OWNER'S MANUAL CONTINUOUS PILOT MODEL NO. KWX - 3V KWX - 4V KWX - 5V KWX - 6V KWX - 7V KWX - 8V KWX - 9V Gas- Fired Cast Iron HOT WATER BOILER • Installation CAUTION • Operation Read all instructions • Repair Parts carefullybefore starting the installation. Save this manual for future reference. These instructions must be affixed on or adjacent to the boiler.
KENNMORE CAST IRON BOILERS FULL ONE YEAR WARRANTY ON HOT WATER AND GAS STEAM CAST IRON BOILERS For one (1) year from the date of installation, when this boiler is installed and maintained in accordance with our instructions. Sears willrepair defects in material or workmanship in the boiler,free of charge.
FIG. 1 -ASME R[[J_¥ VALVE DAMPER C_ --A VI£NT II ,-_ ..... I;[ HPT ? ! , \ "_ i II ENCLOSED SCOHTROL_ -I, [_----J i<\/ I I I i \ \.A I I I I i I JI • _AJN VALVE % _._L_ _.1__ _1__ _ GAS VALVE COH_OL L GAUGE hr_ l l r--- TEMP./PRESS. u ...... ,.Lr'--_l_ [ i 31 ? LEFT S;DE ® RIGHT SIO[ BASIC BOILER MODEL NO. ConUnuous With r' 'E'r'PPLE Pilot NATURAL NO.
CheckIo besureyouhavetherightsizeboilerbeforestartingtheinstallation. Seeratingandcapacitytableon previouspage.Alsobesurethenewboiler is forthetypeofgasyouareusing.Checktheratingplateon therightsideof the boiler. Youmustseethat theboiler is suppliedwith thecorredtypeol gas,freshair forcombustion, anda suitableelectricalsupply.Also,theboilermustbeconnectedtoa suitableventingsystemandanadequate pipingsystem.Finally,a thermostat, properlylocated,is neededforcontroloftheheatingsystem.
the for National Fuel Gas ANSI Z223.1-1atest or applicable provisionsof local buildingVentilation, codes. I Provision combustion andCode, ventilation air must be inrevision, accordance with Section 5.3, Air forthe Combustionand of NOTE WARNING 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 combustion air. Be sure to provide enough fresh air for combustion.
1.Place boiler intheselecled Iocalion (asnear chimney aspossible.) Your boiler isshipped assembled. You need onlyIoinsfall theReliefValveand a drain line to carryanywaleror steamIo a drain. 2. InstallRelielValveinto the3/,,-pipeon thetopol Iheboiler.SeeFigure5. Use¾" Pipeandan elbow(nol furnished)to carrythewaleror steamto a nearbydrain.Donotconnectdirectlyto a drainbul leavean air gap.
CONNECTING THE VENT DAMPER AND VENT CONNECTOR Refer to Fig. 1 flue diagram for the 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 a !/2 square inch hole (approximately 3/4"diameter). 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.
7 Any _mproper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1 -latest revision.
Forsafe,efficientoperation,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 tor 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.
CHECK GASSUPP_ 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. NATURAL GAS The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of I/2 psig (3.5 kPa).
WARNING TURN OFF ELECTRICAL II POWER AT FUSE BOX BEFORE MAKING ANY LINE VOLTAGE FOLLOW LOCAL ELECTRICAL CODES. CONNECTIONS. I All electrical work must conform Canada, electrical ELECTRIC wiring shall comply with the Canadian POWER Prior to making the fuse box. to local codes as well as the National Electrical Electrical Code, ANSI/NFPA-70, Codes, CSA-C22.1 latest revision. In and .2.
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. FIG.
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24 '_0LT TRANSFORMER AQUASTAT I 81 OR W XF._M R PRl_ / [3 BU Q BOILER Y _ SHUT OR= IFL_I ELOCK_ VENT ROLLOUT SA,_L'IY SHUT OFF OR _ y GROUNO ¢ POWER , suP_¥.OT......... NELrmAL 115VAC [ ir -- --_ SENSOR I OR _H______ Tw BK __ .....
120/60/1 HOT pOWIER SUPPLY NEUTRAL OVERCURRENT PROTECTED DISCONNECT CIRCULATOR 120 PUMP V_C. PRIMARY 24 V_C. SECONDARY M3-1 r P3-2 _LL /'_ M3--4 P3--, ; "7 P2-04 ; P1-01 p2-01 K1A $2 ,._>>---<<-_'D'-L-_'-I RVGP-KS--BKF VENT DAMPER STAT P1--02 P2-OS S1B _ m-o4 Kle S1A $3 J _ L o- .---- M3-5 E3 _/_ M3-2 E1 MICROPROCESSOR HIGH UMIT SOR_j 12 M3-3 _ /_ M3-6 Ji-I '-, GAS VALVE VR8200A/VR830OA NOTE: SIA AND SWITCH $2, IF ANY $3.
RELIEF VALVE You must have a relief valve on your boiler. water pressure Water expands will build up inside the boiler and system. as it is heated. Should If there this happen, is no place for the water the relief valve will automatically to expand pre-determined pressure. This will relieve the strain on the boiler and system.
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.
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 the return main to the boiler. This provides positive and rapid response to the thermostat. FILLI"NG SYSTEM WITH WATER Close the air vents on all radiation units. Open the valves to these units.
I WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. I I • Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. *If you cannot reach your gas supplier, call the fire department. A. Some boilers are equipped with an intermittent ignition device which automatically lights the pilot. Do not try to light the pilot by hand.
1. STOP! Read the safety information on page 20 9 Rotate the gas control knob counterclockwise i_ 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 lit. If it goes out, turn gas control knob clockwise to OFE To relight, repeat steps 5-9. 2. Set the thermostat to lowest setting. 3. Turn off all electric power to the appliance. 4. Remove lower front panel. 5.
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BURNERS BOILER 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 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 once each year by a competent Service Technician.
PWX WITH Thermostat STANDING PILOT: calls for heat, completing the circuit to the aquastat and gas valve. The sequence is as follows: The LED light 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.
FIG.19 / SYSTEM LIGHT STATUS LIGHTS @ MAIN POWER r_ CALL FOR HEAT C[RCUL_TORPUMP @ GAS VALVE BURNER STATUS STATUS INDICATES ON L7148F CONTROL ENERGIZED THROUGH OFF L7148F CONTROL NOT ENERGIZED. ON L7148F CONTROL OFF CIRCULATOR ON L7148F CONTROL OFF GAS VALVE NOT ENERGIZED 24 VOLT TRANSFORMER. POWER CALL FOR HEAT/ CIRCULATOR PUMP ENERGIZING CIRCULATOR PUMP CIRCUIT. PUMP IS NOT ENERGIZED.
SYMPTOM POSSIBLE No Power. Boiler is cold. ACTION CAUSE Check for 120V at LIX, L2X Check all wiring and cable connections. L7148F Aquastat Control detects an error. Check the circuit breaker or fuse and, if necessary r reset or replace. Short the W, R terminals on the L7148F Aquastat Control. If the system starts, check the thermostat and low voltage wiring. Check for 24V at R, C. If no voltage, replace the transformer.
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. If you cannot reach the gas supplier, call the fire department. Possible Cause What to do Thermostat is not set correctly Reset thermostat above room temperature.
GAS-FIRED HOT WATER - IMPORTANT READ THESE INSTRUCTIONS BOILERS 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 (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 Description - The Boiler Model No. JACKETTHIS KEY NO.
3ACKET - SECTION AND BASE PARTS @ % 29
LED & COVER PANEL ASSEMBLY JACKET PARTS 3O
CONTROL / BOX ASSEMBL WIRING MARN_SS ITEM IT[M _14E34_03 1146345a2 (21 f6 X i" SL; ITEM 11469504_ SHE[T SCREW Y {7--9 (_-6 SEC.) S£C.) --_ \ RO_£S: r_E t rE_4 r,_t_BI.RS FC_ r_s p_.
GAS TRAIN - NATURAL i/2" I/2" OR 3/4" X 90" STREET - ITEM # 14693801 3/4" i12" I/2" - ITEM # ELL_ I OR 314" CLOSE NIPPLE-- ITEM # 14607030 314" - 112" OR I12" - 314" - ITEM # _ W 14607031 314" ITEM i 14693040 UNION # 14G93043 # 14693044 ITEM PWX "T ° MANIFOLD FOR PARTS 1-7 _ SEE _ REPAIR _ PARTS TABLE BELOW NATURAL GAS BURNER AND MANIFOLD NATURAL KEY NO. DESCRIPTION Part No. ASSEMBLY GAS 9 SECTION 5 SECTION 6 SECTION 7 SECTION 8 SECTION Pa_ No. Pa_ NO.
BOILER CONTROLS AND PIPING _** *° _OTE: ISOLATION BALL VALVES AND CIRCULATOR PUMPAREEHIPPESLOOSEIN CRATE. )_/ KEY NO.
HONEYWELL L7148F TROUBLE SHOOTING GUIDE Start Boiler is cold. Boiler is not reaching proper temperature or will not tum on. 4, Check: L7t 48F Diagnostic LED =ON"? -- Turn power "ON". Check all wiring connections. Replace transformer as appropriate. Check for 12BY at LIX, L2X. Check for 24V at R C No-- I I Yes Thermostat cr Thermostat widng problem. Check system per instructions provided with thermostat. Set room thermostat lO°above room temperature.
Gas - Fired Cast Iron HOT WATER BOILER OWNER'S MANUAL CONTINUOUS PILOT MODEL NO. KWX KWX KWX KWX KWX KWX KWX - 3V - 4V - 5V - 6V - 7V - 8V - 9V 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.