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

Connect Circulator Pump Wiring

See Fig.13-1 for line voltage, thermostat and circulator pump field wiring connections. A 5 foot wiring harness with flexible
metal conduit is supplied to connect the circulator pump to the service switch junction box. If the two 120 volt circulator

wire terminals inside the junction box are not used, please leave the two wire nuts to prevent the short circuit.

FIG. 13-1

12

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THIS PAGE INTENTIONALLY LEFT BLANK

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13

THIS PAGE INTENTIONALLY LEFT BLANK

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14

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POWER , --

suP_¥.OT......... --_ _H______

NELrmAL [

115VAC __

ir .....

ii

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PUMP

2€V _ERMOSrAT

24 '_0LT TRANSFORMER

AQUASTAT

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W XF._MR PRl_ / BU

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OR

BOILER SENSOR

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y SA,_L'IYSHUT OFF

OR

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OR

T w

L BK l

BK

GAS VALVlEVR8200A/VR830OA

BK

WIRE CODE COLOR COOE

MAIN POWER STATUS LIGHT

CALL FOR HEAT/CIRCULATOR PUMP STATUS LIGHT

GAS VALVE/BURNER STATUS LIGHT

-- LINE VOLTAGE P -PINK

.... LINE VOLTAGE Y -YELLOW

-- LOW VOLTAGE G -GREEN

.... LOW VOLTAGE GY -GRAY

DAMPER CABLE BK-BLACK

FIELD WIRING R -RED

FIELD WIRING

BIR-BROWN

W -WRITE

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

BE REPLACE WITH TYPE 105 ° C THERMOPLASTIC WIRE OR IT'S EQUIVALENT

15

OVERCURRENT

PROTECTED

DISCONNECT

RVGP-KS--BKF

VENT DAMPER

HOT

M3-1 P3-2 _LL /'_ M3--4 P3--,

r ; P2-04

; P1-01 p2-01 K1A $2 S1B

120/60/1 pOWIER SUPPLY

CIRCULATOR PUMP

120 V_C.

PRIMARY

24 V_C.

SECONDARY

,._>>---<<-_'D'-L-_'-I _ m-o4

STAT P1--02 P2-OS Kle S1A $3 J

_

- o-

NEUTRAL

"7

L .----

M3-5 E3 _/_ M3-2 E1

MICROPROCESSOR

HIGH UMIT SOR_j 1 -

2 M3-3 _ /_ M3-6 Ji-I

'-,

GAS VALVE

VR8200A/VR830OA

NOTE:

SIA AND SID ARE THE AUTOMATIC OPERATION / HOLD DAMPER OPEN SWITCH.

SWITCH SHOWN IN AUTOMATIC POSITION.

$2, $3. AND $4 ARE CAM ACTUATED SNAP SW_TCHES.

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

BE REPLACE WITH TYPE 105 ° C THERMOPLASTIC W.T_REOR IT'S EQUIVALENT

/_ MAIN POWER STATUS LIGHT

/_ CALL FOR HEAT/CIRCULATOR PUMP STATUS LIGHT

A GAS VALVE/BURNER STATUS UGHT

16

RELIEF VALVE

You must have a relief valve on your boiler. Water expands as it is heated. If there is no place for the water to expand into,
water pressure will build up inside the boiler and system. Should this happen, the relief valve will automatically open at a
pre-determined pressure. This will relieve the strain on the boiler and system. Run a pipe from the relief valve outlet (pipe

must be same size as outlet and the 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.

EXPANSION TANK

In a properly assembled system, the expanding water flows into a expansion tank. This tank should be of the correct size.

The tank is filled with air. As the water expands it compresses the air in the tank to form an air pressure cushion. This

"spring-like" cushion serves to maintain correct operating water pressure regardless of water temperature. This assures a
"full measure" of a water, even in the highest radiation unit of the system. It also prevents blowing off of the relief valve.
The air in the tank in the beginning (with system filled with cold water) is sufficient for proper operation. The tank also

serves as a trap for excess air in the system. The air would cause gurgling in the pipes and inefficient circulation in the

radiators if left in the system. It is possible for a tank to become "water-logged" (filled with water). It can also become

overfilled with air. This can happen after filling the system with new water. Fittings provided on the tank and in the line to

the tank are for bleeding off excess water or air. When installing this tank, it is important: 1) That the tank be higher than

the boiler top. 2) That the pipe to the tank continuously rises up to the tank (so that air can "bubble" up to it).

DIAPHRAGM TYPE EXPANSION TANK

The diaphragm type expansion tank (EX-TROL) takes the place of the conventional expansion tank. Carefully read the

instructions packed with your EX-TROL tank assembly. The EX-TROL tank comes to you with a 10-12 pounds per square

inch air charge. This is the same as the pressure produced in the system by the automatic fill valve. When the system is

first filled, the EX-TROL tank will contain little or no water. As the water is heated its pressure increases. It expands into the

EX-TROL tank, compressing the air in the tank. This compressed air cushion permits the water in the system to expand as

the temperature changes. The diaphragm type tank can be mounted on the air purger fitting or at any convenient place in

the supply or return line.

AIR ELIMINATING FITTING (AIR PURGER)

An air purger is used to remove excess air from the system. It is installed in the supply line. It will eliminate air from the

water before it reaches the radiators and bleed off this air.

MAIN AIR VENT FOR DOWN FLOW SYSTEMS OR DIAPHRAGM TYPE EXPANSION TANK

Before a system isfilled with water, there isair in the pipes and radiation units. Some of it will be trapped as the system is

filled. It is possible to eliminate most of this air through the air vent on the radiation units. A main air vent will speed and

simplify this. It should be installed on the highest point in the supply main when all radiation is below top of boiler.

AUTOMATIC FILL VALVE

For safe, efficient operation, a hot water system must be completely filled with water. Adding new water, when needed
can be done manually (by use of a hand valve in the water supply line). This requires regular attention to the system's

needs. An automatic fill valve accomplishes this without attention. It is installed in the supply line on hot water boilers only.
The valve operates through water pressure differentials. It does not require an electrical connection.

DRAIN VALVE

This manual valve Provides a means of draining all water from the boiler and system. It is often installed in the %" tapping

at the bottom of the end boiler section. Or it can be installed in a tee where the return line enters the boiler.

17

CIRCULATING PUMP

Every forced hot-water system requires a circulating pump. A separate pump or zone valve is required for each zone, if you

have a two or more zone system. This pump must have the capacity to provide the circulation required by your system.

The pump is connected into the return main just ahead of the boiler. It is also wired to the electrical system.

VENT DAMPER

This product is an automatic, motorized stack damper that has been developed to increase the efficiency of heating systems

by reducing standby losses from the heating apparatus and the conditioned air space. The damper closes the chimney vent
when the burner is off and fully opens it when combustion is required.

L7148F ELECTRONIC AQUASTAT CONTROL

The L7148F Electronic Aquastat Control is an immersion type hydronic controller that provides high limit protection and

controls the circulator, gas valve and vent damper. The L7148F Control does not provide a low limit function. An external
transformer (ATI50-B), appropriately sized for this application; a sensor (209659A) and an immersion well are required for
aquastat operation. The L7148F Electronic Aquastat Control has three states of operation: Normal, High-Limit, and Reset:
(The control moves back and forth between the normal and high-limit states, as needed. However, the control only enters
the reset state when there is an abnormal condition such as an internal error or shorted sensor). In the L7148E system, the
circulator and burner are on any time there is a thermostat call for heat, unless the boiler water temperature exceeds the

high limit setting. (The high-limit switch shuts off the burner (B1, B2 output) when the boiler water temperature exceeds the

high limit setting). The water temperature limit control is adjustable and may be set as necessary. Turn the High-Limit dial
on the control to the desired setting. It may be set as low as 130° F., 140° F. is recommended (refer to page 5 for "LOW
DESIGN WATER TEMPERATURE SYSTEMS BELOW 140° F.) or as high as 240 ° F. (we recommend not to exceed 220 ° F.,
refer to page 19 "ADJUST LIMIT CONTROLS'_. This depends on the type and amount of radiation involved and weather

conditions.

ROLLOUT SWITCH (FLAME ROLLOUT SAFETY SHUTOFF)

The rollout switch isa 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 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 (340 ° F), and normally closed contacts. It is located
at the relief opening of the integral draft diverter. In the event of chimney or venting system blockage causing products of
combustion to spill out of the relief opening, the spill switch disc heats up and the spill switch contacts 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.

18

HOW A HOT-WATER SYSTEM OPERATES

Your entire heating system (boiler, piping and radiation units) is filled with water. As the water in the boiler is
heated, it is pumped from the top of the boiler through the supply main to the radiation units. The cooler water
in them flows back through the return main to the boiler. This provides positive and rapid response to the

thermostat.

FILLI"NG SYSTEM WITH WATER

Close the air vents on all radiation units. Open the valves to these units. Make sure the boiler and expansion
tank drain cocks are closed. The air bleed screw on the tank drain fitting should be closed. Open the valve in the

line from the boiler to the expansion tank. Open the water inlet to your boiler and leave it open. Start with the
lowest radiation unit. Open the air vent on this unit. When all the air has escaped and water starts to flow from

the vent, close it. Go to the next radiation unit, and repeat this process. Repeat until you have covered every
radiation unit in the system (ending up at the highest unit in the system). If your units have automatic vents,

this manual venting is unnecessary but it will speed up the proper filling of your system. If your system is a

closed expansion tank system, you may leave it open to refill the system automatically as needed. Check the

temperature pressure gauge. Not the position of the hand indicating pressure. This should be between 10 and

15 Ibs. Any lowering of this movable hand below 10 Ibs. Will indicate loss of water due to leakage. The

automatic fill valve should compensate for this. Instructions are packages with the valve.

WARNING - Never run water into a hot empty boiler.

19

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

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

I

I

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 2i) A match holder is included inthe 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.

• 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.

C.

Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will net 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.

D.

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.

2O

1. STOP! Read the safety information on page 20

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. Remove lower front panel.

5. Rotate gas control knob slightly and turn clockwise
to "OFE"

GAS
INLET

RESET BUTTON

GAS CONTROL KNOB

IN "ON" POSITION

6. 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 page 20. 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. 14.

8. Turn knob on gas control counterclockwise l_ to
"PILOT"

9 Rotate the gas control knob counterclockwise i_ to

"PILOT" Push down and hold the red reset button while
you light pilot burner with a match

After about one minute, release 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 orgas 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."

t 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

t. Set the thermostat to lowest setting

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

3. Push in gas control knob slightly and turn clockwise
_1 to "OFE" Do not force.

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 hotd the gas supply from burner
regardless of the demand of any other control.

SAFETY PILOT

Safety Pilot prevents the flow of gas to burner if the pilot

goes out, or will not ignite.

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.

RELIGHT

The electric and gas shall be off for 5 minutes before relighting

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

is completely self-checking On every cal! 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 lor 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 rewsion

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ADJUST PILOT BURNER

Pilot flame should surround 3/8" to 1/2" of the pilot sensor.
Refer to Fig. 18. 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, clock+

wise to decrease.

3. Replace screw cover over pilot adjusting screw.

MAIN BURNER(S)

The main burners do not require primary air adjustment and
are not equipped with primary air shutters Main burner
flames should form sharp blue inner cones in a softer blue
outer mantef, with no yellow. Puffs of air from blowing on the

flame or stamping on the floor wilt cause the flames to turn
orange momentarily This is not unusual. Remain still when
observing the main burner flames. If the flame appearance is

not correct, check main burner orifices and the burner throat
and flame ports for dust and lint obstruction. It may be nec-

essary to remove the rollout shield to observe the main burn-
er flames Replace rollout shield after observation Refer to
Figure 17+

ADJUST LIMIT CONTROLS

Instructions for each control are included with the controls
These settings can be changed after you have had some

f OUTER MANTEL

,..:..:--.:...-:..:..:,

I111; + +':'+' ':'+1

_SHARP INNERCONES

idea how the system works. Example: If your system does not
give quite enough heat in very cold weather, you can raise

the limit setting to 220° R Use the boiler gauge to check your
settings. Make the adjustments according to its readings.
Check thermostat operation. When set above temperature

indicated on the thermometer, boiler should ignite. Make cer-
tain the thermostat turns off the boiler when room tempera-

ture reaches the selected setting and starts the boiler oper-
ating when room temperature falls a few degrees.

After setting limitcontrol to limit setting, check to see ifit shuts
off the gas supply to the burners. Turn your thermostat up to

call for heat and let your boiler run until the temperature of the
water reaches the limit setting. The gas valve should shut off
and the circulator keep running until the thermostat is satis-
fied, or the water cools enough to restart the burners through

the limit control
FinaPly, set the thermostat for the desired temperature.

Special conditions in your home and the location of the ther-
mostat will govern this setting

3/8" to 1/2"'

RECOMMENDED BOILERWATER TEMPERATURES J

Type of Heating Unit Limit Control Setting

Standing Radiators .................... 180° F.

Baseboard and Convector Radiators ...... 200° F.

I

22

BURNERS

A visual check of the pilot and main burner flames should
be made at least once each year, preferably at the beginning

of the heating season. See page 22

RELIEF VALVE

This valve should open automatically if the system pressure
exceeds the pressure rating (usually 30 psi) of the relief valve.

Should it ever fail to open under this condition, shut down
your system. Drain the system until system pressure is

reduced below the relief valve pressure rating. If valve
discharge occurs, or ifvalve fails to open as described above,
contact an authorized contractor or qualified service

technician to replace the relief valve and inspect the heating

system to determine the cause, as this may indicate an

equipment malfunction.
This valve should be tested every month during periods of

boiler operation, and at the beginning and end of any
extended non-service period. Prior to testing, make certain

discharge pipe is properly connected to valve outlet and
arranged so as to contain and safely dispose of boiler
discharge. Test at normal system operating pressure. Hold

the trip lever fully open for at least five seconds in order
to flush free any sediment that may lodge on the valve seat.
Then permit the valve to snap shut.

EXPANSION TANK

As previously noted, this tank may become waterlogged, or
may receive an excess of air. Frequent automatic opening
of the relief valve indicates water logging. A high boiler
temperature accompanied by unusually low radiation unit
temperature (and "knocking") indicates excess air in tank.

To correct either condition, close the valve between the boiler
and the tank. Drain the tank until it is empty Check all the
tank plugs and fittings Tighten as necessary Open the valve

between the boiler and tank. Water will rise to the normal

height in the tank if you have an automatic fill valve (otherwise,
manually refill the system).

BOILER FLUE PASSAGES

Under normal operating conditions, with the burners properly

adjusted, it should not be necessary to clean the boiler flue
gas passages. However, to assure trouble-free operation, we

recommend that you have the flue passages, burner

adjustment, and operation ofthe controls checked once each

year by a competent Service Technician.
Before the start of each season (or whenever system has

been shut down for some time) recheck the whole system
for leaks.., and recheck the boiler and vent pipe for leaks.
Replace or patch any boiler seals that are faulty

VENT PIPE
The venting of this unit is very important and the piping

should be checked at least once a season. If the vent
piping shows any sign of leaking, replace It immediately.

WATER SYSTEM

If system is to remain out of service during freezing weather,
always drain it completely (water left in to freeze will crack
the pipes and/or boiler).

CLEANING YOUR BOILER AND BURNERS

Flue passages between sections should be examined yearly
and cleaned if necessary To clean, remove burners, pilot,
and vent pipe. Remove top and front jacket panels. Remove

the two screws attaching the intermediate front panel to the

left and right side jacket panels. Remove the draft diverter

and intermediate front panel as a unit. Carefully remove the
cerafelt gasket strips. Clean passageways between sections

with a flexible handle wire brush. Remove dirt from bottom
of boiler and from between sections by vacuuming. Make

sure all flame ports in burners are open and clear. Shake
out or blow out all loose dirt in burners. Reseal seams between

adjacent sections as necessary with 400 F RTV silicone
sealant. Reassemble all parts. Be sure to check tightness

of pilot connections and condition of burner flames after
reassembly (see Figures 17 and 18}. Be sure vent pipe

connections to chimney are secure and no obstructions are
present.

23

PWX WITH STANDING PILOT:

Thermostat calls for heat, completing the circuit to the aquastat and gas valve. The sequence is as follows: The

LED light indicating a call for heat and circulator, in the control panel, will illuminate. The automatic vent damper

will begin to open. When the vent damper is completely open and the end switches are made, the gas valve /

burner LED light will illuminate and the main valve will open, lighting all the burners. The burners will continue to

fire until either the thermostat or high limit, in the aquastat, is satisfied. If the high limit is satisfied and a call for
heat remains from the thermostat, the main valve will close, shutting off gas supply to the burners and the

associated LED light in the control panel. The circulator will continue to operate and circulator LED light will
remain on until the thermostat is satisfied.

Please note the main power LED light, in the control panel, will remain on until line voltage to the boiler is turned
off or disconnected.

INITIAL SERVICE CHECKS

1.

2,

BEFORE TROUBLESHOOTING:

A. MAKE SURE THAT CIRCUIT BREAKER IS ON OR FUSE IS OK AT ELECTRICAL PANEL.

B. MAKE SURE THAT SERVICE SWITCH IS ON.

C. MAKE SURE THAT GAS IS ON AT THE GAS METER, AND THAT ALL APPROPRIATE MANUAL

SHUTOFF VALVES AND GAS CONTROL VALVE ARE OPEN.

D. MAKE SURE THAT THE THERMOSTAT IS CALLING FOR HEAT.
E. CHECK THAT WIRE CONNECTORS AT THE L7148F CONTROL, TRANSFORMER AND $8600 CONTROL

(IF USED) ARE SECURELY PLUGGED IN OR CONNECTED.

TROUBLESHOOTING TOOLS:

A. VOLTMETERTO CHECK 120 VAC AND 24 VAC.
B. CONTINUITY TESTER.

C. U-TUBE MANOMETER OR DIFFERENTIAL PRESSUREGAUGEWITH 0-14" RANGE(0.1" SCALE) FOR

MEASURING INLET AND MANIFOLD GASPRESSURES.

3,

WHAT IS SYSTEM STATUS ?

A. CONSULT THE CHART ON THE FOLLOWING PAGE.

B. FIGURE 19 ON PAGE 25 SHOWS THE LOCATION ON THE BOILER OF THE SYSTEM STATUS LIGHTS.

24

FIG.19

/ STATUS LIGHTS

@ MAIN POWER
r_ CALLFOR HEAT

C[RCUL_TORPUMP

@ GAS VALVE

BURNER

SYSTEM STATUS

LIGHT STATUS INDICATES

POWER

CALL FOR HEAT/ ON L7148F CONTROL ENERGIZING CIRCULATOR PUMP CIRCUIT.

CIRCULATOR PUMP OFF CIRCULATOR PUMP IS NOT ENERGIZED.

GAS VALVE / BURNER

LIGHT STATUS INDICATES

L7148F LED STATUS (2) BLINKS SENSOR ERROR (SHORTED OR OPEN SENSOR).

LIGHT

ON L7148F CONTROL ENERGIZED THROUGH 24 VOLT TRANSFORMER.

OFF L7148F CONTROL NOT ENERGIZED.

ON L7148F CONTROL ENERGIZING GAS CONTROL VALVE (GAS VALVE OPEN)

OFF GAS VALVE NOT ENERGIZED (GAS VALVE CLOSED)

L7148F CONTROL LED ERROR CODES

ON L7148F CONTROL ENERGIZED FULLY FUNCTIONAL.

OFF L714BE CONTROL NOT ENERGIZED.

(3) BLINKS ANOLOG TO DIGITAL ERRORS (SET-POINT POT FAILURE).

(4) BLINKS RELAY FAILURE (CONTROL FAILURE)

25

SYMPTOM POSSIBLE CAUSE

Boiler is cold. No Power.

Defective Thermostat or thermostat
wiring.

Defective transformer.

Defective Ignition module.

L7148F Aquastat Control malfunction

Vent damper is not connected.

when used with vent damper.

L7148F Aquastat Control in reset
mode.

L7148F Aquastat Control high limit
switch shuts off the boiler before the

water temperature reaches the high
limit setting.

L7148F Aquastat Control detects an

error.

Incorrect sensor location.

L7148F Aquastat Control temperature
setting is below the desired

temperature.
Defective sensor.

Defective L7148F Aquastat Control.

Boiler is too hot

Incorrect temperature setting.

Sensor not fully inserted into well.
Defective L7148F Aquastat Control.

ACTION

Check for 120V at LIX, L2X
Check all wiring and cable

connections.
Check the circuit breaker or fuse and,

if necessaryr reset or replace.

Short the W, R terminals on the

L7148F Aquastat Control. If the

system starts, check the thermostat
and low voltage wiring.

Check for 24V at R, C. If no voltage,

replace the transformer.

Check for 24V at the ignition system
and vent damper and check all wiring

connections. If voltage is present at
the ignition system, replace the

ignition system. If no voltage is
present at the ignition system, but 24V

is present at the vent damper, replace
the vent damper.
Verify proper connection at the vent

damper and L7148F Aquastat control.
Verify proper Sensor connections at

the immersion well and L7148F
Aquastat Control.

Check if the boiler water temperature

is below the limit setting.

NOTE: The L7148F Aquastat Control

may remain in reset mode 30 minutes

after the error condition is corrected.
To reset immediately, remove power,

and then restore power.

Follow the boiler manufacturer

recommendations for proper location.

Reset the potentiometer to the correct

temperature.

Check for shorted or open sensor

and/or leads.
Temporarily replace existing sensor

with new sensor. If system starts,

replace the sensor.

Replace the L7148F Aquastat Control.

Adjust the potentiometer to the proper

temperature setting.

Reinsert the sensor fully into the well.

Replace the L7148F Aquastat Control.

26

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

Circulating pump not running
Poor electrical contact

Rollout switch blown

Spill switch blown

Vent damper not operating

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.

Open radiator vents to vent excess air. Check flow control valve (if used). It
may be in closed position.

Check overcurrent protection. Check relay operation.
Check all control terminals and wire joints.
Have your service technician check heat exchanger for blockage. Replace rollout

switch with exact replacement.

Have your service technician check venting system and chimney for blockage,

or down draft condition. Reset spill switch.
Consult troubleshooting guide in Effikal manual, packaged with vent damper.

Possible Cause

Gas input amount is incorrect

Possible Cause
Dirt on seat

Water logged expansion tank

What to do

Contact your service technician,

What to do

Open valve manually Allow water to run and clear valve seat.
Drain tank, see instructions.

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

27

GAS-FIRED HOT WATER 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 Number (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.

JACKET- SECTION AND BASE PARTS

THIS IS A REPAIR PARTS LIST - NOT A PACKING LIST

KEY

NO.

1 Jacket, Right Side Panel

2 #10 x '/2" Sheet Metal Screw
3 Rating Plate

4 Base Insulation - Base Sides (2)

5 Base Baffle
6 Base

7 Jacket "fie Bar
8 Push Nipple

9 Jacket, Left Side Panel

10 Knob, Sen/ice Door (pair)

11 Jacket Service Door

12 Jacket intermediate Panel
13 Jacket Cover Panel

14 Jacket Front Panel
15 '/4" Tie Red and Nut

16 8oiler Section, Left End
17 Boiler Section, Middle
18 Boiler Section, Right End

19 Draft Diverter
20 Jacket Back Panel
21 Jacket Top Panel

22 Vent Damper
++ Jacket Complete

++ Block Assembty
++ Combustible Floor Plate

++ Base Assembly

** Cerafelt Gasket

DESCRIPTION

- Base Front

- Base Rear

3 SECTION

PART NO.

735001050

14695074

14694016

14614130
14614113

14614123
42500643
42500663

42500653
43300976

735001040

13702153
42500913

735001073
735001070

42500811

14605001
41000020

41000022
41000021

42500673
42500903

42500843

14628001
42500943

41000313

14614031
41000313

14614018

4 SECTION

PART NO.

735001050

14695074
14694016

14614130

14614114
14614124

42500644
42500664

42500654
43300976

735001040

13702153

42500914

735001074
735001070

42500804

14605002

41000020
41000022

41000021
42500674

42500904
42500844

14628002

42500944
41000413

14614031

41000413

14614018

5 SECTION

PART NO.

735001050

14695074
14694016

14614130
14614115

14614125

42500645
42500665

42500655
43300976

735001040

13702153

42500915

735001075
735001070

42500805

14605051

41000020
41000022

41000021
42500675

42500905
42500845

14628002

42500945
41000513

14614031

41000513

14614018

NATURAL GAS

6 SECTION

PART NO.

735001050

14695074
14694016

14614130
14614116

14614126

42500646
42500666
42500656

43300976

735001040

13702153

42500916

735001076
735001070

42500806

14605053

41000020
41000022

41000021

42500676
42500906

42500846

14628003

42500946
41000613

14614031

41000613

14614018

7 SECTION

PARTNO.

735001050

14695074

14694016
14614130

14614117
14614127

42500647
42500667
42500657

43300976

735001040

13702153
42500917

735001077
735001070

42500807

14605005

41000020
41000022

41000021
42500677

42500907

42500847

14628003

42500947

41000713
14614032

41000713

14614018

8 SECTION

PARTNO.

735001050

14695074
14694016
14614130

14614118
14614128

42500648
42500668

42500658
43300976

735001040

13702153

42500918

735001078
735001070

42500808

14605007

41000020

41000022

41000021

42500678
42500908

42500848

14628003

42500948

41000813

14614032

41000813

14614018

9 SECTION

PART NO.

735001050

14695074
14694016

14614130
14614119

14614129
42500649
42500669

42500659
43300976

735001040

13702153
42500919

735001079
735001070

425O0809

14605009
41000020
41000022

41000021
42500679

42500909
42500849

14628003
42500949
41000913

14614032
41000913

14614018

++ NOT ILLUSTRATED
** LOCATED AT THE BASE AN[) BLOCK ASSEMBLY TOP

?R

%

3ACKET - SECTION AND BASE PARTS

@

29

LED & COVER PANEL ASSEMBLY

JACKET PARTS

3O

(21 f6 X i" SL; SHE[T SCREW --_
ITEM 11469504_ \

CONTROL BOX ASSEMBL Y

/ WIRING MARN_SS

ITEM _14E34_03 {7--9 SEC.)

IT[M 1146345a2 (_-6 S£C.)

RO_£S:

r_E t rE_4 r,_t_BI.RS FC_ r_s p_._T ¢0_ AS

FCU-C_: 7_ IO;a,a _GTI_, T_ _S r N_

COVER PANEL / CONTROL BOX ASSEMBLY

31

GAS TRAIN - NATURAL

i/2" OR 3/4" X 90" STREET ELL_

I/2" - ITEM # 14693801 i

3/4" - ITEM # 14693040 I

i12" OR 314" CLOSE NIPPLE-- _
I/2" - ITEM # 14607030

314" - ITEM # 14607031

112" OR 314" UNION
I12" - ITEM # 14G93043
314" - ITEM # 14693044

PWX "T ° MANIFOLD _ _ _

W

FOR PARTS 1-7 SEE REPAIR PARTS TABLE BELOW

KEY DESCRIPTION

NO.

1 Gas Valve

2 Pilot Tube
3 10-32 x i12" Hex HD.

Screw (2 req'd)

4 Gas Manifold

S Main Burner Orifice**

6 Main Burner Less Pilot

Bracket*

6A Main Burner With Pilot

Bracket

7 PilotBuFner

-F+

Rollout Shield

++

Thermocouple

Note:

* Quantity required = 2 less than the number of sections.

** Quantity required - i less than the number of sections.

++ Not illustrated

NATURAL GAS BURNER AND MANIFOLD ASSEMBLY

NATURAL GAS

Part No.

3 SECTION

Pa_ No.

146-62-051
146-15-005

146-95-307
146-16-100

146-15-031
146-15 532

146-15-531
146-62-098

425-00 933
146-62-037

4 SECTION

Pa_ No.

146-62-051
146-15-005

146-95-307
146-16-101

146415÷031

146-15-532

146-15-531

146-62-09B

425-00-934

146-62-039

5 SECTION 6 SECTION

Pa_ NO. Pa_ No.
146-62-051 146-62-060
146-15-005 146-15-005

146-95-307 146-95-307

146-16-102 146-16-103
146-15-031 146-15-035

146-15-532 146-15-532

146-15 531 146-15-531

146-62-098 146-62-098

425-00-935 425-00 936

146 62-039 146-62-039

7 SECTION

PartNo.
146-62-060
146-15-005

146-95-307

146-16-104
146-15-035

146-15-532

146-15-531

146-62-098

425-00-937

146-62-039

8 SECTION

PartNo.
146-62-060
146-15-006

146-95-307

146-16-105
146-15-035

146-15-532

146-15-531

146-62 098

426 00 938

146 62-036

9 SECTION

Part No.

146-62-060
146-15-006

146-95-307
146-16 I06

146-15-035

146-15-532

146-15-531

146-62-098

425-00-939

146 62-036

32

BOILER CONTROLS AND PIPING

_** *° _OTE:

)_/ " OP'T{OHALSUPPLY OR RETUDN SIDE PUMPING

ISOLATION BALL VALVES AND CIRCULATOR

PUMPAREEHIPPESLOOSEIN CRATE.

KEY DESCRIPTION Part Number

NO.

1 ¾" ASME Relief Valve 146-22-011

2 3/4" x 7 1/2" Nipple 146-07-041
3 Temperature Pressure Gauge - 5" Stem 146-23-009
4 1 1/4" x 2 1/2" Nipple 146-07-044

5 1 1/4" x 3/4" x 1 1/4"Tee 146-93-049
6 Well 3/4" NPT 123870A 146-62-017

7 Sensor 209659A with Mounting Clip 146-62-400
8 1 1/4" x 6" x 6" Bent Nipple 146-07-003

9 Isolation Ball Valve 146-26-043

10 Taco 007 Circulator 146-26-047
++ Grundfos UP15-42F Circulator 146-26-045
++ 400 ° F Black Silicone Rubber Adhesive 146-06-020
++ Fuse Link G4AM0600 144C 146-29-002

++ Spill Switch Water 36TX16-6281 146-60-001

++ Wiring Harness Vent Damper 146-34-501
++ Sealant (10.3 oz. Cartridge)

++ NOT ILLUSTRATED

_D

HONEYWELL L7148F TROUBLE SHOOTING GUIDE

Start

Boiler is cold.
Boiler is not reaching proper temperature

or will not tum on.

4,

Check:
L7t 48F Diagnostic LED =ON"?

I

Yes

Set room thermostat lO°above room
temperature.
Set boiler 10° (or more) above current

water temperature.
Boiler turns on?

Yes

i

Check Circulator Pump, running?

I

Yes

-- No--

No Boiler starts?

___ Short terminals W-R (T-TW) ___

/

L7148F Diagnostic LED, flashing?

Check: _-_

Check:
L7148F in reset mode (wait 5 minutes
for control to reset).

Vent damper apen?

]

No

Check for 12BY at LIX,
L2X.

Check for 24V at R C

I

on L7148.

I

No

÷

I

No

÷

t

No

Turn power "ON".
Check all wiring connections.

Replace transformer as appropriate.

Thermostat cr Thermostat widng problem.
Check system per instructions provided

with thermostat.

Two Blinks:
Check sensor connections. If good,

replace sensor.

Yes Internal error, replace L7148F control.

_ Three or four blinks:

Check for 24V, at 81, B2? I

-- Yes

J ,

4,

L7148F is OK, check ignition and gas
valve system as described in literature
provided with those products

I

I

Boiler shuts off at high limit setting? I

No

!

Boiler shuts off above high limit setting?

t

No (Below HL)

4,

Check L7148F diagnostic LED Flashing?

I

No

4,

Check:
Temperature/Pressure gauge accuracy.

Thermo Well tocated per boiler OEM
instructions.

Check vent damper cable and I_ t

I

I 120vacatC1,C27 L

connections.
Replace vent damper cable or damper

as appropriate.

_r

Y_s

4,

L7148F is OK
Check other system components:

Circulators, Zone Valves

Yes

Check:
Temperature/Pressure gauge
accuracy

Sensor fully inserted into well
Thermo Well in good condition.
Thermo Well located per boiler OEM

recommendations.

Yes

L_

/

i

Two blinks, replace sensor,
Three or four blinks, replace control.

Check room thermostat, ts it still set at
10° above current room temperature?

7'

No

Replace L7148F.
Control failure, incapable of self

diagnostics.

I Reset thermostat and repeat voltage check I

Yes

_t No

_r

i

I

34

OWNER'S MANUAL

CONTINUOUS PILOT

MODEL NO.

Gas - Fired

Cast Iron

HOT WATER

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:

KWX - 3V

KWX - 4V
KWX - 5V

KWX - 6V
KWX - 7V
KWX - 8V

KWX - 9V

I PART NUMBER

• MODEL NUMBER

• PART DESCRIPTION

• NAME 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 fight. 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.

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

I