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Gas-Fired
Cast Iron
HOT WATER
BOILER
• Installation
• Operation
• RepairParts
WARNING: Improper installation, adjustment, alteration, service or
maintenance
can cause injury or property damage. Refer to this
manual. For assistance or additional information consult a qualified
installer, service agency or the gas supplier.
PRINTED
IN U,S,A.
FORM 608-500-1/01-56519

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   Summary of Contents for Kenmore 229.960041

  • Page 1

    Gas-Fired Cast Iron HOT WATER BOILER • Installation • Operation • RepairParts WARNING: Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency or the gas supplier. PRINTED IN U,S,A.

  • Page 2

    KENNMORE CAST IRON BOILERS FULLONEYEARWARRANTY O NHOTWATER ANDGASSTEAM CASTIRONBOILERS 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.

  • Page 3

    ASME AQUASTAT TEMR/PRESS.GAUGE RELIEF VENT DAMPER VALVE I7," SUPP_ _ I ['-- 1 '/4" RETURN -- -- --]-._._ _ -I I rV/NPT CH" ® L____ 231/4 ROLLOLIT DRAIN VALVE IN]_ PILOT CONTROL SWITCH VALVE LEFT SIDE FRONT RIGHT SIDE GAS-FIRED HOT WATER BOILERS BASIC BOILER UNIT N(_ NATURAL GAS DIMENSIONS...

  • Page 4

    Check to besureyouhavetherightsizeboilerbeforestarting the installation. Where required bytheauthority havingjurisdiction, t heinstallation mustcon- Seeratingandcapacity tableon previous page. A lsobe surethenewboileris formto American Societyof Mechanical E ngineers S afety Codefor Controls forthetypeof gasyouareusing.Check theratingplateontherightsideofthe andSafetyDevices f or Automatically F iredBoilers, N o.CSD-1. boiler.

  • Page 5

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

  • Page 6

    installationinstructions. 1. Placeboiler in lhe selected location(asnearchimney as possible.) Y our boiler is shipped assembled. Y ouneedonlyto installIheBeliefValve and Theminimumdesignreturnwatertemperature t othe boilerto prevent c on- a drainline to carryanywateror steamto a drain. densation in the boilerandventingis 120 ° E Theminimumhigh limit set- tingis 140 °...

  • Page 7

    CONNECTING THE VENT DAMPER AND VENT CONNECTOR Refer to Fig. 1 flue diagram for the size and location of the FLUE AREA IN INCHES Boiler Input vent (flue opening). Use a 28 gauge (minimum) galvanized Btuh *HT. *HT. *HT, pipe to connect to the chimney 15-25 Ft.

  • Page 8

    7. Any_mproper operation of the common ventingsystem shouldbecorrected sotheinstallation c onforms w iththe National Fuel G as Code, ANSI Z 2231-latest revision When resizing anyportion of the common venting system, t he common venting system shouldbe resized to approach the minimum sizeas determined usingthe appropriate tablesin Part11 in the National FuelGasCode,ANSI Z223.1-latest revision.

  • Page 9

    For safe, efficient operation, the vent damper and all flue For further information, and for a vent damper troubleshooting product carrying areas of the appliance must be checked guide, refer to the Effikal manual that was packaged with annually by you, with particular attention given to deterioration the vent damper.

  • Page 10

    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 NATURAL GAS gas utilization equipment connected to it. See Fig. 12 for Pipe Capacity - BTU Per Hour Input the proper size.

  • Page 11

    All electrical work must conform to local codes as well as a vertically mounted outlet box. It should be sensing average the National Electrical Code, ANSI/NFPA-70, latest revision. room temperature, so avoid the following: DEAD SPOTS: ELECTRIC POWER SUPPLY Behind doors Run a separate 120 volt circuit from a separate overcurrent Corners and alcoves protective device in the electrical service entrance panel.

  • Page 12

    INTERMITTENT IGNITION I- "_Z • L8148E //--AQUASTAT W_RE COOE FJ:x"?;_':IT'P':_I DAMPER CABLE l_:z_ ICNIT}ON CABLE --LINE VOLTAGE --LOW VOLTAGE --LOW VOLTAGE FIELD WIRING COLOR COOE BK-BLACK BR-BROWN O -ORANGE Y -YELLOW R -RED BT-BLACK WITH WHITE TRAX_ER W -WHITE B -GREEN _i? r? _?;..

  • Page 13

    STANDING PILOT WIRE CODE F_';'Pr_DAMPER CABLE C_=:zzZ_ICNITrON CABLE --LINE VOLTAGE --LOW VOLTAGE --LOW VOLTAGE FIELO WIRING COLOR CODE BK-BLACK BR-BROWN 0 -ORANGE -YELLOW R -RED BT-BLACK WITH WHITE TRACER -WHIT[ G -GREEN r ......... • ! ',_-' I f-:-! t_ 7_'', ( _J I ',...

  • Page 14

    RELIEF VALVE AIR ELIMINATING FITTING (AIR PURGER) You must have a relief valve on your boiler. Water expands An air purger is used to remove excess air from the system. as it is heated. If there is no place for the water to expand It is installed in the supply line.

  • Page 15

    ROLLOUT SWITCH SPILL SWITCH (FLAME SHUTOFF) ROLLOUT SAFETY (BLOCKED SHUTOFF) VENT SAFETY The rollout switch is a temperature-sensitive fuse link device. The spill switch is a manual reset disc thermostat with a fixed It is located on the boiler base just outside the fire box. In setpoint (340°F), and normally closed contacts.

  • Page 16

    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 17

    1. STOP! Read the safety information on page 14. 9. Rotate the gas control knob counterclockwise "PILOT" Push down and hold the red reset button while 2. Set the thermostat to lowest setting. you light pilot burner with a match. 3.

  • Page 18

    pRESSURE RI_GUI._TO/I WIRING AOJUSTMKNT (UNC)I[ R CA/' SCRI[W MANTEL PRI_SURI_ T| RMIF_AI._II) oo._ € _LOT OUTUtT SHARPINNERCONES (UNr_ER CAP SCREW) ADJUST PILOT BURNER idea how the system works. Example: If your system does not give quite enough heat in very cold weather, you can raise Pilot flame should surround 3/8"...

  • Page 19

    BURNERS BOILER FLUE PASSAGES A visual check of the pilot and main burner flames should Under normal operating conditions, with the burners properly be made at least once each year, preferably at the beginning adjusted, it should not be necessary to clean the boiler flue of the heating season.

  • Page 20

    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 21

    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 No. {not the Key No.) and the Description of each part from the following illustrations and list.

  • Page 22

    FOR USE WITH NATURAL GAS ONLY NOTE: Actual gas valve may look different than gas valve shown NATURAL GAS BURNERS AND MANIFOLD PARTS THIS IS A REPAIR PARTS LIST - NOT A PACKING LIST 9 SECTION 3 SECTION 8 SECTION 2 SECTION 4 SECTION 5 SECTION...

  • Page 23

    BOILER CONTROLS AND PIPING DESCRIPTION PART %" ASME Relief Valve 146-22-011 146-07-041 %" x 71/2"Nipple 146-23-009 Temperature Pressure Gauge - 5" Stem 1Y4"x %" x 1W' Tee 146-93-049 433-00-523 Aquastat Relay Isolation Bail Valve 146-26-043 Grundfos UP15-42F Circulator 146-26-045 "race 007 Circulator 146-62-047 146-07-044 1W' x 2W' Nipple...

  • Page 24

    Gas-Fired Cast Iron HOTWATER BOILER Now that you have purchased your Boiler, should a need ever exist for repair parts or service, simply contact Sears Service Center. Be sure to provide all pertinent facts when you call or visit. The model number of your Boiler will be found on the model plate on the side of the Boiler.

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