Kenmore 3E W.65, Owner'S Manual

Page 1: ...65 3EW 75 3EWI O0 4EW 90 4EWl 25 4EW1 50 5EWl 20 5EW1 75 5EW2 00 CAUTION Read aftinstructions carefully before starting the installation Save this manual for reference Off Fired HotWater Boiler Installation Operation Repair Parts ...

Page 2: ...the merchandise is installed should the workmanship of any Sears arranged installation prove faulty within one year Sears will upon notice from you cause such faults to be corrected at no additional cost to you FOR WARRANTY SERVICE SIMPLY CONTACT THE NEAREST SEARS STORE OR SERVICE CENTER THROUGHOUT THE UNITED STATES This warranty gives you specific legal rights and you may also have other rights w...

Page 3: ...alves a tankless coil for domestic hot water All packaged boilers include a swing door Honeywell aquastat temperature and pressure gage relief valve drain valve 2 Delevan oil nozzles for multiple firing rates only when purchasing a burner flue brush and an extra boiler tap for an expansion tank or air elimination 36 1 4 RETURN NIPPLE RIEDUCING TEE 2o I 2 TIE_ml PRIESSUR_ GAUGIE r i FRONT VIEW UMIT...

Page 4: ...lable to heat water A small portion is heat from the jacket and surfaces of the boiler and it is assumed that this heat stays in the structure The Net I B R Rating represents the portion of the remaining heat that can be applied to heat the radiation or terminal units i e finned tube baseboard cast iron radiators radiant floor etc The difference between the Heating Capacity and the Net I B R Ratin...

Page 5: ...team and hot water which may damage the surroundings Before installing the relief valve read the manufacturer s instructions and maintenance section of the manual on relief valves 12 Installation and sizing of the expansion tank must consider the heating systems total water volume temperature boiler initial fill pressure and system arrangement An improperly installed and sized expansion tank may r...

Page 6: ... and as close to the chimney as possible 2 The boiler must be level If necessary use metal shims beneath the boiler s feet 3 Use a raised base if the floor can become wet or damp 4 Maintain clearances for fire safety as well as servicing An 18 clearance must be maintained at a side where passage is required for access to another side for cleaning servicing inspection or replacement of any parts th...

Page 7: ...TIa_clE I_NSTALLATION REQUIRELMENTS 1 SHUT OFF VALVE OIL RLTER 2 FI LL PiPE MIN 2 VENT PIPE OIL TANK LINES TO OTHER APPLIANCES TO OUTSIDE ELECTRIC LINE AUTOMATIC FILL VALVE NOSHUTOFF EXPANSION TANK DRAFT REGULATO_ VENT PiPE RELIEF VAI TION FROM RADIATION CIRCULATIHG RETURN LINE OR AbTER TI I EXPANSION TANK ...

Page 8: ...ur of the total input rating of all appliances installed in that space EXAMPLE 2 Boiler Located in Confined Space A All Air from Inside the Building The confined space shall be provided with two permanent openings communicating directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space The total input of all combusti...

Page 9: ...ur of total input rating of all equipment in the enclosure 3 When communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of one square inch per 2 000 Btu per hour of total input rating of all equipment in the enclosure 4 When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum...

Page 10: ... air gap No shutoffof any description shall be placed between the safety relief valve and the boiler or on discharge pipes between such safety valves and the atmosphere Installation on the safety relief valve shall conform to the ANSI ASME Boiler and Pressure Vessel Code Section IV The manufacturer is not responsible for any water damage 5 When connecting the cold water supply to the pressure redu...

Page 11: ...STEM PIPING REFER TO THIS MANUAL S SECTION ON FILLING THE SYSTEM _ VITH WATER OPTION 1 BALANCINGVALVE ZONE VALVE RETURNFROM SYSTEM IT I RAIN VALVE FOR POWER PURGING MAIN SHUTOFF VALVE SUPPLY TO SYSTEM CIRCULATOR PUMP SHUTOFFVALVE BOILERSERVICE FILL VALVE FILLTROLWITH AIR PURGER _ _ _ SUPPLYTO SYSTEM ISOLATION VALVES LiNE WITH SHUTOFFVALVE BOILER DRAIN VALVE ...

Page 12: ...ER TO THIS MANI_AL S SECTION ON FILLING THE SYSTEM WITH WATER OPTION 1 RETURN FROMSYSTEM _ DRAINVALVE FOR POWER PURGING MAIN SHUTOFF VALVE AUTOMATIC FiLL VALVE SHUTOFF VALVE BOILERSERVICE _QUASTA BOILER DRAIN VALVE R I0 7 FILLTROLWITH AIR PURGER BALANCINGVALVE FLOWCHECK VALVE _ ZONE CIRCULATOR _I ISOLATIONVALVE SUPPLY TO SYSTEM SUPPLY TO SYSTEM FILLLINEWITH SHUTOFF VALVE ...

Page 13: ...ING ARRANGE_IENT CAN BE USED WITH ZONE VALVES OR ZONE CIRCULATORS RETURN FROM SYSTEM ISOLATION VALVES SHUTOFF VALVE BOILERSERVICE SHUTOFF VALVE BOILERSERVICE CIRCULATOR PUMP SUPPLY TO SYSTEM AUTOMATIC FILLVALVE FILLLINEWITH SHUTOFF VALVE AOUASTAT FILLTROL WITH AIRPURGER BOILER DRAIN VALVE LOCATE CIRCULATORPUMP HERE WHEN SYSTEM PIPING USES ZONE VALVES IFSYSTEM PIPING USES ZONE CIRCULATORS USE THISC...

Page 14: ...the tankless coil By mounting the aquastat on the coil the tankless coil performance is maximized by making the burner respond more quickly to a call for domestic hot water A tempering valve mixing valve is also recommended as shown in figure below A flow restrictor may be required on the tankless coil inlet piping so that flow rates are matched to boiler heat input see table below Boiler Model 3E...

Page 15: ...ption Tankless coil performance will fall as concentration of antifreeze is increased Refer to boiler and piping water volumes tables in this manual BOILER WATER VOLUMES PIPING WATER VOLUMES Number of Boiler Sections 3 4 5 Total Volume Gallons 9 6 11 6 I 13 7 COPPER PIPE STEEL PIPE PIPE SIZE FACTOR FACTOR Y2 82 5 63 5 40 0 36 0 1 23 3 22 2 1 1 4 15 3 12 8 1 1 2 10 8 9 5 2 6 2 5 8 Divide total leng...

Page 16: ...nformation consult the ASHRAE 1996 HVAC Systems and Applications Handbook Chapter 30 Gas Vent and Fireplace Systems or the National Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances ANSI NFPA 211 CHIMNEY CONNECTOR AND DRAFT REGULATOR Venting the boiler requires a 6 diameter chimney connector pipe and using the draft regulator packed with the boiler Properly installed the reg...

Page 17: ...INSTALLED TIGHT SMOOTH CORRECTLY SIZED I I SEALED IN THIMBLE TIGHT CLEAN OUT DOOR MUST BE REQUIRED MIN IMUM HEIGHT MUST RE AT LEAST 3 FT HIGHER THAN HIGHEST PART QF PASSAGE THROUGH ROOF MUST BE AT LEAST 2 FT HIGHER THAN ANY NEIGHBORING OBJECT MUST HAVE AN UNOBSTRUCTED TOP OPENING DRAFT REGULAT VANE CRIMPEDENO BALANCED WEIGHT ALTERNATE POSITIONS TOP 15 ...

Page 18: ...e not familiar with wiring and codes in general have a competent electrician do this job On packaged boilers the boiler controls are all wired at the factory You need only connect a 115 volt electrical supply to the L1 and L2 terminals on the aquastat relay and two thermostat wires to the T and T terminals on the same aquastat relay see figure below Run a separate circuit from a separate overcurre...

Page 19: ...date the merchandise is installed should the workmanship of any Sears arranged installation prove faulty within one year Sears will upon notice from you cause such faults to be corrected at no additional cost to you FOR WARRANTY SERVICE SIMPLY CONTACT THE NEAREST SEARS STORE OR SERVICE CENTER THROUGHOUT THE UNITED STATES This warranty gives you specific legal rights and you may also have other rig...

Page 20: ...ns closed for an additional 15 seconds This allows the burner fan motor to pre purge the combustion chamber and the oil pump to bring the supply oil pressure up to its set point helping to provide a clean light off AQUASTAT RELAY CONTROL provided The water temperature limit control in the aquastat relay is adjustable and may be set as low as 140 F so long as return water temperatures to the boiler...

Page 21: ...the power purging drain valve rims air free close the isolation valve or zone valve Repeat this procedure for the remaining heating zones d Once all zones are filled with water and purged of air close the power purging drain valve and fill line shut off valve open the main shutoff valve and adiust the throttling valves and balancing valves as required OPTION 2 Close the air vents on all radiation ...

Page 22: ... 65 0 60 EZ 1 HP 3EW1 00 0 85 60 B 1 00 0 85 1 00 0 80 EZ 1 HP 4EW 90 0 75 60 B 0 90 0 75 0 75 EZ 1 HP 4EW1 25 1 00 60 B 1 25 0 85 1 00 0 90 EZ 1 HP 4EW1 50 1 25 60 B t 50 1 10 1 25 1 25 EZ 1 HP 5EW1 20 1 00 60 B 1 20 0 85 1 00 0 90 EZ 1 HP 5EW1 75 1 50 60 B 1 75 1 50 1 65 EZ 2 HP 5EW2 00 1 65 70 B 2 00 1 65 1 75 1 95 EZ 2 HP All Carlin EZ 1 HP and EZ 2 HP oi burners are factory preset at 150 psig...

Page 23: ...ot be obtained it will be necessary to verify the burner head and electrode alignment Proper electrode alignment figures are presented on the following pages If the fire continues to be smoky replace the nozzle with a correct replacement Once the burner is completely adjusted the burner should be started and stopped several times to assure good operation with no fluttering or rumbling Verify that ...

Page 24: ...zle 1 16 7 32 to 9 32 lMENSION 1 SEE BELOW _ 5132 _ _CTROOE GAP _ a LI or VI HEAD _ _DIMEMBION N E B LOW BECKETT AFG VARIABLE V1 HEAD ADJUSTMENTS AND SETTINGS _Lfrl LOC I w Ja4_ _ s_JUST UK 4 A0 A_lr T Jll BECKETT AFG BURNER ELECTRODE ADJUSTMENTS F HEADS Burner F Head Model DIMENS1ON N head to nozzle F0 thru F31 1 16 _ELECTROOE E 22 ...

Page 25: ...5 32 4 mm 5 64 to 7 64 or 2 to 2 5 m __ _ 5 32 or 4 mm 5 32 to 13 64 or 4 to 5 mm _ I _ i E E TO 23 ...

Page 26: ...mportant effect on the operation of the boiler system Be sure to FOLLOW THE INSTRUCTIONS included with your thermostat Typically the thermostat is located about five feet above the floor on an inside wall The thermostat should be located to sense average room temperature so avoid the following DEAD SPOTS behind doors corners and alcoves HOT SPOTS concealed pipes fireplace TV sets radios lamps dire...

Page 27: ...the valve to snap shut Refer to the valve manufacturer s instructions packaged with the valve for more details CONVENTIONAL EXPANSION TANK As noted in the EQUIPMENT AND OPTIONAL ACCESSORIES section this tank may become water logged or may receive an excess of air Frequent automatic opening of the relief valve indicates water logging A high boiler temperature accompanied by unusually low radiation ...

Page 28: ...rush offand inserting it into a drill When brushing care should be taken so as not to damage the target wall with the flue brush 6 Carefully vacuum the soot accumulations from the combustion chamber area being particularly careful to not damage any of the refractory or blanket insulation To gain access to the combustion chamber first double check that the shut offvalve on the fuel oil line is clos...

Page 29: ...on this boiler 5 Reinstall the burner drawer assembly making sure the head location and size if applicable are per the manufacturer s recommendations If the burner being used has a damaged head replace the head with the exact same head recommended for use on this boiler 6 Inspect and clean the oil burner blower wheel 7 Remove the oil pump cover and clean replace the pump screen Carefully reassembl...

Page 30: ...ause of short cycling Check thermostat heat anticipator and correct setting if necessary per instruction sheet packaged with thermostat Check overcurrent protection Check to be sure power supply circuit is ON Reset according to instructions packed with controls Open radiator vents to vent excess air Check flow control valve if used It may be in closed position Check relay operation Check all contr...

Page 31: ... _ BK W PROTECTED OISCONNECT _ ua12_c _ mUASTAT j ___ W IGN TRANN OIL VALVE CIRCULATOR OIL 8URN R MOTOR C_OA COOC B EU_X 0 0R C4GE R RED W WMr_ U_ _0LT_C E F_LD MRING o 120v POWER SUPPLY NEUTRAL HOT _ _ _L _ _ 120 60 I OV_RCURR_NT pROTECTED _SCONNECT L8148A AQUASTAT CIRCULATOR 24 VOlT THCRMO_fAT 9 i BK I_ gL 4 X w m4qlE _ VqA T _CZ aJ_S II 24 _ 1_ Fll_l _ISeG _ W IGN TRANS OIL BURNER MOTOR O CAD S...

Page 32: ...AL i i oT _ eK w I L8124C _ _ _ AQUASTAT J_ _ _ R W k CIRCULATOR 8K m IGN TRAN OIL VALVE OIL BURNER MOTOR 0 w _ 24 _ BL 0 CELL 120v POWER SUPPLy 24 VOLT TN RMOSTAT N UTRAL t20 60 1 OVERCURRENT RROT CT B DISCONNECT d ___ B L8148A _ q AQUASTAT CIRCULATOR 8K COLOR COOKE 81 EC UE 0 _ _E Y YIDJ OW W _talt OJ _ a 2 rOt p3 Rf_D W_IN_ IGN TRAN 8K BK W OIL VALVE BK OIL BURNER O CAD w CELL Service Company S...

Page 33: ...CONN CT 24 VOLT THERMOSTAT COLO_ COOL BK BLACX R RED E_ 8K G_m B 8U_ L8124C AOUASTAT E w BK iI _ _CAPAC TOR C TROL AOO W O 20f wl tZOV POWI R 24 VOLT SUPPLY TH RMOSTAT oT _ 120 60 I OV RCURRgNT _ I PROT CTED D_CONNIECT L L8148A AQUASTAT I I CIRCULATO R I 7 COHTROL iS FACTORY WIRED Ire RIEkLO CotJ_ _ BLACX W _fqE Bt BLUE LINE _ IAGI FI_J_ WAeK BK CAPACITOR BK Service Company Serviceman Address Tele...

Page 34: ...ing and the thermostat controls call for domestic space heating The sequence of operation for the burner and circulator is as follows 1 Thermostat calls for heat completing circuit between terminals T T on the aquastat controller energizing the 1K relay coil 2 With the IK relay coil energized contacts IK1 and 1K2 are closed Terminal B1 is energized providing power to the oil burner primary control...

Page 35: ...rgized the burner operation starts and remains running as long as the cad cell senses flame In the event of flame failure or the flame is not fully proven within the trial for ignition period the primary control will lockout and open the burner circuit This will require a manual startup of the burner 4 As long as flame is proven through the cad cell relay the burner will remain on until the circui...

Page 36: ...Steel 3 8 Flat Washer 146 95 114 20 Stainless Steel 318 Top Lock Nut 146 95 115 21 1 1 4 Solid Plug Inot shown 146 93 126 22 Black Silicone Sealant not shown 146 05 020 4EW 403 06 008 406 06 007 403 00 006 433 00 976 145 05 051 146 95 041 433 00 955 146 19 003 146 30 031 426 00 280 425 O0 280 426 00 280 137 04 007 146 96 07 3 146 93 064 146 27 020 146 1 9 001 146 95 113 146 95 114 146 95 115 146 9...

Page 37: ...lock Nut Swing Door Insulation Swing Door Hinge 1 4 x 2 Round Head Rivet 3 8 x 1 Hex Head Serrated Flange Bolt 3 8 x 48 Fiberfrax Round Braid Swing Door ObServation Door 5 16 Lock Washer 3 8 x 3 8 Shoulder Bolt 5 16 18 Thread Pa_ 403 00 006 146 95 125 146 95 126 146 14 014 403 00 010 146 95 121 146 95 124 433 00 905 403 00 009 403 00 014 146 95 123 146 95 122 35 ...

Page 38: ...ower Front Jacket Panel boiler w swing door XX Complete Jacket for Boiler with Swing Door 3EW 425 00 244 425 00 269 425 00 254 425 00 264 425 00 267 146 95 04 146 95 074 146 95 103 425 00 268 425 00 289 4EW 425 00 245 425 00 269 425 00 255 425 00 265 425 00 267 146 95 042 i146 95 074 146 95 103 425 00 268 425 00 290 5EW 425 00 246 425 00 269 425 00 256 425 00 266 425 00 267 146 95 042 146 95 074 1...

Page 39: ... 2 Stem 5a 1 1 4 x 2 1 2 Pipe Nipple 5b 1 1 4 x 3 4 x 1 1 4 Reducing Tee 6 3 4 Drain Valve 7 3 4 Relief Valve 3EW 4EW 5EW 146 19 007 146 19 008 146 19 009 433 00 015 433 00 016 146 19 005 146 19 005 146 19 005 146 19 006 146 19 010 146 19 010 146 19 01G 146 19 011 433 00 521 433 00 521 433 00 521 146 62 022 146 62 022 146 62 022 146 26 047 146 26 047 146 26 047 146 26 048 146 26 048 146 26 048 146...

Page 40: ... 65 0 60 EZ 1 HP 3EW1 00 0 85 60 B 1 00 0 85 1 00 0 80 EZ 1 HP 4EW 90 0 75 60 B 0 90 0 75 0 75 EZ 1 HP 4EW1 25 1 00 60 B 1 25 0 85 1 00 0 90 EZ 1 HP 4EW1 50 1 25 60 B 1 50 1 10 1 25 1 25 EZ 1 HP 5EW 1 20 1 00 60_B 1 20 0 85 1 00 0 90 EZ 1 HP 5EW1 75 1 50 60 B 1 75 1 50 1 65 EZ 2 HP 5EW2 00 1 65 70 B 2 00 1 65 1 75 1 95 EZ 2 HP All Carlin EZ 1 HP and EZ 2 HP oil burners are factory preset at 150 ps...

Page 41: ...G REPAIR PARTS ALWAYS GIVE THE FOLLOWING INFORMATION PART NUMBER MODEL NUMBER PART DESCRIPTION eNAME OF ITEM All parts hsted may be ordered from art Sears Se_ _ce Center If the parts you need are not slocked locally your order wdl be electronically transmitted to a Sears Repair Paqs D_stnbubon Center for handhng When Sears arrar_ges the _nstaltat_on you car_ be sure tl_e job is done r_ghf We wdl a...