Kenmore KWX - 8V, KWX - 7V, KWX - 5V, KWX - 6V, KWX - 4V User Manual

OWNER'S MANUAL

CONTINUOUS PILOT

MODEL NO.

KWX - 3V
KWX - 4V
KWX - 5V
KWX - 6V

KWX - 7V
KWX - 8V
KWX - 9V

Gas- Fired

Cast Iron

HOT WATER

BOILER

CAUTION

Read all instructions

carefullybefore starting

the installation.

Save this manual

for future reference.

These instructions must

be affixed on or adjacent

to the boiler.

• Installation

• Operation

• Repair Parts

WAILING: 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.

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

I

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 willrepair defects in material or workmanship in the boiler,free of charge.

LIMITED 12 YEAR WARRANTY ON STEAM CAST IRON BOILERS

After one (1)year and through twelve (12)years from the date of installation,Sears willfurnish 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 thedate of installation,Sears will furnish a replacement
heat exchanger ifthe heat exchanger in the boiler isdefective. YOU PAY FOR LABOR.

SEARS INSTALLATION WARRANTY

In 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

;_l 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. Filterclearing 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 unsatisfactoryoperation 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.

1 Read the Owner's Manual for SafeOperation 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 cedes and utility requirements before

installation. The installation must be in acordance with their
directives.

3. Before servicing, allow boiler to cool. Always shut off any
electricity and gasto boiler when working on it.Thiswill prevent
any electrical shocks or burns.

4 Never test for gas leaks with an open flame. Use soap and

i

5. Ifthe unit is removed from the place it was originally installed,
this VCarrantybecomes void.

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

SEARS ROEBUCKAND COMPANY

D/817WA

Hoffman Estates,IL60179

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 anotherroom or inside a building

7. Be sure there isadequate air supply for complete combustion

8 Followa regular service and maintenance schedule for efficient

and safe operation.

2

FIG. 1

-ASME R[[J_¥ VALVE

C_ VI£NT

DAMPER

--A u

TEMP./PRESS. GAUGE

l
l

,-_ ..... -I,

r---

I

I;[ HPT , \ \

"_ i \.A

?

L ...... ,.Lr'--_l_ [

!

i

LEFT S;DE

BASIC BOILER MODEL NO.

ConUnuous Pilot

Vent Damper

KWX-3V

KWX-4V
KWX-5V
KWX-6V
KWX-7V
KWX-8V
KWX-9V

With

[_-----

J

i<\/

ENCLOSED

SCOHTROL_

• _AJN VALVE %

COH_OL

NO. OF

SECTIONS

3
4

5

6
7
8
9

I I I
I I i
i I I

INPUT

*MBH

70

105
140

175
210
245
280

hr_

I I II

_._L_ _.1__ _1__ _

AGA/CGA

GAS VALVE

NATURAL GAS

HEATING

CAPACITY

*MBH

57
85

113
142

170
198
226

J I r' 'E'r'PPLE

31?

RIGHT SIO[

DIMENSIONS (INCHES)

NET

I=B=R

Ratin9*MBH

5O
74
98

123
148
172
197

FLUE

DIAMETER

5
6
6
7

7
7

7

"A"

WIDTH

11 1/4
14 1/2

17 ¾

21
24 1/4
27 1/2

30 ¾

®

* MBH = 1,000Btuh Btuh= British Thermal Unit PerHour

For altitudes above 2,000 ft. ratings should bereduced at the rate of 4 _ for each 1,000ft. above sea level•
Heating Capacity is based on D.O.E (Deparirnent of Energy) test procedure.

**Add 5 ½" to height for Vent Damper.

The Ratings marked "Net I=B-R Ratings" indicate the amount of remaining heat input that can be used to heat the radiation or terminal
Units. The net I=B=R Ratings shown are based on an allowance of 1.15 in accordance with the factors shown on the I=B=R Standard
as published by the Hydronies Institute. Selection of boiler size should be based upon "Net I=B=R Rating" being equal to or greater

than the calculated heat loss of the building. The Manufacturer should be consulted before selecting a boiler for installations having
unusual piping and pickup requirements. These boilers must stand on a non-combustible floor. If installed on a combustible floor, use

Combustible Floor Base Number 42135-1 or 146-14-031 (3-6 section boilers) or 42135-2 or 146-14-032 (7-9 section 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 sea level, the input

ratings are reduced by a change in main 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/ANSI Z223.1-1atest edition), or the manufacturer for correct orifice

sizing information. High altitude orifices are available from the boiler manufacturer.

a

CheckIobesureyouhavetherightsizeboilerbeforestartingtheinstallation.
Seeratingandcapacitytableonpreviouspage.Alsobesurethenewboileris

forthetypeofgasyouareusing.Checktheratingplateontherightsideofthe
boiler.

Youmustseethattheboilerissuppliedwiththecorredtypeolgas,freshair
forcombustion,andasuitableelectricalsupply.Also,theboilermustbecon-

nectedtoasuitableventingsystemandanadequatepipingsystem.Finally,a
thermostat,properlylocated,is neededforcontroloftheheatingsystem.Ifyou

haveanydoubtsasto thevariousrequirements,checkwithlocalauthorities
andobtainprofessionalhelpwhereneeded.Takethetimetocompleteall of

thestepsfor SAFEandPROPERoperationof theheatingsystem.
Ifthisboilerisinstalledinabuildingunderconstruction,specialcaremustbe

takentoinsureacleancombustionairsupplyduringtheconstructionprocess.

Airborneparticulatessuchasfromdrywalldustandlromfiberglassinsulation
canclogtheburnerportsandcauseincompletecombustionandsooting.

Whererequiredbytheauthorityhavingjurisdiction,theinstallationmustcon-

formtoAmericanSocietyofMechanicalEngineersSafetyCodeforControl_

andSaletyDevicesfor AutomaticallyFiredBoilers,No.CSD-1.
Theinstallationmustconformto therequirementsol theauthorityhaving

jurisdictionor,in theabsenceofsuchrequirements,totheNationalFuelGas
Code,ANSIZ223.1-1atestrevision.

Installers- Followlocalregulationswith respectto installationof CO
detectors.Followmaintenancerecommendationsin this instruction

manual.
Tecbniciens- Veuillezvousconformerd lareglementationenvigueur

coneemantI"installationdesdefecteursd'oxydedecarbone.Suivreles

consignesd'entretienfigurantdanslemanueldinstrudioncijoinL

I KEEP BOILER AREA CLEAN AND FREE FROM COMBUSTIBLE MATERIALS,

GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS

1. Selecllevellocationascentralizedwithpipingsystem,andasnearchim-
ney,aspossible.

2. Placecratedboiler atselectedlocation,removecrateby pulling crate
sidesfromtopandbottomboards.Combustiblefloors:Whenboileristo

beinstalledona combustiblefloor,aSpecialBasePlatemustbeused-
146-14-031(2-6Section)or 146-14-032(7-9Section).Thisboilermust

notbeinstalledoncarpeting.

3. Boileristo belevel.Metalshimsmaybeusedunderbaselegsforfinal
leveling.

4. Additionalclearancesfor servicemayexceedclearancesforfireprotec-
lion.Alwayscomplywithlhe minimumfireprolectionclearancesshown

on theboiler.An !8 inchclearanceshouldbemaintainedon anyside

wherepassageis requiredtoaccessanothersideforcleaning,servicing,
inspectionor replacementof anypartthatmayneedattention.

Figure2 shows minimum clearancesto combustibleconstruction.
Roomsthatarelargeincomparisonwiththesizeoftheboileraredefined

asroomshavinga volumeequaltoor greaterthan16timesthevolume
ol theboiler.Wheretheactualceilingheightola roomis greaterthat8',

lhevolumeol a roomshallbebguredonthebasisota ceilingheightof
8' Determinationof roomsizeshouldbebasedonthetotalvolumeof all

gasfiredequipmentinslalledin theroom.Consultsection6.3.1of the
NationalFuel Gas Codelot furtherinlormatfon,including.approved

methods[orreducingclearancesin largerooms

5 Equipmentshat!beinstalledina locationinwhichthetacibliesforyen

tilationpermitsatistaclorycembushenofgas,propervenbng,andmain
tenanceo!ambientlempe_alureatsafelimitsundernormalcondibonsoi

use£qulpmentshal!belocatedsoasnotto interferewdhpropercircu-

lationo[air Whennormalinlfltrabondoesnotprovidethenecessaryair,
outside ai_ shall be introduced (See Page 4 - Fresh Air for
Combusbon")

6 AdviseownerIo keepair passagesfreeofobstrucbons.VenblaPngand

combusbonair muslenterboilerroomwithoulreskictions

7. Theboilershallbeinstalledsuchthattheautomaticgasignitionsystem
componentsareprotectedfromwater(dripping,spraying,rain,etc.)dur-
ing applianceoperationandservice(condensatetrap,controlreplace-
ment,etc.).

FIG, 2 - MINIMUM

Alcove, or Room not Large

in Comparison with Boiler

3-5 SECT.

TOP

REAR
RIGHT SIDE
LEFT SIDE

FRONT
FLUE/VENT

CONNECTOR
NEAR BOILER
PIPING

BOILER

BOILER SIZE

VOLUME

(Cu.Ft.)

3 SECT.
4 SECT.

5 SECT.

6 SECT.
7 SECT.

8 SECT.

9 SECT.

FOR ROOM WITH SINGLE BOILER ONLY

THIS UNIT MUST BE SET ON A CONCRETE OR OTHER

NON-COMBUSTIBLE MATERIAL BASE OR FLOOR.

CLEARANCE DTMENSIONS

6-9SECT.

6"
6"

6"
6"

18"

6 tl

i u

5.4

7.0

8.5

10.1

11.7

13.2

14.8

6"
6"

24"

24"

18"

rq

1" 1"

MINIMUM ROOM VOLUME

REQUIRED TO BE LARGE

ROOM (Cu. Ft.) _

Room Large

Comparison
With B6iier

3-9 SECT.

6"

6"

6"
6"

18"

6 t,

86.6

111.6

136.6

161.7

186.7

211.7

236,7

I Provisionfor combustionand ventilation air must be in accordance with Section 5.3, Air for CombustionandVentilation, of

the National Fuel Gas Code, ANSI Z223.1-1atest revision, or applicable provisionsof the local building codes.

WARNING

Be sure to provide enough fresh air for combustion.
Enough air insures proper combustion and assures that

no hazard will develop due to the lack of oxygen.

Youmustprovideforenoughfreshairtoassurepropercombustion.Thefire

in theboilerusesoxygen.It musthaveacontinuoussupply.Theair in a

housecontainsonly enoughoxygento supplylhe burnerforashorttime.
Outsideair mustenterthehousetoreplacethatusedbytheburner.Study

followingexamples1and2 to determineyourfreshair requirements.

EXAMPLE1: Boiler Locatedin UnconfinedSpace

Anunconfinedspaceisdefinedasaspacewhosevolumeis notlessthan
50cubicfeelper1,000Bluperhourofthelotalinputratingofallappliances

installedinthatspace.
Ifyourboileris inanopenarea(unpartitiouedbasement)in aconventional
house,theairthatleaksthroughthecracksarounddoorsandwindowswill
usuallybeadequatetoprovideair forcombustion.Thedoorsshouldnotfit
tightly.Donotcaulkthecracksaroundthewindows.

Equipmentlocatedin buildingsofunusuallytightconstructionshallbepro-
videdwithairfor combustion,ventilation,anddilutionol fluegasesusing
themethodsdescribedin example2Borshall bespeciallyengineered.The
authorityhavingjurisdictionmustapprovespeciallyengineeredinstalla-

tions.

EXAMPLE2: Boiler Locatedin ConfinedSpace

/L All Air from Insidethe Building:Theconfinedspaceshallbepro-

videdwithtwopermanentopeningscommunicatingdirectlywithanaddi-
tionalroom(s)of sufficientvolumeso thatthecombinedvolumeof all
spacesmeetsthecriteriafor anunconfinedspace.Thetotalinputofall
gas:utilizationequipmentinstalledin thecombinedspaceshallbecon-
sideredin makingthisdetermination.Eachopeningshallhavea mini-
mumfreeareaofonesquareinchper1,000Btuperhourolthetotalinput

ratingofall gasutilizationequipmentin theconfinedspace,butnotless

that100squareinches.Oneopeningshallbewithin12inchesofthetop
andonewithin12 inchesofthe bottomoftheenclosure.Theminimum

dimensionof airopeningsshallnolbelessthan3inches.

B.All Airfrom Outdoors:Theconfinedspaceshallcommunicatewiththe

outdoorsinaccordancewithmethods1or 2.Theminimumdimensionof
airopeningsshallnotbelessthan3in.Whereductsareused,theyshall

beof thesamecross-sectionalareaasthe freeareaoftheopeningsto
whichtheyconnect.

1.Twopermanentopenings,onecommencingwithin 12 inchesofthe
top,andonecommencingwithin12inchesoftheboltom,oltheenclo-

sureshallbeprovided.Theopeningsshallcommunicatedirectly,orby
theducts,withtheoutdoorsor spaces(crawlorattic)thaifreelycom-

municatewiththe ouldoors.
a)Wheredirectlycommunicatingwiththeoutdoorsor wherecommu-

nicatingtotheoutdoorsthroughverticalducts,eachopeningshag
haveaminimumtreeareaof 1sq. in.per4000Btuperhourof total
inputratingofall equipmentin theenclosure.(SeeFigure3A.)

b)Wherecommunicatingwiththeoutdoorsthroughhorizontalducts,

eachopeningshal!havea minimumfreeareaof 1sq.in. per2000
Blu perhouroftotalinputratingofall equipmentin theenclosure.

(SeeFigure3B.)

2.Onepermanentopeningcommencingwith12 inchesofthelop of the
enclosure,shallbepermittedwherethe equipmenthasclearanceofat

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 combus-

tion air.

least1inchfromthesidesandbackand6 incheslromIhefronlofthe

appliance.TheopeningshalldirectlycommunicatewithIheoutdoors
or shallcommunicatethrougha verticalor horizonlalducttotheoub

doorsor spaces(crawlorattic)thatfreelycommunicatewiththeout-
doors,andshallhaveaminimumfreeareaof:

a) 1sq. inchper3000Btuperhourol theIolalinputofaftequipment

locatedin lheenclosure(SeeFigure4),and

b)Notlessthanthesumoftheareasofallvenlconnectorsinthecon-

finedspace.

Figure 3A - FRESH AIR DUCT CAPACITIES (Btuh) i

1 Square Inch per 4,000 Btuh

100% Free 75% Free

Area Area

Fresh Air
Duct Size

3"x 12"
8" x 8"

8" X 12"
81/2"X 16"

Figure

I 3B - FRESH AIR DUCT CAPACITIES (Btuh) I

1/4"Wire Metal

Mesh Louvers
144,000 108,000

256,000 192,000
384,000 288,000
512,000 384,000

25% Free
Area

Wood
Louvers

36,000
64,000

96,000

128.000

1 Square Inch per2,000 Btuh

100% Free 75% Free
Area Area

Fresh Air
Duct Size

3" x 12"

! 8" x 8"

8"x 12"

81/2"x 16"

Figure

I FRESH AIR DUCT CAPACITIES (Btuh) i

4

V4"Wire Metal
Mesh Louvers

72,000 54,000
128,000 96,000
192,000 144,000

256,000 192,000

25% Free

Area

Wood

Louvers

18,000

32,000

48,000

64,000

1 Square Inch per 3,000 Bruh

100% Free 75% Free 25% Free

Area Area Area

Fresh Air V,¢'Wire Metal Wood

Duct Size Mesh Louvers Louvers

3" x 12" 108,000 81,000 27,000
8" x 8" 192,000 144,000 48,000
8" x 12" 288,000 216,000 72,000

8V2"x 18" 384,000 288,000 96,000

I

5

1.PlaceboilerintheselecledIocalion(asnearchimneyaspossible.)Your
boilerisshippedassembled.YouneedonlyIoinsfalltheReliefValveand

adrainlinetocarryanywalerorsteamIoadrain.

2.InstallRelielValveinto the3/,,-pipeonthetopol Iheboiler.SeeFigure5.
Use¾" Pipeandanelbow(nolfurnished)to carrythewalerorsteamto

anearbydrain.Donotconnectdirectlytoadrainbulleaveanairgap.No
shutollol anydescriptionshallbeplacedbetweenthesafdy rebelvalve

andtheboiler,or ondischargepipesbetweensuchsafetyvalvesandthe
atmosphere.Installationol the safetyrelielvalveshallconformto the

requirementsof the ANSI/ASMEBoiler and PressureVesselCode,
SeclionIV.Themanulactureris notresponsibleforanywaterdamage.

InstallDrainValvein lowerleftsideof boilerasmarked.

3.ConnectSupplyandReturnLinestoboiler.Theconneclionsmayrequire
certainadditionalfiltingsandparts,as shownondiagram(Figs.5and6).

4.Thisboileris equippedwilh 11/4"supplyandreturnconnectionsonboth
theleftandrightsidesol theboiler.

Inconnectingthecoldwatersupplytothewalerinlelvalve,makesurethat
a cleanwalersupplyis available.Whenthewatersupplyis froma weftor

pump,asandstrainershouldbeinstalledatthepump.
A hotwalerboiler installedaboveradiationlevelmustbeequippedwilha

lowwatercutoffdevice.A periodicinspectionisnecessary,asisflushingof
floattypedevices,permanufacturersspecificinstruction.

FOR USE WITH COOUNG UNITS
A. Thisboiler,whenusedinconnectionwithchilledwatersystems,mustbe

installedso that thechilledwateris pipedin parallelwiththeheating
boiler.Appropriatevalvesmustbeused1oprevenlthechilledwaterfrom

enteringtheheatingboiler(Fig.6).

B. Whenthisboiler is connectedto heatingcoils locatedin air handling

unitswheretheymaybeexposedtorefrigeratedaircirculation,thepip-
ing syslemshallbeequippedwithflowcontrolvalvesorotherautomaf-

icmeanstoprevenlgravgycirculationoftheboilerwalerduringthecool-
ing cycle.

LOW DESIGN WATER TEMPERATURE SYSTEMS
(BELOW 140°)

If Iheboileris tobeusedin aheatingsysfemwheredesignwaterlempera-

luresbelow140° Faredesired(e.g.radianlfloorhealing),a3-wayor4-way
mixingvalveor suitablealternativeis requiredtopreventlowfemperature

returnwaterfromenleringtheboiler.FollowIhemixingvalvemanufacturer's

installationinstructions.
TheminimumdesignreturnwaterLemperatureIotheboilertoprevenlcon-

densationin theboilerandventingis 120° E Theminimumhigh limilset-

tingis 140° F.

THE ISOLATION BALL VALVES CONTAIN TEFLON
SEATS AND SEALS. OVERHEATING THIS VALVE

I CAUTION

MAY CAUSE PREMATURE FAILURE.

COt.o WATE_ LNLET.

TO SYSTEM

VALVES A & B

OPEN FOR HEATING;
CLOSE FOR COOLING

VALVES C & O
CLOSE FOR HEATING:

OPEN FOR COOLING

cd

WAFER

CHILLER

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

in accordance with Part 7, Venting of Equipment, of the National Fue| Gas Code,

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

CHECK YOUR CHIMNEY
Thisis a very imporfantpartof your heatingsystem It mustbe clean,

theright size,properlyconstructedandin GOODCONDITIONNo boiler

canlunctionproperlywith a bad chimney.Fig.7 givestypicalchimney
sizes.Fig.8 givesyouanideahowa boilermightbe ventedto achimney

Nofetha_theheight(HT)ismeasuredfromtheventpipeto thelop.

CHIMNEY SIZING

Chimneysizing,andall otheraspectsof the vent installationmustbe
in accordancewith Part7 of the NationalFuelGasCode,ANSIZ223.1

- laleslrevision,andapplicableprovisionsof thelocalbuildingcodes.
In Canada,follow CSA B149.1and B149.2,InstallabonCodesfor
GasBurningAppliancesandEquipment.

6

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 !/2square inch hole (approximately 3/4"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.

On 2 section boilers equipped with vent damper, the
supplied 4-inch vent damper is equipped with a 3- to

4-inch adapter so that the 4-inch vent damper may be
installed on the boiler's 3-inch flue outlet collar. Fasten

all fittings securely

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 in the open position when appliance
main burners are operating.

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

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

except 2 section boilers with vent damper as noted above.

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 3/4the 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.
_he thimble should be 4 inches larger in diameter than the
vent pipe

Boiler Input

Btuh

Up to 100,000
Up to 155,000
Up to 230,000
Up to 350,000

"HT - top of thimble to top of flue. See F_g 8.

For boiler input refer to table, page 2
For intormaliOn only - no{ meant to imply minimum s_zes

10-15 Ft.

6x6
6x7
7x8
9x9

FLUE AREA IN INCHES

"HT

"HT.

15-25 Ft.

6x5

6x6
7x7
8x9

"HT

25 Ft Up

5×5
6×5
6×7

8×8

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 to the common venting system placed in operation,

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

1. Seal any unused openings in the common venting system.

2. 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.

3. Insofar as is practical, close all building doors and windows

and all doors between the space in which the appliances
remaining connected to the common venting system are
located and other spaces of 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

4. Place in operation the appliance being inspected. Follow
the lighting instructions Adjust thermostat so appliance
will operate continuously.

5 Test for spillage at the draft hood relief opening after 5

minutes of main burner operation. Use the flame of a match

or candle, or smoke from a cigarette, cigar or pipe

6. After it has been determined that each appliance remain-

ing connected to the common venting system properly

vents when tested as outlined above, return doors,
windows, exhaust fans, fireplace dampers and any other

gas-burning appliance to their previous conditions of use.

7 Any _mproper operation of the common venting system

should be corrected so the installation conforms with the

National Fuel Gas Code, ANSI Z223.1 -latest revision. When
res_ztng any portion of the common venting system, the

common venting system should be resized to approach
the minimum size as determined using the appropriate

tables in Part 11 in the National Fue! Gas Code, ANSI
Z2231-latest revision

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
mechanical 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

FLOW _ NO

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

TO FURNACE_ iNSTALLEDIN ANY POSITION

OR BOILER

DAMPER

ACTUATOR MAY BE

U

C_N: IX) NOT INSTALL

THE VENT DAMPER

WITHIN 6 in. (152 mm) OF

COMBUS33BLE MATERIAL

3HIMNEY

BOILER WATER HEATER

TYPICAL INSTALLA'nON FOR VENT DAMPER

NOTE CAUTION AND FOOTNOTES

1 Installthe vent damper to service only the single ap_iance for

which it is intended,if improperly installed,a hazardous cond_on,
such as an explosionorcarbon monoxide pe,,sening,could result.

2_ Do not install the vent damper on vent pipecurve.
3 Do not run wires near high temperature surfaces.Use staed_ff

brackets Jfnecessary

8

Forsafe,efficientoperation,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. If you see corrosion or other

deterioration, contact your heating contractor tor repairs.

Check vent damper operation as follows:

1. When the boiler isoff, 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.

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.

Forfurther information,and for avent damper !roubleshooting
guide, refer to the Effikal manual that was packaged with

the vent damper.

The vent damper must be inspected at 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,

i6 °

iI 010

DAMPER CLOSED OAMPER OPEN

SHOWING OPEN AND CLOSED POSmON

°1

CHECK GASSUPP_

The gas pipe to your boiler must be the correct size for the
length of the run and for the total 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 I/2psig (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 1/zpsig (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 Z223.1-1atest 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 pLpe 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

NATURALGAS

Length of Includes Fittings

Pipe- Ft.

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

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

60 50,000 105,000 195,000 365,000

The length of pipe of tubing should be measured from the gas meter

PipeCapacity - BTU per Hour Input

V2" 3/4" 1" 11/4"

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 ATONCE

WARNING

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

10

WARNING

TURN OFF ELECTRICAL POWER AT FUSE BOX BEFORE MAKING ANY LINE VOLTAGE CONNECTIONS.

FOLLOW LOCAL ELECTRICAL CODES.

II I

All electrical work must conform to local codes as well as the National Electrical Code, ANSI/NFPA-70, latest revision. In
Canada, electrical wiring shall comply with the Canadian Electrical Codes, CSA-C22.1 and .2.

ELECTRIC POWER SUPPLY

Prior to making any line voltage connections, service switch at boiler should be in the offpnsition and the power turned offat

the fuse box.

Run a separate 120 volt circuit from a separate over current protection device in the electrical service entrance panel. This

should be a 15 ampere circuit. A ser+ice switch has been provided and should be mounted to the Junction box located on the

exterior boiler jacket. See Fig. 13-1 for diagram showing power supply connection points.
The boiler, when installed, must be eleotrically 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-70, latest revision. In

Canada, electrical wiring shall comply with the Canadian Electrical Codes, CSA-C22.1 and .2.
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.

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

vertical mounted outlet box. It should be sensing average room temperature. Avoid the Following:

DEAD SPOTS:
Behind doors

Comers and alcoves

Set heat anticipator at 0.1 amps. Connect 24 volt thermostat leads to the two(2) yellow wires located in service switch

junction box, located on outer jacket of boiler. See Fig.13-1 for service switch junction box and thermostat field wiring

connections.

VENT DAMPER WIRING

The boiler is equipped with a factory wired harness with 4 pin molex plug, that plugs into a 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.

COLD SPOTS:
Concealed pipes or ducts

Stairwells - drafts
Unheated rooms on

other side of wall

HOT SPOTS:
Concealed pipes Lamps

Fireplace Direct sunlight

TV sets Kitchens

Radios

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and

dangerous operation. Verify proper operation after servicing.

11