Kenmore 220.960230, Owner'S Manual

Page 1: ...eadall 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 suppl...

Page 2: ...ish 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 caus...

Page 3: ... 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 TOOLS Pipe Wrench Screwdrivers Tin Snips 6 foot tape or folding rule Hack Saw LP Torch if you have copper piping Pipe cutter and threadi...

Page 4: ...ontrol The Net I B R Steam Ratings shown are based on an allowance of 1 333 in accordance with the factors shown in the I B R Code as published by The Hydronics Institute Selection of boiler size should be based upon Net I E_R Rating being equal to or greater than installed radiation in square feet Consult manufacturer before selecting a boiler for installations having unusual piping and pickup re...

Page 5: ...the combustionair openingon the backside of the boiler at the bottom of the rearjacket panel and maybe cut with any wire cutting pliers I1the boileris installedat its minimum clearances it maybe difficultto reachthe wireties after the boileris installed and lhe wire ties shouldbe cut now The wire tiesareonlyneeded duringshipping anddo not needto bereplaced Boilersequipped with stainlesssteel burne...

Page 6: ...g of all gas utilization equipment in the confined space but not less than 100 square inches One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure B All Air from Outdoors The confined space shall be provided with two permanent openings one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure The...

Page 7: ... pop safety valve shall conform to the requirements of the ANSI ASME Boiler and Pressure Vessel Code Section IMThe manufacturer is not responsible for any water damage This boiler is equipped with two 2V2 supply connections and two 2V2 return connections one each on both the left and right sides of the boiler Unused connections must be plugged with the 2V2 plugs furnished Recommended near boiler p...

Page 8: ...ems must be equipped with a Hartford Loop as shown in Figures 5 and 6A 8 When piping the vertical risers from the boiler to the header the bottom of the header must be a minimum of 24 inches above the water level line on the right side of the boiler 9 Steam riser s and header shall be 2V2 pipe size 10 Equalizer line shall be minimum iV2 pipe size 11 The near boiler piping shall include a 21 2 tee ...

Page 9: ... hookup 15 In connecting the cold water supply to the water inlet valve make sure that a clean water supply is available When the water supply is from a well or pump a sand strainer should be installed at the pump FOR USE WITH COOLING UNITS A 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 Appro...

Page 10: ... connected to the black wires marked 24 volt thermostat on the boiler 5 Vent pipe must be same size as the flue outlet collar 6 Slope pipe up from boiler to chimney not less than V4 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 co...

Page 11: ...nection to gas vents or chimneys vent installations shall be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 1atest revision and applicable provisions of the local building codes Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mech anical draft systems operating under positive pressure ROOF RIDGE 3 4 HT ...

Page 12: ...amper iI DAMPER CLOSED DAMPER OPEN SHOWING OPEN AND CLOSED POSITION CHECK GAS SUPPLY The gas pipe to your boiler must be the correct size for the length of the run and for the 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 valve must...

Page 13: ...rical codes I 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 vertically mounted outlet box It should be sensing average room temperature so avoid the fo...

Page 14: ...ted for the boiler to operate 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 24 VOLT TRANSFORMER VENT DAMPER 4 PLN MOLEX PLUG TO LWCO AND IGNITION SYSTEM ISOLATION RELAY 24V SPST N O HONEYWELL Y I R8222A OR EQUIVALENT O _ t...

Page 15: ... _____ j OP_ONAL WF 2U 2_ WATi_ _ l EOER NOTE T_ 1N_ N0 APpFJ_R ONLy ON WATER FEEC_R MODELS WITH tJXNL_I _ 0 PUSH 8U_ ON INTERMITTENT IGNITION _ iiii _LWC 0 pRoBE Wt_RMRTF NT pIL OT CONTRCt R TO PrLOT SAP_ SHUTOFF AI_V VR8204A VR8304M IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 C THERMOPLASTIC WIRE OR ITS EQUIVALENT 15 7411_ ...

Page 16: ...RELAy II 4 POLE CONNECrOR NC C N C I I 12_ _ I i 7J _6 I 15_15 I _2 J A C TO D C POWER CONVERSION CIRCUIT 3 MOTOR _2 4 VAC 50 60 HZ N O N C N C C o _ _ ___J PI_osTAT LIMI T LWCO 1_ 24 V _1 0411yll FLA_E ROLLOUT SHUTOFF _ N UT_ L BLOCKED _NT HOT S_E_ O_RCURRENT SHUTOFF PROTECT D GAS DISCONNECT VAL_ i1_V BOHZ I_ NOTE SlA AND SlB ARE THE AUTOk_T_C Op RATJON HOLD BAMPER OPEN SWITCH SWITCH SHOWN tN AUT...

Page 17: ...I r _ _6 I is i p _L o 1 r ER _OS T Kt r r _ Ll_Ir i Y BK _ o D 1 I S2j a _ _ fv _ _ i L I 2_ I 50 60 HZ 8K N_UIRAL LWC0 _ _HO T 115 V 60HZ II_ NC N0 Nj o1 o kOTD SlA A_O SIB _g THE AUT0_TIC OPg_TrON HIN_ _I_R OPEN NTCH S N_TCH SHNH IN _OMATIC POSmI_ _FFPr 5NUIOFF BLOCKED _T SV_ ET_ SHUTOFF cAs VRB204A VR8304M OV RCURRENI PROT CTED DISCORNECT S8600 F M INI RUlTT N_ PILOI CONTROL Z _ N _ 1234 S 6 g...

Page 18: ...E LIMIT BT I I J y BK FLAME ROLLOUT SAFETY SHUTOFF LOW WATER CUT OFF _ VALVE TR T_ TH B K BLOCKED VENT SAFETY SHUTOFF RVCp KS BKF V_NT OA _pER TO OC POWER CONVERSION CIRCUIT NC C IP1 03 NOTE S1A AND SIB ARE THE AUTO TIC OPERATION HOL0 DAMPER OPEN SWITCH SWITCH SHOWN IN AUrO_ ATIC POSITION 2 3 Nq0 4 ARE CAM ACTUATEDSN_o SWITCHES IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE RE...

Page 19: ...s contact with the probe for a period of 10 seconds Refer to manufacturer s instructions enclosed for more information WATER FEEDER Optional The Model WF 2U 24 water feeder may be used with either of the available low water cut offs The water feeder s job is to maintain a safe minimum water level It s used to keep the boiler running by compensating for minor evaporative steam leaks and to prevent ...

Page 20: ...osion 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 1 STOP Read the safety information on this page 2 Set the thermostat to lowest setting 3 Turn off al electric power to the appliance 4 This appliance is equipped with an...

Page 21: ...ton 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 10 After pilot remains lit when red reset button is released turn gas control knob counterclockwise _ to ON 1 Replace lower front panel 12 Turn on all electric power t...

Page 22: ...temperature If windows are to be opened or heat is not 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 call for heat each component must be functioning properly to permit operation On safety lockout the system has to be reset by turning the ther...

Page 23: ... settings will need to be determined on a system by system basis The cut in setpoint is determined by the system pressure drop to the furthest radiator or terminal unit Double the system pressure drop as a safety factor resulting in the rule that the cut in setting should never be less than twice the system pressure drop The differential setpoint is the steam pressure required at the terminal heat...

Page 24: ...ne Fire the burners and allow normal steam pressure to build up Run a connection from the boiler blowdown valve to a nearby sewer or floor drain or to a safe discharge point outside Shut off the gas burners open the blowdown valve and allow all of the water in the boiler to drain out Close the b owdown valve Allow the boiler to cool thoroughly and then slowly refill the boiler to the water line Re...

Page 25: ... veryimportantandthepipingshouldbechecked at leastonce a season If the vent piping shows any sign of leaking replaceit immediately CLEANING YOUR BOILER FLUE PASSAGES AND BURNERS FluePassages betweensectionsshouldbe examined yearlyandcleaned if necessary To clean removeburners pilot andvenl pipe Remove top andfrontjacketpanels Remove thetwo screwsattaching the intermediate front pand 1o lhe left an...

Page 26: ...e 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 Steam air vents are not operating properly Check flow control valve if used It may be in closed posit...

Page 27: ...25 00 801 137 02 153 9 10 Jacket Service Door 12 Jacket Int d Panel 13 Jacket Front Panel 14 1 4 Tie Rod Nut 15 Boiler Section Left 16 Boiler Section Middle 17 Jacket Top Panel 18 Draft Diverter 19 Boiler Section Right 20 Jacket Back Panel I Jacket Complete l Block Assembly 19 16 15 14 8 qt Combustible Floor Plate i Cerafelt Gasket 21 Vent Damper i Base Assembly 6 5 4 RolloutSwitchBracket Nat GasO...

Page 28: ... 307 146 62 053 146 62 039 5 SECTION PadNo 146 62 052 146 15 005 146 95 307 146 16 035 146 15 031 146 15 523 146 15 522 146 62 092 425 00 418 146 34 061 146 62 051 146 95 307 146 62 053 146 62 039 6 SECTION Pa_No 146 62 058 146 15 005 146 95 307 146 16 013 146 15 035 146 15 523 146 15 522 146 62 092 425 00 418 46 34 061 146 62 060 146 95 307 146 62 053 146 62 039 7 SECTION Pad No 146 62 058 146 15...

Page 29: ...A x Brass Tee PS 802 only I Y2 Brass Coupling PS 802 only W x 3W Brass Nipple PS 802 only Drain Valve WF 2U 24 Water Feeder Optional Rollout Switch Spill Switch 36TX16 6282 280 F 5 Vent Damper 3 Section Boilers 6 Vent Damper 4 5 Section Boilers 7 Vent Damper 6 7 8 9 Section Boilers Vent Damper Operator Motor 400 F Black Silicone Rubber Adhesive Sealant 10 3oz cadridge PART NO 146 22 002 146 93 053...

Page 30: ...our Boiler will be found on the model plate on the side of the Boiler WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE FOLLOWING INFORMATION PART NUMBER eMODEL NUMBER PART DESCRIPTION eNAME 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 handli...