Kenmore 5EWL.20, 3E W.65, 4EW.90 User Manual

[

Owner'sManual

MODELNO.

3E W.65

3EW. 75
3EWI';O0

4EW.90

4EWl ;25

4EW1.50
5EWl.20

5EW1.75
5EW2.00

CAUTION

Readaftinstructions

carefully before

starting the installation.

Off-Fired

HotWater

Boiler

• Installation

• Operation

• Repair Parts

Save this manual

for reference.

KENNMORE CAST IRON BOILERS

FULL ONE YEAR WARRANTY ON HOT WATERAND 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 inmaterial or workmanship in the boiler, free of charge.

LIMITED 12 YEAR WARRANTY ON STEAM CAST IRON BOILERS

After one (1} yearand through twelve(12) years from the date of installation,Sears willfurnish a replacement

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

LIMITED 20 YEAR WARRANTY ON HOT WATER CAST IRON BOILERS

After one (!) year and through twenty(20)yearsfrom the date of installation,Searswillfurnish a replacement
heat exchanger ifthe heat exchanger inthe boiler isdefective. YOU PAY FOR LABOR.

SEARS INSTALLATION WARRANTY

tn addition 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 Searsarranged 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 stateto state.

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 corroswe atmosphere

3 Damage to unit or unsatisfactory operation due to blown

fuses or inadequate or _nterrupted electrical protective
devices

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

accessones not compatible with the unit

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

6 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 AFG, Carlin EZ, or Rie[lo 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.

36"

1/4"

RETURN
NIPPLE

&

RIEDUCING

TEE

--*-- 2o I/2"

TIE_ml

GAUGIE

PRIESSUR_

r i

FRONT VIEW

UMIT

j CONTROL

(W_lh=_t

Tanklos=

oll)

LIMIT

CONTROL

(_Bh

Tonkiel=

co==)

BURN

DRAIN

VALVE

(Furnished)

,7.l/a"

RIEU.O

T3 3/4"

BIECKETT

OR

CARUN

t I P-'f
I I I--.-.I

A

'_ WATIER

OUTLET

RIGHT SIDE VIEW

WITH SWING DOOR

OPTIONAL

TANKLESS

J COIL

WATIER

HEATER

WITH 1/2" NPT

CONNECTIONS

RIEUIEF
VALVIE "_

OUTLET

BACK VIEW

BOILER RATINGS AND CAPACITIES

BOIIiR MOI)EI.NO

Wlill WIIIIOU I

IANK[ISS IANKIESS

('Oil ('OIl

niw (_5I ¸ 3[!W65Z -
31,W 751 3EW 75Z

31!WI OttI ¸ 3EWI IRIZ
4[iw 90T 4EW 99Z

41!WI 251 4EWI 25Z
41LWl 501 4EWl 50Z

5EWI 20'I 5EWI 20Z

5EWI.75 I 5EWI 75Z
5[-W2 00"[ SEW200Z

*MBH 1,000 BTU per hour BTU British Thermal Unit
+'*Heating Capacity based on 13% CO2 with a -0.02" w.c draft over fire, and a #1 smoke or less. Testing was done in accordance with the D.O.E.

(Department of Energy) test procedure.

_GPB Gallons per hour oil at 140,000 BTU per gallon

+ _A F U E. = Annual Fuel Utilization Efficiency based upon DOE test procedure.

NO INPUI **llliA'[ ING

Sli(' +M[_II ( APA('IIY

*MBH

3 91 80

3 105 92
3 140 II9

4 126 II[
4 175 150

4 210 178

5 168 147
5 245 209

5 280 236

NET DIMENSIONS (inches)

I=B:R HRING A t: tJ I MINIMUM

RA'I IN(i RA'II_ _+ CHIMNEY

*MBH +GPH SIZE / HEIGHT A B C

70 0.65 863 8" X 8" X 15' 14+1/2 6 8

80 075 852 8" X 8"X 15' 14-1/2 6 8

103 100 83 4 8" X 8" X 15' 14-1/2 6 8

97 090 860 8" X 8" X 15' 17-3/4 6 9-5/8

130 I +25 839 8" X 8" X 15' 17-314 6 9-5/8
155 150 82.4 8" X 8" X ]5' 17-3/4 6 9-5/8

128 1+20 865 8" X 8" X 15' 21 6 1 I-I/2

182 1.75 836 8" X 8" X 15' 21 6 11-1/2

205 200 820 8" X 8" X 20' 21 6 [ I-I/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.

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

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

3E.75Z, and 3El .00Z are the same boiler, without a tankless coil, except for the firing rate of the oil burner.
Models 4E.90T, 4El .25T, and 4El.50T are the same boiler, with a tankless coil, except for the firing rate of the oil

burner.

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

two firing rates. These boilers operate on #2 Heating Oil.

RULES FOR SAFE INSTALLATION AND OPEIL_TION

1. Read the Owner's Manual for Safe Operation carefidly. Failure to tbllow tile rules tbr sale operation and
the instructions can cause a malflmction of the boiler and resuh in death, serious bodily injury, and/or

property damage.

2. Check your local codes and utility requirements before installation. The installation nmst be in accordance

with their directives, or follow NFPA 31 - Installation of Oil Burning Eqnipment, latest revision.

3. Before serTicing, allow boiler to cool. Always shut offany 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 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.

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.

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

BEFORE YOU START

Complete all of the following prior to installing the boiler.

A. Check to be sure you have selected the right size boiler with the proper capacity. The 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. See boiler rating and capacity table previously

listed in this manual. Any heat loss calculations used should be based on approved methods.

B. Boiler rdust be supplied with the proper oil supply and oil piping, sufficient fresh combustion air, and a suitable

electrical supply.

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

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

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

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

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

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

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

5. Fresh air for combustion must be available at the front of the boiler. Fresh air for ventilation must be available to
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.

6. The floor supporting the boiler must be non-combustible and sufficiently stable. If it is combustible, place the
boiler on 2" concrete patio blocks or 2" Cladlite TM Pad. The blocks or pad must be under the entire boiler to

protect the floor.

7. Be sure installation is in accordance with the requirements of the local authorities having jurisdiction. Compliance
with these regulations is required. In the absence of local codes, follow NFPA 31 - Installation of Oil Burning

Equipment, latest revision.

MINIMUM CLEARANCE DIMENSIONS

f_

I

co'

41

O

24" MIN.

6" MIN.

+

_[ BOILER L 6" MIN.

v _FRONT t "q

,'x.

_C

C

t

6" MIN. / 18" WITH COIL

A_

4

ALWAYS KEEP TILE NL_NUAL FUEL SUPPLY VALVE SHUT OFF, IF THE
BUI_NER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIa_clE.

I_NSTALLATION REQUIRELMENTS

1

SHUT OFF
VALVE

OIL RLTER

2**

FI LL PiPE

MIN 2"

VENT PIPE

OIL

TANK

LINESTO OTHER

APPLIANCES

TO OUTSIDE

ELECTRIC
LINE

AUTOMATIC

FILL VALVE

NOSHUTOFF

EXPANSION TANK

DRAFT
REGULATO_

VENT
PiPE

RELIEF VAI

,TION

,FROM RADIATION

CIRCULATIHG

RETURN LINE

OR AbTER TI-I]£

EXPANSION
TANK

FRESH AIR FOR COMBUSTION

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.

If you use a fireplace or a kitchen or a bathroom exhaust fan, you should install an

I NOTE [

outside air intake. These devices will rob the boiler and water heater of combustion air.

You must provide enough flesh 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.

WARNING I

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 I30,000 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" (24-0 sq. in.) louvered

area would he used.

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

VENTILATING I
GRILLE 1

I'

COMBUSTION

AIR GRILLE

6

I

I

I

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
flee, 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.

FRESH

AIR

FRESH AIRDUCTCAPACITIESFORDUCTSSUPPLYINGFRESH _RTOBOILERINTIGHTLY

CONSTRUCTED HOUSES

Fresh Air

Duct Size

3J/2 '" x 12"

8" x 8"
8" x 12"
8"x 16"

*Btuh = British Thermal Units per hour based on opening covered by ¼" mesh

screen, wood louvers, or metal louvers.

¼" Mesh Screen

(Btuh)*

144,000

256,000
384,000

512,000

Wood Louvers

(Btuh)*

36,000
64,000

96,000

128,000

Metal Louvers

(Btuh)*

108,000

192,000

288,000

384,000

SYSTEM PIPING

I. When the installation of the boiler is for a new heating system, first instal! 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 water 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.

.

The packaged boiler unit is set up with 1-1/4" NPT supply and return piping 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.

,

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 shutoffof 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.

. 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.

RETURN FROM SYSTEM

SHUTOFF VALVE
BOILERSERVICE

I

DRAINVALVE

FOR POWER
PURGING

MAIN SHUTOFF
VALVE

AUTOMATIC
FILL VALVE

FILLTROLWITH

AIR PURGER

MAINTAINAT LEAST12O'F IN THE
BOILERRETURN.THE THROTTLINGVALVES

i/_ADJUST THE TWOTHROTTLINGVALVESTO

ARE USED FOR BYPASSPIPING,IF REQUIRED.

CIRCULATOR

THROTTLINGVALVE l

PUMP l

_FILL LINEWITHSHUTOFFVALVE

OffUNG VALVE

SUPPLY TO
SYSTEM

ISOLATIONVALVES

BOILER
DRAIN

VALVE 8

SYSTEM PIPING ARRANGEMENT

ZONING WITH ZONE VALVES

> CIRCULATOR ON SUPPLY PIPING PUMPS

AWAY FROM EXPANSION TANK

>

PIPING ARRANGED FOR "POWER P[VRGING"
AIR OUT OF SYSTEM PIPING, REFER TO THIS

MANUAL'S SECTION ON "FILLING THE

SYSTEM _,VITH WATER" OPTION #1

BALANCINGVALVE

ZONE VALVE

RETURNFROM SYSTEM

SHUTOFFVALVE
BOILERSERVICE

IT

I RAIN VALVE

FOR POWER
PURGING

MAINSHUTOFF

VALVE

FILL VALVE

FILLTROLWITH
AIR PURGER

SUPPLYTO

SYSTEM

CIRCULATOR
PUMP

_._"-_ SUPPLYTO

SYSTEM

ISOLATIONVALVES

LiNE WITH SHUTOFFVALVE

BOILER
DRAIN

VALVE

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

MANI_AL'S SECTION ON "FILLING THE

SYSTEM WITH WATER" OPTION #1

BALANCINGVALVE

FLOWCHECK VALVE

RETURNFROMSYSTEM

[ _ DRAINVALVE

FOR POWER
PURGING

MAIN SHUTOFF

VALVE

AUTOMATIC

FiLLVALVE

7

SUPPLY TO
SYSTEM

_ ZONE CIRCULATOR

_I ISOLATIONVALVE

SUPPLYTO
SYSTEM

SHUTOFF VALVE

BOILERSERVICE

BOILER
DRAIN

VALVE

_QUASTA

R

I0

FILLTROLWITH

AIR PURGER

FILLLINEWITH SHUTOFF

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 \VATER"

THIS PIPING ARRANGE_IENT CAN BE USED WITH ZONE VALVES OR ZONE CIRCULATORS

SHUTOFF VALVE

RETURN FROM SYSTEM

---BOILERSERVICE

ISOLATION
VALVES

SHUTOFF VALVE

BOILERSERVICE

BOILER
DRAIN

VALVE

CIRCULATOR
PUMP

©

AOUASTAT

SUPPLY TO
SYSTEM

AUTOMATIC
FILLVALVE

FILLTROLWITH
AIRPURGER

FILLLINEWITH
SHUTOFF VALVE

/

II

LOCATE CIRCULATORPUMP HERE WHEN SYSTEM
PIPINGUSES ZONE VALVES.IFSYSTEM PIPING
USES ZONE CIRCULATORS,USE THISCIRCULATOR

AS A ZONE CIRCULATOR