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Owner'sManual
CONTINUOUS
PILOT
MODEL N O.
229.960330
229.960340
229.960360
229.960360
229.960370
229.960380
229.960390
ELECTRONIC
INTERMITTENT
IGNITION
MODEL NO.
220.960230
229.960240
229.960260
229.960260
229.960270
229.960280
229.960290
These instructions mustbe affixed
onor adjacent t o the boiler.
CAUTION
Readall instructions carefully
beforestartingtheinstallation.
Save this manual
for future reference.
®
Gas-Fired
Cast Iron
STEAM
BOILER
• Installation
• Operation
• RepairParts
WARNING:
Improper
installation, adjustment,
alteration,
service or
maintenance can cause injury or property damage. Refer to this manual.
For assistance
or additional
information consult a qualified
installer,
service agency or the gas supplier. Natural gas boilers are not to be
converted to Propane gas.
PRINTED
IN U.S.A.
FOAM e37-_00-02_02-6"7949

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   Summary of Contents for Kenmore 229.960330

  • Page 1

    ® Owner'sManual CONTINUOUS PILOT MODEL N O. 229.960330 229.960340 229.960360 229.960360 229.960370 229.960380 229.960390 ELECTRONIC INTERMITTENT IGNITION MODEL NO. 220.960230 229.960240 Gas-Fired 229.960260 Cast Iron 229.960260 229.960270 STEAM 229.960280 BOILER 229.960290 • Installation These instructions mustbe affixed • Operation onor adjacent t o the boiler. •...

  • Page 2

    Warranty ............ Electrical Wiring ..........Rules for Safe Installation and Operation ....Controls and Accessories - What They Do ....Boiler Ratings and Capacities ......For Your Safety - Read Before Operating ....Before You Start ..........Operating Your Boiler ........Locating the Boiler .........

  • Page 3

    1. Read the Owner's Manual carefully Failure to fallow the 5. Be certain your new boiler will be using the correct gas. rules for safe operation and the instructions can cause Overfiring will result in premature failure of the boiler a malfunction of the boiler and result in death, serious sections and cause dangerous operation.

  • Page 4

    VENT DAMPER ASME PRESSURE LIMIT 43/,= . RESSURE 261/=" GAUGE SAFETY ONTROL VALVE SWITCI-€ 2'/2" NPT _ ", WATER LiNE -- 29" SPILL PROBE ROLLOUT 36_e" CUT'OFF -SWITCH 24" A .._ UNE DESIGN CERTIFIED FRONT RIGHT SIDE LEFT SIDE NATURAL GAS-FIRED STEAM BOILERS "[h_TURALG/_...

  • Page 5

    Checkto besureyouhavetherightsizeboilerbeforestartingtheinstallation. 100% make-upwater.Damage to the boiler resulting from such use shall See rating and capacitytable on previouspage. Also be sure the new not be coveredunderthewarranty boiler is for the type of gas you are using. Checkthe ratingplate on Whererequiredby the authorityhavingjurisdiction,the installationmust the rightsideof theboiler.

  • Page 6

    Provision for combustion and ventilation air must be in accordance with Section 5.3, Air for Combustionand Ventilation, of the National Fuel Gas Code, ANSI Z223.1-1atest revision, or applicable provisions of the local building codes. WARNING NOTE Be sure to provide enough fresh air for combustion. If you use a fireplace or a kitchen or bathroom exhaust fan, you should install an outside air intake.

  • Page 7

    The near boiler piping, that is the piping around the boiler, or on discharge pipes between such safety valves and must be considered as part of the boiler for proper water the atmosphere. Installation of the pop safety valve shall level control, and to produce dry steam.

  • Page 8

    5. For installers choosing to use both supply tappings, Figure 7. All boilers in gravity return systems must be equipped 6A shows the correct way to pipe this system. Figure with a Hartford Loop as shown in Figures 5 and 6A. 6B shows the wrong way to pipe a header with two risers.

  • Page 9

    THIS PIPING CONFIGURATION WRONG WAY DO NOT BULLHEAD,USE IS INCORRECT TO SHOW TWO TAKEOFFS COMMON MISTANES WRONG WAY TAKE OFFS MUST BE BETWEEN RISER & EQUALIZER WRONG WAY SWING JOINTS ARE MISSING )NG WAY MISSING TEE FOR SKIMMING 12. The near boiler piping shall include a 1V2" ball valve B.

  • Page 10

    In accordance with Part 7, VenUng of Equipment, of the National Fuel Gas Code, For boilers for connection to gas vents or chimneys, vent installations shall be ANSI Z223.1-1atest revision and applicable provisions of the local building codes. CHECK YOUR CHIMNEY 7.

  • Page 11

    4 Place in operation t heappliance beinginspected. Follow the lightinginstructions. Adjustthermostat so appliance willoperate continuousl_z 5. Testfor spillage atthe drafthoodreliefopening after5 minutes o fmainburner o peration. Use theflame ofa match or candle, or smoke froma cigarette, cigaror pipe 6. Afterit hasbeendetermined t hateachappliance remain- ing connected to the common ventingsystem properly vents when testedas outlinedabove,return doors, ROOF...

  • Page 12

    For safe, efficient operation, the vent damper and all flue thermostat will control the burner firing as before, while the product carrying areas of the appliance must be checked damper will remain open. DO NOT turn damper open manu- annually by you, with particular attention given to deterioration ally or motor damage will result.

  • Page 13

    NATURAL GAS Pipe Capactty- BTU Per Hourlnput Length of Includes Fittings MANUAL SHUT-OFF Pipe - Ft. ½" ¾" 1" 1%" VALVE 92,000 190,000 350,000 625,000 AUTOMATIC 63,000 130,000 245,000 445,000 VALVE 50,000 ! 05,000 195,000 365,000 GROUND JOINT MANIFOLD UNION S OI.ENTTRAP FLOOR LINE...

  • Page 14

    probetypelowwatercutotis,thismayoccureachtimethe lowwatercutoffdetects a lowwaterconditionIf thisis the case, a n isolation relayis required forthethermostat circuit A24voltsinglepolesingle throw(SPST) normally o pen(N.O.) relay _s required,such as the HoneywellR8222Aor VENT DAMPER equivalent. Wireasshown in Fig.14Aor Fig.14B. VENT DAMPER MOLEX PLUG 24V. -ISOLATION RELAY The boiler is equipped with a factory wired harness with 4 SPST N+O.

  • Page 15

    EFFIKAL RVGP VENT OA,_PER INTERMITTENT IGNITION MOLEX PLUG I 15V/BOHZ/I f pOWER SUPPLY r -l_ \/ j\®/ ..iiii _____.j'--" OP_ONAL WF-2U-2_. WATi_ _"l{EOER NOTE: T_¼1N_. ] APpFJ_R$ ONLy Wt_RMRTF'NT pIL'OT CONTRCt _LWC 0 pRoBE ON WATER FEEC_R MODELS WITH tJXNL_I.

  • Page 16

    STANDING PILOT EFFIKAL RVGP V_NT DAMPER MOLEX PLUG HeVI_OHZll m pOW_ SUpPLy PRESSURE UMIT _SO3NNECT r ..', IQ-÷ ..I_@-4 L_X=/___J- .._--WIRE COLOR CODE 8X-B_ BR-E_ROWN 0 -ORANGE OPI1ONAL _-2U--:14 -YELLOW W_TER R -RED REED_ BT-B_ VCh'H TRACER NOTE: W -WHITE G -GREEN...

  • Page 17

    INTERMITTENT IGNITION EFFIKAL RVGP VENT DAMPER MOLEX PLUG VOLT TRANSFORMER 115V/BOHZ/I_ POWER SUPPLY .oT-_Jo-. _ 0V£RCURRENT PROTECTED DISCONNECT NEUT pR_SSURC LIMIT ..OPTIONAL WF-2U-24 WAFER FEEDER NOTE: FLAME ROLLOUI TERMINAL NO. 3 APPEARS ONLY I_-- WIRE WATER FEEDER MODELS WITH MANUAL FEED PUSH BUTTON...

  • Page 18

    STANDING PILOT EFFIKAL RVGP VENT DAMPER MOLEX PLUG VOLT TRANSFORMER IIBV/6OHZ/I¢ POWER SUPPLY ._----_--_ OVERCURRENT PROTECTED DISCONNECT NEUT PRESSURE LIMIT LOW WATER OPTIONAL WF-2U-24 CUT OFF WATER FEEDER VALVE NOTE: TERMINAL NO. 3 APPEARS ONLY ON WATER FEEDER MODELS WITH MANUAL FEED PUSH...

  • Page 19

    POP SAFETY VALVE WATER FEEDER (Optional) The pop safety valve should open automatically if the boiler The Model WF-2U-24 water feeder may be used with either steam pressure exceeds the pressure rating of the valve (15 of the available low water cut-offs. The water feeder's job is to maintain a safe minimum water level It's used to psig).

  • Page 20

    WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. Some boilers are equipped with an intermittent ignition • Immediately call your gas supplier from a neighbor's device which automatically lights the pilot.

  • Page 21

    1. STOP! Read thesafety information onpage16. 9 Rotate the gas control knob counterclockwise "PILOT" Push down and hold the red reset button while 2. Setthethermostat to lowest s etting. you light pilot burner with a match. 3. Turnoffallelectricpower t otheappliance. After about one minute, re[ease reset button.

  • Page 22

    HOW A STEAM SYSTEM OPERATES THERMOSTAT The water in the boiler is heated until it reaches the boiling Keep it set at a desired room temperature. If windows are point. As the water boils it turns into steam. The steam rises to be opened or heat is not needed, move thermostat pointer from the top of the water through the supply main to the to a lower setting.

  • Page 23

    ADJUST PILOT BURNER differential adjustment at 1 psi, i.e. the steam pressure required in the radiators. This will give us a cut-off setpoint Pilot flame should surround 3/8' to 1/2" of the pilot sensor. of 11/2psi. Refer to Fig. 19. If flame needs adjusting, do it as follows: The above is an example of a typical one pipe system.

  • Page 24

    drop the pressure setting until the boiler shuts down. This will show that the pressure limit is operating properly Refer to control manufacturer's instructions (enclosed} for 3/8" to 1/2" more information. Check thermostat operation. When set above temperature indicated on the thermometer, boiler should ignite.

  • Page 25

    Check thewater level every d ay ortwo. V erify t he water line shown by CLEANING YOUR BOILER FLUE PASSAGES operating thedrain valve onthegauge. BESURE TOP AND BOTTOM AND BURNERS VALVES ON GAUGE ARE A LWAYS OPEN SO THAT ACTUAL WATER LEVEL FluePassages betweensectionsshouldbe examined yearlyandcleaned,...

  • Page 26

    You may avoid inconvenience and service calls by checking these points before you call for service. FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS 1. Do Not try to light any appliance. 2. Do not touch any electric switch, do not use the phone. 3.

  • Page 27

    GAS-FIRED STEAM 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 No. (not the Key No.} and the Description of each part from the following illustrations and list.

  • Page 28

    FOR USE WITH NATURAL GAS ONLY NOTE: Actual gas valve may look different than gas valve shown BURNERS MANIFOLD PARTS THIS iS A REPAIR PARTS LIST - NOT A PACKING LIST 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 SECTION 8 SECTION 9 SECTION DESCRIPTION...

  • Page 29

    BOILER CONTROLS AND PIPING PART DESCRIPTION 146-22-002 ¾' Pop Safety Valve 146-93-053 %" Coupling 146-07-002 Y," x 6W' Nipple 146-23-005 Steam Pressure Gauge 146-93-054 '/4' Coupling 146-07-301 YY x 3" Nipple 146-62-045 AT-140D Transformer, 24 Volt PA-404A Pressuretrol 146-62-015 146-22-005 Glass Water Gauge Set (used with PS-802 LWCO) 146-22-010 Glass Water Gauge Set (used with 67D-1 LWCO)

  • Page 30

    ElectronicIgnition ® Owner'sManual Gas-Fired Cast Iron CONTINUOUS PILOT MODEL NO. STEAM 229.960330 BOILER 229.960340 229.960350 229.960360 Now that you have purchased your Boiler, should a need 229.960370 ever exist for repair parts or service, simply contact 229.960380 Sears Service Center. Be sure to provide all pertinent facts when you call or visit.

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