Electronic Ignition Gas-Fired Hot Water Induced Draft Boiler • Installation • Operation • Repair Parts WARNING: Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or information consult a qualified installer, service agency or the gas supplier. Natural gas boilers are not to be converted to Propanr gas.
Warranty.......................................................... 2 Gas Supply Piping ........................................ RulesforSafe Installation and Operation....... 3 Electrical Wiring/Sequence of Operation ....... Boiler Ratingsand Capacities ......................... 4 Wiring Diagram ............................................. BeforeYou Start.............................................. 5 Equipment and Optional Accessories - What Locating the boiler ..........................................
1. Readthe Owner's Manualfor Sale Operation 5. Be certain your 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 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 in jury, and/or property damage. 2. Check your local codes and utility requirement before installation.
ASME RELIEF VALVE ® 23111 TEMPERATURE PRESSURE 3 <-'-- LiMrr & RELAY CONTROL I I I I I t I I I I I I I DRAII_ VALVE I I I II I Swrm_ U _tTCH [_ _,_" INTERMnTEHT _ILOT CONTROL @ ® DESIGN CER11FIED FOR NA_nJp_,LAND pRGPANE GA_ IANIFOLD I NATURAL MODEL Propane Gas 229.965320 229.965330 229,965340 229.965350 229.965369 229,965370 L FRONT LEFT SIDE Natural Gas 229.965520 229.965530 229.965540 229.965550 229.965560 229.965570 2 No. Sec. 2 3 4 5 6 7 AGA Input *MBH 42,5 75.0 112.
Checkto besureyou havethe rightsizeboilerbefore startinathe installation.See ratingandcapacitytable on previous page.Also be sure the new boiler isfor 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 connected to a suitable chimney or horizontal venting system and an adequate piping system.
If your boiler is part of a planned heating system, locate it where shown on your plan. If boiler isto be part of an existing system, it is usually best to put it where the old one was. !f you plan to change location, you will need additional materials as well as an adequate base. The following rules apply: boiler on Combustible Floor Base No 14614031 for 2-5 section boilers, or No. 14614032 for 6-7 section boilers. We use a 2" cloudlet pad as a combustible floor base.
I Combustion and Ventilation, of the National fuel Gas Code, ANSI Z223.1-latest revision, or Provision for combustion and ventilation be inbuilding accordance with Section 5.3, Air for applicable provisions airofmust the local codes. I I WARNING NOTE Be sure provide enough fresh airfor combustion. Enough air insures proper combustion and assures that hazard will develop due to the lack oxygen. If you use a fireplace or a kitchen or bathroom exhaust fan, you should install an outside air intake.
2, One permanentopening commencingwith 12 inches of the top of the enclosure, shall be permitted where the equipment has clearance of at least 1 inch from the sides and back and 1 Square Inch )er 2,000 Btuh 100% Free 75% Free 25% Free Area Area Area Fresh Air 1/4, Wire Metal Wood Duct Size Mesh Louvers Louvers 3" x 12" 72,000 54,000 18,000 8" x 8" 128 000 96,000 32,000 6 inches form the front of the appliance.
1. Place boiler in the selected location (as near chimney as possible). Your boiler is shipped assembled.You need onlyto installthe circulator, ball valves the relief valve with a drain line to carry any water to a drain, and the drain valve. 2. Install Relief Valve on 3/4"pipe nipple in tapped opening in the left end section. Connect a drain line of the same pipe size (3/4" to carry any water away to a drain.
VALVES A & B - OPEN FOR HEATING; CLOSED FOR COOLING VALVES C & D - CLOSED FOR HEATING; OPEN FOR COOLING TO SYSTEM B 10
with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.l-latest issue I For boilers for connection to gas vents or chimneys, vent installations shell be in accordance and applicable provisions of the local building codes. 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 5. Outside chimneys should not be used unless they are either: a. enclosed in a chase, or b.
If boiler is installed with single wall vent, it must have a 6" clearance between its surface and any combustible material. A new Type B gas vent orflexible liner must be installed in accordance with the instructions furnished For boilers chimneys, for connection to gas vents or vent installations shall be in accordance with Part 7, Venting Equipment, of the national Fuel Gas Code, ANSi Z223.1latest issue and applicable provisions of the local building codes. In Canada, follow CSA 13149.1 or .
REMOVING EXISTING BOILER COMMON VENTING SYSTEM FROM 4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance 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. 5. Test for spillage at the hood relief opening after 5 minutes of main burner operation.
INDUCED DRAFT HIGH EFFICIENCY Maximum Horizontal Vent Length For Stainless Steel Vent Pipe - 30' Plus One 90° Elbow Plus Vent Terminal Minimum HorizontalVent Length - 2' Plus One 90° Elbow Vent Termination Additional elbowsare equivalentto 6 feet of straight pipe for 4" diameter 90 ° elbow or 3 feet of straight pipe for 3° diameter 90° elbow 2, 3, 4, 5, Section Boilers use 3" vent pipe. 6, 7 Section Boilers use 4" vent pipe. CHOICE BOILERS OF VENT PIPE MATERIAL a) U.L.
1. These boilers may be vented horizontally as shown in Fig. 9. The vent pipe is pitchedlml_l from the boiler to the vent termination. Do not connect other appliances to this vent. 2. Vent Pipe Material: a) UL Listed Z-Flex Z-Vent stainless steel vent pipe from boiler to vent termination, 6. Vent Termination Fitting: For all vent pipe materials, a) a 90 ° elbow pointing minimum 1/4" mesh rodents and birds. The same material and size as vent pipe.
c) For single wall pipe through non-combustible For 3" vent pipe runs begin with the male end of the vent pipe over the boilers induced draft walls, the hole through the wall need only be large enough to maintain the pitch of the vent pipe, and provide proper sealing. A thimble is not required for single wall pipe passing through noncombustible walls. d) The venting system shall terminate at least 3 feet above any forced air inlet located within 10 feet.
B. For Heat-Fab Saf-T-Vent stainless steel Inspect the joint to ensure that flue gases will not leak. If necessary apply additional vent pipe use a high temperature red silicone sealant rated for 500"F The outside of the male end and inside of the female end of the sealant around the joint. 4) Horizontal venting shall have a slope not less than 114" (6.4mm) every 12 inches pipe must be cleaned before applying the silicone bead.
3) insert the male end of one into the female end of the other. Push the pipe together so the female end rests up against the stop bead of the male end. 4) Insert a StaR-Joiner Band into the inlet of the beaded channel.
d) ProTech stainless steel vent piping requires one loose fitting FasNSeal support strap (#FSSH) for every 6' of horizontal vent. 10. If the horizontal vent must go th rough a crawl space or other unheated space, the cool temperatures will likely cause the flue gases to continuously condense inside the vent pipe. Do not insulate the vent pipe. It must be visible for monthly inspection.
CHECKGAS SUPPLY The gas pipe toyour boiler must bethe corrects'[zefor the lengthof the runand forthetotal BTU perhour inputof all gas utilization equipment connected to it. See F_J.10 for the proper size. Be sure your gas line complies with local codes and gas company requirements. The boiler and its individual shutoff vaive must be I Never disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3.5 kPa).
INSTALL YOUR THERMOSTAT All electrical work must conform to local codes as well as the National Electrical Code, ANSI/NFPA-70, latest revision. In Canada, eleclncalwiring shall comply with the Canadian Electrical Code, CSA-C22.1. ELECTRIC The thermostat location has an important effect on the operationofyourboilersystem.BE SURETO FOLLOWTHE INSTRUCTIONSINCLUDEDWITH YOUR THERMOSTAT Locatethethermostataboutfivefeet abovetheflooronan POWER SUPPLY insidewall.
INTERMITTENT IGNITION LINE VOLTAGE WIRING LOW VOLTAGE WIRING LOW VOLTAGE FIELD WIRING _ _Fr AT 1tC_ IImJCER ll_k_vO_l C_T_ ER Lrf 1OQ3--6_O _ERIE_ INTERM_'_" pILOT COK_OL TIf IP ! B BLACK BT BLACK WITH TRACER W WHITE O GREEN R RED BL BLUE T -'o Lo mllH ,_ H_ k FL_ _,l_ V HIN4 TH_J_g_TAT LINI_ Al" H+gCTll/l,l_l]tI,ER TO Gl_ V#L.
RELIEF VALVE You must have a relief valve on your boiler. Water expands as it is heated. If there is no place for the water to expand into, water pressure will build up inside the boiler and system. Should this happen, the Relief Valve will automatically open at a predetermined pressure. This will relieve the strain on the boiler and system.
WATER TEMPERATURE CONTROL pressure sw'rtchoperates the intermittentpilotand The water temperature limit control in the relay is gas valve. The air pressure switch is factory set adjustable and may be set as necessary. It may and will only work when the blower operates be set as low as 140 ° F, or as high as 240 ° F This properly. It will not allow the boiler to come on if depends on the type and amount of radiation the blower does notgenerate enough pressure or if the venting system is blocked.
HOWA HOT-WATER SYSTEM OPERATES Your entire heating system (boiler, piping and radialJon units) is filled with water. As the water in the boiler is heated, itis pumped from the top of the boilerthrough the supply main to the radiation units. The cooler water in them flows back through the return.main to the boiler• This provides positive and rapid response to the thermostat. •This appliance is equipped with an ignitiondevice which automatically lights the burner. Do not attempt to light the burner by hand.
1. Set the thermostat 6. WARNING: Wait five (5) minutes to allow any gas in the combustion chamber to vent. If you then smell gas in the appliance area or near the floor, do not touch any electrical switch, do not use the phone. Leave the building immediately and call your gas supplier. If your gas supplier cannot be reached, call the fire department. Failure to do so may result in a fire or explosion. If to lowest setting. 2. Turn off all electric power to the appliance. 3.
GAS VALVE SAFETY SHUTDOWN TEST With main burners firing,disconnect the ign_on 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, ADJUST PILOT BURNER 1. Remove screw cover over pilot adjusting screw. 2. Insert small screwdriver and adjustflame as needed. (Fig. 14). Turn screw counterclockwise to increase flame, clockwise to decrease (Fig. 15).
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 17 and Figures 14, 15 and 16. 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, shutdown your system. Drain the system until system pressure is reduced below the relief valve pressure rating.
CLEANINGYOUR BOILERAND 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. Split the silicone seal on the flue collector and the clean out plates with a razor knife. Remove flue collector. Remove clean out plates by tapping upwards on the bottom of the plate with a hammer. Remove loose silicone sealant from sections, flue collector, and clean out plates.
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. 2. 3. 4. Possible Do Not try to light any appliance. Do not touch any electric switch, do not use the phone. Leave the building immediately, then call your gas supplier. If you cannot reach the gas supplier, call the fire department.
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 Numberfrom 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. Be sure to give us all this information: The Part No. - The Part Descrip'don - The Boiler Motel No. FOR USE WITH NATURAL GAS ONLY NARTUAL GAS MODEL NOS. 229.
FOR USE WITH PROPANE GAS ONLY PROPANE GAS MODEL NOS. 229.965320, 229.965330, 4 229.965340, 229.965350, 229.965360, 229.965370 5 2 NOTE: Actual different gas valve may look than gas valve shown PROPANE GAS BURNER & MANIFOLD PARTS THIS IS A REPAIR PARTS LIST- NOT A PACKING LIST KEY NO.
SEARS INDUCED DRAFT BOILERS 229.965520, 229.965530, 229.965540, 229.965550, 229.965560, 229.965570 229.965320, 229.965330, 229.965340, 229.965350, 229,965360, 229.965370 15 14 / 12 \ \ PART DESCRIPTION KEY 2 SECTION 730-00-1050 730-00-1170 3 SECTION 730-00-1050 730-00-1170 146-80-005 425-01-495 425-01-734 146-14-020 146-14-113 146-14-123 433-01-976 730-00-1040 730-00-1033 146-05-002 146-95-041 410-01-019 1 2 Jacket, Right Side Panel Blower Cover Plate 3 4 5 Rating Plate Jacket Tie Bar Boiler Bas
SEARSINDUCED 229.965520, 229.965320, 229.965530, 229.965330, 229.965540, 229.965340, DRAFT BOILERS 229.965550, 229.965350, 229.965560, 229.965360, 229.966570 229.965370 BOILERS CONTROL AND PIPING Key No. 1 2 3 4 S /4"ASME Relief Valve 146-22-011 /4"x 5½" Nipple 146-07-040 146-23-007 146-07-019 5 6 L8148A Comb Hi Limit & Relay Control 433-00-521 CI-006,01 7A Grundfos Pump UP15-42F 7B Taco Pump 007 9 10 11 12 $ $ $ $ t come pre-installed. 34 Cl-001.
Electronic Ignition Gas-Fired Hot Water Induced Draft Boiler Now that you have purchased your Boiler, should a need ever exist for repair parts or service, simply contact any Sears service Center. Be sure to provide all pertinent facts when you call or visit. The model number of your Boiler will be found on the model plate on the side of the Boiler.
