Kenmore KWX-3V, Owner'S Manual

Page 1: ...tions must be affixed on or adjacent to the boiler Gas Fired Cast Iron HOT WATER BOILER Installation Operation Repair Parts WAILING 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 Sears Roebuck and Co Hoffman Estates I...

Page 2: ...terclearing or replacement 2 Damage to unit or unsatisfactory operation due to improper cleaning or use of unit in corrosive atmosphere 3 Damage to unit or unsatisfactory operation due to blown fuses or inadequate or interrupted electrical protective devices 4 Damage to unit caused by the use of components or other accessories not compatible with the unit 5 Ifthe unit is removed from the place it ...

Page 3: ...terminal Units The net I B R Ratings shown are based on an allowance of 1 15 in accordance with the factors shown on the I B R Standard as published by the Hydronies Institute Selection of boiler size should be based upon Net I B R Rating being equal to or greater than the calculated heat loss of the building The Manufacturer should be consulted before selecting a boiler for installations having u...

Page 4: ...Thisboilermust not beinstalledon carpeting 3 Boileris to belevel Metalshimsmaybeusedunderbaselegsfor final leveling 4 Additionalclearances for servicemayexceed clearances for fire protec lion Alwayscomplywithlhe minimumfire prolection clearances shown on the boiler An 8 inch clearance should bemaintained on anyside wherepassage is requiredtoaccess another sideforcleaning servicing inspection or re...

Page 5: ...ension of airopeningsshallnot belessthan3 in Where ductsareused theyshall beof thesamecross sectional areaas the freeareaof theopeningsto whichtheyconnect 1 Twopermanent openings onecommencing within 12 inchesof the top andonecommencing within12inchesoftheboltom oltheenclo sureshallbeprovided Theopenings shallcommunicate directly orby theducts withtheoutdoors or spaces crawlor attic thaifreelycom ...

Page 6: ...catedin air handling unitswherethey maybeexposed to refrigerated aircirculation thepip ing syslemshallbeequipped withflowcontrolvalvesorotherautomaf ic means to prevenl gravgy circulation of theboilerwalerduringthecool ing cycle LOW DESIGN WATER TEMPERATURE SYSTEMS BELOW 140 If Iheboileris to beusedin aheatingsysfem wheredesignwaterlempera luresbelow140 Faredesired e g radianlfloorhealing a3 wayor...

Page 7: ...h a combustible wall or partition use a ventilated metal thimble _he thimble should be 4 inches larger in diameter than the vent pipe Boiler Input Btuh Up to 100 000 Up to 155 000 Up to 230 000 Up to 350 000 HT 10 15 Ft 6x6 6x7 7x8 9x9 FLUE AREA IN INCHES HT 15 25 Ft 6x5 6x6 7x7 8x9 HT 25 Ft Up 5 5 6 5 6 7 8 8 HT top of thimble to top of flue See F_g 8 For boiler input refer to table page 2 For in...

Page 8: ...tion of mechanical draft systems operating under positive pressure ROOF RIDGE 3 4 HT MAXIMUM HT MUST SLOPE UP AT LEAST 1 4 INCH PER FOOT OF HORIZONTAL RUN HORIZONTAL INSTALLATION FLOW _ NO TO FURNACE VENT TO CHIMNEY OR BOILER DAMPER INSTALL VENT DAMPER WITH ACTUATOR TO SIDES OF VENT ONLY DO NOT MOUNT ABOVE OR BELOW VENT VERTICAL INSTALLATION TO CHIMNEY FLOW VENT DAMPER ACTUATOR MAY BE TO FURNACE_ ...

Page 9: ...indicator returns to the closed position MANUAL OPERATION OF THE VENT DAMPER The Effikal vent damper may be placed in the open position to permit burner operation by using the HOLD DAMPER OPEN switch located on the damper controller The thermostat will control the burner firing as before while the damper will remain open DO NOT turn damper open manu ally or motor damage will result Set switch to A...

Page 10: ...pe of tubing should be measured from the gas meter CONNECTING THE GAS PIPING Refer to Fig 13 for the general layout at the boiler It shows the basic fittings you will need The gas line enters the boiler from the right side The following rules apply 1 Use only those piping materials and joining methods listed as acceptable by the authority having jurisdiction or in the absence of such requirements ...

Page 11: ... a grounded connection in the service panel or a properly driven and electrically grounded ground rod 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 ver...

Page 12: ...ring 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 13 1 12 ...

Page 13: ...I THIS PAGE INTENTIONALLY LEFT BLANK I 13 ...

Page 14: ...THIS PAGE INTENTIONALLY LEFT BLANK J 14 ...

Page 15: ...R GAS VALVlE VR8200A VR830OA BK MAIN POWER STATUS LIGHT CALL FOR HEAT CIRCULATOR PUMP STATUS LIGHT GAS VALVE BURNER STATUS LIGHT WIRE CODE COLOR COOE DAMPER CABLE BK BLACK BIR BROWN LINE VOLTAGE P PINK LINE VOLTAGE Y YELLOW FIELD WIRING R RED W WRITE LOW VOLTAGE G GREEN LOW VOLTAGE GY GRAY FIELD WIRING IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED IT MUST BE REPLACE ...

Page 16: ...j 1 MICROPROCESSOR 2 M3 3 _ _ M3 6 Ji I GAS VALVE VR8200A VR830OA NEUTRAL 7 NOTE SIA AND SID ARE THE AUTOMATIC OPERATION HOLD DAMPER OPEN SWITCH SWITCH SHOWN IN AUTOMATIC POSITION 2 3 AND 4 ARE CAM ACTUATED SNAP SW_TCHES _ MAIN POWER STATUS LIGHT _ CALL FOR HEAT CIRCULATOR PUMP STATUS LIGHT A GAS VALVE BURNER STATUS UGHT IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED ...

Page 17: ... EX TROL takes the place of the conventional expansion tank Carefully read the instructions packed with your EX TROL tank assembly The EX TROL tank comes to you with a 10 12 pounds per square inch air charge This is the same as the pressure produced in the system by the automatic fill valve When the system is first filled the EX TROL tank will contain little or no water As the water is heated its ...

Page 18: ... water temperature exceeds the high limit setting The water temperature limit control is adjustable and may be set as necessary Turn the High Limit dial on the control to the desired setting It may be set as low as 130 F 140 F is recommended refer to page 5 for LOW DESIGN WATER TEMPERATURE SYSTEMS BELOW 140 F or as high as 240 F we recommend not to exceed 220 F refer to page 19 ADJUST LIMIT CONTRO...

Page 19: ...t open Start with the lowest radiation unit Open the air vent on this unit When all the air has escaped and water starts to flow from the vent close it Go to the next radiation unit and repeat this process Repeat until you have covered every radiation unit in the system ending up at the highest unit in the system If your units have automatic vents this manual venting is unnecessary but it will spe...

Page 20: ...will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building C D 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 Use only your hand to push in or turn the gas control knob Never use tools If...

Page 21: ... _1 to OFE Do not force AUTOMATIC GAS VALVE The Automatic Gas Valve opens or closes according to the heat requirements of the thermostat and temperature limit control It closes if the pilot goes out Each individual control must be operating correctly before any gas can pass to the burners Any one control can hotd the gas supply from burner regardless of the demand of any other control SAFETY PILOT...

Page 22: ... essary to remove the rollout shield to observe the main burn er flames Replace rollout shield after observation Refer to Figure 17 ADJUST LIMIT CONTROLS Instructions for each control are included with the controls These settings can be changed after you have had some RECOMMENDED BOILERWATER TEMPERATURES J Type of Heating Unit Limit Control Setting I Standing Radiators 180 F Baseboard and Convecto...

Page 23: ...eight in the tank if you have an automatic fill valve otherwise manually refill the system BOILER FLUE PASSAGES 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 ye...

Page 24: ...t will remain on until the thermostat is satisfied Please note the main power LED light in the control panel will remain on until line voltage to the boiler is turned off or disconnected 1 2 3 INITIAL SERVICE CHECKS BEFORE TROUBLESHOOTING A MAKE SURE THAT CIRCUIT BREAKER IS ON OR FUSE IS OK AT ELECTRICAL PANEL B MAKE SURE THAT SERVICE SWITCH IS ON C MAKE SURE THAT GAS IS ON AT THE GAS METER AND TH...

Page 25: ...UIT CIRCULATOR PUMP OFF CIRCULATOR PUMP IS NOT ENERGIZED ON L7148F CONTROL ENERGIZING GAS CONTROL VALVE GAS VALVE OPEN GAS VALVE BURNER OFF GAS VALVE NOT ENERGIZED GAS VALVE CLOSED L7148F CONTROL LED ERROR CODES LIGHT STATUS INDICATES ON L7148F CONTROL ENERGIZED FULLY FUNCTIONAL OFF L714BE CONTROL NOT ENERGIZED L7148F LED STATUS 2 BLINKS SENSOR ERROR SHORTED OR OPEN SENSOR LIGHT 3 BLINKS ANOLOG TO...

Page 26: ...oltage wiring Check for 24V at R C If no voltage replace the transformer Check for 24V at the ignition system and vent damper and check all wiring connections If voltage is present at the ignition system replace the ignition system If no voltage is present at the ignition system but 24V is present at the vent damper replace the vent damper Verify proper connection at the vent damper and L7148F Aqu...

Page 27: ... 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 Open radiator vents to vent excess air Check flow control valve if used It may be in closed position Check o...

Page 28: ...4 42500644 42500664 42500654 43300976 735001040 13702153 42500914 735001074 735001070 42500804 14605002 41000020 41000022 41000021 42500674 42500904 42500844 14628002 42500944 41000413 14614031 41000413 14614018 5 SECTION PART NO 735001050 14695074 14694016 14614130 14614115 14614125 42500645 42500665 42500655 43300976 735001040 13702153 42500915 735001075 735001070 42500805 14605051 41000020 4100...

Page 29: ...3ACKET SECTION AND BASE PARTS 29 ...

Page 30: ...LED COVER PANEL ASSEMBLY JACKET PARTS 3O ...

Page 31: ...Y 21 f6 X i SL SHE T SCREW _ ITEM 11469504_ WIRING MARN_SS IT M 1146345a2 _ 6 S C ITEM _14E34_03 7 9 SEC RO_ S r_E t rE_4 r _t_BI RS FC_ r_s p_ _T 0_ AS FCU C_ 7_ IO a a _GTI_ T_ _S r N_ COVER PANEL CONTROL BOX ASSEMBLY 31 ...

Page 32: ...a_ No 146 62 051 146 15 005 146 95 307 146 16 101 146415 031 146 15 532 146 15 531 146 62 09B 425 00 934 146 62 039 NATURAL GAS 5 SECTION 6 SECTION Pa_ NO Pa_ No 146 62 051 146 62 060 146 15 005 146 15 005 146 95 307 146 95 307 146 16 102 146 16 103 146 15 031 146 15 035 146 15 532 146 15 532 146 15 531 146 15 531 146 62 098 146 62 098 425 00 935 425 00 936 146 62 039 146 62 039 7 SECTION PartNo 1...

Page 33: ...1 2 Nipple 146 07 044 5 1 1 4 x 3 4 x 1 1 4 Tee 146 93 049 6 Well 3 4 NPT 123870A 146 62 017 7 Sensor 209659A with Mounting Clip 146 62 400 8 1 1 4 x 6 x 6 Bent Nipple 146 07 003 9 Isolation Ball Valve 146 26 043 10 Taco 007 Circulator 146 26 047 Grundfos UP15 42F Circulator 146 26 045 400 F Black Silicone Rubber Adhesive 146 06 020 Fuse Link G4AM0600 144C 146 29 002 Spill Switch Water 36TX16 6281...

Page 34: ...nections Replace transformer as appropriate Thermostat cr Thermostat widng problem Check system per instructions provided with thermostat Two Blinks replace sensor Check sensor connections If good _ Three or four blinks Yes Internal error replace L71 48F control I Check for 24V at 81 B2 I I J Yes 4 L7148F is OK check ignition and gas valve system as described in literature provided with those prod...

Page 35: ......

Page 36: ...T NUMBER MODEL NUMBER PART DESCRIPTION NAME 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 handling When Sears arranges the installation you can be sure the Job is done fight We will arrange for professional workmanship and we ll take ca...