Kenmore 5EW1.75 User Manual

KenmatG

Owner’s Manual

MODEL NO.

3EW.65
3EW.75

3EW1.00

4EW.90

4EW1.25
4EW1.50
5EW1.20
5EW1.75
5EW2.00

CAUTION

Read all instructions

carefully before

starting the installation.

Save this manual

for reference.

Oil-Fired

Hot Water

Boiier

• Installation

• Operation

• Repair Parts

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Sears, Roebuck and Co., Hoffman Estates, fL 60179 U.S.A.

PRINTED IN US A

FOFIM 65^ IM 1!.

Warranty

KENNMORE CAST IRON BOILERS

FULL ONE YEAR WARRANTY ON HOT WATER AND GAS STEAM CAST IRON BOILERS

For one (1) year from the date of Installation, when this boiler Is Installed and maintained in accordance
with our instructions. Sears will repair defects in material or workmanship in the boiler, free of charge.

LIMITED 12 YEAR WARRANTY ON STEAM CAST IRON BOILERS

Affer one (1) year and through twelve (12) years from the date of installation. Sears will furnish a replacement
heat exchanger, if the heat exchanger in the boiler is defective. YOU PAY FOR LABOR.

LIMITED 20 YEAR WARRANTY ON HOT WATER CAST IRON BOILERS

After one (1) year and through twenty (20) years from the date of installation, Sears will furnish a replacement

heat exchanger if the heat exchanger in the boiler is defective. YOU PAY FOR LABOR.

SEARS INSTALLATION WARRANTY

in addition to any \«arranty extended to you on the Sears merchandise inwived, 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 may also have other rights which vary from state to state.

mmmmmmmmmmmmmmmmmmmmmmimmmmmmm

IMPORTANT

The following are the responsibilities of the user and are

not covered by the Warranty.

1. Filter clearing 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 electrical protective
devices.

4, Damage to unit caused by the use of components or other

accessories not compatible with the unit.

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

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

SEARS ROEBUCK AND COMPANY

D/817WA

Hoffman Estates, IL 60179

INTRODUCTION

The Empire Water boiler is a natural draft oil fired hot water boiler comprised of cast iron sections. The Empire
Water boiler is available with 3, 4, or 5 cast iron sections. These sections are held together by cast iron push

nipples.

The Empire Water boiler is capable of firing #2 fuel oil from 0.65 gph up to 2.00 gph. Boilers may be purchased

with or without the following options: a Beckett AEG, Carlin EZ, or Riello 40 oil burner, a Taco or Grundfos
circulator with isolation valves, a tankless coil for domestic hot water. All packaged boilers include a swing
door, Honeywell aquastat, temperature and pressure gage, relief valve, drain valve, 2 Delevan oil nozzles for
multiple firing rates (only when purchasing a burner), flue brush, and an extra boiler tap for an expansion tank or
air elimination.

I—I

RCDUCIHG

TEE

BACK VIEW

BOILER RATINGS AND CAPACITIES

iioii i;r Mooi;i, no.

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¡ANKI.I'.SS

roil.

3i;w (>ir .lliw.f).“?/. 3

.ii;w 7.ST .ii:W.75Z

3i;w!.oor
4FW.40r 4r;w.'K)z
4i':wi.2,vr 4i;wi 25Z

4i;W1.50T 41iW1.50Z
51-:WI.20T .знзугго/.
5L-:W1.75r
5i-;W2-00'r ,51-:W2.(X)Z

*MBH = !,000 BTU per hour BTU = British Thermal Unit
**Hcalirg Capacity based on 13% C02 with a -0.02” w.c draft over fire, and a #I smoke or less. Testing was done in accordance with the D.O.E.

(Department of Energy) test procedure.
+GPH = Gallons per hour oil at 140,000 BTU per gallon
++A.F.U.E. = Annual Fuel LliMi/airon EfTicicncy based upon D.O.E. test procedure.

wrmoirr

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roil. A В

3EW1.(H)Z

,51; W 1.75/.

.SI-( '

NO

INPUl
♦MUM

’••lil;ATINO

CAPACI rV

*MUH

‘J1 80 70

3 105

140 110

3
4 126 11 1 97 0.90 860 8”X8"X 15’

17,5

4
4 210 178

168 147

5
5 245 209 182 1.75 83,6 8"X8”X 15’

5 280 236 205 2.00 82.0 8"X8"X20' 21

02

150 130 1.25 83.9 8”X8"X 15' 17-3/4

ni-;t

1=U-R

КЛ1 INO

*MBH

80 0-75 85.2 8”X8”X 15' 14-1/2

103 1.00 83.4 8” X 8" X 15' 14-1/2

155 1.50
128 1.20 86.5 8”X8”X 15’ 21

I-IRING

RATE

+(iPU

0.65

f-i-

86,3 S"X8"X 15' 14П/2

82.4

MINIMUM
CHIMNEY

SIZE/HEIGHT

S”X8"X 15’

DIMENSIONS - (inches)

6

6 8
17-3/4
17-3/4

6 8

6

6 9-5/8

6 9-5/8

6 11-1/2

21 6 11-1/2

6 11-1/2

These low pressure oil fired hot water boilers are constructed and hydrostatically tested for a maximum working
pressure of 50 psig (pounds per square inch gage) in accordance with A.S.M.E. (American Society of Mechanical

Engineers) Boiler and Pressure Vessel Code Section IV Standards for heating boilers.

The Heating Capacity indicates the amount of heat available after subtracting the losses up the stack. Most of
this remaining heat is available to heat water. A small portion is heat from the jacket and surfaces of the boiler,
and it is assumed that this heat stays in the structure. The Net I=B=R Rating represents the portion of the
remaining heat that can be applied to heat the radiation or terminal units (i.e. finned tube baseboard, cast iron
radiators, radiant floor, etc.). The difference between the Heating Capacity and the Net I=B=R Rating, called the
piping and pickup allowance, establishes a reserve for heating the volume of water in the system and offsetting
heat losses from the system piping. The Net I=B=R Ratings shown are based on a piping and pickup factor of 1.15
in accordance with the I=B=R Standard as published by the Hydronics Institute. The Net I=B=R Rating of the
boiler selected should be greater than or equal to the calculated peak heating load (heat loss) for the building or
area(s) served by the boiler and associated hot water heating systems. The manufacturer should be consulted
before selecting a boiler for installations having unusual piping and pickup requirements.

c

8

9-5/8

Boilers with the same number of sections are identical to each other except for their firing rate. The firing rate is

detennined by the nozzle size in the oil burner and the oil pressure at the nozzle. For example: Models 3E.65Z,

3E.75Z, and 3E1 .OOZ are the same boiler, without a tankless coil, except for the firing rate of the oil burner.
Models 4E.90T, 4E1.25T, and 4E1.50T are the same boiler, with a tankless coil, except for the firing rate of the oil
biimer.

Each boiler rating plate shows three possible model numbers for a given boiler configuration. The actual model
number is determined by the firing rate of the oil bumer. Boilers that are factory packaged include two nozzles for
two firing rates

These boilers operate on #2 Heating Oil.

RULES FOR S AFE INSTALLATION AND OPER.AT10N

1. Read the Owner’s Manual for Safe Operation carefully. Failure to follow 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, or follow NFPA 31 - Installation of Oil Burning Equipment, latest revision.

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

4. Inspect oil line and connections for leaks.

5. Be certain oil burner nozzle is the size required. Overfiring will result in early failure of the boiler sections.

This will cause dangerous operation.

6. Never vent this boiler into an enclosed space. Always vent to the outside. Never vent to another roonr 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.

9. Keep boiler area clean and free of combustible material, gasoline and other flammable vapors and liquids.

10. Oil burners are not do-it yourself items. This boiler must be installed and serviced by qualified
professionals using combustion test instruments.

11. Be aware when piping the relief valve that if the system pressure exceeds the safe limit of 30 pounds per
square inch, the relief valve will automatically lift open. Lifting of the relief valve can discharge large
quantities of steam and hot water, which may damage the surroundings. Before installing the relief valve
read the manufacturer’s instructions and maintenance section of the manual on relief valves.

12. Installation and sizing of the expansion tank must consider the heating systems total water volume,
temperature, boiler initial fill pressure, and system arrangement. An improperly installed and sized
expansion tank may result in frequent lifting of the relief valve or other heating system problems. For
proper installation, sizing, and maintenance of the expansion tank follow the guidelines established by
Dunkirk Radiator Corporation and the expansion tank manufacturer.

13. Expansion tank performance and life expectancy can be hindered by overfilling the boiler. Dunkirk

Radiator Corporation recommends an initial fill pressure of 10-12 psig. For higher fill pressures the
expansion tank’s air charge will need to be increased to match the fill pressure. Consult the manufacturer’s
guidelines for sizing and selection.

14. Purging the heating system of air and gases when first putting the boiler’s into service is critical for proper
circulation and quiet performance. Once the air and gases are purged, for boiler installations using float

type vents, the air vents should be closed for normal operation. If air is heard or noticed by a loss of heat,

purge the system and open the vents for a short period of time.

WARNING

This boiler has been designed for residential installations. If used for commercial applications,

all jurisdictional requirements must be met. This may require wiring and/or piping
modifications. The manufacturer is not responsible for any changes to the original design.

DO NOT USE GASOLINE CRANKCASE DRAININGS OR ANY OIL CONTAINING GASOLINE.

BEFORE YOU START

Complete all of the following pnor to installing the boiler.

Check to be sure you have selected the right size boiler with the proper capacity. The I=B=R rating of the boiler

A.

selected should be greater than or equal to the calculated peak heating load {heat loss) for the building or area(s)
served by the boiler and associated hot water heating systems. See boiler rating and capacity table previously

listed in this manual. Any heat loss calculations used should be based on approved methods.
Boiler must be supplied with the proper oil supply and oil piping, sufficient fresh combustion air, and a suitable

B.

electrical supply.
Boiler must be connected to a suitable venting system and a piping system adequate to distribute the heating load.

c.

A thermostat must be properly located and installed for control of the heating system.

D.

If there are any doubts as to the various requirements, check with local authorities and obtain professional help where
needed. The OPERATING INSTRUCTIONS, FINAL CHECKS AND ADJUSTMENTS, and MAINTENANCE
sections in this manual are vital to the proper and safe operation of the heating system. Take the time to be sure they

are all done.

LOCATING THE BOILER

Place the boiler in a location centralized with the piping system and as close to the chimney as possible.

1.

The boiler must be level. If necessary use metal shims beneath the boiler’s feet.

2.

Use a raised base if the floor can become wet or damp.

3.
Maintain clearances for fire safety as well as servicing. An 18” clearance must be maintained at a side where

4.
passage is required for access to another side for cleaning, servicing, inspection, or replacement of any parts that

normally may require such attention. Boilers must be installed at least 6” from combustible material on all sides

and above. Allow at least 24” front clearance for servicing.
Fresh air for combustion must be available at the front of the boiler. Fresh air for ventilation must be available to

5.

the front AND rear of the boiler. Air passages must be free of obstructions at all times. Ventilating and

combustion air must enter boiler room without restrictions.

The floor supporting the boiler must be non-combustible and sufficiently stable. If it is combustible, place the

6.

boiler on 2” concrete patio blocks or 2” Cladlite™ Pad. The blocks or pad must be under the entire boiler to
protect the floor.

Be sure installation is in accordance with the requirements of the local authorities having jurisdiction. Compliance

7.
with these regulations is required. In the absence of local codes, follow NFPA 31 - Installation of Oil Burning

Equipment, latest revision.

0

5>
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MINIMUM CLEARANCE DIMENSIONS

-A. o "" Cb o ~!b to ~ u ID 'V Q

T

6” MIN.

i.

24" MIN.

6” MIN. /18” WITH COIL

BOILER
FRONT

ALWAYS KEEP THE iVLANUAL FUEL SUPPLY VALVE SHUT OFF, IF THE
BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TLME.

INSTALLATION RJEOUIREMENTS

FRESH AIR FOR COMBUSTION

WARNING
Be sure to provide enough fresh air for combustion. Enough air ensures proper
combustion and assures that no hazard will develop due to the lack of oxygen.

NOTE
If you use a fireplace or a kitchen or a bathroom exhaust fan, you should install an
outside air intake. These devices will rob the boiler and water heater of combustion air.

You must provide enough fresh air to assure proper combustion. The fire in the boiler uses oxygen. It must have a
continuous supply. The air in the house contains only enough oxygen to supply the burner for a short time. Outside
air must enter the house to replace the air used by the burner. Study the 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 the 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 so that the combined volume of all spaces
meets the criteria for an unconfined space. The total input of all combustion 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 the total input rating of all combustion 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.
Example: Your boiler is rated at 100,000 Btu per hour. The water heater is rated at 30,000 Btu per hour. The

total is 130,000 Btu per hour. You need two grilles, each with 130 square inches of FREE opening. Metal grilles
have about 60% FREE opening. To find the louvered area needed, multiply the free opening required by 1.7 (130
X 1.7 = 221.0 sq. in. louvered area). In this example, two grilles each having an 8” x 30” (240 sq. in.) louvered
area would be used.

AIR OPENINGS FOR BOILER LOCATED IN CONFINED SPACE (CLOSET OR UTILITY ROOM!

B. All Air from Outdoors: The confined space shall be provided with two permanent openings, one

commencing within 12 inches of the top and 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 all equipment in the enclosure.

2. When communicating with the outdoors through 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 in

the 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.

f=RESH

AIR

DUCT

BOILER

FRESH AIR DUCT CAPACITIES FOR DUCTS SUPPLYING FRESH AIR TO BOILER IN TIGHTLY

CONSTRUCTED HOUSES

Fresh Air

Duct Size

3-'/2”x 12”

8” X 8”
8”x 12”
8”x 16” 512,000

Mesh Screen
(Btuh)*

144,000
256,000
384,000

Wood Louvers

(Btuh)*

36,000
64,000
96,000

128,000

Metal Louvers

(Btuh)*
108,000

192,000
288,000
384,000

*Btuh = British Thermal Units per hour based on opening covered by ‘/4” mesh

screen, wood louvers, or metal louvers.

SYSTEM PIPING

1. }Vhen the installation of the boiler is for a new heatine system, first install all of the radiation units

(panels, radiators, baseboard, or tubing) and the supply and return mains. After all heating system piping
and components have been installed, make final connection of the system piping to the boiler. It is
recommended to mount the circulating pump on the supply side piping, such that it pumps away from the
expansion tank. Refer to the figures on the next pages.

2. A hot wat^ boiler installed above radiation level must be equipped with a low water cut off device. A

periodic inspection is necessary, as is flushing of float type devices, per low water cut off manufacturers
specific instructions.

3. The packaged boiler unit is set up with 1-1/4” NPT supply and return pipine from the front of the boiler.

The boiler supply and return piping can be moved to the rear of the boiler. The boiler should not be piped

return line to the front, supply line to the rear, or vice versa, as this will cause the boiler water to short

circuit the heat exchanger. Piping connections may require additional fittings and parts.

4. The relief valve is meant to be installed in the back side of the rear section using the 3/4” nipple and street

ell provided in the parts bag. Connect a discharge pipe of the same pipe size (3/4”) to carry any water away
to a drain. Do not connect directly to a drain, but leave an air gap. No shutoff of any description shall be
placed between the safety relief valve and the boiler, or on discharge pipes between such safety valves and
the atmosphere. Installation on the safety relief valve shall conform to the ANSI/ASME Boiler and Pressure
Vessel Code, Section IV. The manufacturer is not responsible for any water damage.

5. When connecting the cold water supply to the pressure reducing 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.

6. The minimum boiler supply water temperature setting on the aquastat is 140°F. If the boiler is used in a

heating system where supply water temperatures below 140°F are desired, a suitable method, such as, the

use of bypass piping shown in the figure below, a 3 way or 4 way mixing valve, or some other means
needs to be used to ensure return water temperatures to the boiler are no less than 120°F. When the boiler is
operated with return water temperatures less than 120°F, condensation may form in the boiler and venting.
This condensation is corrosive and can eventually cause severe damage to the boiler and venting system.

SYSTEM PIPING ARRANGEMENT

ZONING WITH ZONE VALVES

> CIRCULATOR ON SUPPLY PIPING PUMPS

AWAY FROM EXPANSION TANK

> PIPING ARRANGED FOR “POWER PURGING”

AIR OUT OF SYSTEM PIPING, REFER TO THIS
MANUAL’S SECTION ON “FILLING THE

SYSTEM WITH WATER” OPTION #1

SYSTEM PIPING ARRANGEMENT

ZONING WITH CIRCULATORS

> CIRCULATOR ON SUPPLY PIPING PUMPS

AWAY FROM EXPANSION TANK

> PIPING ARRANGED FOR “POWER PURGING”

AIR OUT OF SYSTEM PIPING, REFER TO THIS
MANtlAL’S SECTION ON “FILLING THE

SYSTEM WITH WATER” OPTION #1

RETURN FROM SYSTEM

SUPPLY TO
SYSTEM

VALVE

SYSTEM PIPING ARRANGEMENT

ALTERNATE NEAR BOILER PIPING

> DIAPHRAGM EXPANSION TANK MOUNTED OFF THE BOILER

> CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANK

> PER THIS MANUAL, USE OPTION #2 IN “FILLING THE SYSTEM WITH WATER”

> THIS PIPING ARRANGEMENT CAN BE USED WITH ZONE VALVES OR ZONE CIRCULATORS

SHUTOFF VALVE

11

USES ZONE CIRCULATORS, USE THIS CIRCULATOR

AS A ZONE CIRCULATOR