}
$ RolloutSwitchBracket(Nat,GasOnly)

42500-823
425-00-813
425-00-803
146-05-001
410-00-013
410-00-015
425-00-844
425-00-673
410-00-014

425-00-833

425-00-873

410-00-330

146-14-031
146-14-018

146-28-001
433-00-663
425-00-604

425-00-824
425-00-814

425-00-804
146-05-002
410-00-013
410-00-015

425-00-844
425-00-674
410-00-014

425-00-834
425-00-874

410-00-430
146-14-031

146-14-018
146-28-002

433-00-664

425-00-604

425-00-825
425-00-815
425-00-805
146-05-051

410-00-013
410-00-015
425-00-845
425-00-675
410-00-014
425-00-835
425-00-875
410-00-530

146-14;031

146-14-018

146-28-002
433-00-665
425+00-604

425-00-826
425-00-816
425-00-806
146-05-053
410-00-013
410-00-015
425-00-846
425-00-676
410-00-014
425-00-836
425-00-876
410-00-630
146-14-031
146-14-018
146-28-003
433-00-666
425-00-604

425-00-827
425-00-817
425-00-807
146-05-005
410-00-013
410-00-015
425-00-847
425-00-677
410-00-014
425-00-837
425-00-877
410-00-730
146-14-032
146-14-018
146-28-003
433-00-667
425-00-604

425-00-828
425-00-818
425-00 808
146-05-007
410-00-013
410-00-015
425-00-848
425-00-678
410-00-014
425-00-838
425-00-878
410-00-830
146-14-032
146-14-018
146-28-003
433-00-668
425-00-604

9 SECTION

Part No.

425-00-802
146-95-074

14680-001
146-14-130
146-14-119

146-14-129
425-00-649
425-00-669

425-00-659
433-00-976

425-00-801
137-02-153

425-00-829
426-00-819

425-00-809
146-05-009

410-00-013
410-00-015

425-00-849
425-00-679

410-00-014
425-00-839
425-00-879
410-00-930
146-14-032
146-14-018
146-28-003
433-00-669
425-0O-604

:l-Not illustrated.

27 ....

FOR USE WITH NATURAL GAS ONLY

6

4 5

NOTE: Actual gas valve may look

different than gas valve shown

II

KEY
NO.

1

2
3
4

5

6

6A

7

1
3
7

GAS BURNERS AND MANIFOLD PARTS

THIS iS A REPAIR PARTS LIST - NOT A PACKING LIST

DESCRIPTION

24Volt GasValve,Elect.Inter.Ignition

PilotTube
10-32x 1/2HexHeadScrew

GasManifold
MainBurnerOrifice"

MainBurner,Regular*"
MainBurner,PilotMount
PilotBurner

AirShutter
AirShutterSpring

24VoltGasValve,ContinuousPilot
10-32x 1/2" HexHeadScrew(2 req'd)

PilotBurner
Thermocouple

3 SECTION

PadNo.

146-62-052
146-15-005
146-95-307

146-16-033

146-15-031

146-15-523
146-15-522
146-62-092

425-00-418

146-34-061

146-62-051
146-95-307

146-62-053
146-62-037

4 SECTION

PadNo.

!46-62-052
146-15-005
146-95-307
146-16-034

146-15-031
146-15-523
146-15-522
146-62-092
425-00-418
!46-34-061

146-62-051
146-95-307
146-62-053
146-62-039

5 SECTION

PadNo.

146-62-052
146-15-005
146-95-307
146-16-035

146-15-031
146-15-523
146-15-522
146-62-092
425-00-418
146-34-061

146-62-051
14695-307
146-62-053
146-62-039

6 SECTION

Pa_No.

146-62-058
146-15-005
146-95-307
146-16-013

146-15-035
146-15-523
146-15-522
146-62-092

425-00-418

!46-34-061

146-62-060
146-95-307
146-62-053
146-62-039

7 SECTION

PadNo.

146-62-058

146-15-005

146-95-307

146-16-014
146-15-035

146-15-523
146-15-522
146-62-092

425-00-418

146-34-061

146-62-060
146-95-307
146-62-053
146-62-039

8 SECTION

PadNo.

!46-62-058
146-15-006
146-95-307
146-16-015

146-15-035
146-15-523
146-15-522
146-62-092

425-00-418

146-34-061

146-62-060
146-95-307
146-62-053

146-62-036

Quantity is 1 unless otherwise noted.

*Requites 1 less then the number of sections.

**Requires 2 less than the number of sections.

:i:Not illustrated.

9 SECTION

PadNo.

146-62-058
146-15-006

146-95-307
146-16-016

146-15-035
146-15-523
146-15-522
146-62-092
425-00-418

146-62-060
146-95-307
146-62-053
!46-62-036

..... 28

BOILER CONTROLS AND PIPING

12

KEY
NO. DESCRIPTION

1

2
3

4
5
6

7

8

9

10

11
12

13
14
15
16

I

¾' Pop Safety Valve
%"Coupling

Y,"x 6W' Nipple
Steam Pressure Gauge
'/4' Coupling

YYx 3" Nipple
AT-140D Transformer, 24 Volt
PA-404A Pressuretrol

Glass Water Gauge Set (used with PS-802 LWCO)
Glass Water Gauge Set (used with 67D-1 LWCO)

90" Pigtail (used with PS-802 LWCO)

180" Pigtail (used with 67D-1 LWCO)

PS-802 Low Water Cut-Off
67D-1 Low Water Cut-Off

! $8600F Intermittent Pilot Control, Natural Gas

W' x 3" Brass Nipple (PS-802 only)

'½"x 'A" x ¼"Brass Tee (PS-802 only)

I Y2"Brass Coupling (PS-802 only)
, W' x 3W' Brass Nipple (PS-802 only)

¾" Drain Valve
WF-2U-24 Water Feeder (Optional)

Rollout Switch

Spill Switch (36TX16-6282) 280" F
5" Vent Damper (3 Section Boilers)
6" Vent Damper (4, 5 Section Boilers)

7" Vent Damper (6, 7, 8, 9 Section Boilers)

Vent Damper Operator (Motor)
400° F Black Silicone Rubber Adhesive Sealant (10.3oz.cadridge)

PART

NO.

146-22-002
146-93-053
146-07-002
146-23-005
146-93-054
146-07-301
146-62-045
146-62-015

146-22-005
146-22-010
146-43-004
146-43-005
146-26-041
146-26-042
146-62-303
146-07-025
146-93-051

146-93-052

146-07-024
146-22-001

146-26-040

146-29-002

146-60-002

146-28-301

146-28-002

146-28-003

146-28-006

146-08-020

Not Illustrated

29 ,_,,,

Owner'sManual

CONTINUOUSPILOT

MODELNO.

229.960330

229.960340

229.960350

229.960360

229.960370

229.960380

229.960390

ELECTRONIC

INTERMITTENTIGNITION

MODELNO.

229.960230

229.960240

229.960250

229.960260

229.960270

229.960280

229.960290

HOW TO ORDER

REPAIRPARTS

TELLSEARS YOU

WANTIT INSTALLED

THENRELAX

®

ElectronicIgnition

Gas-Fired

CastIron

STEAM

BOILER

Now that you have purchased your Boiler, should a need
ever exist for repair parts or service, simply contact any
Sears Service Center. Be sure to provide all pertinent facts

when you call or visit.

The model number of your Boiler will be found on the model
plate on the side of the Boiler.

WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE

FOLLOWING INFORMATION:

• PART NUMBER
eMODEL NUMBER

• PART DESCRIPTION
eNAME OF ITEM

All parts listed may be ordered from any Sears Service
Center.

If the parts you need are not stocked locally, your order

will be electronically transmitted to a Sears Repair Parts

Distribution Center for handling.

When Sears arranges the installation, you can be sure the
job is done right. We will arrange for professional

workmanship.., and we'll take care of the entire project•
What's more, during installation you get insured protection

• . . against property damage and also against accidents
to workmen. All you have to do is talk to your nearest Sears
store today for detailed information.