Gas-Fired Cast Iron HOT WATER BOILER • Installation • Operation • RepairParts WARNING: Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency or the gas supplier. PRINTED IN U,S,A.
KENNMORE CAST IRON BOILERS FULLONEYEARWARRANTY ONHOTWATERANDGASSTEAMCASTIRONBOILERS For one (1) year from the date of installation, when this boiler is installed and maintained in accordance with our instructions. Sears will repair defects in material or workmanship in the boiler, free of charge.
ASME RELIEF VALVE VENT AQUASTAT TEMR/PRESS.GAUGE DAMPER !/ ,_ A _, I7," SUPP_ _ I ['-- T 1 '/4" RETURN -- -- --]-._._ I rV/NPT 231/4 I \\ _ -I iL / CH" L____ ® d I__ DRAIN VALVE LEFT SIDE ROLLOLIT SWITCH GAS VALVE 1 IN]_ PILOT CONTROL FRONT RIGHT SIDE GAS-FIRED HOT WATER BOILERS BASIC BOILER UNIT N(_ Electronic Ignition With Continuous NATURAL GAS Pilot Vent Damper With Vent Damper 229.960021 229.960031 229960041 229.960051 229.960061 229,960071 229.960081 229.
Checkto besureyouhavetherightsizeboilerbeforestartingthe installation. Seeratingandcapacitytableon previouspage.Alsobe surethenewboileris forthetypeof gasyouareusing.Checktheratingplateontherightsideofthe boiler. Whererequiredbytheauthorityhavingjurisdiction,theinstallationmustconformto AmericanSocietyof MechanicalEngineers SafetyCodefor Controls andSafetyDevicesfor Automatically FiredBoilers,No.CSD-1.
Provision for combustion and ventilation air must be in accordance with Section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI Z223.1-1atest revision, or applicable provisionsof the local building codes. NOTE If you use a fireplace or a kitchen or bathroom exhaust fan, you should install an outside air intake. These devices will rob the boiler and water heater of combustion air. WARNING Be sure to provide enough fresh air for combustion.
1. Placeboiler in lhe selectedlocation(asnearchimneyas possible.)Your boiler is shippedassembled.Youneedonlyto installIheBeliefValveand a drainline to carryanywateror steamto a drain. 2. InstallRebelValveintothe3/+,,pipeonthetop oftheboiler.SeeFigure5. Use3/4"Pipeandan elbow(notfurnished)to carrythewateror steamto a nearbydrain.Donotconnectdirectlyto a drainbutleaveanair gap.
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 FLUE AREA IN INCHES Boiler Input Btuh IMPORTANT - The damper blade on the furnished vent damper has a V2square inch hole (approximately 3/4"diameter). On boilers equipped with standing pilot, the hole must be teft open.
7. Any_mproper operationof the commonventingsystem shouldbecorrectedsotheinstallation conformswiththe National FuelGasCode,ANSIZ2231-latestrevisionWhen resizinganyportionof the commonventingsystem,the commonventingsystemshouldbe resizedto approach the minimumsizeas determinedusingthe appropriate tablesin Part11 in the NationalFuelGasCode,ANSI Z223.1-latest revision.
For safe, efficient operation, the vent damper and all flue product carrying areas of the appliance must be checked annually by you, with particular attention given to deterioration from corrosion or other sources. If you see corrosion or other deterioration, contact your heating contractor for repairs. Check vent damper operation as follows: 1. When the boiler is off, check that the vent damper position indicator points to the closed position, Fig. 11. 2.
CHECK GAS SUPPLY 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 V2 psig (3.5 kPa).
All electrical work must conform to local codes as well as the National Electrical Code, ANSI/NFPA-70, latest revision. ELECTRIC POWER a vertically mounted outlet box. It should be sensing average room temperature, so avoid the following: DEAD SPOTS: Behind doors Corners and alcoves SUPPLY Run a separate 120 volt circuit from a separate overcurrent protective device in the electrical service entrance panel. This should be a 15 ampere circuit. Locate a shut-off switch at the boiler.
INTERMITTENT I- "_Z • L8148E I L r IGNITION //--AQUASTAT W_RE COOE FJ:x"?;_':IT'P':_I DAMPER CABLE l_:z_ ICNIT}ON CABLE --LINE VOLTAGE --LOW VOLTAGE -- --LOW VOLTAGE FIELD WIRING COLOR COOE BK-BLACK BR-BROWN O -ORANGE Y -YELLOW R -RED BT-BLACK WITH WHITE TRAX_ER W -WHITE B -GREEN _i? r? _?;........ LelIK _,r _,: il F"_ I i\_-,'_ i IiiIi!T t LF--;_!! i !_-°'! ?il "°l _ _ / ,,_- II .1.o I _-_=111 "° _ _ I..............
STANDING PILOT WIRE CODE F_';'Pr_DAMPER CABLE C_=:zzZ_ICNITrON CABLE --LINE VOLTAGE --LOW VOLTAGE ---LOW VOLTAGE FIELO WIRING COLOR CODE BK-BLACK BR-BROWN 0 -ORANGE Y -YELLOW R -RED BT-BLACK WITH WHITE TRACER W -WHIT[ G -GREEN , _ 14 II ! ',_-' ;[ II Y -o II I_?, ,,., .... I 'r ................................. ' I f-:-! t_ 7_'', • _ ( _J I ', ?! li,: ,,_ ,,, ,,",, ,, ,,-L_ I @'_..__' II ---,U , { , ..... :....
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 wi(I relieve the strain on the boiler and system.
ROLLOUT SWITCH (FLAME ROLLOUT SPILL SWITCH SAFETY SHUTOFF) (BLOCKED VENT SAFETY The rollout switch is a temperature-sensitive fuse link device. It is located on the boiler base just outside the fire box. In the event of heat exchanger flueway blockage causing flame to roll out of the fire box, the fuse will blow, shutting down the f!ow of gas to the main burners. The fuse does not change in appearance when blown. If the rollout sw!tch blows, it must be replaced with an exact replacement.
I WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life, A. Some boilers are equipped with an intermittent ignition device which automatically lights the pilot. Do not try to light the pilot by hand. I I *Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. elf you cannot reach your gas supplier, call the fire department.
1. STOP! Read the safety information on page 14. 2. Set the thermostat to lowest setting. 9. Rotate the gas control knob counterclockwise It to "PILOT" Push down and hold the red reset button while you light pilot burner with a match. 3. Turn off all electric power to the appliance. 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. 4. Remove lower front panel. 5.
pRESSURE RI_GUI._TO/I AOJUSTMKNT (UNC)I[ R CA/' SCRI[W WIRING MANTEL TAr PRI_SURI_ TA a T| RMIF_AI._II) IN, € oo._ _LOT OUTUtT (UNr_ER CAP SCREW) 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, clockwise to decrease. 3.
BURNERS BOILER 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 18. 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 of the controls checked once each year by a competent Service Technician.
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. Poseibie Cause What to do Thermostat is not set correctly Reset thermostat above room temperature.
GAS-FIRED HOT WATER BOILERS -- IMPORTANT -READ THESE INSTRUCTIONS BEFORE ORDERING 18 All parts listed in the following Parts List may be ordered through your nearest supplier. When ordering parts, first obtain the Model Number from the data plate on your boiler, then determine the Part No. {not the Key No.) and the Description of each part from the following illustrations and list. Be sure to give us all this information: The Part No. - The Part Description - The Boiler Model No. 0 \10 4 7 1 JACKET -
FOR USE WITH NATURAL GAS ONLY 4 5 NOTE: Actual gas valve may look different than gas valve shown NATURAL GAS BURNERS AND MANIFOLD PARTS THIS IS A REPAIR PARTS LIST - NOT A PACKING LIST KEY NO. DESCRIPTION 2 SECTION Pad NO. 3 SECTION PadNo. 4 SECTION 5 SECTION 7 SECTION 8 SECTION Pad No. Part NO. Pad No. Pad No. 24 VoltGasValve,Elect.Int.
BOILER CONTROLS AND PIPING KEY NO. 1 2 3 6 7 8 1 3 1: 9 10 11 12 13 6 DESCRIPTION %" ASME Relief Valve %" x 71/2"Nipple Temperature Pressure Gauge - 5" Stem 1Y4"x %" x 1W' Tee Aquastat Relay Isolation Bail Valve Grundfos UP15-42F Circulator "race 007 Circulator 1W' x 2W' Nipple 11/4"Ell 1Y4"x 3V2" Nipple Intermittent Pilot Control - Natural Gas - Propane Gas Spill Switch (36TX16-6281) 340" F Rollout Switch 4" Vent Damper (with 3" Adapter) 5" Vent Damper 6" Vent Damper 7" Vent Damper Vent .
I Gas-Fired Cast Iron HOTWATER BOILER Now that you ever exist for Sears Service when you call have purchased your Boiler, should a need repair parts or service, simply contact any Center. Be sure to provide all pertinent facts or visit. The model number of your Boiler will be found on the model plate on the side of the Boiler. WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE FOLLOWING INFORMATION: • PART NUMBER • PART DESCRIPTION eMODEL NUMBER eNAME OF ITEM All parts Center.
