Kenmore 229960230 User Manual GAS FIRED BOILER Manuals And Guides L0511245

KENMORE Boiler Manual L0511245 KENMORE Boiler Owner's Manual, KENMORE Boiler installation guides

User Manual: Kenmore 229960230 229960230 KENMORE GAS-FIRED BOILER - Manuals and Guides View the owners manual for your KENMORE GAS-FIRED BOILER #229960230. Home:Heating & Cooling Parts:Kenmore Parts:Kenmore GAS-FIRED BOILER Manual

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Owner'sManual
CONTINUOUS
PILOT
MODEL
NO.
229.960330
229.960340
229.960360
229.960360
229.960370
229.960380
229.960390
ELECTRONIC
INTERMITTENT
IGNITION
MODEL
NO.
220.960230
229.960240
229.960260
229.960260
229.960270
229.960280
229.960290
Theseinstructionsmustbe affixed
onor adjacentto the boiler.
CAUTION
Readall instructionscarefully
beforestartingtheinstallation.

Save this manual

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 supplier. Natural gas boilers are not to be
converted to Propane gas.

for future reference.

PRINTED

IN U.S.A.

FOAM e37-_00-02_02-6"7949

Warranty ....................................................
Rules for Safe Installation and Operation ..................
Boiler Ratings and Capacities .............................
Before You Start ............................................
Locating the Boiler .........................................
Fresh Air for Combustion ..................................
Installation - System Piping ............
: ...................
Chimney and Vent Pipe Connection .......................
Vent Damper Operation ....................................
Gas Supply Piping .........................................

2
3
4
5
5
6
7
10
!1
12

Electrical Wiring ............................................
Controls and Accessories - What They Do ...............
For Your Safety - Read Before Operating .................
Operating Your Boiler ......................................
Checking and Adjusting ...................................
Cleaning Your Boiler .......................................
Maintaining Your Boiler ......................................
Service Hints ...............................................
Repair Parts ................................................

!3
19
20
22
23
24
25
26
27

E_ AIRS
KENNMORE CAST IRON BOILERS
FULLONE YEAR WARRANTYON HOTWATERAND GAS STEAM CASTIRON BOILERS
For one {1) year from the date of installation, when this boiler is installed and maintained in accordance
with our instructions. Sears will repair defects in material or workmanship in the boiler, free of charge.
LIMITED 12 YEAR WARRANTY ON STEAM CAST IRON BOILERS
After one {1 ) year and through twelve (12} years from the date of installation, Sears willfurnish a replacement
heat exchanger, if the heat exchanger in the boiler is defective. YOU PAY FOR LABOR.
LIMITED 20 YEAR WARRANTY ON HOT WATER CAST IRON BOILERS
After one (1) year and through twenty (20) years from the date of installation,Sears will furnish 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, 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 which vary from state to state.

IMPORTANT
The following are the responsibilities
not covered by the Warranty

of the user and are

5. If the unit is removed from the place it was originally
installed, this Warranty becomes void.

1. Filter cleaning or replacement.

6. Damage to the unit caused by accident, abuse, negligence,
misuse, riot, fire, flood, or acts of God.

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 electricaI protective
devices.

SEARS ROEBUCK AND COMPANY
D/817WA
Hoffman Estates, IL 60179

4. Damage to unit caused by the use of components or other
accessories not compatible with the unit.
®,_E

1. Read the Owner's Manual carefully Failure to fallow the
rules for safe operation and the instructions can cause
a malfunction of the boiler and result in death, serious
bodily injury, and/or property damage.
2. Check your local codes and utility requirements before
installation, The installation must be in accordance with
their directives,
3. Before servicing, allow boiler to cool. Always shut off any
electricity and gas to boiler when working on it. This will
prevent any electrical shocks or burns.

5. Be certain your new 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 space. Always vent
to the outside. Never vent to another room or inside a
building.
7. Be sure there
combustion.

is adequate

air supply

for complete

8. Follow a regular service and maintenance schedule for
efficient and safe operation.

4. Never test for gas leaks with an open flame. Use soap
and check all connections. This will avoid any possibility
of fire or explosion.

TOOLS

MATERIALS

Pipe Wrench

Pipe joint compound suitable for natural and propane gas.

Screwdrivers

Iron or copper pipe for the water lines,

Tin Snips

Black pipe for the gas lines.

6 foot tape or folding rule

Miscellaneous fittings.

Hack Saw

Solder and flux if you have copper piping.

LP Torch, if you have copper piping
Pipe cutter and threading tools
(for iron pipe systems)

The following booklets will help you in making the installation:
Electrical

Wiring - Available at Sears from the Plumbing, Heating or Electrical Departments at nominal cost.

American National Standards, Installation of Gas Appliances and Gas Piping, ANSI Z223.1-1atest
©btain from American Gas Association, 1515 Wilson Boulevard, Arlington (Roslyn), VA 22209

revision.

e07_3,_

VENT
DAMPER

ASME
POP
SAFETY

PRESSURE
GAUGE

LIMIT
RESSURE261/="
ONTROL

43/,=
.

VALVE
,;

i
/

J
2'/2" NPT
\

29"

;

_
:

SWITCI-€

I
WATER
LiNE --

SPILL

-'_

PROBE

ROLLOUT

36_e"

_$8

-SWITCH

CUT'OFF

24"
GAS

_
GAS

A ....
_ UNE
;

FRONT

LEFT SIDE

DESIGN
CERTIFIED FOR
NATURAL GAS

RIGHT SIDE

GAS-FIRED STEAM BOILERS
"[h_TURALG/_

BOILER MODEL NUMBER
INTERMrr_NT
IGNITION
Wr_l

VIg_IT I_MPER

229960230
22996024O
229960250
229960260
229.960270
229.960280
229.960290

s'rANOING
PLOT
WiTH vl_rr

NO.OF
SECTIONS

DAMPER

229.960330
229.960340
229.960350
229960360
229.960370
229.960380
229.960390

3
4
5
6
7
8
9

AGA

HEATING

NET
_B-R

INPUT
"MW'I

CAPAQ'rY
*MOH

RA'J_NG

75
112
150
187
225
262
299

62
91
122
153
183
214
245

47
68
92
115
137
161
184

°MBH

DgMENSlO_
N_ _B_
RARN6

SO.

PJ_4ATIQ#

196
283
383
479
571
67!
767

(_)
FLUE
DIAMErE_

5
6
6
7
7
7
7

"A"
WlEI].I

111_
14V_
!7¾
21
24%
2_/_
303/4

* MBH = 1,000 8tuh.
Btuh = British Tnermat Unit Per Hour
**Add 5Vz"to height for Vent Damper
1"For altitudes above 2,000 ft rabngs should be reduced a[ the rate of 4% fc_ each 1,000 ft above sea level
Heating Capacity is based on DOE. (Department of Energy) test prc_edure

The Ratings marked "Net I=B=R Ratings" indicate the amount
of equivalent direct cast iron radiation each boiler will take
care of under normal conditions and thermostatic control.
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.

of 15 psi (pounds per square inch) in accordance with A.S.M.E.
(American Society of Mechanical Engineers) Boiler and
Pressure Vessel Code Section IV Standards for cast iron
heating boilers.

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 requirements,
Specifications and dimensions are subject to change without
notice.

This boiler is factory equipped for use at altitudes of 0-2,000
feet above sea level. For use at altitudes above 2,000 feet
above sea level, the input ratings are reduced by a change
in main burner orifice size.

BOILERS FOR USE AT HIGH ALTITUDE

For altitudes above 2,000 feet above sea level, input ratings
should be reduced at the rate of 4% for each 1,000 feet
above sea level. Consult the National Fuel Gas Code
(NFPA54/ANSl Z223.1 -latest edition}, or the manufacturer for
correct orifice sizing information. High altitude orifices are
available from the boiler manufacturer.

These Gas-Fired Steam Boilers are low pressure, sectional
cast iron boilers Design Certified by A.G.A. (American Gas
Association} for use with Natural Gas. They are constructed
and hydrostatically tested for a maximum working pressure

r_7_c

Checkto besureyouhavetherightsizeboilerbeforestartingtheinstallation.
See rating and capacitytable on previouspage. Also be sure the new
boiler is for the type of gas you are using. Checkthe ratingplate on
the rightsideof theboiler.
You must see that the boiler is suppliedwith the correct type of gas,
fresh air for combustion,and a suitableelectricalsupply Also,the boiler
mustbe connectedto a suitablechimneyand an adequatepiping system.
Finallya thermostat,properlylocated,is neededfor controlof the heating
system. If you haveany doubts as to the various requirements,check
with local authoritiesand obtain professionalhetp whereneeded.Take
the time to completeall of the steps for SAFEand PROPERoperation
of the heatingsystem.
Theseboilersare designedfor use in closed heatingsystemswhereall
of the steam is returnedto the boiler as condensateand the amount
of make-upwater required is minimal.These boilers are not designed
for or intendedfor use in open systems or processapplicationsusing

100% make-upwater.Damageto the boiler resultingfrom such use shall
not be coveredunderthewarranty
Whererequiredby the authorityhavingjurisdiction,the installationmust
conformto AmericanSocietyof MechanicalEngineersSafetyCode for
ControlsandSafetyDevicesfor Automatically
FiredBoilers,No.CSD-1.
The installationmus_conformto the requirementsof the authorityhaving
jurisdictionor, in the absenceof such requirements,
to the NationalFuel
GasCode,ANSIZ223.1-1atest
revision.
Thefollowingstepsareall necessaryforproperinstallation
andsafeoperation
ol yourboiler.
1. LOCATING
THEBOILER
5. GASSUPPLY
PIPING
2. FRESHAIRFORCOMBUSTION
6. ELECTRICAL
WIRING
3. INSTALLATION
- SYSTEMPIPING
7. CHECKING
& ADJUSTING
4. CHIMNEY& VENTPIPECONNECTION

KEEP BOILER AREA CLEAN AND FREE FROM COMBUSTIBLE MATERIALS,
GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS

1. Select level location as centralizedwith piping system,and as near
chimney,aspossible.
2. Placecratedboiler at selectedlocation,removecrateby pullingcrate
sides from top and bottom boards.Combustiblefloors:Whenboiler
is to be installedon a combustiblefloor, a SpecialBasePlatemust
be used- 146-14-031 (3-6 Section}or 146-14-032(7-9 Section}.
Thisboilermustnotbe installedon carpeting.
3. If this boiler is equippedwith cast iron burners,it is also equipped
with stainlesssteel wire ties to hold the back end of the cast iron
burnersin placeduring shipping.In order to removethe burnersfor
cleaningor inspection,the wire ties must be cut and removed.The
wire ties are accessedthroughthe combustionair openingon the
back side of the boiler at the bottom of the rear jacket panel,and
may be cut with any wire cutting pliers. I1the boiler is installedat
its minimumclearancesit maybe difficultto reachthe wireties after
the boiler is installed,and lhe wire ties shouldbe cut now.The wire
ties are onlyneededduringshipping,anddo not needto be replaced.
Boilersequippedwith stainlesssteel burnersdo not havewire
ties andthis informationdoes notapply.
4. Boiler is to be level. Metal shimsmay be used under baselegs for
finalleveling.
5. Accessibility clearances must take precedence over fire
protectionclearances.18"clearanceshouldbe maintained
at a side
wherepassageis requiredto accessto anotherside for cleaningor
servicing, inspection,or replacementof any parts that normallymay
requiresuchattention.18" clearanceis recommended
on the control
sidefor servicing.
Figure2 showsminimumclearances
to combustibleconstruction.Rooms
that are large in comparisonwith the size of the boiler are defined
as rooms havinga volume equal to or greater than 16 times the
volumeof the boiler. Wherethe actual ceiling heightof a room is
greaterthan 8', the volumeof a roomshaft be figuredon the basis
of a ceilingheighto18'. Determination
of roomsize shouldbe based
on the total volumeof air gas fired equipmentinstalledin the room.
Consutt section 6.3.1 of the National Fuel Gas Code for further
information,includingapprovedmethodsfor reducingclearancesin
largerooms.
6. Equipmentshall be installedin a locationin which the facilitiesfor
ventilationpermit satisfactorycombustionof gas,properventing,and

maintenanceof ambient temperatureat safe limits under normal
conditionsof use. Equipmentshall be locatedso as not to interfere
with propercirculationof air.Whennormalinfiltrationdoesnot provide
thenecessaryair,outsideair shallbe introduced(SeePage6 - "Fresh
Air for Combustion").
7. Advise ownerto keep air passagesfree of obstructions.Ventilating
andcombustionair mustenterboiler roomwithoutrestrictions.
8. Theboilershallbe installedsuchthattheautomaticgasignitionsystem
componentsare protectedfrom water (dripping,spraying,rain, etc.)
during applianceoperationand service (condensatetrap, control
replacement,
etc.).

Alcove,orRoomNMLarge
RoomLargeIn
In Comparison
WithBoiler Comparison
WithBoiler
Top

Rear

Control Side

Opposite Side

Front

18"

18'

Flue/Vent Connecto_

Near Boiler Piping

BoilerSize

BoilerVolume
(Cu.Ft.)

Minimum
RoomVolumeRequired
ToBe
LargeRoom(Cu.Ft.)*

3 sect.

100.4

4 sect.

129.4

5 sect.

158.4

6 sect.

11.7

187.4

7 sect.

13.5

216,4

8 sect.

153

245.4

9 sect.

17.2

274,5

* FOR ROOMWITHSINGLEBOILERONLY
THIS UNIT MUST BE SET ON A CONCRETE OR OTHER
NON-COMBUSTIBLE MATERIAL BASE OR FLOOR.

Provision for combustion and ventilation air must be in accordance with Section 5.3, Air for Combustionand
Ventilation, of the National Fuel Gas Code, ANSI Z223.1-1atest revision, or applicable provisions of the local building codes.

WARNING

NOTE

Be sure to provide enough fresh air for combustion.
Enoughair insuresproper combustionand assures that
no hazardwilldevelopdue to the lackof oxygen.

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.

You must provide for enough fresh air to assure proper
combustion. The fire in the boiler uses oxygen. It must have
a continuous supply. The air in a house contains only enough
oxygen to supply the burner for a short time. Outside air
must enter the house to replace that used by the burner.
Study following examples 1 and 2 to determine your fresh
air requirements,

2. When communicating with the outdoorsthrough vertical
ducts, each opening shall have a minimum free area
of one square inch per 4,000 Btu per hour 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.

EXAMPLE 1: Boiler Located in Unconfined Space

4. When ducts are used, they shall be of the same crosssectional area as the free area of the openings to which
they connect. The minimum dimension of rectangular
air ducts shall be not less than three inches.

If your boiler is in an open area (unpartitioned basement)
in a conventional house, the air that leaks through the cracks
around doors and windows will usually be adequate to provide
air for combustion. The doors should not fit tightly. Do not
caulk the cracks around the windows,
An unconfined space is defined as a space whose volume
is not less than 50 cubic feet per 1,000 Btu per hour of
the total input rating of all appliances installed in that space.

Fresh Air Duct Capacities for Ducts Supplying Fresh Air to
boiler in tightly constructed houses. British Thermal Units per
hour Input (Btuh)*.

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 sothat the combined volume of all spaces
meets the criteria for an unconfined space. The total input
of all gas utilization equipment installed in the combined
space shall be considered in making this determination.
Each opening shall have a minimum free area of one
square inch per 1,000 Btu per hour of the total input rating
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,

1/,- Mesh
Screen
Btuh

Wood
Louvers
Btuh

Metal
Louvers
Btuh

3' x 12'

144,000

36,000

108,000

8" x

256,000

64,000

192,000

8' x 12"

384,000

96,000

288,000

8V2' x 16'

512,000

128,000

384,000

*Basedon

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 openings
shall communicate directly, or by ducts, with the outdoors
or spaces (crawl or attic) that freely communicate with
the outdoors.

opening covered by

V4"meshscreen,woodIouvers,or metallouvers.

AIR
DUCT
FRESH

FRESH AIR DUCT
FOR TIGHTLY
SEALED
HOUSE

1. When directly communicating with the outdoors, each
opening shall have a minimum free area of one square
inch per 4,000 Btu per hour of total input rating of alt
equipment in the enclosure.

,_,*

Fresh Air
Duct
Size

The near boiler piping, that is the piping around the boiler,
must be considered as part of the boiler for proper water
level control, and to produce dry steam. Correct near boiler
piping is crucial to the proper operation of the boiler and
the heating system. Follow these recommendations carefully
1 Place boiler in selected
possible.

location, as near chimney

or on discharge pipes between such safety valves and
the atmosphere. Installation of the pop safety valve shall
conform to the requirements of the ANSI/ASME Boiler and
Pressure Vessel Code, Section IM The manufacturer is not
responsible for any water damage

2. Install the pop safety valve, using the furnished 3/4"
coupling, into the 3/4' pipe nipple on the top of the boiler.
Make a discharge pipe, using 3/4' pipe (not furnished}
to carry the water or steam to a nearby drain. Do not
connect the discharge pipe directly to a drain but leave
an air gap. The downstream end of the discharge pipe
must be unthreaded. No shutoff of any description shall
be placed between the pop safety valve and the boiler,

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 piping for gravity return
systems is shown in Figure 5. This configuration uses one
supply and one return tapping. This setup can be used
on any size boiler in this series. The supply and return
connections may be piped both into the same side (either
left or right} or one into each side of the boiler.

STEAMMAINS

PiPEFULLSIZESAME
ASBOILER
TAPPING

(2
POPSAFETY
VALVE

6" TO 10"
- REDUCINGELL POINTING
DOWN

MAINVENT

DRYRETURN
MAIN

FLUE
1 1/2" MIN
PIPESIZE
15" MIN.

28' MIN - DIMENSIONA
2 1/2" TEEWITH
PLUGFOR
24"
NIPPLE
)RD LOOP

WETRETURN
-GATE VALVE(NOT FURNISHED)

JFEED

DRAINVALVE(FURNISHED)
FOR FLUSHING SYSTEM

I 1/2" FULL PORT BALL VALVE
FOR BOTTOMBLOWDOWN
AND DRAINING BOILER
& SYSTEM(NOT FURNISHED)

7,_

5. For installers choosing to use both supply tappings, Figure
6A shows the correct way to pipe this system. Figure
6B shows the wrong way to pipe a header with two risers.
• Headers must be fitted with header offsets or swing joints,
or be equipped with expansion joints, so that thermal
expansion and contraction of the header will not damage
the boiler. Headers shall not be welded.
• System takeoffs from the header must be between the
equalizer and the riser to the header nearest the
equalizer. System takeoffs must never be between two
risers.
6. System takeoffs from the header must never be bullheaded. If the steam main goes in two directions, there
must be two takeoffs from the header, one for each main.

7. All boilers in gravity return systems 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 with a
plug located on the supply line as shown for skimming
{i.e. surface blowdown).

STEAM MAINS

PIPEFULLSIZESAN_E
AS BOILERTAPPING
MIN
(2 1/2"
6" TO 10"

POP SAFETY VALVE

ELLPOINTING

CONNECTRISERTO BOILERWITH
2 I/2" ELBOW AND NIPPLE
(NOT SHOWN)

MAINVENT

DOWN
DRY RETURN
MAIN

FLUE
COLLAR

1 1/2" MIN.
PIPESIZE
1S" MIN.
28" MIN

DIMENSIONA

2 1/2" TEEWITH
PLUGFOR
@

24"
NIPPLE
HARTFORD LOOP

RETURN

-GATEVALVE
(NOTFURNISHED)
W_AfERFEED

_ORAIN

VALVE(FURNISHED)
FOR FLUSHINGSYSTEM

I I/2"FULLPORT BALLVALVE
FOR BOTFOM BLOW DOWN
AND DRAININGBOILER
& SYSTEM(NOTFURNISHED)

WRONG WAY
DO NOT BULLHEAD,USE
TWO TAKEOFFS

THIS PIPING CONFIGURATION
IS INCORRECTTO SHOW
COMMONMISTANES
WRONG WAY
TAKE OFFS MUST BE BETWEEN RISER & EQUALIZER

WRONG WAY
SWING JOINTS ARE MISSING

)NG WAY
MISSING TEE
FOR SKIMMING

12. The near boiler piping shall include a 1V2" ball valve
in the return piping as shown for bottom blowdown and
draining.
13. For gravity return systems, the bottom of the lowest steam
carrying pipe, be it a dry return, or the end of the steam
main, must be at least 28' above the normal water level
line on the right side of the boiler. This is known as
"Dimension A."
14. For pumped return systems, follow the condensate pump
or boiler feed pump manufacturer's instructions for proper
installation and 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.

B. When this boiler is connected to heating coils located
in air handling units where they may be exposed to
refrigerated air circulation, the piping system shall be
equipped with flow control valves or other automatic means
to prevent gravity circulation of the boiler water during
the cooling cycle.

SYSTEM

VALVES A & B
OPEN FOR HEATING;
CLOSE FOR COOLING
VALVES C & D
CLOSE FOR HEATING:
OPEN FOR COOLING
C

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. Appropriate valves must
be used to prevent the chilled water from entering the
heating boiler (Fig. 7).

O
CHILLER

_4_o7

In accordance with Part 7, VenUng of Equipment, of the National Fuel Gas Code,
For boilers
for connection
gas
vents or provisions
chimneys, vent
shall
be
ANSI
Z223.1-1atest
revision to
and
applicable
of theinstallations
local building
codes.

CHECK YOUR CHIMNEY

7. Run pipe as directly as possible with as few elbows as
possible.

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 properly with a bad chimney Inspect the chimney and verify that the construction and
size of the chimney meets all applicable provisions of the
National Fuel Gas Code and local building codes. Fig. 8
gives you an idea how a boiler might be vented to a chimney.
Note that the height (HT) is measured from the vent pipe
to the top.
CHIMNEY

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 connection.
10. Horizontal run should not be longer than 3A the chimney
height (HT) (Fig. 8).
The sections of vent pipe should be fastened with sheet metal
screws to make the piping rigid. Horizontal portions of the
vent system must be supported to prevent sagging. Use
stovepipe wires every 5' to support the pipe from above.
If the vent pipe must go through a crawl space, double wall
vent pipe should be used. Where vent pipe passes through
a combustible wall or partition, use a ventilated metal thimble,
The thimble should be 4 inches larger in diameter than the
vent pipe.

SIZING

Chimney sizing and all other aspects of the vent installation
must be in accordance with Part 7 of the National Fuel Gas
Code, ANSI Z223.1-latest revision, and applicable provisions
of the local building codes.

CONNECTING THE VENT DAMPER
AND VENT CONNECTOR

MINIMUM

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

VENT PIPE CLEARANCE

Wood and other combustible materials must not be closer
than 6' from any surface of single wall metal vent pipe. Listed
Type B vent pipe or other listed venting systems shall be
installed in accordance with their listing.

IMPORTANT - The damper blade on the furnished vent
damper has a 1/2square inch hole (approximately 3A,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.

REMOVING EXISTING BOILER FROM
COMMON VENTING SYSTEM
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.

1. Position furnished vent damper on top of flue outlet collar,
Fasten damper securely to flue outlet collar with sheet
metal screws. Make sure damper blade has clearance
to operate inside of diverter.
As An Option
The damper may be installed in any horizontal or vertical
position, closer to the flue outlet collar preferred. Follow
the diagrams - Figures 9, 10 and 11.

At the time of removal of an existing boiler, the following
steps shall be followed with each appliance remaining
connected to the common venting system placed in operation,
while the other appliances remaining connected to the
common venting system are not in operation.
Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deficiencies which
could cause an unsafe condition.
1,

2. Install the vent damper to service only the single boiler
for which it is intended. The damper position indicator
shall be in a visible location following installation. Locate
the damper so that it is accessible for servicing.
3. The damper must be in the open position when appliance
main burners are operating.

4. The boiler is equipped with a factory wired harness that
plugs into the vent damper. The thermostat must be
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.
,,_

I
I

Insofar as is practical, close all building doors and windows
and all doors between the space in which the appliances
remaining connected to the common venting system are
located and other spaces of the building. Turn on clothes
dryers and any appliance not connected to the common
venting system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will operate at
maximum speed. Do not operate a summer exhaust fan.
Close fireplace dampers.

4 Placein operation
theappliancebeinginspected.Follow
the lightinginstructions.
Adjustthermostat
so appliance
willoperatecontinuousl_z
5. Testfor spillageatthe drafthoodreliefopeningafter5
minutes
ofmainburneroperation.
Usetheflameofa match
or candle,or smokefroma cigarette,
cigaror pipe
6. Afterit hasbeendetermined
thateachapplianceremaining connectedto the commonventingsystemproperly
vents when testedas outlinedabove,return doors,
windows,exhaustfans,fireplacedampersandanyother
gas-burning
appliancetotheirprevious
conditions
ofuse
7 Any_mproper
operationof the commonventingsystem
shouldbecorrectedsothe installation
conformswiththe
National
FuelGasCode,ANSIZ223.1-latestrevision.
When
resizinganyportionof the commonventingsystem,the
commonventingsystemshouldbe resizedto approach
the m_n_mum
sizeas determinedusingthe appropriate
tablesin Part11 in the NationalFuelGasCode,ANSI
Z223.1-latestrewsion.
For boilers for connection 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 mechanical draft systems operating under positive pressure.

ROOF
RIDGE

3/4

HT MAXIMUM

MUST SLOPE
UP
AT LEAST
1/4 INCH
PER FOOT OF
HORIZONTAL

RUN

HORIZONTAL INSTALLATION

TO FURNACE
OR BOILER

VENT
DAMPER

TO CHIMNEY
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

TO FURNACE N
OR BOILER

INSTALLED

MAY BE

IN ANY POSITION

TYPICAL INSTALLATION
FOR VENT DAMPER
NOTE CAUTION AND FOOTNOTES
1. Install the vent damper to service only the single appliance for
which it is intended, ff improperly installed,a hazardous condition,
such as an explosion or carbon monoxide poisoning, could result.
2. Do not install the vent damper on vent pipe curve.
3. DO not run wiras near high temperature surfaces. Use stand-off
brackets it necessary

For safe, efficient operation, 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 for repairs.
Check vent damper operation as follows:

thermostat will control the burner firing as before, while the
damper will remain open. DO NOT turn damper open manually or motor damage will result. Set switch to "AUTOMATIC
OPERATION" to close vent damper during burner off cycle.
For further information, and for a vent damper troubleshooting
guide, refer to the Effikal manual that was packaged with
the vent damper.

1. When the boiler is off, check that the vent damper position
indicator points to the closed position, Fig. 11.
2. Turn the thermostat or controller up to call for heat and
check that the vent damper indicator points to the open
position, Fig. 11.
3. Turn the thermostat or controller down again and check
that the vent damper position indicator returns to the closed
position.
4. If you have central air conditioning, set the thermostat to
COOL and turn it down to call for cooling. Cooling system
should operate.
5. Return thermostat to desired position.

The vent damper must be Inspected st least once a
year by a trained, experienced service technician, The
name of the person who originally installed your vent
damper is shown on the installation label.

DAMPER

MANUAL

OPERATION

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

CHECK

CLOSED

DAMPER

OPEN

OF THE VENT DAMPER

SHOWING OPEN AND CLOSED POSITION

GAS SUPPLY

or in the absence of such requirements, by the National
Fuel Gas Code, ANSI Z223.1-latest revision.

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 be
disconnected from the gas supply piping system during any
pressure testing of that system at test pressures in excess
of V2 psig (3.5 kPa).

2. Use pipe joint compound
threads only.

suitable for LP gas on male

3. Use ground joint unions.
4. Install a sediment trap upstream of gas controls.
5. Use two pipe wrenches when making the connection
to the gas valve to keep it from turning.
6. Install a manual shut-off valve in vertical pipe about 5
feet above floor.
7. Tighten all joints securely

The boiler must be isolated from the gas supply piping system
by closing its individual manual shutoff valve during any
pressure testing of the gas supply piping system at test
pressures equal to or less than V2 psig (3.5 kPa).

CHECKING THE GAS PIPING
Upon completion of piping, check immediately for gas leaks.
Open the manual shut-off valve. Test for leaks by applying
soap suds (or a liquid detergent) to each joint. Bubbles
forming indicate a leak. CORRECT EVEN THE SMALLEST
LEAK AT ONCE.

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,
....

Never use a match WARNING
or open flame to test for leaks.

NATURAL GAS
Pipe Capactty- BTU Per Hourlnput
Includes Fittings

Length of
Pipe - Ft.
½"

¾"

MANUAL
SHUT-OFF

1%"

92,000

190,000

350,000

625,000

63,000

130,000

245,000

445,000

50,000

! 05,000

195,000

365,000

VALVE

AUTOMATIC
VALVE

GROUND
JOINT
MANIFOLD

UNION

S OI.ENTTRAP
FLOOR
LINE

ELECTRIC

POWER

SUPPLY

All electrical work must conform to local codes, as well as
the National Electrical Code, ANSI/NFPA-70, latest revision.
Run a separate 120 volt circuit from a separate overcurrent
protective device in your electrical service entrance panel.
This should be a 15 ampere circuit. Locate a shut-off switch
at the boiler. It must be turned off during any maintenance.
Connect 120 volt electrical supply to the primary leads on
the 24 volt transformer. Solder and tape or securely fasten
these connections with wire nuts.
The boiler, when installed, must be electrically grounded in
accordance with the requirements of the authority having
jurisdiction or, in the absence of such requirements, with the
National Electrical Code, ANSI/NFPA No. 70-latest revision.
Run a 14 gauge or heavier copper wire from the boiler to
a grounded connection in the service panel or a properly
driven and electrically grounded ground rod.

]

WARNING

Turn off electric power at fuse box before making any
line voltage connections. Follow local electrical codes.

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 following:

pl
_u

DEAD SPOTS:
Behind doors
Corners and alcoves
HOT SPOTS:
Concealed pipes
Fireplace
TV sets
Radios
Lamps
Direct sunlight
Kitchens
COLD SPOTS:
Concealed pipes or ducts
Stairwells - drafts
Doors - drafts
Unheated rooms on other side of wall
Set heat anticipator at 0.4 amps for boilers equipped with
standing pilot, and at 0.6 amps for boilers equipped with
intermittent ignition. The 24 volt thermostat leads shall be
connected to the two wires tagged "24 volt thermostat" on
the boiler. For boilers with 67D-1 float type low water cutoff, the two wires are black. One wire is located on the
secondary of the 24 volt transformer, the second wire is
located on the pressure limit control. For boilers with PS802 probe type low water cut-off, one wire is green and
is located on terminal B of the PS-802, the second wire is
black and located on the pressure limit control.
ELECTRONIC
THERMOSTATS
Certain types of electronic therrnostats may lose their memory
or shut down. With 67D-! float type low water cut offs,
this may occur each time the thermostat calls for heat,
due to the internal circuit in the vent damper. With PS-802

probetypelowwatercutotis,thismayoccureachtimethe
lowwatercutoffdetectsa lowwaterconditionIf thisis the
case,an isolationrelayis requiredforthethermostat
circuit
A24voltsinglepolesinglethrow(SPST)
normally
open(N.O.)
relay _s required,such as the HoneywellR8222Aor
equivalent.
Wireasshownin Fig.14Aor Fig.14B.

VENT

DAMPER

VENT DAMPER

PLN

MOLEX PLUG

The boiler is equipped with a factory wired harness with 4
pin molex plug, that plugs into the 4 pin molex receptacle
inside the vent damper operator.

-ISOLATION

SPST N+O. HONEYWELL
I R8222A OR EQUIVALENT

The vent damper must be connected for the boiler to operate.
Wiring diagrams follow for the various different models.

] _,_?
L........

i PRESSURE

LIMIT

p.J

....

CAUTION

.+tJ
%\

ELECTRONIC
THERMOSTAT

TO LWCO
AND
IGNITION
SYSTEM

FIELD WLRING

....

Label all wires prior to disconnection
when
servicing
controls.
Wiring errors can cause
improper and dangerous operation, Verify proper
operation after servicing.

,_-----t----I
BK

24 VOLT
TRANSFORMER

24V.

RELAY

VENT DAMPER
4 PIN
MOLEX PLUG
_y

_-ISpOs[TA
TI?o ' REoLNAYy
W22
EVL

BK
R8222A
24

VOLT

TRANSFORMER

°
+

L -,"
-o" o---

TO LWCO AND
IGNITION SYSTEM

EQUIVALENT

.....

__±,,",PRES_

LIMIT

TERMINAL++

OF LWCO

ELECTRONIC
THERMOSTAT
---

FIELD WLRING

EFFIKAL
MOLEX

I 15V/BOHZ/I f

pOWER
SUPPLY

B_X

r -l_

RVGP
PLUG

VENT

OA,_PER

)

j\®/ .....
L_

INTERMITTENT IGNITION

iiii

_____.j'--"

OP_ONAL
WF-2U-2_.
WATi_
_"l{EOER
NOTE:
T_¼1N_.
N0 ] APpFJ_R$ ONLy
ON WATER FEEC_R MODELS WITH
tJXNL_I. _£0
PUSH 8U_'ON.
_

-- WIRE

COLOR

Wt_RMRTF'NT

pIL'OT CONTRCt

_LWC

0 pRoBE

NUT

CODE

8K-BIJ_CK
BR-BROWN
0 -ORA_C£
y -_AA_OW
R -RED
BT-BIJ_CN
WITH TRACER
W -11_41rE
G -GRE[]_
8 -BLUE

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_

STANDING PILOT
EFFIKAL
MOLEX

HeVI_OHZll
m

RVGP
PLUG

pOW_
SUpPLy

V_NT

DAMPER

)@(
Y

PRESSURE UMIT
_

_SO3NNECT

r ......

', IQ-÷ .......

I
I
I

I_@-4
L_X=/___J-

_--WIRE

.....

NUT

COLOR

CODE

8X-B_
BR-E_ROWN
0 -ORANGE
y -YELLOW
R -RED
BT-B_
VCh'H TRACER
W -WHITE
G -GREEN
8 -BLUE

RVGP-KS-BKF

OPI1ONAL _-2U--:14
W_TER
REED_
NOTE:
TERMIteS. NO, 3 APpF_S
C_NLY
ON WATER F_ER
MOC_'LS
MANUAL BEF.,D PUSH t_,rrTON

VENT

OA._PER

OOUBL_

POLE,

DOUBLE

RELAy

/-;
II

12_._? I
i 7J-_6
15_15

THROW

POLE

CONNECrOR

I
I
PI_osTAT

LIMI T

....

A.C.

TO D.C

CONVERSION

LWCO

J
POWER
CIRCUIT

,3-

MOTOR
_1-0411yll

_2 4 VAC
50/60
HZ

N.C.

N.C,

N'O
N,C,

FLA_E

ROLLOUT

SHUTOFF

N[UT_

i1_V/BOHZ/I_

®..o._
_-___J

BLOCKED
S_E_
SHUTOFF

_NT

HOT

GAS
VAL_

O_RCURRENT
PROTECT[D
DISCONNECT

NOTE:
SlA AND SlB ARE THE AUTOk_T_C Op[RATJON / HOLD BAMPER OPEN SWITCH
SWITCH SHOWN tN AUTOMATICPOSLTION.
$2, $3. AND S4 ARE CAXt ACTUATEDSNAP SV_TCHES

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.

INTERMITTENT
EFFIKAL

RVGP
MOLEX

VENT
PLUG

IGNITION

DAMPER

VOLT

TRANSFORMER

115V/BOHZ/I_
POWER

SUPPLY

.oT-_Jo-.
_
0V£RCURRENT

PROTECTED

DISCONNECT
W
NEUT

pR_SSURC

LIMIT

)

\(_

.....

OPTIONAL WF-2U-24
WAFER FEEDER

I_--

WIRE

NOTE:
TERMINAL NO. 3
APPEARS ONLY ON
WATER FEEDER MODELS
WITH MANUAL FEED PUSH

NUT

RVCp-KS-BKF

FLAME

ROLLOUI

BUTTON

GAS VALVE

V,ENT O_IpzR

I 7
_
_6

i
I
I

i ......

°,"

ZNr

DAtaPER

C_.81E

r.ER'_OS,^T

Ll_Ir

,°'-°",1
I

( _°,fv°_
50/60

'p._L"
o,1

_--i L#

HZ.

S2j'a-_

I ;2_;, I.
LWC0

8K
_

_HO

N_UIRAL
T

115'V/60HZ/

II_

OV£RCURRENI
PROT[CTED
DISCORNECT
NC

.-%

S8600(F,M)

.o1o

INI[RUlTT[N_

PILOI

CONTROL

_FFPr
5NUIOFF

BLOCKED
SV_"ET_
SHUTOFF

>>>Z

1234

TO pILOt

BURN£R

kOTD
SlA

A_O

OPg_TrON

SIB
/

S,N_TCH SHNH

_g
HIN_

THE AUT0_TIC
_I_R

IN _OMATIC

OPEN NTCH
POSmI_.

cAs
VRB204A

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.

1 7

741_3

EFFIKAL RVGP VENT DAMPER
MOLEX PLUG

STANDING PILOT

24 VOLT
TRANSFORMER

IIBV/6OHZ/I¢
POWER SUPPLY
HOT

._----_--_

OVERCURRENT
PROTECTED
DISCONNECT
W
NEUT

PRESSURE

I
I
J

LIMIT

LOW WATER
CUT OFF

OPTIONAL WF-2U-24
WATER FEEDER

NOTE:

VALVE

TERMINAL NO. 3 APPEARS ONLY
ON WATER FEEDER MODELS
WITH
MANUAL FEED PUSH BUTTON.

B
TR T_

I_ -- WIRE

K
TH

NUT
FLAME ROLLOUT
SAFETY SHUTOFF

RVCp-KS-BKF

V_NT

BLOCKED
VENT
SAFETY SHUTOFF

OA._pER

TO OC.
CONVERSION

POWER
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 ACTUATED SN_o SWITCHES.

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.
.....

POP SAFETY VALVE
The pop safety valve should open automatically if the boiler
steam pressure exceeds the pressure rating of the valve (15
psig). Should it ever fail to open under this condition, shut
down your boiler. If valve discharge occurs, or valve fails
to open as described above, contact an authorized contractor
or qualified service technician to replace the pop safety valve
and inspect the heating system to determine the cause, as
this may indicate an equipment malfunction.
Run a p_pe from the safety valve outlet (pipe must be same
size as outlet and open end must not be threaded) to an
open drain, tub or sink, or other suitable drainage point not
subject to freezing. Failure to do so may cause Water damage
or injury should relief valve release Do not cap off the drain
line from this valve!

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 freeze-ups if the
homeowners are away and a return line should spring
a leak.
McDonnell and Miller Model 101 water feeders may be
used, however the water feed rates are too high and need
to be regulated or throttled, and wiring will have to be
revised. Consult the boiler manufacturer before using these
or any other non-standard types of controls.
The automatic water feeder is a safety device, not a
convenience item. It is not designed to maintain a "normal"
water line. The water feeder does not take the place of
a responsible person monitoring and maintaining the
normal water line. Steam boilers require personal attention.

STEAM PRESSURE GAUGE
Every system should have a pressure gauge installed in the
boiler. This gauge enables you to monitor the pressure in
the system. If the safety devices fail to shut off your boiler
at the proper settings, notify your serviceman immediately
WATER

VENT DAMPER
This is an automatic, motorized stack damper that has
been developed to increase the efficiency of heating
systems by reducing standby losses from the boiler end
the conditioned air space. The damper closes the chimney
vent when the burner is off and fully opens it when
combustion is required.

LEVEL GAUGE

The water level in the boiler can be seen through the glass
tube in the water level gauge at side of boiler. Correct cold
boiler water revel is stamped on side jacket panel. The water
level should be checked regularly for the proper level.
On the right side jacket panel of the boiler, there are three
holes for the glass water level gauge. The top hole is common
for both types of low water cut off, and is used for the upper
gauge glass fitting. The middle hole, 9" down from the top
hole, is used for the bottom gauge glass fitting for the Model
67D-1 and 47-2 float type low water cut off. The lowest hole,
12V4" down from the top hole, is used for the bottom gauge
glass fitting for the Model PS-802 probe type low water cut
off. The hole that is not being used is covered with a sheet
metal knockout.
STEAM

PRESSURE

ROLLOUT

SWITCH

(FLAME ROLLOUT

SAFETY

SHUTOFF)

The rollout switch is a temperature-sensitive fuse link
device. It is located on the boiler base just outside the
fire box. In the event of heat exchanger flueway blockage
causing flame to roll out of the fire box, the fuse will blow,
shutting down the flow of gas to the main burners. The
fuse does not change in appearance when blown.
If the rollout switch blows, it must be replaced with an
exact replacement. Check heat exchanger flueways for
blockage when restoring system to operating condition.
Do not operate system without a rollout switch.
SPILL SWITCH

CONTROL

The steam pressure limit control {pressuretrol) shuts off the
gas to the main burners when the steam pressure in the
boiler reaches the cut-off setpoint (i.e. the sum of the cutin and the differential setpoints). Burners retire when the steam
pressure drops to the cut-in setpoint. System pressure
requirements are based on the size and condition of the
pipes, and the load.

(BLOCKED VENT SAFETY

SHUTOFF)

The spill switch is a manual reset disc thermostat with
a fixed setpoint (280 ° F), and normally closed contacts.
It is located at the relief opening of the draft diverter. In
the event of chimney or venting system blockage causing
products of combustion to spill out of the relief opemng,
the spill switch disc heats up and the spill switch contacts
will open, shutting down the flow of gas to the main burners
by removing power to the gas valve.

LOW WATER CUT-OFF
1 Model 67D-1
This is a float operated switch which shuts down the gas
burner if water falls below the visible bottom of the gauge
glass.
2. Model PS-802
This is an electronic probe type LWCO. The probe is
located inside the boiler. The LWCO will shut down the
burners if the water loses contact with the probe for a
period of 10 seconds.
Refer to manufacturer's instructions {enclosed) for more
information.

In the event that the spill switch contacts open, the reset
button on the back of the switch will pop up. The spill
switch must be reset manually, after the switch has cooled
off, by pushing the reset button down. Check the venting
system and chimney for blockage when restoring the
system to operating condition. DO NOT operate the boiler
without a spill switch.
1 9

7_ISH

WARNING: If you do not follow these instructions exactly, a fire or explosion
may result causing property damage, personal injury or loss of life.
A. Some boilers are equipped with an intermittent ignition
device which automatically lights the pilot. Do not try to
light the pilot by hand.

• 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.

Some boilers are equipped with a continuous pilot and
must be manually lighted. (See lighting instructions on page
17.) A match holder is included in the parts bag.
B. BEFORE OPERATING smell all around the appliance area
for gas. Be sure to smell next to the floor because some
gas is heavier than air and will settle on the floor.

Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or turn
by hand, don't try to repair it, call a qualified service
technician. Force or attempted repair may result in a fire
or explosion.

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.

E_ 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.

7. Wait five (5) minutes to clear out any gas. Then smell
for gas, including near the floor. If you smell gas, STOP!
Follow "B" in the safety information on this page. If you
don't smell gas, go to next step.

2. Set the thermostat to lowest setting.
3. Turn off al! electric power to the appliance.
4. This appliance is equipped with an ignition device which
automatically lights the pilot. Do not try to light the pilot
by hand.

8. Rotate the gas control knob counterclockwise

I# to "ON."

9. Replace lower front panel.
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the instructions
"To Turn Off Gas To Appliance" and call your service
technician or gas supplier.

GAS
INLET |

TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
GAS CONTROL KNOB
SHOWN IN "ON" POSITION

2. Turn off all electric power to the appliance if service is
to be performed.

5. Remove lower front panel.

3. Push in gas control knob slightly and turn clockwise
to "OFE" Do not force.

6. Rotate the gas control knob clockwise _ to "OFE"

.....

1. STOP!
Readthesafetyinformation
onpage16.
2. Setthethermostat
to lowestsetting.
3. Turnoffallelectricpowertotheappliance.
4. Removelowerfrontpanel.
5. Rotategas controlknob slightlyand turn clockwise
to
GAS CONTROL KNOB
[-SHOWN

9 Rotate the gas control knob counterclockwise
_, to
"PILOT" Push down and hold the red reset button while
you light pilot burner with a match.
After about one minute, re[ease reset button. Pilot should
remain lit If it goes out, turn gas control knob clockwise
to OFE To relight, repeat steps 5-9.
• If button does not pop up when released, stop and
immediately call your service technician or gas supplier.

IN "ON" POSITION

•

• 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."

GAS
INLET

1 !. Replace lower front panel.
12. Turn on all electric power to the appliance.
RESET

1 3 Set thermostat to desired setting.

BUTTON

6. Wait five (5) minutes to clear out any gas. Then smell
for gas, including near the floor. If you smell gas, STOP!
Follow "B" in the safety information on page 16. If you
don't smell gas, go to next step.

TO TURN

OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

7. Find pilot - follow metal tube from gas control. The pilot
is between two burner tubes as shown in Fig. 15.

2. Turn off all electric power to the appliance if service is
to be performed.

8. Turn knob on gas control
"PILOT"

3. Push in gas control knob slightly and turn clockwise
_i to "OFE" Do not force.

MATCH

counterclockwise

P_ESSUR(
R£GULATOR
ADJUSTMENT

HOLDER

CONVENIENCE
TERMINAl{2}

WIRING
TERMINAL3

{UNDERpRESSUREINLET
CAPTApSCREW)_I_i_(OPTION_L}

OAUpTLET

PRESSURE

;,:LoToU*L'T

THERMOCOUP
CONNECTION

(2)

OT ADJUSTt'_E

'RREE
N
BUTTON

11,523A

\GA

(UNDER

CAP SCREW)

CONTROL/VALVE
KNOll

PRESSUR_R{GULATOR
A_JUSTMENT
(UNDER
CAP SCREW)

WIRING
TERMINALS(3)
OUTLETPRESSUR£
TAP

PRESSURETA_

GROUNO
TERMCNAL$(2)

INLET

.: , ;:LOTOUT
OTADJ_STM_NT

{UNOERCAPSCREW)
_GA$
CONTROL
KNOE

7_0t 7H

HOW A STEAM SYSTEM OPERATES

THERMOSTAT

The water in the boiler is heated until it reaches the boiling
point. As the water boils it turns into steam. The steam rises
from the top of the water through the supply main to the
radiation units. As it passes through the radiators it releases
its heat and condenses into water. The water returns to the

Keep it set at a desired room temperature. If windows are
to be opened or heat is not needed, move thermostat pointer
to a lower setting.

NOTE

boiler through the return main. Most residential systems
operate at less than 1 pound steam pressure.
FILLING

SYSTEM

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 thermostat to the lowest setting for one
minute, then back to the normal setting.

WITH WATER

©n steam heating systems the boiler is partially filled with
water. It is very important to the proper operation of the entire
system that your boiler be filled to the proper level. The correct
water level is about halfway up the glass water level gauge
as marked on the boiler jacket. To fill:
1. Close the boiler drain valve.

Safe lighting and other performance criteria were met with
the gas manifold and control assembly provided on the boiler
when the boiler underwent tests specified in ANSI Z21.13
- latest revision.

2. Open the valves at the top and bottom of the glass water
level gauge. Also open the drain valve at the bottom of
the gauge.
3. Open the fill valve and allow water to run into the boiler.
J

WARNING

- Never run water into a hot empty boiler,

4. Allow boiler to fill until water runs out the gauge drain
valve. Then close the gauge drain valve.
5. Continue to fill boiler until water reaches the indicated water
line. This is about halfway up the glass tube.
WATER LEVEL
The normal water level is shown on the right side of the
boiler and is 24' above the floor. The normal water level
is determined when the boiler is off and cold, i.e. when all
of the water in the system is inside the boiler and the return
piping below the water line, and everything above the water
line is air, no steam. When the boiler is making steam, the
water level win drop two to three inches below the normal
water line.

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 hold the gas supply from burner
regardless of the demand of any other control.

.....

ADJUST

PILOT BURNER

differential adjustment at 1 psi, i.e. the steam pressure
required in the radiators. This will give us a cut-off setpoint
of 11/2psi.

Pilot flame should surround 3/8' to 1/2" of the pilot sensor.
Refer to Fig. 19. If flame needs adjusting, do it as follows:

The above is an example of a typical one pipe system. For
larger systems or other types of systems such as two pipe
systems, or systems with convectors or fan coil units, the
pressuretrol settings will need to be determined on a systemby-system basis.

1. Remove screw cover over pilot adjusting screw.
2. Insert small screwdriver and adjust flame as needed. Turn
screw counterclockwise to increase flame, clockwise to
decrease.
3. Replace screw cover over pilot adjusting screw.
MAIN BURNER

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.

AIR ADJUSTMENT

The primary air shutters on the cast iron main burners should
be adjusted so the flame forms a sharp blue cone with no
yellow. Refer to Fig. 18.

The differential setpoint is the steam pressure required at
the terminal heating units.

li_[_ll i1I:]

0000@@0@0000
°°'''°°''
I_ARKIER BLUE

INNER

)

GAS VALVE SAFETY

SHUTDOWN

CONE

.Lo.

CHECKING

TEST

2. For boilers equipped with intermittent ignition, with main
burners firing, disconnect the ignition 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.
STEAM

PRESSURE

If your boiler is equipped with the optional WF-2U-24 water
feeder, continue to keep the thermostat calling for heat after
the low water cut off recognizes the low water condition. After
a one minute time delay, the water feeder should start feeding
water to the boiler, The feeder should feed for one minute,
and then go into another one minute waiting period. This
cycle of alternately waiting and feeding should repeat until:

CONTROL

The steam pressure limit control (pressuretrol) shuts off the
gas to the main burners when the steam pressure in the
boiler reaches the cut-off setpoint (i.e. the sum of the cutin and the differential setpoints). Burners retire when the steam
pressure drops to the cut-in setpoint. System pressure
requirements are based on the size and condition of the
pipes, and the load.

1. For Model 67D-1 float type low water cut offs - as the
water leve! raises the float above the burner cut off switch
level, the burners should ignite. The water feeder remains
powered until the water level raises the float to the water
feeder switch level, satisfying the water feeder,
2. For Model PS-802 probe type tow water cut offs - the
water level wil! rise until water in the boiler makes contact
with the probe, satisfying the water feeder, and igniting
the burners

For 'good system operation, the cut-in setting of the
pressuretrol should never be less than twice the system
pressure drop. In a typical single family residence with a
clean one pipe heating system and cast iron radiation, this
means that the cut-in will usually be set at the minimum setting,
i.e. 1/2psi.
Steam radiation
equivalent direct
pressure in the
in our example

CONTROLS

To check the Low Water Cut-Off, turn off power to the boiler
or turn the thermostat down to the lowest setting. Drain water
to below the visible bottom of the water gauge glass. Turn
power on and turn the thermostat to call for heat. When the
boiler is equipped with the float type LWCO, the gas valve
should not open on a call for heat when the water is low.
When the boiler is equipped with a probe type LWCO, the
gas control should be powered for approximately 10 seconds
(the time delay on the probe type LWCO), then the gas valve
will close and the red indicator will illuminate on the LWCQ

1. For boilers equipped with continuous pilot, with main
burners firing, disconnect the thermocouple from the gas
valve. The gas valve should immediately shut off the main
burners and the pilot.

ADJUST

Now your boiler will operate in the correct pressure range.
It will maintain enough steam pressure to send the steam
out to the furthest radiator, and not go over the optimum
steam pressure that is required at the radiators.

In either case, there should be between one and two inches
of water visible in the gauge glass when both the water feeder
is satisfied, and the burners are allowed to ignite.
The time delays in the feed cycles are designed to prevent
the boiler from flooding due to slow return lines.

is usually sized based on square feet of
radiation (EDR). This is based on a steam
radiator of just less than 1 psi. Therefore,
system from above, we would set the

To check the pressure limit, run the boiler until the pressure
reaches system demand. Then turn the pressure screw and
3

_21A

drop the pressure setting until the boiler shuts down. This
will show that the pressure limit is operating properly
Refer to control manufacturer's
more information.

instructions

(enclosed} for

3/8"

to 1/2"

Check thermostat operation. When set above temperature
indicated on the thermometer, boiler should ignite. Make
certain the thermostat turns off the boiler when room
temperature reaches the selected setting and starts the boiler
operating when room temperature falls a few degrees.
Finally, set the thermostat for the desired temperature. Special
conditions in your home and the location of the thermostat
will govern this setting.

Close the b!owdown valve. Allow the boiler to cool
thoroughly and then slowly refill the boiler to the water
line. Repeat this step as many times as necessary until
the blowdown water is clear.

It is very important to clean a new steam boiler after it has
been installed and put into continuous operation. This must
be done to remove any accumulation of oil, grease, sludge,
etc., that may have been present in the system. These
substances may cause the boiler water to foam and surge,
thus producing a very unsteady water line, throwing water
into the steam header, and possibly preventing steam
generation. Follow these steps in order to remove these
contaminants.
SKIMMING

Now, let the boiler steam for a few days, to give the majority
of the system dirt a chance to work its way back to the boiler.
Then check the water in the gauge glass. The gauge glass
should be dry above the water line. The water line should
not bounce more than one inch when the boiler is steaming.
If you see water droplets carrying over from the top of the
gauge glass, or excessive bouncing of the water line, the
boiler needs further cleaning. Take a water sample and boil
it on the stove, to see if it foams. If it does, this also indicates
the boiler needs to be cleaned.

AND BLOWDOWN

New boilers must be skimmed at the time of installation to
remove threading oil and other impurities that float on the
surface of the water.
1. Remove the plug from the skimmer tapping and pipe to
a floor drain or bucket.
2. Raise the water level to the skimmer tapping.
3. Fire the boiler to maintain a water temperature of 180200 degrees.
4. Feed water to the boiler to maintain the water level. Adjust
the water feed rate to keep water continuously flowing
out of the skimmer tapping without the water level going
above or falling below the tapping. Cycle the burners to
prevent boiling.
5. Continue skimming until the water runs clear. This may
take several hours.

If cleaning is necessary, repeat the skimming and blow down
procedure from above. Usually a long skim will be all you
need to clean the boiler.
In more troublesome cases it may be desirable to flush the
system as well. This is accomplished by closing the gate
valve in the Hartford Loop, and opening the drain(s) at the
end of the wet return(s). Run a hose from the drain valve
on the wet return to a nearby floor drain or bucket. Run
the boiler at two pounds of steam pressure. Feed just enough
water to compensate for the waste condensate going down
the drain, and to keep the boiler from going off on low water
cut off. Run the boiler until all waste condensate runs clear.

6. Float type low water cut offs must be blown down after
skimming. The float chamber of the low water cut off must
be flushed clean and maintained clear of sediment to allow
free movement of the float: This must be done frequently
during initial operation of the boiler, and at least once
a week thereafter. Follow the instructions on the tag
attached to the control.

NOTE
Boiler cleaners and chemical cleaning additives are not
recommended. If used and not rinsed properly, they
will do more harm than good. The cleaning procedures
laid out above will clean out the typical oils and impurities
found in new boilers and in residential heating systems.
The best thing for your boiler and heating system is
clean water with no additives.

Probe type low water cut offs require no maintenance
at this time.
7. After blowing down the low water cut off and before
blowing down the boiler, fill the boiler to the water line.
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.
,,+_

Following the final blow down, allow the boiler to thoroughly
cool, and then add fresh water slowly up to the normal
water line. Start the burners and maintain at least 180
degrees for 15 minutes to remove dissolved gasses from
the fresh water. Shut off burners.

In very extreme cases it may be necessary to chemically
clean and flush the heating system. Consult the boiler manufacturer before introducing any chemicals into the boiler.
24

CLEANING YOUR BOILER FLUE PASSAGES
Check
thewater
levelevery
dayortwo.Verifythewater
lineshown
by
operating
thedrainvalveonthegauge.
BESURE
TOPANDBOTTOM AND BURNERS
VALVES
ONGAUGE
ARE
ALWAYS
OPEN
SOTHAT
ACTUAL
WATER
LEVEL FluePassagesbetweensectionsshouldbe examinedyearlyandcleaned,
WILL
BESHOWN
ATALLTIMES,
if necessaryTo clean,removeburners,pilot, and venl pipe,Removetop
Thegauge
glass
should
bedryabove
thewater
line.
Thewater
lineshould and front jacketpanels.Removethetwo screwsattachingthe intermediate
notbounce
morethanabout
oneinchwhen
theboileris steaming.
If
front pand 1o lhe left and righl side jacket panels. Removethe draft
youseewater
droplets
carrying
overthrough
thetopofthegauge
glass, diverlerandintermediatefront panelasa unit.Carefullyremovethecerafeg
orexcessive
bouncing
ofthewater
line,theboilerneeds
to be cleaned.
gasketstrips. Cleanpassageways
betweensectionswith a flexiblehandle
wire brush.Removedirt from botlomof boiler andfrom betweenseclions
by vacuuming,Makesure all flame ports in burnersare openand clear.
Shakeout or blow out all loose dirt in burners.Resealseamsbetween
adjacentsectionsas necessarywith400F RTVsiliconesealant.Reassemble
all parts.Be sure to checktightnessof pilot connectionsand condftion
of burnerflamesafter reassemNy(seeFigures18 and 19). Be sure vent
pipeconnectionsto chimneyaresecureand no obslructionsare present.

Followthe instructionsunder"CleaningYourBoiler."
POP SAFETY

VALVE

This valve should openautomaticallywhenthe steampressureexceeds
the safe limit (per instructionspackagedwith valve).Shouldit ever fail
to open under these conditions,shut downyour system.Havethe valve
replacedimmediately
LOW WATER

CUT-OFF

FOAMING, PRIMING OR SURGING
Theseterms are used to describea fluctuatingwaterline - whenwater
leavestheboiler withthesteam.
It is causedby anycombinationof the following:
1. Threadingoil and organicmatterin the boiler water,(Mineraloil, or
coresanddoesnot causesurging.)Followinstructionsunder"Cleaning
YourBoiler."
2. Faultyquick ventsthat do not releaseair unlil a sizeablepressure
is built up - if old style, reptace it dirty cleanso you can easily
blowthroughvalve.
3. Improperheaderdesign - when steam flowsin oppositedirection
of equalizerline on "HartfordLoop." Generallya 15" horizontalrun
betweenriser and main takeoffwill allow entrainedwaterto fall out
of the steam vapor so it can return to boiler. (See Figures5, 6A
& 6B on pages7,8 and9).
4. Adjustment
of steamlimitcontroltoa widedifferentialincreases
difficulty
if quick ventsare old style, slow-releasingtype or dirty Alwaysset
steamlimitcontrol differentialas low aspossible.
5. Soapand detergentsin the boiler watercauseextremesurging.Boiler
cleanersand chemicalcleaningadditivesare notrecommended.
If used
andnot rinsedproperlytheywill de moreharmthangood.Thecleaning
procedureslaid out in these instructionswill clean out the typical
oilsandimpuritiesfoundin newboilersandin residentialheatingsystems.
Thebest thing for yourboiler and heatingsystemis cleanwaterwith
no additives.

The Low WaterCut-Offwill interruptthe electricalcurrentto the burner
whenthewaterline in the boilerdropsto a low level.
On float type low water cut-offs, it is very importantto keep the float
chamberfree from sediment,a conditionessenlialto dependabilityTo
keepanyaccumulation
from interferingwithfloatactionis to "BLOWDOWN"
or flush out the control regularly.This must be done two to threetimes
duringthe first weekafter installationand oncea weekthereafterduring
the heatingseason.Do it whilethe boiler is in operation.Firstnote water
level in gauge glass.Open blow-off valve at bottom of control; water
will pour out, flushing awaysediment.Drain until water is clear, about
a pailful, then close valve, g water level in gaugeglass has dropped,
addwaterto boilerto restorelevel.Consultlowwatercut-off manufacturer's
instructionsincludedwith boiler.
NOTE: Openingblow-off valve checks cut-off operationtoo. As float
drops with falling waterlevel, burnerswill shut off. After valve is closed
andnormaloperatingconditionsare restored,burnerswill resumefiring.
Forprobe type Low WaterCut-Offs,checkactionof the LowWaterCutOffmonthlyto makesureit isprovidingtheproperprotection.See"Checking
and Adjusting"on page 23. Low Water Cut-0ff remote probesmust be
removedfor periodicinspectionand cleaning,preferablyat the beginning
of eachheatingseason.Morefrequentcleaningmaybe requiredon boilers
requiringconstantor very frequentadditionsof makeup water.
BURNERS
A visual check of the pilot and mainburner flamesshouldbe madeat
least once eachyear,preferablyat the beginningof the heatingseason.
Seepage23.
BOILER

Never refill a hot boiler with cold water - the danger
of thermal shock mayCAUTION
crack a section.

FLUE PASSAGES

Under norma]operatingconditions,with the burners properlyadjusted,
it shouldnot be necessaryto cleantheboiler flue gaspassages.However,
to assuretrouble-freeoperation,we recommendthat you havethe flue
passages,burner adjustment,and operationof the controlscheckedonce
eachyearby a competentServiceTechnician.
Beforethestart of eachseason(or wheneversystemhasbeenshut down
for some time) recheckthe wholesystemfor leaks ... and recheckthe
boilerandvent pipefor leaks.

BOILER WATER TREATMENT

(Other

]

Than Cleaners)

In steamsystemswhere the systemis tight, free from leaks,and all
the steamis returnedto the boiler as condensate,the amountof make
up wateris small,Watertreatmentis generallynotrequired.
In steamsystemswith less than 90% of the steam being returnedas
condensate,or wilh very hard or corrosivemakeup water,treatmentmay
bedesirable.Followtherecommendations
of'yourlocalboilerwatertreatment
speciafisl.

VENT PIPE

BETWEEN

Theventingof this unitis very importantandthepiping shouldbe checked
at least once a season.If the vent piping shows any sign of leaking,
replaceit immediately

HEATING

SEASONS

Boilersshouldnotbe drainedbetweenheatingseasons.Steamboilersshould
beentiretyfilledwithwaterduringthesummermonthsto excludeair.
5

_1_

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.

Burner is not operating properly

Check flame. 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.

No electric power to boiler

Check overcurrent protection. Check to be sure electric power supply circuit
is "ON."

Controls out of adjustment

Reset according to instructions.

Radiators not heating

Steam air vents are not operating properly. Check flow control valve (if used).
It may be in closed position.

Poor electrical contact

Check all control terminals and wire joints.

Rollout switch blown

Have your service technician check heat exchanger for blockage. Replace rollout
switch with exact replacement.

Chimney flue is blocked

Spill switch contacts open, requiring manual reset of spill switch. Have your
service technician check and correct chimney problem.

Vent damper not operating

Consult troubleshooting

Possible Cause

What to do

Gas input amount is incorrect

Contact your service technician.

Possible Cause

What to do

Not enough ventilation

Contact your service technician.

Chimney flue is blocked

Have your service technician check and correct, if necessary

Possible Cause

What to do

Air in system

Refer to "Radiators Not Heating Properly" above

guide in Effikal manual, packaged with vent damper,

Possible Cause
Dirt on seat

HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT.
.....

GAS-FIRED

STEAM

BOILERS

-- IMPORTANT -READ THESE INSTRUCTIONS BEFORE ORDERING

18
15\

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 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:

16.
.

The Part No, - The Part Description - The Boiler Model No.

0
/
10
4

JACKET

- SECTION

AND BASE PARTS

THIS IS A REPAIR PARTS LIST - NOT A PACKING LIST
KEY
NO.

1
2
3
4

5
6
7
8

DESCRIPTION

Jacket, Right Side Panel
:#10 x 1/2 Sheet Metal Screw
Rating Plate
Base Insulation - Base Sides (2)
-Base Front
Base Rear

Base Baffle
Base
Jacket Tie Bar
Push Nipple
Jacket, Left Side Panel
Knob, Service Door (Pair}

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,GasOnly)

3 SECTION
Part No.

4 SECTION
Part No.

5 SECTION
Part No.

6 SECTION
Part No.

7 SECTION
Part No,

8 SECTION
Part No,

9 SECTION
Part No.

425-00-802
146-95-074
146-80-001
146-14-130

425-00-802
146-95-074
I46-80-001
146-14-130
146-14-114
146-14-124
425-00-644
425-00-664
425-00-654
433-00-976
425-00-801
137-02-153
425-00-824
425-00-814
425-00-804
146-05-002
410-00-013
410-00-015
425-00-844
425-00-674
410-00-014
425-00-834
425-00-874
410-00-430
146-14-031
146-14-018
146-28-002
433-00-664
425-00-604

425-00-802
146-95-074
146-80-001
146-14-130
146-!4-115
146-14-125
425-00-645
425-00-665
425-00 655
433-00-976
425-00-801
137-02-153
425-00-825
425-00-815
425-00-805
146-05-051
410-00-013
410-00-015
425-00-845
425-00-675
410-00-014
425-00-835
425-00-875
410-00-530
146-14;031
146-14-018
146-28-002
433-00-665
425+00-604

425-00-602
146-95-074
146-80-001
146-14-130

425-00-802
146-95-074
146-80-001
146-!4-130
146-14-1!7
146-14-127
425-00-647
425-00-667
425-00-657
433-00-976
425-00-801
t37-02-153
425-00-827
425-00-817
425-00-807
146-05-005
410-00-013
410-00-015
425-00-847
425-00-677
410-00-014
425-00-837
425-00-877
410-00-730
146-14-032
146-14-018
146-28-003
433-00-667
425-00-604

425-00-802
146-95-074
146-80-001
146-!4-130
146-14-118
146-14-128
425-00-648
425-00-668
425-00-658
433-00-976
425-00-801
137-02-153
425-00-828
425-00-818
425-00 808
146-05-007
410-00-013
410-00-015
425-00-848
425-00-678
410-00-014
425-00-838
425-00-878
410-00-830
146-14-032
146-14-018
146-28-003
433-00-668
425-00-604

425-00-802
146-95-074
146 80-001
146-14-130
146-14-119
146-14-129
425-00-649
425-00-669
425-00-659
433-00-976
425-00-801
137-02-153
425-00-829
426-00-819
425-00-809
146-05-009
410-00-013
410-00-015
425-00-849
425-00-679
410-00-014
425-00-839
425-00-879
410-00-930
146-14-032
146-14-018
146-28-003
433-00-669
425-0O-604

146-14-113
146-14-123
425-00-643
425-00-663
425-00-653
433-00-976
425-00-801
137-02-153
425 00-823
425-00-813
425-00-803
146-05-001
410-00-013
410-00-015
425-00-844
425-00-673
410-00-014
425-00-833
425-00-873
410-00-330
146-14-031
146-14-018
146-28-001
433-00-663
425-00-604

146-14-116
146-14-126
425-00-646
425-00-666
425-00-656
433-00-976
425-00-801
137-02-153
425-00-826
425-00-816
425-00-806
146-05-053
410-00-013
410-00-015
425-00-846
425-00-676
410-00-014
425-00-836
425-00-876
410-00-630
146-14-031
146-14-018
146-28-003
433-00-666
425-00-604

:l-Not illustrated.
27

....

FOR USE WITH NATURAL GAS ONLY

6
4

NOTE: Actual gas valve may look
different than gas valve shown

GAS BURNERS
AND MANIFOLD
PARTS
THIS iS A REPAIR PARTS LIST - NOT A PACKING LIST

II
KEY
NO.
1
2
3
4
5
6
6A
7

DESCRIPTION
24 Volt GasValve,Elect.Inter.Ignition
PilotTube
10-32x 1/2 HexHeadScrew
GasManifold
MainBurnerOrifice"
MainBurner,Regular*"
MainBurner,PilotMount
Pilot Burner
Air Shutter
Air ShutterSpring

1
3
7

24Volt GasValve,ContinuousPilot

3 SECTION
Pad No.
146-62-052
146-15-005
146-95-307
146-16-033
146-15-031
146-15-523
146-15-522
146-62-092
425-00-418
146-34-061

10-32x 1/2" HexHeadScrew(2 req'd)
Pilot Burner

146-62-051
146-95-307
146-62-053

Thermocouple

146-62-037

4 SECTION
PadNo.
!46-62-052
146-15-005
146-95-307
146-16-034

5 SECTION
PadNo.
146-62-052
146-15-005
146-95-307
146-16-035

6 SECTION
Pa_No.
146-62-058
146-15-005
146-95-307
146-16-013

7 SECTION
Pad No.
146-62-058
146-15-005
146-95-307
146-16-014

8 SECTION

146-15-031
146-15-523
146-15-522
146-62-092
425-00-418
!46-34-061

146-15-031
146-15-523
146-15-522
146-62-092
425-00-418
146-34-061

146-15-035
146-15-523
146-15-522
146-62-092
425-00-418
!46-34-061

146-15-035
146-15-523
146-15-522
146-62-092
425-00-418
146-34-061

146-15-035
146-15-523
146-15-522
146-62-092
425-00-418

146-62-051
146-95-307
146-62-053
146-62-039

146-62-051
146 95-307
146-62-053
146-62-039

146-62-060
146-95-307
146-62-053
146-62-039

146-62-060
146-95-307
146-62-053
146-62-036

146-62-060
146-95-307
146-62-053
!46-62-036

Quantity is 1 unless otherwise noted.
*Requites 1 less then the number of sections.
**Requires 2 less than the number of sections.
:i:Not illustrated.

.....

Pad No.
!46-62-058
146-15-006
146-95-307
146-16-015

9 SECTION
PadNo.
146-62-058
146-15-006
146-95-307
146-16-016

BOILER CONTROLS AND PIPING

KEY
NO.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

DESCRIPTION

¾' Pop Safety Valve
%" Coupling
Y," x 6W' Nipple
Steam Pressure Gauge
'/4' Coupling
YY x 3" Nipple
AT-140D Transformer, 24 Volt
PA-404A Pressuretrol
Glass Water Gauge Set (used with PS-802 LWCO)
Glass Water Gauge Set (used with 67D-1 LWCO)
90" Pigtail (used with PS-802 LWCO)
180" Pigtail (used with 67D-1 LWCO)
PS-802 Low Water Cut-Off
67D-1 Low Water Cut-Off
! $8600F Intermittent Pilot Control, Natural Gas
W' x 3" Brass Nipple (PS-802 only)
'½" x 'A" x ¼" Brass Tee (PS-802 only)
I Y2"Brass Coupling (PS-802 only)
, W' x 3W' Brass Nipple (PS-802 only)
¾" 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)

Not Illustrated

PART
NO.

146-22-002
146-93-053
146-07-002
146-23-005
146-93-054
146-07-301
146-62-045
146-62-015
146-22-005
146-22-010
146-43-004
146-43-005
146-26-041
146-26-042
146-62-303
146-07-025
146-93-051
146-93-052
146-07-024
146-22-001
146-26-040
146-29-002
146-60-002
146-28-301
146-28-002
146-28-003
146-28-006
146-08-020

,_,,,

ElectronicIgnition

Owner'sManual

Gas-Fired
Cast Iron
STEAM
BOILER

CONTINUOUS
PILOT
MODELNO.
229.960330
229.960340
229.960350
229.960360
229.960370
229.960380
229.960390
ELECTRONIC
INTERMITTENT
IGNITION
MODEL
NO.
229.960230
229.960240

Now that you
ever exist for
Sears Service
when you call

have purchased your Boiler, should a need
repair parts or service, simply contact any
Center. Be sure to provide all pertinent facts
or visit.

The model number of your 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

• PART DESCRIPTION

eMODEL NUMBER

eNAME OF ITEM

229.960250
229.960260

All parts listed
Center.

may be ordered

from

any Sears Service

229.960270
229.960280
229.960290
HOW TO ORDER
REPAIRPARTS

TELLSEARS YOU
WANT IT INSTALLED
THEN RELAX

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
right. We will arrange
for professional
workmanship..,
and we'll take care of the entire project•
What's more, during installation you get insured protection
• . . against property damage and also against accidents
to workmen. All you have to do is talk to your nearest Sears
store today for detailed information.

Source Exif Data:

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File Type Extension             : pdf
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Page Layout                     : SinglePage
Page Mode                       : UseNone
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Create Date                     : Thu Apr 05 15:13:49 2007
Author                          : 
Title                           : 
Subject                         :

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Kenmore 229960230 User Manual GAS FIRED BOILER Manuals And Guides L0511245

KENMORE Boiler Manual L0511245 KENMORE Boiler Owner's Manual, KENMORE Boiler installation guides

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