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Kenmore 3EW.75 Boiler User Manual

1. fire the 3EW 65 on rate the oil pressure must be increased to 175 psig All Beckett oil burners for the EW boiler are factory preset at 140 psig CARLIN OIL BURNER NOZZLE AND AIR SETTINGS BOILER DELEVAN FIRIN HEAD AIR BAND CARLIN MODEL RATE gph 65 0 55 70 B 0 65 0 50 0 52 2 1 HP 3EW 75 0 65 60 0 75 0 60 0 65 0 60 EZ 1 HP 1 00 0 85 60 B 1 00 0 85 1 00 0 80 2 1 4EW 90 0 75 60 B 0 90 0 75 0 75 EZ 1 HP 4EW1 25 1 00 60 B 1 25 0 85 1 00 0 90 2 1 HP 4EW1 50 1 25 60 1 50 1 10 1 25 1 25 EZ 1 HP 5 1 20 1 00 60 1 20 0 85 1 00 0 90 EZ 1 HP 5EW1 75 1 50 60 B 1 75 1 50 1 65 EZ 2 HP 5EW2 00 1 65 70 8 2 00 1 65 1 75 EZ 2 HP 1 95 Carlin EZ 1 HP and EZ 2 HP oil burners are factory preset at 150 psig RIELLO 40 OIL BURNER NOZZLE AND AIR SETTINGS BOILER DELEVAN FIRING TURBULATOR AIR OIL PRESSURE RIELLO 40 MODEL OIL NOZZLE RATE gph SHUTTER SETTING PSIG BURNER MODEL 3EW 65 0 50 70 W 0 65 0 5 2 0 155 F5 3EW 75 0 65 70 W 0 75 20 22 150 F5 1 00 0 85 70 W 1 00 20 32 170 F5 4EW 90 0 75 70 W 0 90 1 5 2 6 160 5 4 1 25 1 00 70 1 25 2 5 3 8 170 F5 4EW1 50 1 25 70 W 1 50 4 0 7 0 175 FS 5EW1 20 1 00 70 W 5 5EW1 75 1 50 70 W F10 5EW2 00 1 75 70 W 10 Riello 40 F5 and 10 burners are fact
2. 5 3 Ne i e COVER MAIE FOR 204549 MTHOUT AMXL SS MOT SHO BALLOON SYMBOL KEY 0 e 11 47 SQUazE HEAQ PLUCS SHOW 400 F BLACK SILICONE RUBBER SHOWN 23 AOHESIVE SEALANT 5 DESCRIPTION 4 SEW 1 Water Boiler Back Section 3 403 00 008 403 00 008 403 00 008 403 00 00 e i 7 4 6 4 Cast Iron Machined Nipples 2 433 00 976 433 00 976 433 00 97 5 Uw4 TieRods 146 05 002 148 05 051 1146 05 053 5 5 3 3 6 8 TagetWal 146 19 003 146 19 003 146 19 003 9 12 thick Ourablanket 1146 30 031 Collector Base plus items 11 12 13 11 425 00 279 425 00 280 137 04 007 146 95 070 15 Coil Housing 146 93 064 146 93 064 16 37 GPM Tankless Co 146 27 020 146 19 001 146 95 113 146 95 113 146 95 114 21 11 47 Solid Plug not shown 146 93 126 146 93 126 146 93 126 Black Silicone Sealant not shown 46 06 020 Note item quantities marked XXX vary depending upon the number of sections Four cast iron nipples for first middle replacement section and two for each additional section Durablanket is sold as one oversized piece to be cut to fit the appropriate boiler 6 127 3EW 9 x20 4EW 12 x20 SEW Black silicone sealant is sold in 10 3 ounce cartridges 34 go REPAIR PAR
3. commencing within 12 inches of the top and commencing within 12 inches of the bottom of the enclosure The openings shall communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors 1 When directly communicating with the outdoors each opening shall have a minimum free area of one square inch per 4 000 Btu per hour of total input rating of all equipment in the enclosure 2 When communicating with the outdoors through vertical ducts each opening shall have a minimum freearea of one square inch per 4 000 Btu per hour of total input rating of all equipment in the enclosure 3 When communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of one square inch per 2 000 Btu per hour of total input rating of all equipment in the enclosure 4 When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall be not less than three inches FRESH AIR DUCT les FRESH AIR DUCT CAPACITIES FOR DUCTS SUPPLYING FRESH AIR TO BOILER IN TIGHTLY CONSTRUCTED HOUSES Duct Size Btub Btuh Btuh 3 x 12 128 000 384 000 Btuh British Thermal Units per hour based on opening covered by mesh screen wood louvers or metal louvers SYSTEM PIPING When the installation of the boiler is for a new heating system
4. Kenmore Owner s Manual MODEL NO 3EW 65 3EW 75 3EW1 00 4EW 90 4EW1 25 4EW1 50 5EW1 20 5EW1 75 5EW2 00 Oil Fired Hot Water Boiler Installation CAUTION Operation Read all instructions carefully before Repair Parts Starting the installation 2 SES gem 2 WARNING Improper ins adjust nt alte anon sc nce manb Daie een Cause or property damage Beter to this Save this manual manual Por assi nane com s ensult a for reference iil rime ge es ofthe o Supplier Sears Roebuck and Co Hoffman Estates IL 60179 U S A PRINTED INUS A FORM 652 IM 9494 53410 I DO DO YORE CE CE CILE PO SEARS 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 will repair 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 WAT
5. 0 02 WC otherwise adjust the draft as necessary After operating 10 minutes to warm up the boiler use the combustion test equipment to take a smoke reading in the flue pipe between the boiler and the draft regulator The smoke reading should be zero to a trace Shell Bacharach Scale At times a new boiler requires more than 10 minutes to burn clean due to the oil film on the new heat exchanger If the smoke reading is zero gradually close the burner s air adjustment to obtain a smoke reading showing a trace smoke reading Once the smoke reading is a trace measure the CO and as an insurance margin increase the air to sufficiently reduce the CO by 1 2 to 1 If a clean fire cannot be obtained it will be necessary to verify the burner head and electrode alignment Proper electrode alignment figures are presented on the following pages If the fire continues to be smoky replace the nozzle with a correct replacement Once the burner is completely adjusted the burner should be started and stopped several times to assure good operation with no fluttering or rumbling Verify that there are no oil leaks and then record the nozzle size oil pressure combustion readings and air settings on a tag or label that can be attached to the burner or boiler OIL BURNER MAINTENANCE For the Beckett AFG Carlin EZ 1 or EZ 2 and the Riello 40 F3 F5 or F10 the following preventative maintenance items should be performed annually preferably prior to the
6. AQUASTAT CONTROL CARLIN EZ BURNER SHOWN CARLIN EZ BURNER SHOWN 24 VOLT 120 THERMOSTAT POWER 24 VOLT SUPPLY THERMOSTAT NEUTRAL GD HOT 120 60 1 OVERCURRENT DISCONNECT 120 POWER SUPPLY NEUTRAL HOT 7 120 50 1 OVERCURRENT PROTECTED DISCONNECT L8124C 18148 AQUASTAT AQUASTAT OIL BURNER MOTOR BURNER MOTOR CIRCULATOR Service Company Serviceman Address Telephone WITH TANKLESS AND BOILER WITHOUT TANKLESS HONEYWELL L8124C AQUASTAT CONTROL HONEYWELL L8148A AQUASTAT CONTROL RIELLO 40 BURNER SHOWN RIELLO 40 BURNER SHOWN m 120 i ind S GD dh un d NEUTRAL P h BK 1 8148 AQUASTAT AQUASTAT a 51 14151151 21081 5 I V UM cot dE VALVE XU oron 4 CIRCULATOR 9 CAPACITOR BR BK E CONTROL IS FACTORY WIRED BY RIELLO P d CONTROL 15 FACTORY WIRED BY RIELLO Service Company Serviceman Address Telephone 31 SEQUENCE OF OPERATION BOILER WITH TANKLESS COIL INTERNAL WIRING FOR HONEYWELL AQUASTAT 1 8124 Aquastat high limit controller UNE The aquastat controls high limit contacts open and tum off the 1 burner when the boiler water temperature reaches the control s high limit set poi
7. heating season 1 Oil Burner Motor For Beckett and Carlin burners add 2 3 drops of non detergent electric motor oil to each oil cup located at the front and rear of the motor Riello burners are permanently lubricated Excessive oiling will shorten the life expectancy of the motor 2 Fuel Filter This should be replaced so as to prevent contaminated fuel from reaching the nozzle A partially blocked fuel filter can cause premature failure of the fuel pump 3 Fuel Pump Unit Replace pump screen and clean pump unit to maintain fuel delivery to the nozzle 4 Ignition Electrodes Clean and adjust as per manufacturer s recommendations so as to maintain reliable ignition of oil 5 Nozzle Replace so as to maintain safe and reliable combustion efficiency Always replace with the exact nozzle as required in the charts in the back of this manual 6 Fan and Blower Housing These must be kept clean free of dirt lint and oil so as to maintain the proper amount of air the fuel requires to burn 7 Check the final burner adjustments NOTE If any component parts must be replaced always use parts recommended by the burner manufacturer 21 BECKETT AFG BURNER ELECTRODE ADJUSTMENTS VARIABLE V1 HEADS BOILER DIMENSION N DIMENSION MODEL electrode to nozzle head to nozzle 1 16 7 32 to 9 32 SEW HSN SEE BELOW ELECTROOE GAP DIMENSION N SEE BELOW BECKETT AFG VARIABLE V1 HE
8. AND CHIMNEY CONNECTIONS This is a very important part of your heating system No boiler however efficient its design can perform satisfactorily if the chimney that serves it is inadequate Check your chimney to make certain that it is the right size properly constructed and in sound condition It is cheaper to rebuild a poor chimney than to pay excessive fuel bills If yours is an old chimney a new steel liner or a new prefabricated chimney may be the best solution The following chart shows recommended minimum chimney sizes based on Table 3 and Figure 6 of the I B R Testing and Rating Standard for Heating Boilers Sixth Edition June 1989 RECOMMENDED MINIMUM CHIMNEY SIZES NOMINAL ROUNDLINER SQUARE LINER F rs cd HEIGHT fy CHIMNEY INSIDE INSIDE AREA DIAMETER DIMENSIONS 060 130 15 87 8 6 6 3 4 x 6 3 4 131 180 8 8 6 3 4 6 3 4 1 81 2 00 6 3 4 x 6 3 4 For elevations above 2 000 feet above sea level add 3 feet to the chimney heights See Figure below For additional chimney design and sizing information consult the ASHRAE 1996 HVAC Systems and Applications Handbook Chapter 30 Gas Vent and Fireplace Systems or the National Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances ANSI NFPA 211 CHIMNEY CONNECTOR AND DRAET REGULATOR Venting the boiler requires a 6 diameter chimney connector pipe and using the draft regulator packed with the boiler Properly install
9. BOILER HAVE YOUR BOILER CHECKED EACH YEAR BY A QUALIFIED TECHNICIAN OIL BURNER CLEANING 7 8 9 10 11 12 These are general instructions for cleaning an burner For specifics consult the burner manufacturer s instructions Make sure all electrical power to the boiler burner and the fuel supply to the burner are shut off With the swing door open clean any soot accumulations from the end of the burner and if applicable burner head Remove the burner drawer assembly clean the electrodes and then reset the electrode spark gap per the manufacturer s recommendations Refer back to the section in this manual on OPERATING THE BOILER Nozzles and Electrodes Replace the oil nozzle with the exact same size and type recommended for use on this boiler Reinstall the burner drawer assembly making sure the head location and size if applicable are per the manufacturer s recommendations If the burner being used has a damaged head replace the head with the exact same head recommended for use on this boiler Inspect and clean the oil bumer blower wheel Remove the oil pump cover and clean replace the pump screen Carefully reassemble ensuring the pump cover makes a proper seal Securely fasten the swing door shut Replace the fuel filter 1f applicable Reconnect the electrical and fuel supplies Fire the burner checking for proper combustion using combustion test equipment and making adjustments
10. PLATE GASKET This gasket should be checked at least twice a year for leakage and replaced if necessary If the gasket is replaced make sure that when the coil plate or cover plate is reattached that the ten nuts are torqued in an alternating pattern to ensure equal force is applied to the entire gasket creating a good seal The nuts should be torqued such that the gasket does not squeeze out from behind the plate OIL BURNER Oil burner maintenance is listed in this manual under OPERATING THE BOILER Never burn garbage or paper in the unit and never leave combustible material around it 25 OIL BOILER BURNER CLEANING INSTRUCTIONS OIL BOILER CLEANING Shut off all electrical power to the boiler burner and shut off fuel oil supply 2 Remove the vent pipe from the top of the boiler nspect the pipe and chimney for signs of corrosion and deterioration Clean out the base of the chimney If the vent pipe shows any signs of corrosion or deterioration replace 1t immediately If chimney damage or deterioration is discovered contact a competent professional 3 Remove the top jacket panel screws 5 the brass wing nuts 2 holding the flue collector top and then the flue collector top Inspect the gasket on the underside of the flue collector and replace as necessary 4 Before beginning to clean the flue passageways ensure that the combustion chamber blanket is covered If the blanket is not covered prior to cleaning replace th
11. SERVICE FILLTROL WITH AIR PURGER BOILER DRAIN VALVE SYSTEM PIPING ARRANGEMENT ZONING WITH ZONE VALVES gt CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANK gt PIPING ARRANGED FOR POWER PURGING AIR OUT OF SYSTEM PIPING REFER TO THIS MANUAL S SECTION ON FILLING THE SYSTEM WITH WATER OPTION 1 BALANCING VALVE ZONE VALVE RETURN FROM SYSTEM SUPPLY TO SYSTEM DRAIN VALVE ua SHUTOFF PURGING CIRCULATOR SUPPLY TO SYSTEM ISOLATION VALVES SHUTOFF VALVE BOILER SERVICE FILLTROL WITH AIR PURGER FILL LINE WITH SHUTOFF VALVE BOILER DRAIN VALVE SYSTEM PIPING ARRANGEMENT ZONING WITH CIRCULATORS gt CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANK gt PIPING ARRANGED FOR POWER PURGING AIR OUT OF SYSTEM PIPING REFER TO THIS MANUAL S SECTION ON FILLING THE SYSTEM WITH WATER OPTION 1 BALANCING VALVE FLOW CHECK VALVE RETURN FROM SYSTEM DRAIN VALVE SHUTOFF FOR POWER SUPPLY TO PURGING VALVE SYSTEM SUPPLY TO SYSTEM SHUTOFF VALVE BOILER SERVICE FILLTROL WITH AIR PURGER FILL LINE WITH SHUTOFF VALVE BOILER DRAIN VALVE SYSTEM PIPING ARRANGEMENT ALTERNATE NEAR BOILER PIPING gt DIAPHRAGM EXPANSION TANK MOUNTED OFF THE BOILER gt CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANK gt THIS MANUAL USE OPTION 2 IN FILLING THE SYSTEM WITH WATER gt THIS PIPING ARRANGEMENT CAN BE USED W
12. as necessary Refer to the section in this manual on OPERATING THE BOILER Final Burner Adjustments Insure that all safety controls and operating controls are functioning properly 27 SERVICE HINTS You may avoid inconvenience and service calls by checking these points before you for service IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT Possible Cause What to do Thermostat is not set correctly Reset thermostat above room temperature Boiler or Burner may be dirty Clean all flue passages and the vent pipe Have burner cleaned and readjusted may not be firing at proper rate Check nozzle size if there is any doubt Have burner adjusted Burner may be short cycling Short cycling too frequent off and on of bumer will cause sooting If boiler and or burner become dirty at frequent intervals after correcting the dirty condition also correct the aquastat control setting or other cause of short cycling Check thermostat heat anticipator and correct setting 1f necessary per instruction sheet packaged with thermostat No power to boiler Check overcurrent protection Check to be sure power supply circuit is Controls out of adjustments Reset according to instructions packed with controls Radiators not heating Open radiator vents to vent excess air Check flow control valve if used It may be in closed position
13. cast iron sectional seals flue collector be checked once each year by a competent Service Technician Before the start of each heating season or whenever the system has been shut down for extended periods of time recheck the whole system for water oil and vent piping leaks Replace or patch any leaks or seals that are faulty VENT PIPE Visually inspect the entire venting system once a month for any signs of leakage deterioration or soot build up If the vent pipe shows any signs of leaking or deterioration replace it immediately If it shows any signs of soot build up clean the vent pipe and have the burner settings and combustion checked by a competent professional RELIEF VALVE This valve should open automatically when the system pressure exceeds the pressure rating usually 30 psi of the relief valve Should the valve ever fail to open under this condition shut down the system Drain the system until system pressure is reduced below the relief valve pressure rating Then contact a competent Service Technician to replace the valve and inspect the heating system and determine the cause as this problem may indicate an equipment malfunction The relief valve should be tested monthly during the heating season Prior to testing make certain a discharge pipe is properly connected to the valve outlet and arranged so as to contain and safely dispose of boiler discharge Hold the trip lever fully open for at least five seconds in order to flush fr
14. must be supplied with the proper oil supply and oil piping sufficient fresh combustion air and a suitable electrical supply C Boiler must be connected to a suitable venting system and a piping system adequate to distribute the heating load D A thermostat must be properly located and installed for control of the heating system If there are any doubts as to the various requirements check with local authorities and obtain professional help where needed The OPERATING INSTRUCTIONS FINAL CHECKS AND ADJUSTMENTS and MAINTENANCE sections in this manual are vital to the proper and safe operation of the heating system Take the time to be sure they are all done LOCATING THE BOILER Place the boiler in a location centralized with the piping system and as close to the chimney as possible The boiler must be level If necessary use metal shims beneath the boiler s feet Use a raised base if the floor can become wet or damp Maintain clearances for fire safety as well as servicing An 18 clearance must be maintained at a side where passage is required for access to another side for cleaning servicing inspection or replacement of any parts that normally may require such attention Boilers must be installed at least 6 from combustible material on all sides and above Allow at least 24 front clearance for servicing 5 Fresh air for combustion must be available at the front of the boiler Fresh air for ventilation must be available to the f
15. 2 6 160 5 1 00 70 W 1 25 2 5 3 8 170 FS 1 25 70 1 50 4 0 7 0 175 5 1 20 1 00 70 W 1 20 2 513 5 150 5 5EW1 75 1 50 70 W 1 75 2 0 3 8 155 F10 5 2 00 1 75 70 W 2 00 2 5 4 1 155 F10 Riello 40 F5 and F10 oil burners are factory preset at 145 psig NOTE All burners use an insertion depth of 2 1 4 and fired at a overfire draft of 0 02 inches w c The burner settings provided are intended for initial start up only Final adjustment must be made using combustion test instruments 38 Kenmore Owner s Manual MODEL 3EW 65 3EW 75 3EW1 00 4EW 90 4EW1 25 4bEW1 50 5EW1 20 1 75 5 2 00 HOW TO ORDER REPAIR PARTS TELL SEARS YOU WANT IT INSTALLED THEN RELAX F464 1388 Oil Fired 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 Cail or visit The model number of your Boiler will be tound on the n ode plate on the side of the Boiler WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE FOLLOWING INFORMATION ePART NUMBER eMODEL NUMBER DESCRIPTION eNAME OF ITEM Alt parts listed may be ordered from 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 h
16. AD ADJUSTMENTS AND SETTINGS OCATION OF AT 707 7 1 C33 agus TING PLATE N r 1 471327 Le 46Ju T ABA 40 avt TURE BECKETT AFG BURNER ELECTRODE ADJUSTMENTS F HEADS IMENSION head to nozzle 1 16 Burner F Head Model D FO thru 3 32 GAP ELECTRODE 22M NOZZLE 7 18 ABOVE OIMENSION N SEE BELOW 22 RIELLO 40 F5 BURNER ELECTRODE ADJUSTMENTS 5 32 4 mm 5 64 to 7 64 or 2 to 2 5 mm RIELLO 40 F10 BURNER ELECTRODE ADJUSTMENTS 5 32 or 4 mm 5mm 23 CHECKING AND ADJUSTING CONTROLS A boiler using a tankless coil is configured with a Honeywell L8124C Combination Hi Low Limit Aquastat Relay refer back to the SYSTEM PIPING section for more details A boiler not using a tankless coil is configured with a Honeywell L8148A Hi Limit Aquastat Relay Instructions for the control provided are included with the boiler IMPORTANT You or your installer must follow these instructions carefully ADJUST OPERATING CONTROLS For both aqaustats use the following settings for the first adjustment High Limit Baseboard and Convectors 200 F Standing Radiators 180 F Low Limit when used 140 F increase if hotter domestic water is required but low limit set point must be at least 20 F less than the high limit set point Differential when used 10 F ADJUST THERMOSTAT HEAT A
17. C2 are energized providing power to the circulator Terminal Bl is energized providing power to the oil burner primary control This in turn powers the ignition coil and burner motor 3 With the primary control energized the burner operation starts and remains running as long as the cad cell senses flame In the event of flame failure or the flame is not fully proven within the trial for ignition period the primary control will lockout and open the burner circuit This will require a manual startup of the burner 4 Aslong as flame is proven through the cad cell relay the burner will remain on until the circuit is interrupted by the boiler water temperature reaching the aquastat s high limit setting opening high limit contacts BR or the thermostat is satisfied breaking the T T circuit 5 Ifthe boiler water temperature reaches the aquastat s high limit setting the high limit contact BR is de energized turning the burner off However the circulator pump will continue to run as long as the thermostat calls for heat 6 After the high limit contact BR is de energized the boiler water temperature must fall 10 F below the aquastat s high limit setting for the high limit contacts BR to close and energize the burner 7 When the thermostat is satisfied the call for domestic space heating is ended Relay coil is de energized opening and 1K2 contacts Both the burner and circulator pump operation stop 33 5
18. Circulating pump not running Check relay operation Poor electrical contact Check all control terminals and wire joints IF BURNER IS NOISY Possible Cause What to do Oil burner fan wheel may be dirty Clean fan wheel with a stiff brush and cleaning solvent Readjust oil burner Draft regulator may be stuck Check to see if vane swings freely Clean if vane is stuck IF RADIATORS ARE NOISY Possible Cause What to do Air in the system Open radiator vents to vent the air Check expansion tank RELIEF VALVE IS LEAKING Possible Cause What to do Dirt on seat Open valve manually Allow water to run and clear valve seat Water logged expansion tank Drain tank see instructions HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT ELECTRICAL WIRING BOILER WITH TANKLESS COIL AND HONEYWELL L8124C AQUASTAT CONTROL BECKETT AFG BURNER SHOWN 24 VOLT THERMOSTAT 120 POWER SUPPLY NEUTRAL L8124C AQUASTAT OIL BURNER MOTOR Service Company Serviceman Address Telephone BOILER WITHOUT TANKLESS COIL HONEYWELL L8148A AQUASTAT CONTROL BECKETT AFG BURNER SHOWN 320v POWER SUPPLY 24 THERMOSTAT NEUTRAL HOT 120 60 1 OVERCURRENT PROTECTED DISCONNECT L8148A AQUASTAT CIRCULATOR 29 BOILER WITH TANKLESS AND BOILER WITHOUT TANKLESS COIL HONEYWELL L8124C AQUASTAT CONTROL HONEYWELL 1 8148
19. ER 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 CENTER THROUGHOUT THE UNITED STATES This warranty gives you specific legal rights and you may also have other rights which vary from state to state 2 RR SAINI ONEONTA ERTIES ETE ROO OO OI EUM UAR ARRA 00101010 IMPORTANT The following are the responsibilities of the user and are 5 If the unit is removed from the place it was originally not covered by the Warranty installed this Warranty becomes void 1 Filter clearing or replacement 6 Damage to the unit caused by accident abuse negligence 2 Damage to unit or unsatisfactory operation due to improper misuse riot fire flood or acts of God cleaning or use of unit in corrosive atmosphere 3 Dama
20. FG 50 MD 1 50 45 B 2 3 4 AFG 50 MD 1 65 60 B 2 3 4 AFG 50 MD BOILER MODEL 3EW 65 3EW 75 3EW 1 00 4EW 90 4EW1 25 4EW 1 50 SEW 1 20 5EW1 75 5EW2 00 fire the 3EW 65 on rate the oil pressure must be increased to 175 psig Ali Beckett oil burners for the EW boiler are factory preset at 140 psig CARLIN OIL BURNER NOZZLE AND AIR SETTINGS BOILER DELEVAN FIRIN HEAD AIR BAND CARLIN MODEL NOZZLE RATE gph SETTING SET POINT BURNER 3EW 65 0 55 70 B 0 65 0 50 0 52 2 1 HP 75 0 65 60 0 75 0 60 0 65 0 60 2 1 1 00 0 85 60 B 1 00 0 85 1 00 0 80 2 1 4EW 90 0 75 60 0 90 0 75 0 75 2 1 4EW1 25 1 00 60 1 25 0 85 1 00 0 90 EZ 1 HP 4EW 1 50 1 25 60 1 50 1 10 1 25 1 25 EZ 1 HP 5EW1 20 1 00 60 B 1 20 0 85 1 00 0 90 EZ 1 HP 5EW1 75 1 50 60 1 75 1 50 1 65 EZ 2 HP SEW2 00 1 65 70 2 00 1 65 1 75 1 95 EZ 2 HP Carlin EZ 1 HP and EZ 2 HP oil burners are factory preset at 150 psig RIELLO 40 OIL BURNER NOZZLE AND AIR SETTINGS BOILER DELEVAN FIRING TURBULATOR AIR OIL PRESSURE RIELLO 40 MODEL OIL NOZZLE RATE gph SHUTTER SETTING PSIG BURNER MODEL 3EW 65 0 50 70 W 0 65 0 5 2 0 155 F5 75 0 65 70 W 0 75 2 0 2 2 150 FS 1 00 0 85 70 W 1 00 2 0 32 170 F5 0 75 70 0 90 1 5
21. ITH ZONE VALVES OR ZONE CIRCULATORS SHUTOFF VALVE RETURN FROM SYSTEM BOILER SERVICE IT SUPPLY TO SYSTEM FILL LINE WITH ISOLATION i SHUTOFF VALVE VALVES FILL VALVE SHUTOFF VALVE BOILER SERVICE FILLTROL WITH AQUASTAT AIR PURGER BOILER DRAIN VALVE LOCATE CIRCULATOR PUMP HERE WHEN SYSTEM PIPING USES ZONE VALVES IF SYSTEM PIPING USES ZONE CIRCULATORS USE THIS CIRCULATOR AS A ZONE CIRCULATOR 7 Boilers may be factory packaged with a tankless heater coil see figure below This provides instantaneous heating of water for domestic use if proper burner and water supply line controls are used Tankless coils are meant to provide domestic hot water for intermittent draws not continuous flow IMPORTANT Do not use a tankless coil if your water is excessively hard with lime or other deposits which will accumulate inside the coil When using a tankless coil the boiler has been configured so the Honeywell L8124C Combination Hi Low Limit Aquastat Relay mounts on a thermowell provided which needs to be installed in the 3 4 tapping on the tankless coil By mounting the aquastat on the coil the tankless coil performance is maximized by making the burner respond more quickly to a call for domestic hot water A tempering valve mixing valve is also recommended as shown in figure below A flow restrictor may be required on the tankless coil inlet piping so that flow rates are matched to boiler heat inp
22. NTICIPATOR TO 0 2 AMPS CHECK THERMOSTAT OPERATION The thermostat location has an important effect on the operation of the boiler system Be sure to FOLLOW THE INSTRUCTIONS included with your thermostat Typically the thermostat is located about five feet above the floor on an inside wall The thermostat should be located to sense average room temperature so avoid the following DEAD SPOTS behind doors corners and alcoves HOT SPOTS concealed pipes fireplace TV sets radios lamps direct sunlight kitchens COLD SPOTS concealed pipes or ducts drafty stairwells or door ways unheated room or wail of an unheated room When the temperature on the thermostat is set above the indicated thermostat temperature the boiler s burner should start Make certain once the room temperature reaches the selected temperature setting the thermostat should turn the boiler s burner off and once the room temperature falls a few degrees the boiler starts operating again Do not start the burner unless all cleanout doors are secured in place Do not attempt to start the burner when excess oil has accumulated when the unit is full of vapor or when the combustion chamber is very hot MAINTENANCE ANUALLY To assure trouble free operation it is recommended that the flue passages combustion chamber area target wall fire door insulation durablanket burner adjustment operation of the controls and boiler seals fire door gasket or silicone seal
23. T OFF R RETURN LINE VALVE B EXPANSION OIL FILTER zi 4 1 TD CNN CO EO IEEE 72 GENERAL PRINCIPAL REQUIREMENTS FOR A TYPICAL INSTALLATION un FRESH AIR FOR COMBUSTION WARNING Be sure to provide enough fresh air for combustion Enough air ensures proper combustion and assures that no hazard will develop due to the lack of oxygen NOTE If you use a fireplace or a kitchen or a bathroom exhaust fan you should install an outside air intake These devices will rob the boiler and water heater of combustion air You must provide enough fresh air to assure proper combustion The fire in the boiler uses oxygen It must have a continuous supply The air in the house contains only enough oxygen to supply the burner for a short time Outside air must enter the house to replace the air used by the burner Study the following examples 1 and 2 to determine your fresh air requirements EXAMPLE 1 Boiler Located in Unconfined Space If your boiler is in an open area unpartitioned basement in a conventional house the air that leaks through the cracks around the doors and windows will usually be adequate to provide air for combustion The doors should not fit tightly Do not caulk the cracks around the windows An unconfined space is defined as a space whose volume is not less than 50 cubic feet per 1 000 Btu per hour of the total input
24. TS BALLOON SYMBOL KEY TEM a ITEM DESCRIPTION Empire Water Front Section EW 1 1403 00 006 a Swing Door Insulation 146 14 014 Swing Door Hinge Nm 1 4 2 Round Head Rivet 146 95 121 O e D aA Of Aje e o SwigDoo 0007 40830000 12 34345 Shoulder Bolt 516718 Thread 146 95 12 35 I REPAIR PARTS GALLOON SYMBOL KEY IUANTITY ITEM 425 00 246 2 Back Jacket Panel 000000 425 00 269 425 00 269 425 00 260 3 TopJacket Panel 7 425 00 254 425 00 255 425 00 256 4 LefSidejacketPane 425 00 264 1425 00 265 4325 00 26 5 UpperFronJacketPane 425 00 267 425 00 267 425 00 267 9 sne acomNut 146 95 042 146 95 042 1146 55 042 8 Standoff 1 146 95 103 146 05 103 146 95 103 9 Lower Front Jacket Panel boiler w swing door 425 00 268 Complete Jacket for Boiler with Swing Door 425 00 289 425 00 290 425 00 291 36 5 2 Without Tankless 2b With Tankless Coll HEATER WITH 1 2 NPT CONNECTIONS RIGHT SIDE VIEW FRONT VIEW DESCRIPTION ITEM SEW Beckett AFG F Head Oil Burner 146 19 007 146 19 008 Beckett AFG Variable Head Oil Burner 146 19 009 00711 Beckett AFG F Head Low Fire Kit 0 65
25. ULATOR MUST SLOPE UP AT LEAST 1 4 INCH PER OF HORIZONTAL RUN TIGHT SMOOTH CORRECTLY SIZED CRIMPED END BALANCED WEIGHT SEALED IN THIMBLE DRAWBAND LAST PIECE INSTALLED TIGHT CLEAN OUT DOOR ALTERNATE POSITIONS ELECTRICAL CONNECTIONS Thermostat Install a 24 volt thermostat not provided in a proper location The location of the thermostat has an important effect on boiler system operation BE SURE TO FOLLOW THE INSTRUCTIONS INCLUDED WITH THE THERMOSTAT Grounding Permanently ground the boiler according to local codes and the National Electrical Code 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 WARNING Turm off electric power at fuse box before making any line voltage connections Follow local electrical codes Electric Power Supply All electrical work must conform to your local codes as well as the National Electrical Code If you are not familiar with wiring and codes in general have a competent electrician do this job On packaged boilers the boiler controls are all wired at the factory You need only connect a 115 volt electrical supply to the L1 and L2 terminals on the aquastat relay and two thermostat wires to the T and T terminals on the same aquastat relay see figure below Run a separate circuit from a separate overcurrent protection device in your electrical service en
26. URNER i Furtished RIGHT SIDE VIEW BACK VIEW WITH SWING DOOR BOILER RATINGS AND CAPACITIES NOE NET DIMENSIONS inches WITH WITHOUT NO INPUT lIEATING I B R FIRING AFUE MINIMUM TANKLESS TANKLESS SEC MBH CAPACITY RATING RATE H CHIMNEY MBH MBH GPH SIZE HEIGHT A 3EW esz 3 91 80 70 0 65 86 3 8 X 8 X15 751 xwasz 3 105 92 80 0 75 852 8 3EWEOOT 007 3 140 119 103 1 00 834 8 AEW S0T 4UW 907 4 1 97 0 90 86 0 8 AEWI2ST 4EWI23Z 4 175 150 130 125 83 9 8 7481501 4 1 507 4 210 178 155 1 50 824 8 SEWI20T SEWI 207 5 168 147 128 8 X8 X 15 21 SEWL7ST SEWI 757 5 245 209 182 1 75 83 6 87 8 15 21 SEW2 00T 5 2 007 5 280 236 205 2 00 820 8 X8 X20 21 MBH 1 000 BTU per hour BTU British Thermal Unit Hcating Capacity based on 13 CO2 with a 0 02 w c draft over fire and a 1 smoke or less Testing was done in accordance with the D O E Department of Energy test procedure GPH Gallons per hour oil at 140 000 BTU per gallon A F ULE Annual Fuel Utilization Efficiency based upon D O E test procedure These low pressure oil fired hot water boilers are constructed and hydrostatically tested for a maximum working pressure of 50 psig pounds per square inch gage in accordance wit
27. acts of God 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 SEARS ROEBUCK AND COMPANY 4 Damage to unit caused by the use of components or other D 817WA accessories not compatible with the unit Hoffman Estates iL 60179 MAIN AIR VENT for down flow systems or diaphragm type expansion tanks not provided Before a system is filled with water there is air in the pipes and radiation units Some of the air will be trapped as the system is filled It is possible to eliminate most of this air through the air vents on the radiation units A main air vent will speed and simplify this process The main air vent should be installed on the highest point in the supply main when all radiation is below the top of the boiler AUTOMATIC FILL VALVE not provided For safe efficient operation a hot water system must be 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 or pressure reducing 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 BURNER SOLENOID VALVE provided The Beckett and Carlin oil burner s use a standard solenoid v
28. afety valves and the atmosphere Installation on the safety relief valve shall conform to the ANSI ASME Boiler and Pressure Vessel Code Section IV The manufacturer is not responsible for any water damage When connecting the cold water supply to the pressure reducing valve make sure that a clean water supply is available When the water supply is from a well or pump a sand strainer should be installed at the pump The minimum boiler supply water temperature setting on the aquastat is 140 F If the boiler is used in a heating system where supply water temperatures below 140 F are desired a suitable method such as the use of bypass piping shown in the figure below a 3 way or 4 way mixing valve or some other means needs to be used to ensure return water temperatures to the boiler are no less than 120 F When the boiler is operated with return water temperatures less than 120 F condensation may form in the boiler and venting This condensation is corrosive and can eventually cause severe damage to the boiler and venting system ADJUST THE TWO THROTTLING VALVES TO MAINTAIN AT LEAST 120 F IN THE BOILER RETURN THE THROTTLING VALVES ARE USED FOR 55 PIPING IF REQUIRED RETURN FROM SYSTEM THROTTLING VALVE DRAIN VALVE FOR POWER PURGING MAIN SHUTOFF VALVE AUTOMATIC THROTTUNG VALVE FILL VALVE 52 SUPPLY TO SYSTEM ISOLATION VALVES FILL LINE WITH SHUTOFF VALVE SHUTOFF VALVE BOILER
29. alve Upon burner shut down a standard solenoid valve stops the flow of oil to the nozzle Without the solenoid valve the oil pump continues to pump oil to the burner nozzle until the burner motor winds down below the pumps cut off speed The Riello oil burner has a delay solenoid valve The delay solenoid valve provides the same shut down action as the standard solenoid valve plus on burner start up the delay solenoid valve remains closed for an additional 15 seconds This allows the burner fan motor to pre purge the combustion chamber and the oil pump to bring the supply oil pressure up to its set point helping to provide a clean light off AQUASTAT RELAY CONTROL provided The water temperature limit control in the aquastat relay is adjustable and may be set as low as 140 F so long as return water temperatures to the boiler no less than 120 F as high as 240 F so long as the boiler and heating system have adequate circulation to remove the heat from the boiler otherwise steam may be created in the boiler Refer back to SYSTEM PIPING section for more information DRAIN VALVE provided The drain valve is a manually operated valve that provides a means of draining all the water from the boiler and heating system It should be installed in the reducing tee where the return line enters the boiler CIRCULATOR provided Every forced hot water system requires a circulator A separate circulator or zone valve is required for each zo
30. andling When Sears arranges the installation you can be sure the job is done We wil arrange for professional workmanship and we ll take care of the entire project Whats more during installation you get insured protection agains property damage also against accidents lo workmen Ali you have to do is talk to your nearest Sears store today for detailed informatiun Sears Roebuck and Co Hoffman Estates IL 60179 U S A
31. boiler Dunkirk Radiator Corporation recommends an initial fill pressure of 10 12 psig For higher fill pressures the expansion tank s air charge will need to be increased to match the fill pressure Consult the manufacturer s guidelines for sizing and selection Purging the heating system of air and gases when first putting the boiler s into service is critical for proper circulation and quiet performance Once the air and gases are purged for boiler installations using float type vents the air vents should be closed for normal operation If air is heard or noticed by a loss of heat purge the system and open the vents for a short period of time WARNING This boiler has been designed for residential installations If used for commercial applications all jurisdictional requirements must be met This may require wiring and or piping modifications The manufacturer is not responsible for any changes to the original design BEFORE YOU START Complete all of the following prior to installing the boiler A Check to be sure you have selected the right size boiler with the proper capacity The rating of the boiler selected should be greater than or equal to the calculated peak heating load heat loss for the building or area s served by the boiler and associated hot water heating systems See boiler rating and capacity table previously listed in this manual Any heat loss calculations used should be based on approved methods B Boiler
32. 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 CENTER THROUGHOUT THE UNITED STATES This warranty gives you specific legal rights and you may also have other rights which vary from state to state Z 7 100000 00000000 a lll a ev afe D 1 if AT AT JU 1 A RA A IN it V 0 M 1 t V t 0 it RT M it t t uU 1 M t it Ni A V The following are the responsibilities of the user and are 5 If the unit is removed from the place it was originally not covered by the Warranty installed this Warranty becomes void 1 Fitter clearing or replacement 6 Damage to the unit caused by accident abuse negligence 2 Damage to unit or unsatisfactory operation due to improper misuse riot fire flood or
33. e blanket once cleaning is completed 5 Now with access to the flue passageways remove the soot from the fireside surfaces by brushing diagonally through the flue passages see drawing below Brushing can be made easier by cutting the end of the flue brush off and inserting it into a drill When brushing care should be taken so as not to damage the target wall with the flue brush 6 Carefully vacuum the soot accumulations from the combustion chamber area being particularly careful to not damage any of the refractory or blanket insulation To gain access to the combustion chamber first double check that the shut off valve on the fuel oil line is closed and then disconnect the fuel oil line Then open the swing door by simply removing the whiz lock nut holding the door shut 7 Now inspect the target wall fire door refractory and combustion chamber blanket when included for cracking and deterioration If there is any signs of cracking or deterioration replace the refractory or blanket before reassembling the burner front plate 8 Inspect the door s braided gasket for wear and damage Replace when necessary with braided gasket of the same material and size See repairs parts section of this manual 9 Now inspect and clean the oil burner f IMPORTANT OPERATING AND MAINTENANCE REQUIREMENTS KEEP YOUR BOILER AND THE AREA AROUND IT CLEAN NEVER BURN REFUSE OR ANY MATERIAL OTHER THAN THE SPECIFIED FUEL EN YOUR
34. e lowest radiation unit When ali the air has escaped and water starts to flow from the vent close it Go to the next radiation unit and repeat this process until finishing with the highest radiation unit If the heating system has automatic vents this manual venting is unnecessary but it will speed up the proper filling of the system If the system is a closed expansion tank system an automatic fill valve is needed Leave the automatic fill valve open to refill the system automatically as needed Note the initial fill pressure on the boiler s temperature pressure gauge which should be 10 15 psig Any lowering of the pressure from its initial fill pressure indicates a loss of water due to leakage The automatic fill valve should then compensate for this water pressure loss If it does not manually open this valve to refill the system until the needle is again pointing to the same pressure reading Instructions are packaged with the valve 19 BECKETT OIL BURNER NOZZLE AND AIR SETTINGS AIR SHUTTER BAND 10 0 10 0 10 2 8 0 10 0 10 2 BOILER DELEVAN FIRING HEAD ADJ MODEL OIL 221 RATE gph OR SETTING 65 0 50 80 B 0 11 8 3bEW 75 0 65 70 B 11 8 3EW1 00 0 85 70 B F3 11 8 4EW 90 0 75 80 A F3 1 1 8 4EW1 25 1 00 807A F6 1 1 8 4EW1 50 1 25 807A F6 1 1 8 5EW1 20 1 00 60 B 0 5EW1 75 1 50 45 2 5EW2 00 1 65 6078 4 LOW FIRE BAFFLE YES YES NO
35. ed the regulator will control the draft automatically It is better to install it in a horizontal section of pipe but it may be installed in an angled or vertical section of pipe Make certain that the of the regulator is at the top and that the short pipe section which holds the vane is horizontal Even though locating the draft regulator close to the chimney reduces noise install the draft regulator as close as practicable to the boiler To install the chimney connector start at the boiler with a vertical pipe and then elbow then install the draft regulator making it horizontal When the regulator is in place start at the chimney and work back to the regulator Join the two sections with a drawband The horizontal pipe must slope up toward the chimney at least 1 4 inch per linear foot of venting The chimney connector must not leak and must be firmly supported Join each of the sections with at least two sheet metal screws Support every second section with a stovepipe wire Maintain a minimum vent pipe clearance of 18 from the surface of the vent to wood and other combustible materials 14 TYPICAL CHIMNEY CONNECTION MUST BE REQUIRED MIN IMUM HEIGHT MUST BE AT LEAST 3 FT HIGHER THAN HIGHEST PART OF PASSAGE THROUGH ROOF MUST BE AT LEAST 2 FT HIGHER THAN ANY NEIGHBORING OBJECT MUST HAVE AN UNOBSTRUCTED TOP OPENING MUST BE AT LEAST 4 INCHES THICK AND BE TIGHT DRAFT REG
36. ee any sediment that may lodge on the valve seat Then permit the valve to snap shut Refer to the valve manufacturer s instructions packaged with the valve for more details CONVENTIONAL EXPANSION TANK As noted in the EQUIPMENT AND OPTIONAL ACCESSORIES section this tank may become water logged or may receive an excess of air Frequent automatic opening of the relief valve indicates water logging high boiler temperature accompanied by unusually low radiation unit temperature and knocking noises indicates excess air in the tank To correct either condition close the valve between the boiler and the tank Drain the tank until 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 the system has an automatic fill valve otherwise manually refill the system DIAPHRAGM EXPANSION TANK As noted in the EQUIPMENT AND OPTIONAL ACCESSORIES section this tank may become water logged Frequent automatic opening of the relief valve indicates water logging A high boiler temperature accompanied by unusually low radiation unit temperature and knocking noises indicates excess air in the tank To correct this condition replace the diaphragm expansion tank WATER SYSTEM If the 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 TANKLESS COIL OR COVER
37. enclosed space Always vent to the outside Never vent to another room or inside a building Be sure there is adequate air supply for complete combustion Follow a regular service and maintenance schedule for efficient and safe operation Keep boiler area clean and free of combustible material gasoline and other flammable vapors and liquids Oil burners are do it yourself items This boiler must be installed and serviced by qualified professionals using combustion test instruments Be aware when piping the relief valve that if the system pressure exceeds the safe limit of 30 pounds per square inch the relief valve will automatically lift open Lifting of the relief valve can discharge large quantities of steam and hot water which may damage the surroundings Before installing the relief valve read the manufacturer s instructions and maintenance section of the manual on relief valves Installation and sizing of the expansion tank must consider the heating systems total water volume temperature boiler initial fill pressure and system arrangement An improperly installed and sized expansion tank may result in frequent lifting of the relief valve or other heating system problems For proper installation sizing and maintenance of the expansion tank follow the guidelines established by Dunkirk Radiator Corporation and the expansion tank manufacturer Expansion tank performance life expectancy can be hindered by overfilling the
38. first install all of the radiation units panels radiators baseboard or tubing and the supply and return mains After all heating system piping and components have been installed make final connection of the system piping to the boiler It is recommended to mount the circulating pump on the supply side piping such that it pumps away from the expansion tank Refer to the figures on the next pages A hot water boiler installed above radiation level must be equipped with a low water cut off device A periodic inspection is necessary as 15 flushing of float type devices per low water cut off manufacturers specific instructions The packaged boiler unit is set up with 1 1 4 NPT supply and return piping from the front of the boiler The boiler supply and return piping can be moved to the rear of the boiler The boiler should not be piped return line to the front supply line to the rear or vice versa as this will cause the boiler water to short circuit the heat exchanger Piping connections may require additional fittings and parts The relief valve is meant to be installed in the back side of the rear section using the 3 4 nipple and street ell provided in the parts bag Connect a discharge pipe of the same pipe size 3 4 to carry any water away to a drain Do not connect directly to a drain but leave an air gap No shutoff of any description shall be placed between the safety relief valve and the boiler or on discharge pipes between such s
39. ge to unit or unsatisfactory operation due to blown fuses or inadequate or interrupted electrical protective devices SEARS ROEBUCK AND COMPANY 4 Damage to unit caused by the use of components or other D 817WA accessories not compatible with the unit Hoffman Estates IL 60179 INTRODUCTION The Empire Water boiler is a natural draft oil fired hot water boiler comprised of cast iron sections The Empire Water boiler is available with 3 4 or 5 cast iron sections These sections are held together by cast iron push nipples The Empire Water boiler is capable of firing 2 fuel oil from 0 65 gph up to 2 00 gph Boilers may be purchased with or without the following options a Beckett AFG Carlin EZ or Riello 40 oil burner a Taco or Grundfos circulator with isolation valves a tankless coil for domestic hot water packaged boilers include a swing door Honeywell aquastat temperature and pressure gage relief valve drain valve 2 Delevan oil nozzles for multiple firing rates only when purchasing a burner flue brush and an extra boiler tap for an expansion tank or air elimination 20 1 2 TEMP PRESSURE GAUGE SSS UMIT CONTROL Without Tankless UNIT CONTROL Wilh Tonkiess Coll 1 1 47 RETURN NIPPLE amp REDUCING TEE FRONT VIEW 17 34 2 RIELLO 15 3 4 CAR N RELIEF VALVE OUTLET OPTIONAL TANKLESS COIL WATER HEATER WITH 1 27 NPT CONNECTIONS OIL B
40. gph 433 00 015 Beckett AFG F Head Low Fire Kit 0 90 gph 433 00 016 Carlin EZ 10il Burner 146 19 005 146 19 005 146 19 00 19 5 1 201 146 19 006 Riello 40 F10 Oil Burner 146 19 011 L8148A 1124 Aquastat Control no tankless coil 433 00 521 146 26 047 146 26 047 146 26 048 1146 26 048 146 26 048 146 26 050 146 26 050 007 Circulator with Gaskets 433 00 047 433 00 047 Temperature Pressure Gauge 2 Stem 146 23 003 146 23 003 146 23 003 1 1 4 x 2 1 2 Pipe Nipple 146 07 044 146 07 044 6 X 34 Drain Valve 146 22 000 146 22 000 146 22 000 3 4 Relief Valve 146 22 011 146 22 011 Note Beckett AFG F Head low fire kits include static plate burner head and oil nozzle The temperature pressure gauge connects to the boiler using a 3 4 x 1 4 bushing The relief valve connects to the boiler using a 3 4 x 2 nipple and a 3 4 street elbow 37 BECKETT OIL BURNER NOZZLE AND AIR SETTINGS DELEVAN FIRING HEAD ADJ LOW FIRE AIR STATIC OIL OIL NOZZLE RATE gph SETTING BAFFLE SHUTTER BAND PLATE BURNER 0 50 80 B 0 65 FO 1 1 8 YES 10 0 3 5 8 0 65 70 B F3 1 1 8 YES 10 0 3 1 2 0 85 70 B F3 11 8 NO 10 2 3 1 2 AFG F HEAD 0 75 80 A F3 1 1 8 NO 8 0 3 1 2 AFG F HEAD 1 00 80 6 11 8 NO 10 0 3 3 8 AFG F HEAD 1 25 80 A F6 1 1 8 NO 10 2 3 3 8 AFG F HEAD 1 00 60 B 2 3 4 A
41. h A S M E American Society of Mechanical Engineers Boiler and Pressure Vessel Code Section IV Standards for heating boilers The Heating Capacity indicates the amount of heat available after subtracting the losses up the stack Most of this remaining heat is available to heat water A small portion is heat from the jacket and surfaces of the boiler and it is assumed that this heat stays in the structure The Net I B R Rating represents the portion of the remaining heat that can be applied to heat the radiation or terminal units 1 e finned tube baseboard cast iron radiators radiant floor etc The difference between the Heating Capacity and the Net I B R Rating called the piping and pickup allowance establishes a reserve for heating the volume of water in the system and offsetting heat losses from the system piping The Net I B R Ratings shown are based on a piping and pickup factor of 1 15 in accordance with the I B R Standard as published by the Hydronics Institute The Net I B R Rating of the boiler selected should be greater than or equal to the calculated peak heating load heat loss for the building or area s served by the boiler and associated hot water heating systems The manufacturer should be consulted before selecting a boiler for installations having unusual piping and pickup requirements Boilers with the same number of sections are identical to each other except for their firing rate The firing rate is determined by the nozzle s
42. ize in the oil burner and the oil pressure at the nozzle For example Models 3E 65Z 3 757 and 3 1 007 are the same boiler without a tankless coil except for the firing rate of the oil burner Models 4 90 4 1 25 and 4E1 50T are the same boiler with a tankless coil except for the firing rate of the oil burner Each boiler rating plate shows three possible model numbers for a given boiler configuration The actual model number is determined by the firing rate of the oil bumer Boilers that are factory packaged include two nozzles for two firing rates These boilers operate on 2 Heating Oil D N ROR 12 13 14 RULES FOR SAFE INSTALLATION AND OPERATION Read the Owner s Manual 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 Check your local codes and utility requirements before installation The installation must be in accordance with their directives or follow 31 Installation of Oil Buming Equipment latest revision Before servicing allow boiler to cool Always shut off any electricity and oil to boiler when working on it Inspect oil line and connections for leaks Be certain oil burner nozzle is the size required Overfiring will result in early failure of the boiler sections This will cause dangerous operation Never vent this boiler into an
43. k and the RW contacts make When the boiler water temperature rises above the low limit adjustable differential setting and the thermostat controls cali for domestic space heating The sequence of operation for the burner and circulator is as follows Thermostat calls for heat completing circuit between terminals T amp T on the aquastat controller energizing the 1K relay coil 2 With the 1K relay coil energized contacts 1 1 and 1K2 are closed Terminal B1 is energized providing power to the oil burner primary control This in tum powers the ignition coil and burner motor 3 With the primary control energized the burner operation starts and remains running as long as the cad cell senses flame n the event of flame failure or the flame is not fully proven within the trial for ignition period the primary control will lockout and open the burner circuit This will require a manual startup of the burner 4 Aslong as flame is proven through the cad cell relay the burner will remain on until the circuit is interrupted by the boiler water temperature reaching the aquastat s high limit setting opening high limit contacts RB or the thermostat is satisfied breaking the T T circuit 5 Circulator pump is powered through terminal and will run when boiler water temperature is above the low limit setting and there is a call for heat from the thermostat If the boiler water temperature reaches the aquastat s high limit setting and high limit co
44. ne if there are two or more zones The circulator must have the capacity to provide the circulation required by the heating system The circulator should be connected to the supply main and must be wired into the boiler s electrical system See the SYSTEM PIPING section for piping configurations with the circulator located on the supply main piping using zone circulators or zone valves When the piping is arranged with zone circulators and no bypass piping the circulator provided with the boiler may be used as a zone circulator Both piping arrangements allow the circulator to pump away from the expansion tank and show how the piping should be arranged to allow the heating system to be easily purged of air FILLING THE BOILER HOW A HOT WATER SYSTEM OPERATES The entire heating system boiler piping and radiation units is filled with water As the water in the boiler is heated it is circulated from the top of the boiler through the supply main to the radiation units The cooler water in the radiation units flows back through the return piping through the return main into the boiler This arrangement provides positive and rapid response to the thermostat FILLING THE SYSTEM WITH WATER OPTION 1 This method utilizes the boiler piping as shown in the figure on the previous page a Close the main shutoff valve isolation valves and zone valves if applicable If bypass piping is installed also close the two throttling valves Leave the b
45. nt The high limit contacts automatically reset after the boiler water temperature drops past the set point by 10 F which is a fixed differential Aquastat low limit and circulator control With the adjustable differential at the minimum setting of 10 F boiler water temperature rise above the low limit set point the burner circuit contacts RB break and the circulator circuit contacts RW make e boiler water temperature drop of 10 F below the low limit set point the RB contacts make and the RW contacts break With the adjustable differential setting greater than 10 F When the boiler water temperature is at or below the low limit set point the RB contacts make and fire the burner and the RW contacts break leaving the circulator off The burner will fire until the boiler water temperature reaches the low limit set point plus the adjustable differential setting minus 10 F At this point the RB contacts break stopping the burner and the RW contacts make With no call for space heating operating in this way keeps the circulator off and allows the boiler to give preference to the domestic water heating requirements Example Consider the boiler water temperature drops to 150 F with the low limit set at 160 F and the differential is set at 15 F The burner will begin to fire When the aquastat probe senses a boiler water temperature of 165 F 15 F 10 F 5 F then 160 F 5 F 165 F the RB contacts brea
46. ntact RB is de energized the burner stops but the circulator pump will continue to run as long as the thermostat calls for heat 6 Whenever the boiler water temperature reaches the aquastat s high limit setting the high limit contact RB is de energized shutting the burner off Then the boiler water temperature must fall 10 F below the aquastat s high limit setting for the high limit contacts RB to close and the burner to be energized 7 When the thermostat is satisfied the call for domestic space heating 15 ended Relay coil is de energized opening and 1 2 contacts Both the burner and circulator pump operation stop SEQUENCE OPERATION BOILER LESS TANKLESS COIL Aquastat high limit controller The aquastat control s high limit contacts open and turn off the burner when the boiler water temperature reaches the control s high limit set point The high limit contacts automatically reset after the boiler water temperature drops past the set point by 10 F which is a fixed differential INTERNAL WIRING FOR HONEYWELL AQUASTAT L8148A JUMPER UNE VOLTAGE When the thermostat controls call for domestic space heating The sequence of operation for the burner and circulator is as follows 1 Thermostat calls for heat completing circuit between terminals amp T on the aquastat controller energizing the relay coil 2 With the relay coil energized contacts 1 1 and 1K2 are closed Terminals C1 and
47. oiler service shutoff valve if installed and the balancing valves to each heating zone fully open b Open the following valves in order the drain valve for power purging isolating valves before and after the boiler circulator if applicable both throttling valves if applicable and then open the fill line shutoff valve Water will fill the bypass piping and push the air through the piping and out the power purging drain valve When the power purging drain valve runs air free close the bypass piping throttling valve leaving the throttling valve to the supply piping fully open c Next open the isolation valve or zone valve to the first zone Water will fill the piping and push any air out the power purging drain valve When the power purging drain valve runs air free close the isolation valve or zone valve Repeat this procedure for the remaining heating zones d Once all zones are filled with water and purged of air close the power purging drain valve and fill line shut off valve open the main shutoff valve and adjust the throttling valves and balancing valves as required OPTION 2 Close the air vents on all radiation units Open the valves to the radiation units Make sure the boiler drain valve expansion tank drain cock and the air bleed screw the expansion tank drain fitting are closed Open the fill valve on the piping to the expansion tank Open the water inlet to the boiler and leave it open Open the air vent on th
48. ory preset at 145 psig NOTE All burners use an insertion depth of 2 1 4 and fired at a overfire draft of 0 02 inches w c The burner settings provided are intended for initial start up only Final adjustment must be made using combustion test instruments 38 STATIC OIL PLATE BURNER 5 8 3 3 1 2 3 1 2 3 1 2 3 3 8 3 3 8 2 3 4 2 3 4 2 3 4 AFG F HEAD AFG 50 MD AFG 50 MD AFG 50 MD NOZZLES AND ELECTRODES Use the proper size spray angle and spray pattern nozzle Refer to the recommended nozzle selection charts at the end of this manual To install a nozzle remove the nozzle line electrode assembly if necessary remove the retention ring assembly and then install and tighten the nozzle Be careful not to damage the electrode insulators or the bend the electrode tips After installing the nozzle reassemble the nozzle line electrode assembly and set the electrode tip spacing Depending on the burner purchased the electrode tip spacing may need to be set prior to reassembling the nozzle line electrode assembly Refer to the figures on the following pages for setting the electrode tip spacing on Beckett Carlin and Riello burners FINAL BURNER ADJUSTMENTS Final burner adjustments must be made using combustion test instruments Initial settings for the burner are shown at the back of this manual Set the burner accordingly Check the draft over fire to verify that it is between 0 01 WC and
49. rating of all appliances installed in that space EXAMPLE 2 Boiler Located in Confined Space A All Air from Inside the Building The confined space shall be provided with two permanent openings communicating directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space The total input of all combustion equipment installed in the combined space shall be considered in making this determination Each opening shall have a minimum free area of one square inch per 1 000 Btu per hour of the total input rating of all combustion equipment in the confined space but not less than 100 square inches One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure Example Your boiler is rated at 100 000 Btu per hour The water heater is rated at 30 000 Btu per hour The total is 130 000 Btu per hour You need two grilles each with 130 square inches of FREE opening Metal grilles have about 60 FREE opening To find the louvered area needed multiply the free opening required by 1 7 130 x 1 7 221 0 sq in louvered area In this example two grilles each having an 8 x 30 240 sq in louvered area would be used AIR OPENINGS FOR BOILER LOCATED IN CONFINED SPACE CLOSET OR UTILITY ROOM H VENTILATING GRILLE COMBUSTION AIR GRILLE B All Air from Outdoors The confined space shall be provided with two permanent openings
50. ront AND rear of the boiler Air passages must be free of obstructions at all times Ventilating and combustion air must enter boiler room without restrictions 6 The floor supporting the boiler must be non combustible and sufficiently stable If it is combustible place the boiler on 2 concrete patio blocks or 2 Cladlite Pad The blocks pad must be under the entire boiler to protect the floor 7 Be sure installation is in accordance with the requirements of the local authorities having jurisdiction Compliance with these regulations is required In the absence of local codes follow 31 Installation of Oil Burning Equipment latest revision BU KM MINIMUM CLEARANCE DIMENSIONS BOILER FRONT 4 6 MIN 18 WITH COIL E ALWAYS KEEP THE MANUAL FUEL SUPPLY VALVE SHUT OFF IF THE BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIME INSTALLATION REQUIREMENTS me ar e E EE Eee r N E AUTOMATIC o H LINE FILL VALVE Ee AND SHUTOFF H amp C ENTRANCE 7 4 Lj 1 SWITCH EJ E 7 as FILL rw DRAFT ri 1 MIN 27 I D 201 REGULATOR rr x DG 0 VENT t1 cC amp 5 VENT a TO OTHER 2 gn ES i APPLIANC RELIEF VALV TO OUTSIDE EVE M j 0 FROM RADIATION CIRCULATING HH OIL BURNER yh PUMP IN SHU
51. trance panel This should be a 15 ampere circuit Locate a shut off switch at the boiler It must be turned off during any maintenance Solder and tape or securely fasten these connections with wire nuts Oil Burner Wiring For boilers packaged with oil burners the burners are wired at the factory For boilers shipped knockdown or packaged without a burner wiring connections are shown in the electrical wiring diagrams of this manual 115V 60 CYCLE SUPPLY tf 24 VOLT 115 SUPPLY AQUASTAT RELAY ICD EDGE DS SEARS 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 will repair 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
52. ut see table below Model Rate gph MBH Rating gpm 4ew 90T 090 126 315 3 50 Gallons of water per minute heated from 40 F to 140 F with 200 F boiler water temperature intermittent draw UNTEMPERED HOT WATER FO AUTOMATE OGMWASAUR eek TEMPERED HOT WATER TANKLESS COIL CENTER LINE OF COLD TAP TEMPERING VALVE ua CONTROL epe e SHUT OFF VALVE CONTROL WELL COLO WATER INLET 8 Antifreeze added to boilers must be non toxic and must be of a type specifically intended for use closed hydronic heating systems Under no circumstances should automotive antifreeze be used Antifreeze used in any boiler may reduce capacity by 10 or more and increase fuel consumption Tankless coil performance will fall as concentration of antifreeze is increased Refer to boiler and piping water volumes tables in this manual BOILER WATER VOLUMES PIPING WATER VOLUMES Number of Total Volume Boiler Sections mm COPPER PIPE STEEL PIPE 360 ie I Lac e Divide total length of 22 ERE factor in table to determine volume in gallons For oil fired boilers for connections to vents chimneys vent installations shall be accordance with applicable provisions of INSTALLATION OF OIL BURNING EQUIPMENT 31 latest revision and applicable provisions of local building codes CHIMNEY

Kenmore 3EW.75 Boiler User Manual

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