OWNER'S MANUAL

CONTINUOUS PILOT

MODEL NO.

KWX - 3V

KWX - 4V

KWX - 5V

KWX - 6V

KWX - 7V

KWX - 8V

KWX - 9V

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.

Gas- Fired

Cast Iron

HOT WATER

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.

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 will furnish a replacement

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

:_LIMITED 20 YEAR WARRANTY ON HOT WATER CAST IRON BOILERS

After one (1)year and through twenty (20) years from the date of installation,Sears will furnish a replacement heat exchanger if the heat exchanger in the boiler is defective. YOU PAY FOR LABOR.

SEARS INSTALLATION WARRANTY

In addition to any warranty extended to you on the Sears merchandise involved, which warranty becomes effective the date the merchandise is installed, should the workmanship of any Sears arranged installation ;_prove faulty within one year, Sears will, upon notice from you, cause such faults to be corrected at

no additional cost to you.

FOR WARRANTY SERVICE, SIMPLY CONTACT THE NEAREST SEARS STORE OR SERVICE

;_lCENTER THROUGHOUT THE UNITED STATES. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

i

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 unsatisfactory operation due to blown fuses or inadequate or interrupted electrical protective devices.

4.Damage to unit caused by the use of components or other accessories not compatible with the unit.

1Read the Owner'sManual for Safe Operation carefully Failure to follow the rules for safe operation and the instructions can cause a malfunction of the boiler and result in death, serious bodily injury,and/or property damage.

2 Check your local 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 gas to 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

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, or acts of God.

SEARS ROEBUCKAND COMPANY

D/817WA

Hoffman Estates,IL 60179

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 another room or inside a building

7.Be sure there is adequate air supply for complete combustion

8Followa regular service and maintenance schedule for efficient and safe operation.

2

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

**Add 5 ??" 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.

CheckIo besureyouhavetherightsizeboilerbeforestartingtheinstallation. SeeratingandcapacitytableonpreviouspageAlsobesurethenewboileris. forthetypeofgasyouareusing.Checktheratingplateontherightsideof the boiler.

Youmustseethat theboileris suppliedwiththecorredtypeol gas,freshair forcombustion,andasuitableelectricalsupplyAlso,theboilermustbecon.- nectedtoasuitableventingsystemandanadequatepipingsystem.Finally,a thermostat,properlylocated,is neededforcontroloftheheatingsystem.Ifyou haveanydoubtsasto thevariousrequirements,checkwithlocalauthorities andobtainprofessionalhelpwhereneededTakethetimeto. completeall of thestepsfor SAFEandPROPERoperationof theheatingsystem.

Ifthisboileris installedinabuildingunderconstruction,specialcaremustbe takento insureacleancombustionairsupplyduringtheconstructionprocess. Airborneparticulatessuchasfromdrywalldustandlromfiberglassinsulation canclogtheburnerportsandcauseincompletecombustionandsooting.

Whererequiredbytheauthorityhavingjurisdiction,theinstallationmustcon- formto AmericanSocietyof MechanicalEngineersSafetyCodefor Control_ andSaletyDevicesfor AutomaticallyFiredBoilers,No. CSD-1.

The installationmustconformto therequirementsol the authorityhaving jurisdictionor,in theabsenceof suchrequirements,totheNationalFuelGas Code,ANSIZ223.1-1atestrevision.

Installers- Followlocalregulationswith respectto installationof CO detectorsFollowmaintenancerecommendationsin. this instruction

manual.

Tecbniciens- Veuillezvousconformerd lareglementationenvigueur coneemantI" installationdesdefecteursd'oxydecarboneSuivreles. consignesd'entretienfigurantdanslemanueldinstrudioncijoinL

I KEEP BOILERGASOLINEAREAANDCLEANOTHERANDFLAMMABLEFREE FROMVAPORSCOMBUSTIBLEAND LIQUIDSMATERIALS,

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

FIG, 2 - MINIMUM CLEARANCE DTMENSIONS

lhevolumeol a roomshall bebguredon thebasisota ceilingheightof 8'Determinationof roomsizeshouldbebasedonthetotalvolumeof all

gasfiredequipmentinslalledin theroom.Consultsection6.3.1of the NationalFuel Gas Code lot furtherinlormatfon,including.approved methods[or reducingclearancesin largerooms

TOP

REAR

RIGHT SIDE

LEFT SIDE

FRONT

FLUE/VENT

CONNECTOR

NEAR BOILER

PIPING

BOILER SIZE

3SECT.

4SECT.

5SECT. 6 SECT. 7 SECT.

8 SECT.

9 SECT.

6AdviseownerIo keepair passagesfreeof obstrucbonsVenblaPngand. combusbonair muslenterboilerroomwithoulreskictions

FOR ROOM WITH SINGLE BOILER ONLY

THIS UNIT MUST BE SET ON A CONCRETE OR OTHER

NON-COMBUSTIBLE MATERIAL BASE OR FLOOR.

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

I Provision for combustion and ventilation air must be inwith Section 5.3, Air for Combustionand Ventilation, of

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.

YoumustprovideforenoughfreshairtoassurepropercombustionThe. fire in the boilerusesoxygen.It musthaveacontinuoussupply.Theair in a housecontainsonly enoughoxygento supplylhe burnerfor ashorttime. Outsideair mustenterthehouseto replacethatusedbytheburner.Study followingexamples1 and2 to determineyourfreshair requirements.

EXAMPLE1: Boiler Locatedin UnconfinedSpace

Anunconfinedspaceis definedas a spacewhosevolumeis not lessthan 50cubicfeelper1,000Bluperhourof thelotalinputratingof allappliances installedin thatspace.

Ifyour boileris inanopenarea(unpartitiouedbasement)in aconventional house,theairthatleaksthroughthecracksarounddoorsandwindowswill usuallybeadequateto provideair forcombustionThedoorsshouldnotfit. tightly.Donotcaulkthecracksaroundthewindows.

Equipmentlocatedin buildingsof unusuallytightconstructionshallbepro- videdwith airfor combustion,ventilation,anddilutionol flue gasesusing themethodsdescribedin example2Borshall bespeciallyengineeredThe. authorityhavingjurisdictionmustapprovespeciallyengineeredinstalla- tions.

EXAMPLE2: Boiler Locatedin ConfinedSpace

/L All Air from Inside the Building:Theconfinedspaceshall bepro-

videdwithtwopermanentopeningscommunicatingdirectlywithanaddi- tional room(s)of sufficientvolumeso thatthecombinedvolumeof all spacesmeetsthe criteriafor anunconfinedspace.Thetotalinput of all gas:utilizationequipmentinstalledin the combinedspaceshallbecon- sideredin makingthis determinationEachopeningshall. havea mini- mumfreeareaof onesquareinchper1,000Btuperhourolthetotalinput ratingof all gasutilizationequipmentin theconfinedspace,butnot less that100squareinchesOneopeningshallbewithin12inchesof. thetop andonewithin12 inchesof the bottomof theenclosureTheminimum. dimensionof airopeningsshallnolbelessthan3 inches.

B.All Air from Outdoors: Theconfinedspaceshallcommunicatewiththe outdoorsinaccordancewithmethods1or 2.Theminimumdimensionof

airopeningsshallnot belessthan3 in. Whereductsareused,theyshall beof thesamecross-sectionalareaas the freeareaof theopeningsto

whichtheyconnect.

1.Twopermanentopenings,onecommencingwithin 12 inchesof the

top,andonecommencingwithin12inchesoftheboltom,oltheenclo- sureshallbeprovidedTheopeningsshallcommunicatedirectly,orby. theducts,withtheoutdoorsor spaces(crawlor attic)thaifreelycom- municatewiththe ouldoors.

a)Wheredirectlycommunicatingwiththeoutdoorsor wherecommu- nicatingto theoutdoorsthroughverticalducts,eachopeningshag haveaminimumtreeareaof 1sq. in. per4000Btuperhourof total inputratingof all equipmentin theenclosure(SeeFigure3A..)

b)Wherecommunicatingwiththe outdoorsthroughhorizontalducts, eachopeningshal!havea minimumfreeareaof 1sq. in. per2000 Blu perhourof totalinputratingof all equipmentin theenclosure.

(SeeFigure3B.)

2.Onepermanentopeningcommencingwith12 inchesof thelop of the enclosure,shallbepermittedwherethe equipmenthasclearanceof at

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.

least1 inchfromthesidesandbackand6 incheslromIhefronlof the

applianceTheopeningshall. directlycommunicatewithIhe outdoors or shallcommunicatethrougha verticalor horizonlalductto theoub

doorsor spaces(crawlor attic)thatfreelycommunicatewiththeout- doors,andshallhaveaminimumfreeareaof:

a)1sq. inchper3000Btuperhourol theIolalinputof aftequipment locatedin lheenclosure(SeeFigure4), and

b)Notlessthanthesumof theareasof allvenlconnectorsinthecon- finedspace.

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

5

1.PlaceboilerintheselecledIocalion(asnearchimneyaspossibleYour.) boilerisshippedassembledYouneedonlyIoinsfall.theReliefValveand

adrainlineto carryanywalerorsteamIo adrain.

2.InstallRelielValveinto the3/,,-pipeonthetopol Iheboiler.SeeFigure5. Use??" Pipeandanelbow(nolfurnished)to carrythewalerorsteamto anearbydrain.Donotconnectdirectlyto adrainbulleaveanairgap.No shutollol anydescriptionshallbeplacedbetweenthesafdy rebelvalve andtheboiler,or ondischargepipesbetweensuchsafetyvalvesandthe atmosphere.Installationol the safetyrelielvalveshall conformto the requirementsof the ANSI/ASMEBoiler and PressureVesselCode, SeclionIV. Themanulactureris not responsiblefor any waterdamage. InstallDrainValvein lowerleftsideof boilerasmarked.

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

4.Thisboileris equippedwilh 11/4"supplyandreturnconnectionsonboth theleftandrightsidesol the boiler.

installationinstructions. TheminimumdesignreturnwaterLemperatureIo theboilerto prevenlcon- densationin theboilerandventingis 120?? E Theminimumhigh limil set- ting is 140?? F.

THE ISOLATION BALL VALVES CONTAIN TEFLON

SEATS AND SEALS. OVERHEATING THIS VALVE

ICAUTION

MAY CAUSE PREMATURE FAILURE.

COt.o WATE_ LNLET.

In connectingthecoldwatersupplytothewalerinlelvalve,makesurethat a cleanwalersupplyis availableWhen.thewatersupplyis froma weftor pump,asandstrainershouldbeinstalledat thepump.

A hot walerboiler installedaboveradiationlevelmustbeequippedwilh a lowwatercutoffdeviceA. periodicinspectionis necessary,as is flushingof floattypedevices,permanufacturersspecificinstruction.

FOR USE WITH COOUNG UNITS

A.Thisboiler,whenusedinconnectionwithchilledwatersystems,mustbe installedso that thechilled wateris pipedin parallelwith theheating boiler.Appropriatevalvesmustbeused1oprevenlthechilledwaterfrom enteringtheheatingboiler(Fig.6).

B.Whenthisboiler is connectedto heatingcoils locatedin air handling

unitswheretheymaybeexposedto refrigeratedaircirculation,thepip- ing syslemshallbeequippedwithflowcontrolvalvesorotherautomaf-

ic meansto prevenlgravgycirculationof theboilerwalerduringthecool- ing cycle.

TO SYSTEM

VALVES A & B

OPEN FOR HEATING;

CLOSE FOR COOLING

VALVES C & O

LOW DESIGN WATER TEMPERATURE SYSTEMS

(BELOW 140 ??)

If Iheboileris to beusedin aheatingsysfemwheredesignwaterlempera- luresbelow140?? Faredesired(e.g.radianlfloorhealing),a3-wayor4-way mixingvalveor suitablealternativeis requiredto preventlowfemperature returnwaterfromenleringtheboiler.FollowIhemixingvalvemanufacturer's

CLOSE FOR HEATING:

OPEN FOR COOLING

c d

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 imporfantpart of your heatingsystem It must be clean, theright size, properlyconstructedandin GOODCONDITIONNo boiler can lunctionproperlywith a bad chimney.Fig. 7 givestypical chimney sizes.Fig.8 givesyouanideahowa boilermightbe ventedto achimney Nofetha_theheight(HT)is measuredfromtheventpipeto the lop.

CHIMNEY SIZING

Chimneysizing, and all other aspectsof the vent installationmust be in accordancewith Part 7 of the NationalFuelGasCode,ANSIZ223.1 - laleslrevision,andapplicableprovisionsof the localbuildingcodes.

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's3-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

"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

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.

HT

ROOF

RIDGE

3/4 HT MAXIMUM

'MUST SLOPE UP AT LEAST 1/4 INCH

PER FOOT OF

HORIZONTAL RUN

HORIZONTAL INSTALLATION

VERTICAL INSTALLATION

C_N: IX) NOT INSTALL

THE VENT DAMPER

WITHIN 6 in. (152 mm) OF

COMBUS33BLE MATERIAL

3HIMNEY

BOILERWATER HEATER

TYPICAL INSTALLA'nON FOR VENT DAMPER

NOTE CAUTION AND FOOTNOTES

1Install the vent damper to service only the single ap_iance for which it is intended,if improperly installed,a hazardous cond_on, such as an explosionor carbon monoxide pe,,sening,could result.

2_ Do not install the vent damper on vent pipecurve.

3Do 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 is off, 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.

For further information,and for a vent 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,

iIi6010?? ??1

SHOWING OPEN AND CLOSED POSmON

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

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 AT ONCE

WARNING

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

NATURAL GAS

Pipe Capacity - BTU per Hour Input

Length ofIncludes Fittings Pipe - Ft.

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

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:

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.

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

I

THIS PAGE INTENTIONALLY LEFT BLANK

I

13

THIS PAGE INTENTIONALLY LEFT BLANK

J

14

24 '_0LT TRANSFORMER

AQUASTAT

I

81

OR

[3 Q

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

L .----

MICROPROCESSOR

HIGH UMIT SOR_j 1 -

'-,

GAS VALVE

VR8200A/VR830OA

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

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 is filled with water, there is air 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 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 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

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 in the 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 CONTROL KNOB

IN "ON" POSITION

GAS

INLET

RESET BUTTON

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'tsmell 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"

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

2For 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.

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.

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

2I

INf.(7

11._ L_ERCAP SCRElW|

_G_S

???O_TROS.

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

RECOMMENDED BOILER WATER TEMPERATURES J

o+

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 limit control to limit setting, check to see if it 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"'

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 if valve 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 of the 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.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.

2,

3,

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.VOLTMETER TO CHECK 120 VAC AND 24 VAC.

B.CONTINUITY TESTER.

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

MEASURING INLET AND MANIFOLD GAS PRESSURES.

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_ CALL FOR HEAT

C[RCUL_TORPUMP

@ GAS VALVE

BURNER

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

(4)BLINKS RELAY FAILURE (CONTROL FAILURE)

25

SYMPTOM

Boiler is cold.

L7148F Aquastat Control malfunction 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.

Boiler is too hot

POSSIBLE CAUSE

No Power.

Defective Thermostat or thermostat wiring.

Defective transformer.

Defective Ignition module.

Vent damper is not connected.

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. 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 necessary r 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.

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

NATURAL GAS

NO.

DESCRIPTION

1 Jacket, Right Side Panel

2#10 x '/2"Sheet Metal Screw

3Rating Plate

4Base Insulation - Base Sides (2)

-Base Front

-Base Rear

5Base Baffle

6Base

7Jacket "fie Bar

8Push Nipple

9 Jacket, Left Side Panel

10 Knob, Sen/ice Door (pair)

11 Jacket Service Door

12Jacket intermediate Panel

13Jacket Cover Panel

14Jacket Front Panel

15'/4"Tie Red and Nut

168oiler Section, Left End

17Boiler Section, Middle

18Boiler Section, Right End

19Draft Diverter

20Jacket Back Panel

21Jacket Top Panel

22Vent Damper

++Jacket Complete

++Block Assembty

++Combustible Floor Plate

++Base Assembly

**Cerafelt Gasket

++ NOT ILLUSTRATED

** LOCATED AT THE BASE AN[) BLOCK ASSEMBLY TOP

?R

3ACKET - SECTION AND BASE PARTS

@

%

29

LED & COVER PANEL ASSEMBLY

JACKET PARTS

3O

CONTROL BOX ASSEMBL Y

/WIRING MARN_SS

ITEM _14E34_03 {7--9 SEC.) IT[M 1146345a2 (_-6 S??C.)

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

RO_??S:

COVER PANEL / CONTROL BOX ASSEMBLY

31

GAS TRAIN - NATURAL

FOR PARTS 1-7 SEE REPAIR PARTS TABLE BELOW

NATURAL GAS BURNER AND MANIFOLD ASSEMBLY

1 Gas Valve

2Pilot Tube

310-32 x i12" Hex HD. Screw (2 req'd)

4Gas Manifold

S Main Burner Orifice**

6Main Burner Less Pilot Bracket*

6A Main Burner With Pilot

Bracket

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

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

++Not illustrated

32

BOILER CONTROLS AND PIPING

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

++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?

-- No--

/No ___

Check for 12BY at LIX, L2X.

Check for 24V at R C

I

on L7148.

BoilerShort terminalsstarts? W-R (T-TW)

I

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.

L7148F Diagnostic LED, flashing?

Check:

I

_r

Yes

No

_tNo

Replace L7148F.

Control failure, incapable of self diagnostics.

_r

I Reset thermostat and repeat voltage check

i

I

Thermo Well tocated per boiler OEM instructions.

34

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

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:

IPART 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 o f 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.