JVC DR-DX5SE Universal Remote User Manual
Contents
1. 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 34 tapping at the bottom of the end boiler section Or it can be installed in a tee where the return line enters the boiler 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 no2. x 6 Bent Nipple 10 Taco 007 Circulator 146 26 047 Grundfos UP15 42F Circulator 146 26 045 400 Black Silicone Rubber Adhesive 146 06 020 Fuse Link G4AM0600 144C 146 29 002 Spill Switch Water 36TX16 6281 146 60 001 Wiring Harness Vent Damper 146 34 501 Sealant 10 3 oz Cartridge NOT ILLUSTRATED 9 La HONEYWELL 17148 TROUBLE SHOOTING GUIDE Start Boiler is cold Boiler is not reaching proper temperature or will not turn on Turn power ON Check all wiring connections Replace transformer as appropriate Check L7148F Diagnostic LED ON Check for 120V at L1X L2X Check for 24V at R C No Yes Thermostat cr Thermostat wiring problem Check system per instructions provided with thermostat Short terminals W R T TW 17148 Boiler starts Yes Set room thermostat 10 above room temperature Set boiler 10 or more above current water temperature Boiler turns on No Two Blinks No Check sensor connections f good replace sensor Three or four blinks Internal error replace L7148F control Yes Check L7148F Diagnostic LED flashing Check L7148F in reset mode wait 5 minutes Yes Check for 24V at B1 B2 for control to reset Vent damper open L7148F is OK check ignition and gas valve system as described in literature provide
3. ARE OPEN D MAKE SURE THAT THE THERMOSTAT IS CALLING FOR HEAT E CHECK THAT WIRE CONNECTORS AT THE L7148F CONTROL TRANSFORMER AND S8600 CONTROL IF USED ARE SECURELY PLUGGED IN OR CONNECTED 2 TROUBLESHOOTING TOOLS CHECK 120 VAC AND 24 CONTINUITY TESTER C U TUBE MANOMETER OR DIFFERENTIAL PRESSURE GAUGE WITH 0 14 RANGE 0 1 SCALE FOR MEASURING INLET AND MANIFOLD GAS PRESSURES 3 WHAT IS SYSTEM STATUS A CONSULT THE CHART ON THE FOLLOWING PAGE B FIGURE 19 ON PAGE 25 SHOWS THE LOCATION ON THE BOILER OF THE SYSTEM STATUS LIGHTS TROUBLE SHOOTING STATUS LIGHTS MAIN POWER 9 CALL FOR HEAT CIRCULATOR PUMP GAS VALVE BURNER STATUS INDICATES m L7148F CONTROL ENERGIZED THROUGH 24 VOLT TRANSFORMER L7148F CONTROL NOT ENERGIZED CALL FOR ON L7148F CONTROL ENERGIZING CIRCULATOR PUMP CIRCUIT CIRCULATOR PUMP CIRCULATOR PUMP IS NOT ENERGIZED x L7148F CONTROL ENERGIZING GAS CONTROL VALVE GAS VALVE OPEN GAS VALVE BURNER GAS VALVE NOT ENERGIZED GAS VALVE CLOSED L7148F CONTROL LED ERROR CODES INDICATES L7148F CONTROL ENERGIZED FULLY FUNCTIONAL L7148F CONTROL NOT ENERGIZED L7148F LED STATUS 2 BLINKS SENSOR ERROR SHORTED OR OPEN SENSOR LIGHT 3 BLINKS ANOLOG TO DIGITAL ERRORS SET POINT POT FAILURE 4 BLINKS RELAY FAILURE CONTROL FAILURE 25 T
4. Adjust thermostat so appliance will operate continuously 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 C 7 Any improper 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 resizing 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 Z223 1 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 2223 1 iatest revision and applicable provisions of the local building codes Vent connectors serving appliances vented by natural draft shail not be connected into any portion of mechanical draft systems operating under positive pressure HORIZONTAL INSTALLATION FLOW NO TO CHIMNEY NO TO FURNACE VENT OR BOILER DAMPER INSTALL VENT DAMPER WITH ACTUATOR TO S
5. flames after reassembly see Figures 17 and 18 Be sure vent pipe connections to chimney are secure and no obstructions are present SEQUENCE OF OPERATION PWX WITH STANDING PILOT Thermostat calls for heat completing the circuit to the aquastat and gas valve The sequence is as follows The LED tight 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 TROUBLE SHOOTING INITIAL SERVICE CHECKS 1 BEFORE TROUBLESHOOTING MAKE SURE THAT CIRCUIT BREAKER IS ON OR FUSE IS AT ELECTRICAL PANEL B MAKE SURE THAT SERVICE SWITCH IS ON C MAKE SURE THAT GAS IS ON AT THE GAS METER AND THAT ALL APPROPRIATE MANUAL SHUTOFF VALVES AND GAS CONTROL VALVE
6. or explosion may result causing property damage personal injury or loss of life A Some boilers are equipped with an intermittent ignition device which automatically lights the pilot Do not try to light the pilot by hand Some boilers are equipped with a continuous pilot and must be manually lighted See lighting instructions on page 21 A match holder is included in the parts bag 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 20 mmediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions eif you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas control knob Never use tools If the knob will not 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 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 STOP Read the safety information on page 20 Set the thermostat to lowest setting T
7. 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 IF BURNER IS NOISY What to do Contact your service technician RELIEF VALVE LEAKING What to do Open valve manually Allow water to run and clear valve seat Drain tank see instructions HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT 27 REPAIR PARTS 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 n
8. 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 Y square inch hole approximately Ya diame ter On boilers equipped with standing pilot the hole must be left open On boilers equipped with intermittent ignition the hole should be plugged by using the plug supplied with the vent damper 1 Position furnished vent damper on top of flue outlet collar Fasten damper securely to flue outlet collar with sheet metal screws Make sure damper blade has clearance to operate inside of diverter On 2 section boilers equipped with vent damper the supplied 4 inch vent damper is equipped with a 3 to 4 inch adapter so that the 4 inch vent damper may be installed on the boiler s 3 inch flue outlet collar Fasten all fittings securely As An Option The damper may be installed in any horizontal or vertical position closer to the flue outlet collar preferred Follow the diagrams Figures 9 10 and 11 2 install the vent damper to service only the single boiler for which it is intended The damper position indicator shall be in a visible location following installation Locate the damper so that it is accessible for servicing 3 The damper must be in the open position when appliance main burners are operating 4 The boiler is equipped with a factory wired harness that plugs into the vent damper 5 Vent pi
9. the potentiometer to the correct limit setting setting is below the desired temperature temperature Defective sensor Check for shorted or open sensor and or leads Temporarily replace existing sensor with new sensor If system starts replace the sensor Defective L7148F Aquastat Control Incorrect temperature setting Adjust the potentiometer to the proper temperature setting Sensor not fully inserted into well Reinsert the sensor fully into the well Defective L7148F Aquastat Control Replace the L7148F Aquastat Control Boiler is too hot 2 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 tf you cannot reach the gas supplier call the fire department IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT 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 Possible Cause Gas input amount is incorrect Possible Cause Dirt on seat Water logged expansion tank What to do Reset thermostat above
10. to be level Meta shims may be used under base legs for final leveling 4 Additional clearances for service may exceed clearances for fire protec tion Always comply with the minimum fire protection clearances shown on the boiler An 18 inch clearance should be maintained on any side where passage is required to access another side for cleaning servicing inspection or replacement of any part that may need attention Figure 2 shows minimum clearances to combustible construction Rooms that are large in comparison with the size of the boiler are defined as rooms having a volume equal to or greater than 16 times the volume ol the boiler Where the actual ceiling height of a room is greater that 9 Ihe volume of a room shall be figured on the basis of a ceiling height of 8 Determination of room size should be based on the total volume of al gas fired equipment installed in the room Consult section 6 3 1 of the National Fuel Gas Code for further information including approved methods for reducing clearances in large rooms Equipment shall be installed in a location in which the facilities for ven tilation permit satisfactory combustion of gas proper venting and main tenance of ambient temperature at safe limits under normal conditions o use Equipment shall be located so as not to interfere wilh proper circu lation of air When normal infiltration does not provide the necessary air outside as shail be introduced See Page 4 Fresh
11. 0649 Base 42500663 42500664 42500665 42500666 42500667 42500668 42500669 Jacket Tie Bar 42500653 42500654 42500655 42500656 42500657 42500658 42500659 Push Nipple 43300976 43300976 43300976 43300976 43300976 43300976 43300976 Jacket Left Side Panel 735001040 735001040 735001040 735001040 735001040 735001040 735001040 Knob Service Door pair 13702153 13702153 13702153 13702153 13702153 13702153 13702153 Jacket Service Door 42500913 42500914 42500915 42500916 42500917 42500918 42500919 Jacket Intermediate Panel 735001073 735001074 735001075 735001076 735001077 735001078 735001079 Jacket Cover Panel 735001070 735001070 735001070 735001070 735001070 735001070 735001070 Jacket Front Panel 42500811 42500804 42500805 42500806 42500807 42500808 42500809 Ya Tie Rod and Nut 14605001 14605002 14605051 14605053 14605005 14605007 14605009 Boiler Section Left End 41000020 41000020 41000020 41000020 41000020 41000020 41000020 Boiler Section Middle 41000022 41000022 41000022 41000022 41000022 41000022 41000022 Boiler Section Right End 41000021 41000021 41000021 41000021 41000021 41000021 41000021 Draft Diverter 42500673 42500674 42500675 42500676 42500677 42500678 42500679 Jacket Back Panel 42500903 42500904 42500905 42500906 42500907 42500908 42500909 Jacket Top Panel 42500843 42500844 42500845 42500846 42500847 42500848 42500849 Vent Damper 14628001 14628002 14628002 14628003 14628003 14628003 14628003 Jacket Complete 42500943 42500944 42500945 42500946 42500947
12. 42500948 42500949 Block Assembly 41000313 41000413 41000513 41000613 41000713 41000813 41000913 Combustible Floor Plate 14614031 14614031 14614031 14614031 14614032 14614032 14614032 Base Assembly 41000313 41000413 41000513 41000613 41000713 41000813 41000913 Cerafelt Gasket 14614018 14614018 14614018 14614018 14614018 14614018 14614018 NOT ILLUSTRATED LOCATED AT THE BASE AND BLOCK ASSEMBLY 28 REPAIR PARTS CONTINUED JACKET SECTION AND BASE PARTS REPAIR PARTS CONTINUED LED amp COVER PANEL ASSEMBLY STATUS UCHT ITEM 14611001 UGH MAAMESS ITEM 443300883 LIGHT LABEL TEM 14600114 COVER PANEL TEH 9735001070 WAIN POWER STATUS UGHT 4 1 CALL FOR HEAT CWRCULATOR PUMP STATUS UGHT 5 2 CAS VALYE BURMER STATUS LIGHT 8 3 JACKET PARTS LEFT SIDE PANEL 2 28 32 x 3 4 MEX MACH ITEM 71459537 RIGHT 506 PANEL N 9735001050 N CU OUT INSULATION Z BOIN PANELS x 2 m u 14531082 lu pression L PROT goumo ss900w 14662070 COVER KACO 855 i C42 48 32 MUT 714851085 Mews 42695048 BELONG IN PARIS BAC MACO CONMECTON MEM 414624012 REPAIR PARTS CONTINUED CONTROL BOX ASSEMBLY WIRING HARNESS 14654502 3 6 SEC WEM 414534503 7 9 SEC 2 6 X 17 SLT SHEET SCREW 414695045 2 8 X 1 27 SLT SHEET SCREW ITEM 414695046 TRAN
13. 6 95 307 146 16 100 146 16 101 146 16 102 146 16 103 146 16 104 146 16 105 146 16 106 146 15 031 146 15 031 146 15 031 146 15 035 146 15 035 146 15 035 146 15 035 Gas Valve Pilot Tube 10 32 x 1 2 Hex HD Screw 2 req d Gas Manifold Main Burner Orifice Main Burner Less Pilot Bracket Main Burner With Pilot Bracket Pilot Burner 146 15 532 146 15 532 146 15 532 146 15 532 146 15 532 146 15 532 146 15 532 146 15 531 146 62 098 425 00 939 146 62 036 146 15 531 146 62 098 426 00 938 146 62 036 146 15 531 146 62 098 425 00 933 146 15 531 146 62 098 425 00 934 146 15 531 146 62 098 425 00 935 146 15 531 146 62 098 425 00 936 146 62 039 146 15 531 146 62 098 425 00 937 146 62 039 Rollout Shield Thermocouple Note Quantity required 2 less than the number of sections Quantity required 1 less than the number of sections Not illustrated 32 REPAIR PARTS CONTINUED BOILER CONTROLS AND PIPING NOTE ISOLATION BALL VALVES AND CIRCULATOR PUMP ARE SHIPPED LOOSE N CRATE KEY DESCRIPTION Part Number 34 ASME Relief Valve 34 x 7 A Nipple 1 4 x 2 V2 Nipple 1 Va x 3A x 1 V4 Tee Well 34 NPT 123870A 7 1 1 4 x 6
14. Air for Combustion Advise owner to keep air passages free of obstructions Ventilating and combustion air must enter boiler room without restrictions en D 7 The boiler shall be installed such that the automatic gas ignition system components are protected from water dripping spraying rain etc dur ing appliance operation and service condensate trap control replace ment etc FIG 2 MINIMUM CLEARANCE DIMENSIONS Alcove or Room not Large Room Large Comparison in Comparison with Boiler With Boiler 3 sECr 6 9 SECT 3 9 SECT NOR T oq cir CS aa EREAR c SSK masa e gno 6 AoT DEE 96 tl FLUE VENT CONNECTOR PIPING BOILER VOLUME MINIMUM ROOM VOLUME REQUIRED TO BE LARGE Cu Ft ROOM Cu Ft 3 SECT 86 6 4 SECT 111 6 5 SECT 136 6 BOILER SIZE FOR ROOM WITH SINGLE BOILER ONLY THIS UNIT MUST BE SET ON A CONCRETE OR OTHER NON COMBUSTIBLE MATERIAL BASE OR FLOOR Fresh Air for Combustion 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 You must provide for enough fresh air to assure proper combustion The fire in the boiler uses oxygen It must have a continuous supply The air in a house contains only enough oxygen to supply the burner for a short time Outside air must enter the house to rep
15. IDES OF VENT ONLY DO NOT MOUNT ABOVE OR BELOW VENT VERTICAL INSTALLATION TO CHIMNEY VENT DAMPER ACTUATOR MAY BE INSTALLED IN ANY POSITION TO FURNACE OR BOILER FIG 8 TYPICAL MASONRY CHIMNEY REQUIREMENTS 3 4 HT MAXIMUM MUST SLOPE UP AT LEAST 1 4 INCH PER FOOT OF HORIZONTAL RUN CAUTION DO NOT INSTALL THE VENT DAMPER WITHIN 6 in 152 mm OF COMBUSTIBLE MATERIAL BOILER WATER HEATER TYPICAL INSTALLATION FOR VENT DAMPER NOTE CAUTION AND FOOTNOTES 1 Install the vent damper to service only the single appliance for which it is intended If improperty installed a hazardous condition such as an explosion or carbon monoxide poisoning could result 2 Do not install the vent damper on vent pipe curve 3 Do not run wires near high temperature surfaces Use stand off brackets if necessary For sate efficient operation the vent damper and all flue product carrying areas of the appliance must be checked annually by you with particular attention given to deterioration from corrosion or other sources If you see corrosion or other deterioration contact your heating contractor for repairs Check vent damper operation as follows 1 When the boiler is off check that the vent damper position indicator points to the closed position Fig 11 2 Turn the thermostat or controller up to cali for heat and check that the vent damper indicator points to the open position Fig 11 3 Turn the thermostat or co
16. MUST BE REPLACE WITH TYPE 105 C THERMOPLASTIC WIRE OR IT S EQUIVALENT 15 LADDER WIRING DIAGRAM STANDING PILOT 120 60 1 POWER SUPPLY OVERCURRENT PROTECTED DISCONNECT 120 VAC PRIMARY 1 01 2 01 gt lt RVGP KS BKF VENT DAMPER STAT P1 02 P2 05 x18 gt lt HIGH LIMIT MICROPROCESSOR FLAME ROLLOUT SAFETY SHUT OFF BLOCKED VENT SAFETY SHUT OFF GAS VALVE VRB8200A NR8300A NOTE MAIN POWER STATUS LIGHT 1 AND 51 ARE THE AUTOMATIC OPERATION HOLD DAMPER OPEN SWITCH vet SWITCH SHOWN IN AUTOMATIC POSITION CALL FOR HEAT CIRCULATOR PUMP STATUS LIGHT 2 53 AND 4 CAM ACTUATED SNAP SWITCHES GAS VALVE BURNER STATUS LIGHT 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 16 EQUIPMENT AND OPTIONAL ACCESSORIES 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 wil 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 dam
17. 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 Sears Roebuck and Co Hoffman Estates IL 60179 U S A Gas Fired Cast Iron HOT WATER BOILER e Installation e Operation e Repair Parts WARING 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 2 PIV OVI T Y PT EY PL ET TEL TY TY EN Y SEARS x KENNMORE CAST IRON BOILERS FULL ONE YEAR WARRANTY ON HOT WATER AND GAS STEAM CAST IRON BOILERS For 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
18. ROUBLE SHOOTING SYMPTOM POSSIBLE CAUSE ACTION Boiler is cold No Power Check all wiring and cable connections Check the circuit breaker or fuse and if necessary reset or replace Defective Thermostat or thermostat Short the W R terminals on the wiring L7148F Aquastat Control If the system starts check the thermostat and low voltage wiring Defective transformer Check for 24V at R C If no voltage replace the transformer Defective Ignition module 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 when used with vent damper damper and L7148F Aquestat control L7148F Aquastat Control in reset L7148F Aquastat Control detects an Verify proper Sensor connections at mode error the immersion well and L7148F Aquastat Control 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 L7148F Aquastat Control high limit Incorrect sensor location Follow the boiler manufacturer switch shuts off the boiler before the recommendations for proper location water temperature reaches the high L7148F Aquastat Control temperature Reset
19. SFORMER ITEM 414662046 ITEM 414562025 NOTES THE ITEM NUMBERS FOR THIS PART CORRESPOND AS FOLLOWS 73506 107343 SECTION THE LAST NUMBER INDICATES THE SIZE BOILER INTERMEDIATE PANEL NUMBERS 235001075 THROUGH 735001079 SEE NOTE 5 t 3 87 HOLE INSERT REQUIRED WIRING 5 8 OA HOLE INSERT REQUIRED WIRING COVER PANEL CONTROL BOX ASSEMBLY 10 X 3 8 SHEET SCREW 414595075 1 2 TABS COVER PANEL ITEM g 45500550 MOLEX CONNECTOR FEMALE 57 PC CORRUGATED 5 LUME TUBIMG 414654020 INTERMEDIATE PANEL VENT SWITCH VENT WIRE LEADS MOLEX CONNECTOR MALE WIRRING HARNESS PARTS CONTINUED GAS TRAIN NATURAL 172 GR 374 X 90 STREET ELL 142 ITEM 14693801 3 4 TEM 14693040 1 9 OR 374 CLOSE NIPPLE 1 27 ITEM 14607030 3 4 ITEM 8 14607031 1 2 OR 3 4 UNION 172 ITEM amp 14693043 3 4 ITEM 14693044 PWX 7 MANIFOLD FOR PARTS 1 7 SEE REPAIR PARTS TABLE BELOW NATURAL GAS BURNER AND MANIFOLD ASSEMBLY NATURAL GAS DESCRIPTION 3SECTION 4SECTION 5 SECTION 6 SECTION 7 SECTION 8 SECTION 9 SECTION 146 62 051 146 62 051 146 62 051 146 62 060 146 62 060 146 62 060 146 62 060 146 15 005 146 15 005 146 15 005 146 15 005 146 15 005 146 15 006 146 15 006 146 95 307 146 95 307 146 95 307 146 95 307 146 95 307 146 95 307 14
20. age 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 t
21. 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 496 for each 1 000 feet ibove sea level Consult the National Fuel Gas Code NFPA54 ANSI Z223 1 latest edition or the manufacturer for correct orifice sizing information High altitude orifices are available from the boiler manufacturer Before You Start Check to be sure you have the right size boiler before starting the installation See rating and capacity table on previous page Also be sure the new boiler is for the type of gas you are using Check the rating plate on the right side of the boiler You must see that the boiler is supplied with the correct type of gas fresh air for combustion and a suitable electrical supply Also the boiler must be con nected to a suitable venting systern and an adequate piping system Finally a thermostat properly located is needed for control of the heating system if you have any doubts as to the various requirements check with local authorities and obtain professional help where needed Take the time to complete all of the steps for SAFE and PROPER operation of the heating system If this boiler is installed a building under construction special care must be taken to insure a clean combustion air supply during the construction process Airborne particulat
22. ank 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
23. apacities ASME VALVE VENT DAMPER TEMP PRESS GAUGE 1 SUPPLY peg 1 NIPPLE RIGHT SIDE Continuous Pilot With Vent Damper AGA CGA HEATING m capacity MBH MBH Rating MBH DIAMETER WIDTH BASIC BOILER MODEL NO BE Axa Rm NATURAL GAS DIMENSIONS INCHES MBH 1 000 Btuh Btuh British Thermal Unit Per Hour For altitudes above 2 000 ft ratings should be reduced at the rate of 4 for each 1 000 ft above sea level Heating Capacity is based on D O E Department of Energy test procedure Add 5 4 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 Hydronics 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
24. d with those products Check Circulator Pump running Yes Check vent damper cable and connections Replace vent damper cable or damper as appropriate Check room thermostat ts it still set at 10 above current room temperature Boiler shuts off at high limit setting 120 vac at C1 C2 No L7148F Control failure incapable of self diagnostics L7148F is OK Boiler shuts off above high limit setting Check other system components Circulators Zone Valves Yes No Below HL Check Temperature Pressure gauge accuracy Check L7148F diagnostic LED Flashing Sensor fully inserted into well Thermo Well in good condition Thermo Well located per boiler OEM recommendations Reset thermostat and repeat voltage check Yes Check Two blinks replace sensor Temperature Pressure gauge accuracy Three or four blinks replace control Thermo Well located per boiler OEM instructions 34 Kenmore OWNER S MANUAL CONTINUOUS PILOT MODEL NO KWX KWX 4V KWX 5V KWX 6V KWX 7V KWX 8V KWX 9V Sears Roebuck and Co Hoffman Estates IL 60179 U S A 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
25. e return main to the boiler This provides positive and rapid response to the thermostat FILLING 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 For Your Safety Read Before Operating WARNING If you do not follow these instructions exactly a fire
26. ease 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 mantel with no yellow Puffs of air from blowing on the flame or stamping on the floor will 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 Type of Heating Unit Limit Control Setting Standing Radiators Baseboard and Convector Radiators 22 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 F 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 bo
27. er supply is available When the water supply is from a well or pump a sand strainer should be installed at the pump hot waler boiler installed above radiation level must be equipped with a low waler cutoff device A periodic inspection is necessary as is flushing of float type devices per manufacturers specific instruction FOR USE WITH COOLING UNITS This boiler when used in connection with chilled water systems must be installed so that the chilled water is piped in parallel with the heating boiler Appropriate valves must be used to prevent the chilled water from entering the heating boiler Fig 6 B When this boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation the pip ing system shall be equipped with flow control valves or other automat ic means to prevent gravity circulation of the boiler water during the cool ing cycle LOW DESIGN WATER TEMPERATURE SYSTEMS BELOW 140 If the boiler is to be used in a heating system where design water tempera tures below 140 F are desired e g radiant floor heating a 3 way or 4 way mixing valve or suitable alternative is required to prevent low temperature return water from entering the boiler Foltow the mixing valve manufacturer s installation instructions The minimum design return water temperature to the boiler to prevent con densation in the boiler and venting is 120 The minimum high limit
28. es such as from drywall dust and from fiberglass insulation can clog the burner ports and cause incomplete combustion and sooting Where required by the authority having jurisdiction the installation must con form to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers No CSD 1 The installation must conform to the requirements of the authority haying jurisdiction in the absence of such requiremenis to the National Fuel Gas Code ANS Z223 1 latest revision Installers Follow locat regulations with respect to installation of CO detectors Follow maintenance recommendations in this instruction manual Techniciens Veuillez vous conformer la r glementation en vigueur concernant 1 installation des d tecteurs d oxyde de carbone Suivre les consignes d entretien figurant dans manuel dinstruction cijoint KEEP BOILER AREA CLEAN AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS Locating the Boiler 1 Select level location as centralized with piping system and as near chim ney as possible 2 Place crated boiler at selected tocation remove crate by pulling crate sides from top and bottom boards Combustible floors When boiler is to be installed on a combustible floor a Special Base Plate must be used 146 14 031 2 6 Section or 146 14 032 7 9 Section This boiler must not be installed on carpeting 3 Boiler is
29. function 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 vaive 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 23 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 o
30. he unit 5 If the unit is removed from the place it was originally installed this Warranty becomes void 6 Damage to the unit caused by accident abuse negligence misuse riot fire flood or acts of God SEARS ROEBUCK AND COMPANY D 817WA Hoffman Estates iL 60179 Rules for Safe Installation and Operation check connections This will avoid any possibility of fire Read the Owner s Manual for Safe Operation carefully Faiture 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 codes 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 This will prevent any electrical shocks or burns 4 Never test for gas leaks with an open flame Use soap and 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 8 Follow a regular service and maintenance schedule for efficient and safe operation Boiler Ratings and C
31. iler 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 Finally 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 Maintaining Your Boiler 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 mal
32. l be permitted where the equipment has clearance of at Provision for combustion and ventilation air must be in accordance with Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI 2223 1 latest revision or applicable provisions of the local building codes NOTE If you use a fireplace or a kitchen or bathroom exhaust fan you should install an outside air intake These devices will rob the boiler and water heater of combus tion least 1 inch from the s des and back and 6 inches from the front of the appliance The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the out doors or spaces crawl or attic that freely communicate with the out doors and shall have a minimum free area of a 1 sq inch per 3000 Btu per hour of the total input of aH equipment located in the enclosure See Figure 4 and b Not less than the sum of the areas of all vent connectors in the con fined space Figure 3A FRESH AIR DUCT CAPACITIES Btuh 1 Square Inch per 4 000 Btuh 10096 Free 75 Free 2596 Free Area Area Area Mes Louvers Figure 3B FRESH AIR DUCT CAPACITIES Btuh 1 Square Inch per 2 000 Btuh 10096 Free 7596 Free 2595 Free Area Area Area Mesh Louvers Louvers Figure 4 FRESH AIR DUCT CAPACITIES Btuh 1 Square Inch per 3 000 Btuh 10096 Free 7596 Free 2596 Free Area Area Area Fresh Air ya Wire Metal Wood D
33. lace that used by the burner Study following examples 1 and 2 to determine your fresh requirements EXAMPLE 1 Boiler Located in Unconfined Space 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 rating of all appliances installed in that space If your boiler is in an open area unpartitioned basement in a conventional house the air that leaks through the cracks around 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 Equipment located in buildings of unusually tight construction shalt be pro vided with air for combustion ventilation and dilution of flue gases using the methods described in example 2B or shall be specially engineered The authority having jurisdiction must approve specially engineered installa tions EXAMPLE 2 Boiler Located in Confined Space All Air from Inside the Building The confined space shall be pro vided with two permanent openings communicating directly with an addi tional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space The total input of alt gas utilization equipment installed in the combined space shall be con sidered in making this determination Each opening shall have a mini mum free area of one square inch per 1 000 Btu per hour of the total inp
34. nce 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 outor 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
35. ng 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 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 vent ng system and chimney for blockage when restoring the system to operating condition DO NOT operate the boiler without a spill switch STARTING YOUR BOILER 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 th
36. ntroller down again and check thatthe 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 troubleshooting 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 FIG 11 EFFIKAL VENT DAMPER POSITION INDICATOR w NOILY LOH Mz NOI Y1OM MO 5 9 INIA 035012 uo 3 z z 2 2 nh a o DAMPER CLOSEO DAMPER OPEN SHOWING OPEN AND CLOSED POSITION Gas Supply Piping CHECK GAS SUPPLY The gas pipe to your boiler must be the correct size for the length of the run and for the total Btu per hour input of all gas utilization equipment connected to it See Fig 12 for the proper size Be sure your gas line complies with local codes and gas company requirements The boiler and its individual shutoff val
37. 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 e PART NUMBER MODEL NUMBER PART DESCRIPTION NAME OF ITEM All parts listed may be ordered from any Sears Service Center If the parts you need are not stocked locally your order will be electronically transmitted to a Sears Repair Parts Distribution Center for handling When Sears arranges the installation you can be sure the Job is done right We will arrange for professional workmanship and we ll take care of the entire project What s more during installation you get insured protection against property damage and also against accidents to workmen All you have to do is talk to your nearest Sears store today for detailed information
38. ot 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 for heat each componenti must be functioning properly to permit operation On safety lockout the system has to be reset by turning the thermostat to the lowest setting for one minute then back to the normali 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 revision FIG 14 LIGHTING PILOT PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW GROUND YERMINALS 2 LOT ADJUSTMENT UNDER CAP SCARE W FIG 15 VR8200A VR8300A AUTOMATIC GAS VALVE PRESSURE REGULATOR CONVENIENCE ADJUSTMENT TERMINALS UNDER CAP SCAE OPTIONAL IRING TERMINALS 2 OUTLET PRESSUPK TAP INLET PRESSURE PLOT OUTLET PILOT ADJUSTMENT UNDER CAP SCREW THERMOCOUPLE CONNECTION E GAS BUTTON CONTAOL VALVE 625 KNOS OUTER MANTEL SHARP INNER CONES Checking and Adjusting 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 incr
39. ot the Key No and the Description of each part from the following illustrations and list Be sure to give us all this information Part No The Part Description The Boiler Model No JACKET SECTION AND BASE PARTS THIS IS A REPAIR PARTS LIST NOT A PACKING LIST fum NATURAL GAS NO DESCRIPTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 SECTION 9 SECTION PART NO PART NO PART NO PART NO 735001050 14695074 14694016 14614130 14614118 14614128 735001050 14695074 14694016 14614130 14614116 14614126 735001050 14695074 14694016 14614130 14614117 14614127 735001050 14695074 14694016 14614130 14614119 14614129 735001050 14695074 14694016 14614130 14614115 14614125 735001050 14695074 14694016 14614130 14614113 14614123 735001050 14695074 14694016 14614130 14614114 14614124 Jacket Right Side Panel 10 x V2 Sheet Metal Screw Rating Plate Base Insulation Base Sides 2 Base Front Base Rear Base Baffle 42500643 42500644 42500645 42500646 42500647 42500648 4250
40. pe 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 Ya 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 34 the 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 The thimble should be 4 inches larger in diameter than the vent pipe FIG 7 TYPICAL CHIMNEY SIZES Boiler Input Btuh HT HT HT 10 15 Ft 15 25 Ft 25 Ft Up Up to 100 000 6x6 6x5 5x5 Up to 155 000 6x7 6x6 6x5 Up to 230 000 7x8 7x7 6x7 Up to 350 000 9x9 8x9 8x8 HT top of thimble to top of flue See Fig 8 For boiler input refer to table page 2 For information only not meant to imply minimum sizes MINIMUM VENT PIPE CLEARANCE Wood and other combustible materials must not be closer than 6 from any surface of single
41. pen flame to test for leaks 10 FIG 12 GAS PIPE SIZES Pipe Capacity BTU Per Hour Input Length of Includes Fittings Pipe Ft ee tu 625 000 445 000 365 000 7m ooo ao 245000 sos tsooo The length of pipe or tubing should be measured from the gas meter FIG 13 GAS PIPING AT BOILER MANUAL SHUT OFF VALVE AUTUMATIC GAS VALVE SEDIMENT TRAP FLOOR LINE ELECTRICAL WIRING WARNING TURN OFF ELECTRICAL POWER AT FUSE BOX BEFORE MAKING ANY LINE VOLTAGE CONNECTIONS FOLLOW LOCAL ELECTRICAL CODES electrical work must conform to local codes as well as the National Electrical Code 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 off position and the power turned off at 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 service 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 electrically grounded in accordance with the requirements of the authority having jurisdiction o
42. r in the absence of such requirements with the National Electrical Code 70 latest revision In Canada electrical wiring shall comply with the Canadian Electrical Codes CSA C22 1 and 2 Run a 14 gauge or heavier copper wire from the boiler to a grounded connection in the service panel or a properly driven and electrically grounded ground rod INSTALL YOUR THERMOSTAT The thermostat location has an important effect on the operation of your boiler system BE SURE TO FOLLOW THE INSTRUCTIONS INCLUDED WITH YOUR THERMOSTAT Locate the thermostat about five feet above the floor on an inside wall It may be mounted directly on the wall or on a vertical mounted outlet box It should be sensing average room temperature Avoid the Following DEAD SPOTS COLD SPOTS HOT SPOTS Behind doors Concealed pipes or ducts Concealed pipes Lamps Corners and alcoves Stairwells drafts Fireplace Direct sunlight Unheated rooms on TV sets Kitchens other side of wall Radios 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 opera
43. set ting is 140 F CAUTION THE tSOLATION BALL VALVES CONTAIN TEFLON SEATS AND SEALS OVERHEATING THIS VALVE MAY CAUSE PREMATURE FAILURE FIG 5 TYPICAL HOT WATER PIPING SUPPLY MAIN PUAGER FULTROL TANK LIMIT CONTROL RETURN LINE VALVES A amp B OPEN FOR HEATING CLOSE FOR COOLING VALVES C amp D CLOSE HEATING OPEN FOR COOLING Chimney and Vent Pipe Connection CHECK YOUR CHIMNEY This is a very important part of your heating system It must be clean the right size properly constructed and in GOOD CONDITION No boiler can function properly with a bad chimney Fig 7 gives typical chimney sizes Fig 8 gives you an idea how a boiler might be vented to a chimney Note that the height HT is measured from the vent pipe to the top For boiters for connection to gas vents or chimneys vent installations shall be in accordance with Part 7 Venting of Equipment of the Nationai Fuel Gas Code ANSI Z223 1 latest revision and applicable provisions of the local building codes CHIMNEY SIZING Chimney sizing and all other aspects of the vent installation must be in accordance with Part 7 of the National Fuel Gas Code ANSI 2223 1 latest revision and applicable provisions of the local building codes In Canada follow CSA B149 1 and B149 2 Installation Codes for Gas Burning Appliances and Equipment CONNECTING THE VENT DAMPER AND VENT CONNECTOR Refer to Fig 1 flue diagram for the
44. t provide a low limit function An external transformer AT150 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 L7148F 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 1409 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 causi
45. te 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 FIELD WIRING CONNECTIONS FIG 13 1 120 VOLT CIRCULATOR 24 YOLT THERMOSTAT NEUTRAL G E GROUND POWER SUPPLY THIS PAGE INTENTIONALLY LEFT BLANK THIS PAGE INTENTIONALLY LEFT BLANK SCHEMATIC WIRING DIAGRAM STANDING PILOT 24 VOLT TRANSFORMER GROUNO 115 POWER suppuy GAS VALVE VRB200A NRB 300A CIRCULATOR t UMP 24V THERMOSTAT WIRE CODE COLOR COOE MAIN POWER STATUS LIGHT 5555559 DAMPER CABLE BK BLACK BR BROWN LINE VOLTAGE P PINK LINE VOLTAGE 4 SM GAS VALVE BURNER STATUS LIGHT FIELD WIRING LOW VOLTAGE G GREEN LOW VOLTAGE GY GRAY FIELD WIRING CALL FOR HEAT CIRCULATOR PUMP STATUS LIGHT IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST REPLACED IT
46. tting 10 11 12 13 TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Push in gas control knob slightly and turn clockwise w to OFF Do not force Operating Your Boiler 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 hold the gas supply from burner regardless of the demand of any other control SAFETY PILOT Safety Pilot prevents the flow of gas to burner if the pilot goes out or will not ignite GAS VALVE SAFETY SHUTDOWN TEST 1 For boilers equipped with continuous pilot with main burners firing disconnect the thermocouple from the gas valve The gas valve should immediately shut off the main burners and the pilot 2 For boilers equipped with intermittent ignition with main burners firing disconnect the ignition cable from the intermittent pilot control box The gas valve should shut off the main burners TURN OFF ELECTRIC POWER to boiler before reconnecting ignition cable to prevent electric shock 21 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 n
47. uct Size Mesh Louvers Louvers 108 000 81 000 27 000 8 x 12 288 000 216 000 72 000 8 x 16 384 000 288 000 96 000 Fresh Air Duct Size 3 x 12 8 x 8 8 x 12 8 x 16 Installation System Piping 1 Place boiler in the selected location as near chimney as possible Your boiler is shipped assembled You need only to install the Relief Valve and a drain line to carry any water or steam lo a drain 2 Install Relief Valve into the 3 pipe on the top of the boiler See Figure 5 Use 34 Pipe and an elbow not furnished to carry the water or steam to a nearby drain Do nol 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 safety valves and the atmosphere Installation of the safety relief valve shall conform to the requirements of the ANSI ASME Boiler and Pressure Vessel Code Section iV The manufacturer is not responsible for any water damage Install Drain Valve in lower left side of boiler as marked 3 Connect Supply and Return Lines to boiler The connections may require certain additional fittings and parts as shown on diagram Figs 5 and 6 4 This boiler is equipped with 14 supply and return connections on both the left and right sides of the boiler In connecting the cold water supply to the water inlet valve make sure that a clean wal
48. urn off all electric power to the appliance Remove lower front panel Rotate gas control knob slightly and turn clockwise w to OFF gi Cono GAS CONTROL KNOB SHOWN IN ON POSITION f 6 2 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 t smell gas go to next step 7 Find pilot follow metal tube from gas control The pilot is between two burner tubes as shown in Fig 14 8 Turn knob on gas control counterclockwise to PILOT Continuous Pilot Boiler VR8200A VR8300A Gas Valve Operating Instructions 9 Rotate the gas control knob counterclockwise ye 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 ht If it goes out turn gas control knob clockwise m to OFF To relight repeat steps 5 9 f button does not pop up when released stop and immediately call your service technician or gas 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 After pilot remains lit when red reset button is released turn gas control knob counterclockwise je to ON Replace lower front panel Turn on all electric power to the appliance Set thermostat to desired se
49. ut rating of all gas utilization equipment in the confined space but not less that 100 square inches One opening shail be within 12 inches of the top and one within 12 inches of the bottom of the enclosure The minimum dimension of air openings shall not be less than 3 inches B Ail Air from Outdoors The confined space shall communicate with the outdoors in accordance with methods 1 or 2 The minimum dimension of air openings shall not be less than 3 in Where ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect 1 Two permanent openings one commencing within 12 inches of the top and one commencing within 12 inches of the boltom of the enclo Sure shall be provided The openings shal communicate directly or by the ducts with the outdoors or spaces crawl or attic that freely com municate with the outdoors a Where directly communicating with the outdoors or where commu nicating to the outdoors through vertical ducts each opening shali have a minimum free area of 1 sq in per 4000 Btu per hour of total input rating of all equipment in the enclosure See Figure 3A b Where communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 sq in per 2000 Btu per hour of total input rating of all equipment in the enclosure See Figure 3B 2 One permanent opening commencing with 12 inches of the top of the enclosure shal
50. ve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of Ve psig 3 5 kPa The boiler must be isolated from the gas supply piping system by closing its individua manual shutoff vaive during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig 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 latest 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 pipe 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 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 o
51. 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 tothe common venting system placed in operation while the other appliances remaining c nnected 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
52. 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 PUN XI ATRIA AAA AR ANA M ARAL AD ARAL ANYUT NUWUN WUWU UU JU UV UU T UA UU UA UN IMPORTANT The following are the responsibilities of the user and are not covered by the Warranty 1 Filter clearing 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 t
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