Kenmore 229965320 Gas-Fired Hot Water Induced Draft Boiler User Manual

Electronic Ignition

Gas-Fired

Hot Water

Induced Draft

Boiler

• Installation

•Operation

•Repair Parts

WARNING: Improper installation, adjustment, alteration,

service or maintenance can cause injury or property

damage. Refer to this manual. For assistance or

information consult a qualified installer, service agency

or the gas supplier. Natural gas boilers are not to be

converted to Propanr gas.

Warranty..........................................................2

RulesforSafe Installationand Operation.......3

BoilerRatingsand Capacities.........................4

BeforeYou Start..............................................5

Locatingtheboiler..........................................6

FreshAirforCombustion ................................7

Installation-SystemPiping.................................9

Chimney and VentPipeConnection...............11

HorizontalVenting...........................................14

Gas Supply Piping ........................................ 20

Electrical Wiring/Sequence of Operation ....... 21

Wiring Diagram ............................................. 22

Equipment and Optional Accessories - What

They Do ........................................................ 23

Checking and Adjusting ................................. 27

Maintaining "Your Boiler ................................ 28

Service Hints ................................................. 30

Repair Parts ................................................ 31

SEARS

KENMORE CAST IRON BOILERS

FULL ONE YEAR WARRANTY ON HOT WATER AND GAS STEAM CAST IRON BOILERS

For one (1) year from the date of installation, when this boiler is installed and maintained in accordance

with our instructions. Sears 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 thoughtwelve(12) yearfrom the dateof installation,Sears willfumish a replacement

heat exchange, ifthe heat exchanger inthe boilerisdefective. YOU PAYFOR 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 willfurnish a

replacement heat exchanger in the boiler isdefected 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 with 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 of the user

and are cover by the Warranty.

1. Filter clearing 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 _e use of components

or other accessoriesnot compatible with the unit:

5. If the unit is removed from the place it was

originally installed, this Warranty becomes void.

6. Damage to the unit caused by accident, abuse,

negligence, misuse, riot,fire, flood,or acts of God.

SEARS ROEBUCK AND COMPANY

D/817WA

Hoffman Estates, IL 60179

1. Readthe Owner'sManualfor SaleOperation

carefully. Failure to follow the rules for safe

operation and the instructions can cause a

malfunction of the boiler and result in death,

serious bodily in jury, and/or property damage.

2. Check your local codes and utility requirement

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.

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.

5. Be certain your 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 is adequate air supply for

complete combustion.

8. Follow a regular service and maintenance

schedule for efficient and safe operation.

TOOLS

Pipe Wrench

Screwdriver

Tin Snips

6 foot tape or folding rule

Hack Saw

LP Torch, if you have copper piping

Pipe cutter and threading tools

(for iron pipe systems)

MATERIALS

Pipe joint compound suitable for natural and propane gas.

Iron or copper pipe for the water lines.

Black pipe for the gas lines.

Miscellaneous fittings.

Solder and flux if you have copper piping.

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 Appliance and Gas Piping, National Fuel

Gas Code ANSIZ223.1 -latest revision.

Obtain from American Gas Association, 1515 Wilson Boulevard, Arlington (Roslyn), VA 22209

ASME

RELIEF

VALVE

LEFT SIDE

DRAII_

VALVE

TEMPERATURE

PRESSURE

IIII

tII

I I

I I I-

I I I

LiMrr & RELAY

CONTROL

Swrm_

IANIFOLD 2

23111

3 <-'--

U _tTCH

[_ _,_" INTERMnTEHT

_ILOT CONTROL

FRONT RIGHT SIDE

DESIGN CER11FIED FOR

NA_nJp_,LAND pRGPANE GA_

MODEL

Natural Propane

Gas Gas

229.965520 229.965320

229.965530 229.965330

229.965540 229,965340

229.965550 229.965350

229.965560 229.965369

229.965570 229,965370

AGA Heating

NATURAL AND PROPANE GASES

Net IBR Vent Diameter(INCHES)

Rating

*MBH

109

135

162

Width

14¼

17%

20¾

27¼

To Chimney

(Category I)

No. Input

Sec. *MBH

2 42,5

3 75.0

4 112.5

5 150.0

6 167.5

7225.0

Capacity

+MGB

125

155

186

Horizontal Vent

(Category III)

*MBH = 1,000 Btuh =British Thermal Unit Per Hour

Boilers are equipped foraltitudes upto2,000 feet only: o

U.S.A. Only -For altitudes above 2,000 feet, ratings should be reduced at the rat of4 _ for each 1,000 feet above sea level.

Canada Only -Boilers may be used at highaltitude by using a certified field conversion, kit, resulting in a 10% derate.

+ Heating Capacity based on D.O.E. (Department of Energy}test procedure.

The Ratings marked "Net 1=B=R Ratings" indicate

the amount of remaining heat input that can be

used to heat the radiation or 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 Hydronics 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 unusual

piping and pickup requirements. These boilers must

stand on a noncombustible floor. If installed on a

combustible floor, use Combustible Floor Base.

These Gas-Fired Hot Water Boilers are low

pressure, sectional cast iron boilers Design

Certified by CSA (Canadian Standards

Association) for use with Natural and Propane

Gases. They are constructed and hydrostatically

tested for a maximum working pressure of 50psi

(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.

BOILERS FOR USE AT HIGH ALTITUDE

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.

Checktobesureyouhavetherightsizeboilerbefore

startinatheinstallation.Seeratingandcapacitytable

onpreviouspage.Also besurethe newboilerisfor

the type of gas you are using. Check the rating

plate onthe rightside of the boiler.

You must see that the boiler is supplied with the

correcttypeofgas,fresh airfor combustion,and a

suitable electrical supply. Also, the boiler must be

connected to a suitable chimney or horizontal venting

system and an adequate piping system. Finally, a

thermostat, properly located, is needed for control

of the heating system. If you have any doubts as to

the various requirements, check with localauthorities

and obtain professional help where needed. Take

the time to complete all of the steps for SAFE and

PROPER operation of the heating system.

Were required by the authority having jurisdiction,

the installation must conform toAmerican Society

of Mechanical Engineers Safety Code for Controls

and Safety Devices for Automatically Fired

Boilers, No. CSD-I*

The installation must conform to the requirements

of the authority having jurisdiction or, in the

absence of such requirements, to the National

Fuel Gas Code, ANSI Z223. l-latest revision.

The following steps are all necessary for proper

installation and safe operation of your boiler.

1. LOCATING THE BOILER

2. FRESH AIR FOR COMBUSTION

3. SYSTEM PIPING

4. CHIMNEY & VENT PIPE CONNECTION

5. GAS SUPPLY PIPING

6. ELECTRICAL WIRING

7. CHECKING &ADJUSTING

KEEP BOILERAREA CLEAN AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE I

AND OTHER FLAMMABLE VAPORS AND LIQUIDS I

If your boiler is part of a planned heating system,

locate it where shown on your plan. If boiler isto

be part of an existing system, it is usually best to

put itwhere the old one was. !f you plan to change

location, you will need additional materials as well

as an adequate base. The following rules apply:

1. The boiler must be level. Metal shims may be

used under base legs for final leveling.

2. Use a raised base iffloor can become wet or damp.

3. The vent pipe connection should be as short

as possible.

4. Additional clearances for service may exceed

clearances for fire protection. Always comply

with the minimum fire protection clearances

shown on the boiler.An 18 inch clearance should

be maintained on any side where passage is

required to access another side for cleaning,

servicing, inspection or replacement of any part

that may need attention. An 18 inch clearance is

recommended on the control side for servicing.

Figure 2 shows minimum clearances to

combustible construction. Rooms that are large

in comparison with the size of the boiler are

defined as rooms having a volume equal to or

greater than 16 times the volume of the boiler.

Where the actual ceiling height of a room is

greater that 8', the volume of a room shall be

figured on the basis of a ceiling height of 8'.

Determination of room size should be based

on the total volume of all gas fired equipment

installed in theroom. Consult section 6.3.1 of

the National Fuel Gas Code for further

information, including approved methodes for

reducing clearances in large room.

5. Equipment shall be installed in a location in

which the facilities for ventilation permit

satisfactory combustion of gas, proper venting,

and maintenance of ambient temperature at

safe limits under normal conditions of use.

Equipment shall be located so as not to interfere

with proper circulation of air. When normal

infiltration does not provide the necessary air,

outside air shell be introduced (See Page 4 -

"Fresh Air for Combustion").

6. Advise owner to keep air passages free of

obstructions. Ventilating and combustion air

must enter boiler room without restrictions.

7.The floor supporting the boiler must be

noncombustible. If it is combustible, place the

boiler on Combustible Floor Base No 14614031

for 2-5 section boilers, or No. 14614032 for 6-7

section boilers. We use a 2" cloudlet pad as a

combustible floor base. These are available from

your Iocalsupplier. Use 24" x 30" pad for 2-5

section boilers, and a minimum 30" x 30" pad for

6-7 sections boilers. The boiler must be centered

on the combustible floor base.

8.The boiler shall be installed such that the automatic

gas ignition system components are protected

from water (dripping, spraying, rain, etc.) during

appliance operation and service(circulator

replacement, control replacement, etc..)

Alcove, or

Room Not Large Room Large

In Comparison In Comparison

With Boiler With Boiler

Top 6" 6"

Rear 6" 6"

Control Side 8" 8"

Opposite Side 6" 6"

Front 18" 18"

FlueNent Connector 6" 6"

Near Boiler Piping 1" 1"

Minimum Room

Boiler Boiler Volume Required

Size Volume To Be Large

(Cu. Ft.) Room (Cu. Ft)*

2 sect. 4.3 68.7

3 sect. 5.6 89

4 sect. 6.8 109.3

5 sect. 8.1 129.5

6 sect. 9.4 149.8

7 sect. 10.6 170.1

ITHIS UNIT MUST BE SET ON ACONCRETE OR OTHER

NONCOMBUSTIBLE MATERIAL BASE OR FLOOR. IT MUST NOT

BE INSTALLED ON CARPETING I

I Provision for combustion and ventilation air must be in accordance with Section 5.3, Air for I

Combustion and Ventilation, of the National fuel Gas Code, ANSI Z223.1-latest revision, or I

applicable provisions of the local building codes.

WARNING

Be sure provide enough fresh airfor combustion.

Enough air insures proper combustion and

assures that hazard will develop due to the

lack oxygen.

NOTE

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 bythe burner. Study

following examples I and 2 to determine your fresh

air requirements.

EXAMPLE 1: Boiler Located in Unconfined Space

An unconfned space isdefined as a space whose

volume is not less than 50 cubic feet per 1,000

Btu per hour ofthe total input rating of allappliances

installed in that space.

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.

Equipment located in buildings of unusually tight

construction shall be provided with air for

combustion, ventilation, and dilution of flue gases

using the methods described in example 2B or

shall be specially engineered. The authority having

jurisdiction must approve specially engineered

installations.

EXAMPLE 2: Boiler Located in Confined Space

A. All Air from Inside the Building: The confined

space shall be provided with two permanent

openings communicating directly with an additional

room(s) of sufficient volume so that the combined

volume of all spaces meets the criteria for an

unconfined space. The total input of all gas

utilization equipment installed in the 7

combined space shall be considered in making this

determination. Each opening shall have a

minimumfree 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 that

100 square inches. One opening shall be within 12

inches of the top and one within 12 inches of the

bottom of the enclosure. The minimum dimension of

air openings shall not be less than 3 inches.

B. All Air from Outdoors: The confined space

shall communicate with the outdoors in accordance

with methods 1 or 2. The minimum dimension of

air openings shall not be less than 3 in. Where

ducts are used, they shall be of the same cross-

sectional area as the free area of the openings to

which they connect.

1.Two permanent openings, one commencing

within 12 inches of the top, and one commencing

within 12 inches of the bottom, of the enclosure

shall be provided. The openings shall

communicate directly, or by the ducts, with the

outdoors or spaces (crawl or attic) that freely

communicate with the outdoors.

a) Where directly communicating with the

outdoors or where communicating to the

outdoors through vertical ducts, each

opening shall have a minimum free area of

1 sq. in, per 4000 Btu per hour oftotal input

rating of all equipment in the enclosure.

(See Figure 3A.)

b) Where communicating with the outdoors

throughhorizontal ducts, each opening shall

have a minimum free area of 1 area ofsq.

in. per 2000 Btu per hour of total rating of

all equipment in the enclosure. (See Fig.3B.)

2, Onepermanentopeningcommencingwith 12

inches of the top of the enclosure, shall be

permitted where the equipment has clearance

of at least 1 inch from the sides and back and

6 inches form the front of the appliance. The

opening shell directly communicate with the

outdoorsor shallcommunicate through avertical

or horizontal duct to the outdoors or spaces

(crawl or attic) that freely communicate with

the outdoors, and shall have a minimum free

area of:

a) 1 sq. inch per3000 Btu per hour ofthe total

inputofallequipment locatedinthe enclosure

(See Fig. 4), and the front of the appliance

b) Not less than the sum of the areas of all

vent connectors in the confined space.

1 Square Inch

100% Free

Area

Fresh Air 1/4, Wire

Duct Size Mesh

3" x 12" 72,000

8" x 8" 128 000

8"x 12" 192,000

81/2"x 16" 256,000

)er 2,000 Btuh

75% Free 25% Free

Area Area

Metal Wood

Louvers Louvers

54,000 18,000

96,000 32,000

144,000 48,000

192,000 64,000

1Square Inch )er 4,000 Btuh

100% Free 75% Free 25% Free

Area Area Area

Fresh Air 1/4" Wire Metal Wood

Duct Size Mesh Louvers Louvers

3"x 12" 144,000 108,000 36,000

8" x 8" 256,000 192,000 64,000

8" x 12" 384,000 288 000 96,000

81/2" x 16" 512,000 384,000 128,000

1Square Inch

100% Free

Area

Fresh Air 1/4" Wire

Duct Size Mesh

3" x 12" 108,000

8" x 8" 192,000

8" x 12" 288,000

81/2"x 16" 384,000

oer 3,000 Btuh

75% Free 25% Free

Area Area

Metal Wood

Louvers Louvers

81,000 27,000

144,000 48,000

216,000 72,000

288,000 96,000

1. Place boiler in the selected location (as near

chimney as possible). Your boiler is shipped

assembled.Youneedonlyto installthecirculator,

ball valves the relief valve with a drain line to

carryanywater to adrain, andthe drain valve.

2. Install ReliefValveon 3/4"pipenippleintapped

openinginthe leftend section. Connecta drain

line of the same pipe size (3/4" to carry any

water away to a drain. No shutoff of any

descriptionshall be placed betweenthe safety

reliefvalveand theboiler,orondischargepipes

betweensuchsafetyvalvesandtheatmosphere.

Installationofthesafetyreliefvalveshallconform

to the requirements of theANSI/ASME Boiler

and PressureVessel Code,Section IV.

3. Install Drain Valve on lower left side of boiler

as marked.

4. Connect Supply and Return Lines to boiler.

The connections may require certain

additional fittings and parts, as shown on

diagram (Figs. 5 and 6).

Ifyou are installing an entire newheatingsystem,

first install all of your radiation units (panels,

radiatorsorcabinets) and theSupplyand Return

Mains- then make the connections atthe boiler.

Inconnecting the cold water supply to the water

valve, make sure that a clean water supply is

available. When the water supply isfrom a well

or pump, a sand strainer should be installed at

the pump.

A hotwater boiler installed above radiation level

must beequipped with a lowwater cutoff device.

Aperiodic inspection is necessary,as isflushing

of float type devices, per manufacturers specific

instructions.

When boiler is used in connection with

refrigeration systems it shall be installed sothat

the chilled medium is piped in parallel with the

heating boiler with appropriate valves to prevent

the chilled medium from entering the heating

boiler (Fig. 7).

When this boiler isconnected 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.

LOW DESIGN WATER TEMPERATURE

SYSTEMS (BELOW 140 ° F)

If the boiler is to be used in a heating system

where design water temperatures below 140 °

F are desired (e.g. radiant floor heating), a 3-

way or 4-way mixing valve or suitable alternative

is required to prevent low temperature return

water from entering the boiler. Follow the mixing

valve manufacturers installation instructions.The

minimum design return water temperature to

the boiler to prevent condensation in the boiler

and venting is 120 ° F The minimum high limit

setting is 140 ° F.

VALVES A & B - OPEN FOR HEATING; CLOSED FOR COOLING

VALVES C & D - CLOSED FOR HEATING; OPEN FOR COOLING

TO SYSTEM

I For boilers for connection to gas vents or chimneys, vent installations shell be in accordance

with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.l-latest issue

and applicable provisions of the local building codes.

CHECK YOUR CHIMNEY

This is a very important part of your heating system.

Itmust be clean, the right size, properly constructed

and in GOOD CONDITION. No boiler can function

properly with a bad chimney.

1. Use local codes for installation or National Fuel

Gas Code Z223.1-1atest issue. In Canada,

follow CSA 13149.1 or .2 Installation Codes. It

is very important to properly size the venting

system for induced draft appliances. Consult

the Vent Sizing Tables, in the National Fuel

Gas Code ANSI Z223.1-1atest revision for

correct sizing information In Canada, consult

the Vent Sizing Tables, Amendment #1 to CSA-

13149.1 and .2 Installation Codes.

2. The boiler's induced draft blower has a 3" outlet.

A 3" X 4" increaser fitting isincluded in the parts

bag. Locate the increaser fitting on the outlet

of the induced draft blower, and secure gastight

with a bead of the furnished silicone sealant.

The increaser fitting is required on this boiler

for Category I venting, and 4" is the minimum

permissible vent diameter. This does not imply

that the vent connector is intended to be 4"

diameter pipe. The vent connector shall be sized

according to the appropriate venting tables in

the National Fuel Gas Code or the Canadian

Installation Codes, and may be required to be

larger than 4" diameter.

The boiler installation for chimney venting

is not complete unless the 3" x 4" increaser

fitting is located and secured.

3. These are high efficiency boilers with a low stack

or exhaust temperature.

4. Ifventing into a masonry chimney without a liner,

line the chimney from top to bottom with either:

a, listed Type B vent pipe

b. listed fexible vent liner

c. poured ceramic liner.

5. Outside chimneys should not be used unless

they are either:

a. enclosed in a chase, or

b. lined with Type B vent pipe, or listed flexible

vent liner, or other certifEEI chimney lining system.

6. The vent connector from the boiler to the

chimney should run as directly as possible with

as few elbows as possible.

7. Where possible, it is recommended to common

vent the water heater and boiler. Consult the

appropriate Vent Sizing Tables in either the

National Fuel Gas Code, or the Canadian

Installation Codes for specific requirements

of multiple appliance venting.

8. If the boiler is the only appliance connected to

the vent, Type B vent pipe is recommended

for the vent connector.

9. Slope pipe up from boiler to chimney not less

than 1/4" per foot.

10. End of vent pipe must be flush with the inside

face of the chimney flue. Use a sealed-in

thimble for the chimney connection.

11. The sections of vent pipe should be fastened

with sheet metal screws to make the piping

rigid. Use stovepipe wires to support the pipe

from above.

12. Do not connect to fireplace flue.

13. Do not install a damper on this boiler.

MINIMUM VENT PIPE CLEARANCE

if the vent pipe must go through a crawl space,

Type B 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.

If boiler is installed with single wall vent, it must

have a 6" clearance between its surface and any

combustible material. Anew Type B gas vent

orflexible liner must be installed in accordance

with the instructions furnished with the vent.

Maintain clearances as specified for the vent pipe.

Check the vent pipe to see if it is firestopped

where it goes through the floor or ceiling. It

should have an approved vent cap with

clearances from the roof as shown in Fig. 8. If

clearances are less than shown in Fig. 8, have

the vent checked by local authorities.

For boilers for connection to gas vents or

chimneys, vent installations shall be in

accordance with Part 7, Venting Equipment,

of the national Fuel Gas Code, ANSi Z223.1-

latest issue and applicable provisions of the

local building codes. In Canada, follow CSA

13149.1 or .2 Installation Codes.

Vent connectors sewing appliances vented

by natural draft shall not be connected into

any portion of mechanical draft systems

operating under positive pressure.

"_- LINE R

10'_'_I Ni i

' "-J THE VENT PIPE MUST BE AT

LEAST 2 FEET HIGHER THAN

ANY PART OF THE ROOF

WITHIN A [0 FT RADIUS

OFTHE VENT,

SHEET NETAL

FIRESTO_

0 0

REMOVING EXISTING BOILER FROM

COMMON VENTING SYSTEM

When an existing boiler isremoved 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.

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

appliance remaining connected to the common

venting system are not in operation.

1. 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.

3. 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. Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat

so appliance will operate continuously.

5. Test for spillage at the hood relief opening after

5 minutes of main burner operation. Use the

flame of a match or candle, or smoke from a

cigarette, cigar or pipe.

6. After ithas been determined that each appliance

remaining connected to the common venting

system properly vents when tested as outlined

above, return doors, windows, exhaust fans,

fireplace dampers and any other gas-burning

appliance to their previous conditions of use.

7. Any improper operation of the common venting

system should be corrected so the installation

conforms with the National Fuel Gas Code,

ANSI Z223.1-1atest issue. When resizing any

portion of the common venting system, the

common venting system should be resized to

approach the minimum size as determined using

the appropriate tables in Part 11 in the National

Fuel Gas Code, ANSI Z223.1-1atest issue. In

Canada, follow CSA B149.1 or.2 Installation

Codes.

NOTE

It is recommended that existing gas vents be

checked to be sure they meet local codes.

INDUCED DRAFT HIGH EFFICIENCY BOILERS

Maximum Horizontal Vent Length For Stainless

Steel Vent Pipe -30' Plus One 90°Elbow Plus

VentTerminal

Minimum HorizontalVent Length - 2' PlusOne 90°

ElbowVent Termination

Additional elbowsare equivalentto6 feet ofstraight

pipe for 4" diameter 90° elbow or 3 feet of

straight pipe for 3° diameter 90° elbow

2, 3, 4, 5, Section Boilers use 3"vent pipe.

6, 7 Section Boilers use 4" vent pipe.

OPTIONAL TERMINATION F[TTTNG

TJERNLUNB SIDE WALL VENT HOOD

VH-I_3" FOR 2,3,4,5 SECTION BOILERS

VH-I-4' FOR 6,7 SECTION BOILERS

PER FBBT_\

CHOICE OF VENT PIPE MATERIAL

a) U.L. Listed Z-Flex Z-Vent Stainless Steel Vent Pipe.

b) UL ListedHeat-FabSat-T-VentSlainlessSteelVentPipe.

c) U.L Listed Flex-L Star-34 Stainless Steel VentPipe.

d) U.L Listed ProTech Systems FssNSeal Stainless st_eel

Vent Pipe.

TERMINATION FITTING

90" EL_OW, POINT;NO DOWN, SAME MATERIAL AN_

PIPE SIZE AS VENT[NO SYSTEM, EQUIP WITH SCREEN

(M[N. I/4" MESH) TO KEEP OUT BI_S ANB RODENTS,

FOR A COMBUSTIBLE WALL, USE A THIMBLE, SELECT Ag

FOLLOWS=

VENT RIPE; Z-VENT, SAF-T-VENT, STAR-34

THIMBLE: SIMPSON DURAVENT THIMBLE

#905295 - 3" THIMBLE

#915_95 -4" THIMBLE

VENT PIPE_ FASNSE_L

TH[MBLD FASNSEAL WALL THIMBLE

#FSVT03 - 3" TH[MBLE

#FS_T04 - 4" THTMBLE

PITCH DOWN TOWARD

OUTSIDE I/4"

PER FOD___

HORIZONTAL VENTING ACCESSORIES PART NUMBERS

DESCRIPTION

3" side Wall Vent Hood (Tjernlund VH-1-3")

4" side Wall Vent Hood (Tjernlund VH-1-4")

3" Thimble (Simpson 905295)

4" Thimble (Simpson 915295)

PART NUMBER

146-29-010

146-29-011

146-29-013

146-29-014

1. These boilers may be vented horizontally as

shown in Fig. 9. The vent pipe is pitchedlml_l

from the boiler to the vent termination. Do not

connect other appliances to this vent.

2. Vent Pipe Material:

a) UL Listed Z-Flex Z-Vent stainless steel vent

pipe from boiler to vent termination,

-or-

b) UL Listed Heat-FabSaf-T-Vent stainless steel

vent pipe from boiler to vent termination,

-or-

c) UL Listed Flex-L StaR-34 stainless steel vent

pipe from boiler to vent termination,

-or-

d) UL Listed ProTech FasNSeal stainless steel

vent pipe from boiler to vent termination.

3. Clearance to Combustible Materials:

For stainless steel vent pipe maintain 6" minimum

air space clearance to combustible materials.

4. Vent Pipe Size:

a) 2, 3, 4 and 5 section boilers use 3" vent pipe

connected directly to the outlet of the induced

draft blower.

b) 6 and 7 section boilers use 4" vent pipe,

starting with a 3" to 4" stainless steel vent

pipe transition that is connected directly to

the outlet of the induced draft blower. Do not

use 3" vent pipe on 6 or7 section boilers.

5. Vent Pipe Length:

a) For stainless steel vent pipe, the maximum

horizontal vent length is 30 feet plus one 90°

elbow plus termination fitting.

b) Minimum horizontal vent length for all vent

materials is 2 feet plus one 90 °elbow plus

termination fitting.

c) For additional elbows reduce the maximum

vent length as shown:

3"- 90° elbow -reduce vent ler_glh3 feetpereach 3''

elbow,

4" - 90 °elbow - reduce vent length 6 feet per

each 4" elbow.

Example: 6 section boiler requires 3 elbows

plus the termination fitting. This means 2

additional 4" elbows will be used, at 6 feet

per elbow. This is equivalent to 12 feet of

pipe (2 x 6 =12), therefore maximum vent

length is now 18 feet (30 -12 =18). 15

6. Vent Termination Fitting:

For all vent pipe materials, you may use either:

a) a 90°elbow pointing down, fitted with a

minimum 1/4" mesh screen to keep out

rodents and birds. The elbow shall be of the

same material and size as vent pipe. The

elbow exit should be at least 6" away from

exterior wall as shown in Figure 9.

-or-

b) Tjernlund VH-1 Series side wall vent hood.

For 2, 3, 4, 5 section boilers use VH-1-3", For

6, 7 section boilers use VH-1-4".

7. Vent Pipe Termination Location:

a) When venting through combustible walls,

combustible clearances must be considered.

The VH-1 Side wall vent hood provides both

the outside vent termination and a double

wall pipe for passing through a combustible

wall up to 8" thick (VH-1-4") or 9" thick (VH-

1-3"). The hole in the wall must be 6%" square

for 3" vent pipe and 7 1/2" square for 4" vent

pipe, in order to insert the VH-1 side wall

vent hood. The VH-1 may also be used in

noncombustible walls.

b) If the 90' elbow is the termination fitting of

choice, then the single wall pipe willbe passing

through the side wall. For combustible walls,

a UL listed thimble shall be used where the

single wall pipe passes through the wall. For

combustible walls using Z-Vent, Sat-T-Vent,

or StaR-34 vent pipe, use the following:

3" vent pipe - use Simpson's Duravent

#905295 3" thimble or equivalent

4" vent pipe - use Simpson's Duravent

#915295 4" thimble or equivalent Maximum

wall thickness with this thimble is 7 inches.

For combustible walls using ProTech

FasNSeal where the single wall vent pipe must

pass through the side wall, a UL Listed

FasNSeal wall thimble shall be used as

follows:

3" FasNSeal vent pipe - use 3" FasNSeal Wall

Thimble #FSWT03 4" FasNSeal vent pipe - use

4" FasNSeal Wall Thimble #FSWT04

The thimble is adjustable for different wall

thickness, with a maximum wall thickness of

7 inches. Seal the thimble along the outside

edge of the plate with caulk or silicone and

fasten to the wall with screws or nails.

c) For single wall pipe through non-combustible

walls, the hole through the wall need only be

large enough to maintain the pitch of the vent

pipe, and provide proper sealing. Athimble is

not required for single wall pipe passing

through noncombustible walls.

d) The venting system shall terminate at least 3

feet above any forced air inlet located within

10 feet. The venting system shall terminate

at least 4feet below, 4 feet horizontally from,

or 1 foot above any door, window, or gravity

air inlet into any building. The bottom of the

vent shall be located at least 12 inches above

grade. Termination of the vent shall be not

less than 7 feet above an adjacent public

walkway. The vent terminal shall not be

installed closer than 3 feet from the inside

corner of an L shaped structure. Termination

of the vent should be kept at least 3 feet away

from vegetation. The venting system shall

terminate at least 4 feet horizontally from, and

in no case above or below, unless a 4 foot

horizontal distance is maintained, from electric

meters, gas meters, regulators, and relief

equipment,

e) The venting system shall terminate at least 4

feet below any eave, soffit, or roof overhang.

f) The venting system shall not terminate

underneath any deck, patio, or similar

structure.

g) Put vent on a wall away from the prevailing

winter wind. Locate or guard the vent to prevent

accidental contact with people or pets.

h) Terminate the vent above normal snowline.

Avoid locations where snow may drift and block

the vent. Ice or snow may cause the boiler to

shut down if the vent becomes obstructed.

i) Under certain conditions, flue gas will condense,

forming moisture. In such cases, steps should

be taken to prevent building materials at the

vent terminal from being damaged by exhaust

of flue gas.

8. Joining and Sealing the Vent Pipe:

The vent pipe needs to be both watertight and

gastight. Seal a!l joints and seams as follows:

A. For Z-Flex Z-Vent stainless steel vent pipe

use a hightemperature red silicone sealant rated

for 500°F. The outside ofthe male end and inside

ofthe female end ofthe pipe must be cleaned with

brake cleaner before applying silicone bead, 16

For 3"vent pipe runs begin with the male end of

the vent pipe over the boilers induced draft

blower outlet. For 4" vent pipe runs begin with a

6" length of 3" Z-Vent (#02SVEPxx0306) over

the boiler's induced draft blower outlet, to which

an even bead of high temperature silicone sealant

should be applied. Then connect the 3" Z-Vent

to a Z-Vent 3" to 4" reducer (#02SVERxx0403).

Then continue the 4" Z-Vent pipe run by

connecting the 4" male end of the Z-Vent to the

reducer. (A locking band may be used around

this joint for additional support.) Then following

the sealing instructions, push the 4" male end of

the Z-Vent over the 4" increaser fitting. When

using the Tjernlund VH-1 vent hood, the female

end (flared end) of the vent pipe will be

connected to the termination hood. The male

end of the vent hood must be crimped before

pushing the Z-Vent over the vent hood's

connecting pipe. Before the pipes are joined,

apply a 1/4" bead of silicone one inch from the

end of themale end. Then push the pipes

together as far as they will go making sure any

seams are aligned and oriented upward. Now

apply another bead of silicone around this joint

and smooth out. Then use a Z-Flex locking band

around the center of the joint.

Z-Flex Z-Vent Size Lockina Band Part #

3" #02SVSLBX03

4" #02SVSLBX04

1) Apply the high temperature silicone

approximately one inch from the end, around

the male end of the pipe in an even 1t4" bead.

2) Pipes can now be pushed together as far

as they will go. The seams on pipe should

be aligned and oriented upward in all

horizontal appliances. Apply another bead

of silicone around this joint and smooth

out.3) Slide locking band over center ofjoint

and tighten gear clamps. Make sure locking

band is centered on joint.

4) Check alljoints and seams for gas tightness.

5) Horizontal venting shall have a slope not

less than 1/4" (6.4mm) every 12 inches

(305mm) downward away from the boiler

to prevent collection of condensate

throughout the assembly.

6)Allow the sealant to cure for 24 hours before

operating the appliance.

B. For Heat-Fab Saf-T-Vent stainless steel

vent pipe use a high temperature red silicone

sealant rated for 500"F The outside of the

male end and inside of the female end of the

pipe must be cleaned before applying the

silicone bead. For 3" vent pipe runs, the male

end of the vent pipe which goes over the outlet

of the boiler's induced draft blower must be

crimped. The vent pipe should be crimped

as minimal as possible to provide a tight fit

over the outlet. After crimping is completed

follow the instructions for applying silicone

sealant. For 4" vent pipe runs, begin with a

Saf-T-Vent 3" to 4" increaser fitting

(#7374GC) over the boiler's induced draft

blower outlet, to which an even bead of high

temperature silicone sealant should be

applied. Then continue the 4" Saf-T-Vent pipe

run by connecting the 4" male end of the Sal-

T-Vent to the increaser. (A locking band may

be used around this joint for additional

support.) The vent flow must bein the

direction indicated on the vent pipe. When

using the Tjernlund VH-1 vent hood, the female

end (flared end) of the vent pipe will be

connected to the termination hood. Apply high

temperature silicone in an even 1/4" bead

approximately 1/4" to 3/8" from the end of

the vent hood's connecting vent pipe. Also,

run a similar size bead of silicone sealant

down the seam weld of the vent pipe. Then

push the female end over the vent hood's

connecting vent pipe.

1) Apply the high temperature silicone around

the male end of the pipe (without the tabs)

in an even W' bead. Silicone bead should be

approximately 1/4" to 3/8" from the end of

the male end. Also, run a similar size bead

of silicone sealant down the seam weld at

the end of each joint.

2) Pipes can now be pushed together as far as

theywill go. The seams onthe vent pipeshould

be aligned and oriented upward in all

horizontal appliances. With a moistened finger

or fiat tool, spread any sealant that squeezes

out around the circumference of the joint.

3) Attach the sections together with the

locking rings and tabs (except at the blower

outlet where no locking ring exists.) 17

Inspect the joint to ensure that flue gases

will not leak. If necessary apply additional

sealant around the joint.

4) Horizontal venting shall have a slope not

less than 114" (6.4mm) every 12 inches

(305mm) downward away from the boiler

to prevent collection of condensate

throughout the assembly.

5) Allow the sealant to cure for 24 hours

before operating the appliance.

For Flex-L StaR-34 stainless steel vent

pipe use a high temperature red silicone

sealant rated for 500°F. Before applying

silicone, the outside of the male end and

inside of the female end of the pipe must be

cleaned using a cleaner, such as methyl ethyl

ketone (MEK) or naptha. For 3" vent pipe

runs, begin with the male end of the vent pipe

over the boiler's induced draft blower outlet.

For4" vent pipe runs begin with a StaR-34 3"

to 4" increaser fitting (#SR10304) over the

boiler's induced draft blower outlet. For both

3" and 4" vent pipe runs, apply a bead of

silicone sealant around the blower outlet and

around the inside of the male end of vent

pipe going over the blower's outlet. When

using the Tjemlund VH-1 vent hood, the female

end (flared end) of the vent pipe will be

connected to the termination hood. Apply high

temperature silicone in an even %4" bead

approximately 1/4"frem the end of the vent

hood's connecting vent pipe. Also, run a similar

size bead of silicone sealant down the seam

weld of the vent pipe. Then push the female

end over the vent hood's connecting vent pipe.

Now fillin the channel inlet with silicone sealant.

Do not try to insert the joiner band, instead

fasten the vent pipe to the vent hood's pipe

with a steel gear clamp.

1) Apply the high temperature silicone around

the male end of the pipe in an even 114"

bead. Silicone bead should be approximately

1/4" from the end of the male end. Also, run

a similar size bead of silicone sealant down

the seam weld at the end of each joint.

2) The seams on the vent pipe should be

aligned and oriented upward in all horizontal

vent pipe runs.

3) insert the male end of one into the female end

of the other. Push the pipe together so the

female end rests up against the stop bead of

the male end.

4) Insert a StaR-Joiner Band into the inlet of the

beaded channel. Feed the Joiner Band in so it

makes itsway aroundthe pipe,back to the channel

inlet and it overlaps itself by about lf2".

5) Cut the excess Joiner Band so it lays fiat in

the beaded channel. Fillthe inlet of the beaded

channel with high temperature silicone. Smooth

out the silicone over the channel inlet and the

silicone between the female end and the stop

bead of the male end.

6) Horizontal venting shall have a slope not less

than 1/4" (6.4mm) every 12 inches (305ram)

downward away from the boiler to prevent

collection of condensate throughoutthe assembly.

7) Allow the sealant to cure for 24 hours before

operating the appliance.

D. For ProTech Systems FasNSeal stainless

steel vent pipe no cleaning fluid is required.

For 3" vent pipe runs on 2, 3, 4 and 5 section

boilers begin by locating the FasNSeal Ametek

Adapter (part #FSAMETEK) over the boiler's

induced draft blower. Continue the vent pipe run

with 3" FasNSeal vent pipe. For 6 and 7 section

boilers begin by locating the FasNSeal Ametek

Adapter (part #FSAMETEK) over the boiler's

induced draft blower. Then connect a

FasNSeal 3" to 4" increaser (part #FS341 ) to

the 3" adapter outlet. Continue the vent pipe

run with 4" FasNSeal vent pipe. Other than

the Ametek Adapter and increaser fitting, DO

NOT use 3" vent pipe on 6 or7 section boilers.

FasNSeal vent pipe is joined and sealed by

the use of an internal sealing gasket and a

locking band on the female end of each vent

pipe. All components should be examined for

possible shipping damage prior to installation.

Align all vent pipe seams and orient upward in

all horizontal applications. Adjustable vent

lengths are available for 4" diameter vent

piping. For 3" diameter vent piping, square cut

male end atthe desired length. For2, 3, 4 and

5 section boilers using the VH-1-3" vent hood,

connect the FasNSeal Vent to the VH-1-3" vent

hood using FasNSeal Adapter #FSC-DUN-3.

This adapter has no internal sealing gasket.

To attach the adapter to the vent hood, crimp

the 3" vent hood pipe, apply a 1/4" bead of high

temperature red silicone sealant around the

outside of the vent hood's crimped connecting

pipe and a similar bead of high temperature

silicone around the inside of the FasNSeal

adapter. After pressing the two pipes together

and tightening the locking band, finish creating a

complete seal by filling the FasNSeal adapter's

notched hole with high temperature silicone.

For 6 and 7 section boilers using the VH-1 -4" vent

hood, an adapter is not required. The 4" FasNSeal

vent pipe connects directly to the VH-1-4" vent

hood, and isjoined and sealed bythe intemal gasket

and locking band.

To join and seal the FasNSeal vent pipe:

1) Insert male end into female section.

2) Push the units together as far as possible.

3) Firmly tighten locking band with a nut driver.

4) DO NOT penetrate the FasNSeal vent pipe

with fasteners.

5) Horizontalventingshallhave a slope of notlessthan

1/4" (6.4mm),every 12 inches (305ram) downward

away from the boiler to prevent the collection of

condensate throughout the assembly.

9, Support Spacing:

Do not restrict thermal expansion movement

of the vent, The vent pipe must expand and

contract freely with temperature change. Each

run of vent piping shall be supported as

follows:

a) Z-Flex stainless steel vent piping requires

a loose fitting metal strap or similar support

at each joint at amaximum of 4 feet

between supports.

b) Heat-Fab stainless steel vent piping requires

a support for every 6 feet of horizontal piping

run. The support must be secured using at

least #10 fasteners to a solid material (solid

masonry or woodframing or blocking.) Do

not fasten to drywall sheathing using hollow

wall anchors. Each support will be 1 1/2 inch

lower than the previous support when

spaced 6 feet apart.

c) Flex-L stainless steel vent piping requires

a loose fitting metal strap or similar support

at each joint at a maximum of 4 feet

between supports.

d) ProTech stainless steel vent piping requires

one loose fitting FasNSeal support strap

(#FSSH) for every 6' of horizontal vent.

10. If the horizontal vent must go th rough a crawl

space or other unheated space, the cool

temperatures will likely cause the flue gases

to continuously condense inside the vent pipe.

Do not insulate the vent pipe. It must be visible

for monthly inspection. Insure that the vent

pipe is properly pitched away from the boiler,

with no low spots, so that condensate in the

vent willdrain away from the boiler. An insulated

enclosure or chase, with access for inspection

and servicing of the vent, may be required to

prevent freezing of liquid condensate. Consult

the vent pipe manufacturer's instructions for

specific guidelines.

11. At the beginning of each heating season and

monthly during the heating season, check all

vent pipes and the vent terminal to make sure

there are no obstructions. Periodically clean

the screen in the vent terminal.

Horizontal venting with a power venter is an

alternate method of sidewall venting. This boilers

CSA listed for sidewall venting with standard

single wall galvanized or Type B vent pipe when

using the following power venter kits, which were

specifically sized for these boilers:

Number of

Boiler Sections Kit

2,3,4,5

6,7

Field Controls

Power Venter

SWG-4D

SWG-5D

Some possible reasons for using a power venter

for sidewall venting:

1. May be preferred by local codes.

2. Need avent piping run beyond 30' (but

not more than 50').

3. The boiler installation site experiences

gusting or high winds. A power venter can

help prevent the boiler from short cycling

due to gusting or high winds by providing

vent exhaust pressures greater than the

boiler's induced draft blower alone.

4. When installers or homeowner's prefer a

negative pressure vent system instead of

a positive pressure vent system.

5. May be more cost effective than stainless

steel venting, particularly at longer vent

lengths.

The Field Controls power vent kit includes either

a SWG-II-4HD or SWG-II-5 power venter, a

MG-1 4" barometric draft controller, and the

CK-43D controls kit.

Confirm that installing a power venter is an option

allowed by local codes. Follow the specific power

venter installation instructions issued with the

power venter kits. Although the power venter is

equipped with its own fan, the fan on the boiler

remains in place and is unaltered when apower

venter is used. When sidewall venting, flue gases

must be vented to a point in relation to the

prevailing wind so that they may freely disperse

without being blown back at the building causing

discoloration, or into the building through doors

or windows causing odors. Also, under certain

conditions flue gases will condense, forming

moisture. In such cases, steps should be taken

to prevent building materials at the vent terminal

from being damaged by the exhausted flue gas.

When installing single wall galvanized vent pipe

for power venting follow the specific power

venter installation instructions for layout, location

of the barometric draft control and termination

connections. When joining and sealing the single

wall galvanized or Type B vent piping, use R-IV

silicone sealant with a minimum temperature

rating of 400°F. For 3" vent pipe runs, begin with

the female end of the vent pipe over the boiler's

induced draft blower outlet. For 4" vent pipe runs

begin with the galvanized 3" to 4" increaser fitting

(included in the boiler's parts bag) over the

induced draft blower outlet. Then follow by

placing the female end of the 4" vent pipe over

the increaser fitting. When joining pieces of single

wall galvanized vent pipe, a substantial bead of

silicone should be used at the joint to insure a

leakproof connection.

CHECKGAS SUPPLY

The gaspipe toyour boiler must bethe corrects'[zefor the

lengthofthe runand forthetotal BTU perhour inputofall

gas utilization equipment connected to it.See F_J.10for

the proper size. Be sure your gas linecomplies with local

codes and gas company requirements.

The boiler and its individual shutoff vaive must be

disconnected from the gas supply piping system during

any pressure testing of thatsystem at test pressures in

excess of 1/2 psig (3.5 kPa).

The boiler must be isolated from the gas supply piping

system bydosing itsindividualmanualshutoffvak_during

any pressure testing of the gas supply piping system at

test pressures equal to or less than 1/2 psig (3.5 kPa).

CONNECTING THE GAS PIPING

Refer to Fig, 11 for the general layout at the boiler. It

showsthe basic f-_ngs you will need. The gas lineenters

the boiler from the right side.

following rules apply:

1.Use only those piping materials and joining metheds

listed as acceptable bythe authority having jurisd_on,

or inthe absence ofsuch requirements, bythe Nationel

Fuel Gas Code, ANSI ZX223.1-1atest revision. In

Canada, follow the CSA B149.1 and .2 Installation

Codes for Gas Burning Appliances and Equipment

2. All pipe compound must be resistant to liquefied

pe'm3leumgas.

3. Install ground joint union in gas supply line between

shut-off valve and boiler controls.

4. Install a sediment Imp upskeam of gas controls.

5. Use two pipewrenches when making the conneclJon

to the gas valve to keep itfrom turning.

6. Install manual shut-off valve in ver'dcal pipe about 5

feet above floor.

7. rKjhten alljoints securely.

8. Propane gas conneclions should only be made by a

licensed propane installer.

9.Two-stage regulation should be used bythe propane

installer.

10. Propane gas piping should be checked out by the

propane installer.

CHECKING THE GAS PIPING

Upon completion of piping, check right away 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. 2O

I WARNING I

Never use a match or open flam to test for leaks.

Length of

Pipe - Ft.

NATURAL GAS

Pipe Capacity -BTU Per Hour Input

Includes Fittings

1/2" 3/4" 1" 1 1/4"

92,000 190,000 350,000 625,000

63,000 130,000 245,000 445,000

50,000 105,000 195,000 365,000

PROPANE GAS

Pipe Capacity - BTU Per Hour Input

Length of Includes Fittings

Pipe - Ft. Copper Tubin@* Iron Pipe

5/8" 3/4" 1/2" 3/4!'

20 131,000 216,000 189,000 393,000

40 90,000 145,000 129,000 267,000

60 72,000 121,000 103,000 217,000

*Outside diameter

The length of pipe or tubing should be measured from the

gas meter or propane second stage regulator,

FLOOR LINE

All electrical work must conform to local codes as

well asthe National Electrical Code, ANSI/NFPA-70,

latest revision. InCanada, eleclncalwiring shall comply

with the Canadian Electrical Code, CSA-C22.1.

ELECTRIC POWER SUPPLY

Run a separate 120 volt circuit from a separate

overcurrent protective device in the electrical service

entrance panel. This should be a 15 ampere circuit.

Locate ashut-off switch atthe boiler. Itmust be tumed

off during any maintenance. Connect 120 volt power

supply to aquastat terminals L1 (HOT) and L2.

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 Electiical 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 ora properly driven

and electrically grounded ground rod.

I WARNING I

Tum offelectric power at fuse box before making any

linevoltage connections. Follow localelectricalcodes.

INSTALL YOUR THERMOSTAT

The thermostatlocation has an important effect on the

operationofyourboilersystem.BESURETO FOLLOWTHE

INSTRUCTIONSINCLUDEDWITHYOURTHERMOSTAT

Locatethethermostataboutfivefeet abovetheflooronan

insidewall.It maybe mounteddirectlyon thewall orona

verticallymountedoutletbox.Itshouldbesensingaverage

morntemperature,soavoidthefollowing:

DEAD SPOTS:

Behind doors

Corners and alcoves

HOTSPOTS:

Concealedpipes

Fireplace

TV sets

Radios

Lamps

Directsunlight

Kitchens

COLDSPOTS:

Concealedpipesorducts

Stairwells-dra_

Doors-drafts

Unheatedroomonothersideofwall

Setheatantidpatorat.2amps.24voltthermostatconnects

toaquastatterminalsTandT

1.Thermostat calls for heat, powering the 1K relay

coil and closing contacts 1 K1 and 1 K2.

2. Circulator pump is powered through terminals

Cl and C2.3. Induced dra_ blower and AT140C

transformer primary are powered through

terminals B1 and B2.

4. When blower gets up to speed and blower

suction pressure reaches pressure switch

setpoint, pressure switch contacts close sending

24 volts to $8600 intermittent pilot control from

AT140C transformer secondary.

5. Pilot gas valve opens and spark initiates to light

pilot burner. 6. When pilot flame is proven, spark

drops out.

7. Main gas valve opens and pilot burner ignites

main burners.

8. If boiler water temperature reaches high limit

setpoint,highlimitcontacts B-Ropen, cut'dngpower

to blower and $8600 intermittent pilot control. 21

Bumere extinguish and blower stops. Circulator

pump continues to run as long as the thermostat

continues to call for heat. When boiler water

temperature drops past the high limit setpoint

and through the differential, high limit contacts

B-R close, repeating steps 3-7.

9. If venting system becomes blocked, blower

suction pressure will drop below the pressure

switch setpoint, opening the pressure switch

contacts and cutting power to the $8600

intermittent pilotcontrol. Bumere willextinguish,

but blower will remain powered as long as the

thermostat continues to call for heat. Ifventing

system clears, steps 4-7 will repeat.

10. Thermostat is satisfied, ending call for heat:

Relay coil 1 K is de-energized, opening 1K1

and 1K2 contacts. Burners extinguish. Blower

and circulator pump stop.

INTERMITTENT IGNITION

C_T_

_ _Fr IImJCER

AT 1tC_ ll_k_vO_l ER

Lrf 1OQ3--6_O _ERIE_

INTERM_'_" pILOT COK_OL

TIf IP ! T-'o Lo

mllH ,_

LINE VOLTAGE WIRING

LOW VOLTAGE WIRING

LOW VOLTAGE FIELD WIRING

BLACK

BLACK WITH TRACER

WHITE

GREEN

RED

BLUE

FL_

_,l_ VTH_J_g_TAT

HIN4 LINI_

Al" H+gCTll/l,l_l]tI,ER

TO Gl_

V#L.V[

pI_E,_+_I1_ RaLLI_CJT

_+i'll_t ll,iT _ T

pil,_ T _lll_ltllk

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.

NOTE: The circulator harness is factory wired to the aquastat. This harness needs to be

connected to the circulator in the field. 22

RELIEF VALVE

You must have arelief valve on your boiler. Water

expands as it is heated. If there is no place for the

water to expand into, water pressure will build up

inside the boiler and system. Should this happen,

the Relief Valve will automatically open at a pre-

determined pressure. This will relieve the strain on

the boiler and system. Run a pipe from the relief

valve outlet (pipe must be same size as outlet and

the 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.

EXPANSION TANK (Optional)

In a properly assembled system, the expanding

waterflowsintoanExpansion Tank,Thistankshould

be of the correct size.

The tank is filled with air. As the water expands it

compresses the air in the tank to form an air

pressure cushion. This "spring-like" cushion serves

to maintain correct operating water pressure

regardless of water temperature. This assures a

"full measure" of water, even in the highest radiation

unit of the system. It also prevents blowing off of

the relief valve.

The air in the tank in the beginning (with system

filled with cold water) is sufficient for proper

operation. The tank also serves as a trap for

excess air in the system. The air would cause

gurgling in the pipes and inefficient circulation in

the radiators if left in the system.

It is possible for a tank to become "waterlogged"

(filled with water). It can also become overfilled

with air. This can happen after filling the system

with new water. Fittings provided on the tank and

in the line to the tank are for bleeding off excess

water or air.

When installing this tank, it is important: 1) That

the tank be higher than the boiler top. 2) That the

pipe to the tank continuously rises up to the tank

(so that air can "bubble" up to it).

DIAPHRAGM TYPE EXPANSION

TANK (Optional)

The Diaphragm Type Expansion Tank (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 pressure increases. It

expands into the EX-TROL Tank, compressing the

air in the tank. This compressed air cushion permits

the water in the system to expand as the

temperature changes.

AIR ELIMINATING FI'n'ING (AIR PURGER)

(Optional)

An Air Purger is used to remove excess air from

the system. It is installed in the supply line. It will

help to eliminate air from the water before it

reaches the radiators and bleed off this air.

MAIN AIR VENT FOR DOWN FLOW

SYSTEMS OR DIAPHRAGM TYPE

EXPANSIONTANK(Optional)

Before a system is filled with water, there is air

in the pipes and radiation units. Some of it will

be trapped asthe system is filled. It is possible

to eliminate most of this air through the air vents

on the radiation units. AMain Air Vent will speed

and simplify this. It should be installed on the

highest point in the main when all radiation is

below top of boiler:

AUTOMATICFILLVALVE (Optional)

For safe, efficient operation, a hot water system

must be filled with water. Adding new water, when

needed can be done manually (by use of a hand

valve in the water supply line). This requires regular

attention to the system's needs. An Automatic Fill

Valve accomplishes this without attention. It is

installed in the Supply Line on hot water boilers

only. The Valve operates through water pressure

differentials. It does not require an electrical

connection.

DRAIN VALVE

This manual valve provides a means of draining all

water from the boiler and system. It is often installed

in the 3/4°tapping at the bottom of the left boiler

section. Or it can be installed in a tee where the

return line enters the boiler.

WATER TEMPERATURE CONTROL

The water temperature limit control in the relay is

adjustable and may be set as necessary. It may

be set as lowas 140° F, oras highas 240°F This

depends on the type and amount of radiation

involvedand weather conditions.

CIRCULATING PUMP

Every Forced Hot-Water System requires a

Circulating Pump. Aseparate pump or zone valve is

required for each Zone, if you have a two or more

Zone System. This pump must have the capacity to

provide the circulation required by your system.

The pump does not come pre-installed on the boiler.

It must be connected to the circulator harness in

the field according to the pump manufacturer's

instructions and the wiring diagrams in this manual.

BLOWER (DRAFT INDUCER)

The blower provides a means for pulling air through

the boiler and exhausting the flue gasses into the

vent system. The blower shuts off when the burners

are not firing. This keeps heat in the house rather

than having it go up the chimney.

PRESSURE SWITCH

The air pressure switch works on a negative

pressure. When the blower comes on the air

pressure sw'rtchoperatesthe intermittentpilotand

gas valve. The air pressure switch is factory set

and will only work when the blower operates

properly.It will not allow the boilerto come on if

the blowerdoes notgenerate enough pressure or

ifthe venting system is blocked.

FACTORY PRESSURE SWITCH SETPOINT:

-0.4" wc. for 2-5 section boilers.

-0.5" w.c. for 6-7 section boilers.

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 rellout 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.

HOWA HOT-WATER SYSTEM OPERATES

Your entireheating system (boiler, piping and radialJon

units) is filled with water. As the water in the boiler is

heated, itis pumped from the top of the boilerthrough

the supply main to the radiation units. The cooler

water in them flows back through the return.main to

the boiler• This provides positive and rapid response

to the thermostat.

FILLING SYSTEM WITH WATER

Close the Air Vents on all radiation units. Open

the Valves to these units. Make sure the boiler

and Expansion Tank Drain Cocks are closed• The

Air Bleed Screw on the tank Drain Fitting should

be closed. Open the valve in the line from the

boiler to the expansion tank (see page 15 for

additional information). Open the water inlet to

your boiler and leave itopen. 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 speed up the

proper filling of your system.

Ifyour system is a closed expansion tank system,

you may have an Automatic Fill Valve. You may

leave it open to refill the system automatically as

needed. Check the temperature-pressure gauge.

Note the position of the hand indicating pressure.

This should be between 10 and 15 Ibs. Any

lowering of this movable hand below 10 Ibs. will

indicate loss of water due to leakage. The

automatic fill valve should compensate for this.

Instructions are packaged with the valve.

WARNING-Never run water into a hot empty boiler. I

•This appliance isequipped with an ignitiondevice

which automatically lights the burner. Do not

attempt to light the burner by hand.

WARNING: If you do not follow these

instructions exactly, fire or explosion may

result with property damage, personal injury,

or loss of life.

2. 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.

WARNING: IF YOU SMELL GAS:

Do not attempt to operate any appliance, do

not touch any electrical switch, do not use

the phone.

Leave the building immediately and call your

gas supplier.

If your gas supplier cannot be reached, call

the fire department.

3. WARNING: When turning or depressing the

gas control knob, use only your hand to push

down or turn the knob. Never use tools. If

the knob will not operate by hand, the control

must be replaced by a qualified service

technician. Force or attempted repair may

result in a fire or explosion.

4. WARNING: If any part of this appliance has

been under water, do not operate.

Immediately call a qualified service technician

to inspect the appliance and to replace any

part of the gas control system which has been

under water.

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance.

3. This appliance is equipped with an ignition device

which automatically lights the burner. Do not

attempt to light the burner by hand.

4. Remove burner access panel.

5. Depress gas control knob slightly and turn

clockwise to "OFF" position.

GAS CBNTRnL KNOB_

SHB_VN IN "[_N" Pf]SITION

IOTE: Knob cannot be turned to "OFF" unless I

knob isdepressed slightly. Do not force. I

6. WARNING: Wait five (5) minutes to allow any

gas in the combustion chamber to vent. If

you then smell gas in the appliance area or

near the floor, do not touch any electrical

switch, do not use the phone. Leave the

building immediately and call your gas

supplier. If your gas supplier cannot be

reached, call the fire department. Failure to

do so may result in a fire or explosion. If

you don't smell gas, go to next step.

7, Turn gas control knob counterclockwise

to "ON."

8. Turn on all electric power to the appliance.

9. Set thermostat to desired setting.

10.After visually inspecting the flame, replace the

lower front panel,

11.WARNING: if the appliance will not operate

after several tries, turn the gas control knob

to "OFF" and call your service technician or

gas supplier.

1, Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if

servicing is to be performed.

3. Depress gas control knob slightly and turn

clockwise F-_, to "OFF" position. Do

not force.

GAS VALVE SAFETY SHUTDOWN TEST

With main burners firing,disconnect the ign_on cable

from the intermittent pilotcontrol box. The gas valve

should shut off the main burners. TURN OFF

ELECTRIC POWER to boiler before reconnecting

ignition cable, to prevent electric shock,

ADJUST PILOT BURNER

1. Remove screw cover over pilot adjusting screw.

2. Insert small screwdriver and adjustflame as needed.

(Fig. 14). Turn screw counterclockwise to increase

flame, clockwise to decrease (Fig. 15).

3, Replace screw cover over pilot adjusting screw.

MAIN BURNER(S)

The main burners do not require primary air

adjustment and are not equipped with primary air

shutters. Main burner flames should form sharp

blue inner cones in a softer blue outer mantel, with

no yellow. Puffs of air from blowing on the flame or

stamping on the floor will cause the flames to turn

orange momentarily. This is not unusual. Remain

still when observing the main burner flames. If the

flame appearance is not correct, check main burner

orifices and the burner throat and flame ports for

dust and lint obstruction. It may be necessary to

remove the rolloutshield to observe the main burner

flames. Replace rollout shield after observation.

Refer to Figure 16.

ADJUST LIMIT CONTROLS

Instructionsforeachcontrolareincludedwiththecontrols

RECOMMENDEDBOILERWATERTEMPERATURES I

Tvoe of Heatino Unit Limit Control Seffinq I

StandingRadiators.............................................180 F I

BaseboardandConvectorRadiators..............200°E I

These settings can be changed after you have had

some idea howthe system works. Example: Ifyour

system does notgive quite enough heat invery cold

weather, you can raise the limit setting to 220 ° E

ADJUST THERMOSTAT HEATANTICIPATOR

INSTRUCTIONS FOR THE FINALADJUSTMENT

OF THE THERMOSTATARE PACKAGED WITH

THE THERMOSTAT. Set Heat anticipator at .2.

Check thermostat operation. When set above

temperature indicated on the thermometer, boiler

burners should ignite. Make certain the thermostat

turns offthe boilerwhen room temperature reaches

the selected setting and starts the boiler operating

when room temperature falls afew degrees.

Aftersetting limit control to desired setting, check 27

to see if it shuts off the gas supply to the

burners.Turn your thermostat up to call for heat

and let your boiler run until the temperature of the

water reaches the limit setting. The gas valve should

shut off and the circulator keep running until the

thermostat is satisfied, or the water cools enough

to restart the burners through the limit control.

To check the operation of the contacts in the

pressure switch, disconnect the rubber tubing

(located between the blower and the pressure

switch) from the pressure switch, while the boiler

is operating. The burners should extinguish and

the blower should keep running. When the tubing

is reconnected to the pressure switch, the ignition

sequence should begin, resulting in ignition of the

main burners.

Finally, set the thermostat for the desired

temperature. Special conditions in your home and

the location of the thermostat will govem this setting.

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.

_ on sensor

PRESSURE REGULATOR

AOJUSTMENT

(UNDER C_P SCREW)

INLET

PRESSURE

TAP \

INLET _ I_QUTLET

BURNERS

A visual check of the pilotand main burner flames

should be made at least once each year, preferably

at the beginning of the heating season. See page

17 and Figures 14, 15 and 16.

RELIEF VALVE

This valve should open automatically if the system

pressure exceeds the pressure rating (usually 30

psi) of the relief valve. Should it ever fail to open

under this condition, shutdown your system. Drain

the system until system pressure is reduced below

the relief valve pressure rating. If valve discharge

occurs, or ifvalve fails to open as described above,

contact an authorized contractor or qualified service

technician to replace the relief valve and inspect the

heating system to determine the cause, as this may

indicate an equipment malfunction.

This valve should be tested every month during

periods of boiler operation, and at the beginning

and end of any extended non-service period. Prior

to testing, make certain discharge pipe is properly

connected to valve outlet and arranged so as to

contain and safely dispose of boiler discharge. Test

at normal system operating pressure. Hold the trip

lever fully open for at least five seconds in order to

flush free any sediment that may lodge on the valve

seat. Then permit the valve to snap shut.

EXPANSION TANK

As previously noted, this tank may become

waterlogged, or may receive an excess of air.

Frequent automatic opening of the relief valve

indicates water logging. A high boiler temperature

accompanied by unusually low radiation unit

temperature (and "knocking") indicates excess air

in tank.To correct either condition, close the valve

between the boiler and the tank. Drain the tank until

it is empty. Check all the tank plugs and fittings.

"13ghtenasnecessary. Open the valve between the

boiler and tank, Water will riseto the normal height in

the tank ifyou have an automatic fill valve (otherwise,

manually refill the system).

BOILER FLUE PASSAGES

Under normaloperatingconditions,withtheburners

properly adjusted, it should not be necessary to

clean the boiler flue gas passages. However, to

assuretrouble-freeoperation,we recommendthat

you have the flue passages, burner adjustment,

and operation ofthe controlschecked once each

year by a competent Service Technician.

Before the start of each season

(or whenever system has been shut down for some

time) recheck the whole system for leaks.., and

recheck the boiler and vent pipe for leaks. Replace

or patch any boiler seals that are faulty.

VENT PIPE

The venting of this unit is very important and

the piping should be checked at least once a

month. If the vent piping shows any sign of

leaking, replace it immediately.

WATER SYSTEM

If system isto remain outof service during freez-

ingweather, always drain itcompletely (water left

in to freeze will crack the pipes andtor boiler).

CLEANINGYOUR BOILERAND BURNERS

Flue passages between sections should be

examined yearly and cleaned if necessary. To

clean, remove burners, pilot and vent pipe.

Remove top and front jacket panels. Split the

silicone seal on the flue collector and the clean

out plates with arazor knife. Remove flue collector.

Remove clean out plates by tapping upwards on

the bottom of the plate with a hammer. Remove

loose silicone sealant from sections, flue collector,

and clean out plates. Clean passageways

between sections with a flexible handle wire brush

and astraightened out wire coat hanger. Remove

dirt from the bottom of the boiler and from

between sections by vacuuming. Make sure all

flame ports in burners are open and clear: Shake

out or blow out all loose dirt in burners. Reassemble

all parts. Seal flue collector and clean out plates to

sections with silicone sealant (400 ° F RTV silicone

sealant or equivalent). Reseal seams between

adjacent sections where necessary. All joints must

be airtight. Be sure to check tightness of pilot

connections and condition of burner flames after

reassembly (see Figure 16). Be sure vent pipe

connections to chimney are secure and no

obstructions are present.

BLOWER

The blower motor features a permanently lubricated

ball bearing construction. Lubrication is not

required.

CIRCULATOR PUMP ISOLATIONVALVES

The isolation valves in the circulator pump flanges

should be operated manually once or twice per

year to prevent the valves from becoming stuck in

the open position. Rotate the valves from the open

position to the closed position and back to the

open position.

f-OUTER lqANTEL

z /

_SHARP INNER C[3NE$

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 lightany appliance.

2. Do not touch any electric switch,do not use the phone.

3. Leave the buildingimmediately,then call your gas supplier.

4. If you cannot reach the gas supplier,call the fire department.

Possible Cause

Thermostat is not set correctly

Burner is not operating properly

No electric power to boiler

Controls out of adjustment

Radiators not heating

Circulating pump not running

Poor electrical contact

Chimney flue is blocked

Rollout switch blown

What to do

Reset thermostat

check flame. If it is yellow, .the burner is not getting enough air.

Or, ifflame is blue and noisy and seems to lift off the burner, the

burner is getting too mush 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 excess air. Check flow control valve (if

used). It may be in closed position.

Check overcurrent protection. Check relay operation.

Check all control terminals and wire joints.

Pressure switch will not close and pilot spark will not operate to

start pilot. Have your service technician check and correct, if

necessary.

Have your service technician check heat exchanged for blockage.

Replace rollout switch with exact replacement.

Possible Cause

Gas input amount is incorrect What to do

Contact your service technician.

Possible Cause

HAVE YOUR SERVICE TECHNICIAN CHECKANY PROBLEM YOU ARE UNABLE TO CORRECT.

IMPORTANT - READ THESE INSTRUCTIONS BEFORE ORDERING

All parts listed in the following Parts Listmay be ordered through your nearest supplier. When ordering parts,

firstobtain the Model Numberfrom the data plate onyour boiler, then determine the Part No.(not the Key No.)

and the Description ofeach part from the following illustrations and list. Besure to give us allthis information:

The Part No. -The Part Descrip'don - The Boiler Motel No.

FOR USE WITH NATURAL GAS ONLY

NARTUAL GAS MODEL NOS.

229.965520, 229.965530, 229.965540, 229.965550, 229.965560, 229.965570

NOTE: Actual gas valve may look

different than gas valve shown

NATURAL GAS BURNER & MANIFOLD PARTS

THIS IS A REPAIR PARTS LIST - NOTA PACKING LIST

DESCRIPTION

KEY

NO.

124 Vott Gas Valve, Natural Gas

2 Pilot Tube

310-32 x 3/16" SlottedHex Head Screws

4 Gas Manifold

5Orifice - Natural Gas*

6 Main Burner Less Pilot Bracket**

6A Main Burner with Pilot Bracket

7 Pilot Burner with Orifice, NeUral Gas

_: Rollout Shield

229.965520

2 Section

146-62-052

146-15-005

146-95-301

146-16-042

146-15-030

146-15-529

146-15-528

146-62-091

425-00-932

PART NUMBERS FOR NATURAL GAS MODELS

229.965530

3 Section

146-62-052

146-15-005

146-95-301

146-16-043

146-15-031

146-15-529

146-15-528

146-62-092

425-00-933

229.965540

4 Section

146-62-052

146-15-005

146-95-301

146-15-044

146-15-031

146-15-529

146-15-528

146-62-092

425-00-934

229.965550

5 Section

146-62-052

146-15-005

146-96-301

146-16-045

146-15-031

146-15-529

146-15-528

146-62-092

426-00-935

229.965560

6 Section

146-62-058

146-!5-006

146-95-301

146-16-024

146-15-035

146-15-529

146-15-528

146-62-092

425-00-936

!229.965570

7 Section

146-62-058

146-15-006

146-95-301

146-16-025

146-15-035

146-15-529

146-15-528

146-62-092

425-00-937

Notillustrated.

Quan_tyis 1 unlessotherwisenoted.

*RequiresI lessthanthenumberofsections.

**Requires2 lessthanthe numberofsections.

FOR USE WITH PROPANE GAS ONLY

PROPANE GAS MODEL NOS.

229.965320, 229.965330, 229.965340, 229.965350, 229.965360, 229.965370

4 5

NOTE: Actual gas valve may look

different than gas valve shown

PROPANE GAS BURNER & MANIFOLD PARTS

THIS IS AREPAIR PARTS LIST- NOT APACKING LIST

KEY DESCRIPTION

NO.

1 24 Volt Gas Valve, NaturalGas

2 PilotTube

310-32 x 3/16" Slotted Hex HeadScrews

4Gas Manifold

5Orifice - Natural Gas*

6 Main Burner Less Pilot Bracket**

6A Main Burner with PilotBracket

7PilotBurner with Orifice, Natural Gas

_olleut Shield

:Not illustrated.

Quantityis 1 unlessotherwise noted.

*Requires 1 lessthan the number of sec_ons.

**Requires 2 less than the nun'_er of sections.

229.965320

2 Section

146-62-062

146-16-005

146-95-301

146-16-020

14e-15-044

146-15-529

146-16-528

146-62-093

426-00-932

PART NUMBERS FOR PROPANE GAS MODELS

229,965330 229.965340 229.965350 229,965360

3 Section

146-62-062

146-15-005

146-96-301

146-16-021

146-15-036

146-15-029

146-16-528

146-62-094

426-00-933

4 Section

146-62-062

146-16-005

146-95-301

146-16-022

146-16-036

146-15-029

146-16-528

146-62-094

426-00-934

5 Section

146-62-062

146-16-005

146-95-301

146-16-023

146-16-036

146-15-029

146-15-528

146-62-094

425-00-935

6 Section

146-62-059

146-16-006

146-96-301

146-16-024

146-16-036

146-16-029

145-15-528

145-62-094

_-25-00-936

229.965370

7 Section

146-62-059

146-t6-006

146-96-301

146-16-025

146-15-036

146-16-029

146-16-528

146-62-094

425-00-937

SEARS INDUCEDDRAFTBOILERS

229.965520, 229.965530, 229.965540, 229.965550, 229.965560, 229.965570

229.965320, 229.965330, 229.965340, 229.965350, 229,965360, 229.965370

12 \

DESCRIPTION

KEY

1 Jacket, Right Side Panel

2 Blower Cover Plate

3 Rating Plate

4 Jacket Tie Bar

5 Boiler Base

6Insulation, Base Side (2 Required)

6Insulation, Base Front

6 Insulation, Base Rear

7Nipple, Boiler

8 Jacket, Left Side Panel

9 Jacket, Front Panel

10 1/4" Tie Rod, (2 Reqired)

11 Nut & Washer

12 Section, Left End

13 Section, Intermediate

14 Jacket, Top Panel

15 Cleanout Plate(s)

16 Flue Collector

17 Section, Right End

18 Jacket, Back Panel

:1: Jacket, Complete

19 #1g x 1/2 Sheet Metal Screw

:[: Block Assembly (7,10,11,12,13,17))

Combustable Floor Plate

:1:Not illustrated

2 SECTION

730-00-1050

730-00-1170

146-86-005

425-01-494

425-01-733

146-14-020

146-14-112

146-14-122

433-01-976

736-00-1040

730-06-1032

146-05-008

146-95-041

410-01-019

730-06-1012

425-01-539

730-00-3002

410-01-017

730-06-1022

730-00-1002

146-95-074

416-0%212

146-14-031

3 SECTION

730-00-1050

730-00-1170

146-80-005

425-01-495

425-01-734

146-14-020

146-14-113

146-14-123

433-01-976

730-00-1040

730-00-1033

146-05-002

146-95-041

410-01-019

416-01-018

730-00-1013

425-01-540

730-00-3003

410-01-017

730-00-1023

730-00-1003

146-95-074

416-0%312

146.-14-031

PART NUMBERS FOR

4 SECTION 5 SECTION

736-06-1050 730-00-1050

730-00-1170 730-00-1170

146-80-005 146-80-005

425-01-496 425-01-497

425-01-735 425-01-736

146-14-020 146-14-020

146-14-114 146-14-115

146-14-124 146-14-125

433-01-976 433-01-976

730-00-1040 736-00-1040

730-00-1034 730-06-1035

146-05-002 146-05-051

146-95-041 146-95-041

410-01-019 410-01-019

410-01-018 410-01-018

730-00-1014 730-06-1015

425-01-541 425-01-542

730-00-3004 736-06-3005

410-01-017 416-01-017

730-00-1024 730-00-1025

730-00-1004 736-00-1005

146-95-074 146-95-074

410-01-42 410-0%512

146-14-031 146-14-031

6 SECTION

730-00-1050

730-00-1170

146-80005

425-01-498

425-01-737

146-14-020

146-14-116

146-14-126

433-01-976

730-00-1040

736-00-1036

146-05-053

146-96-041

410-01-019

410-01-018

730-00-1016

425-01-540

425-01-541

730-06-3006

410-01-017

730-00-1026

730-00-1006

146-95-074

410-01-612

146-14-032

7 SECTION

730-00-1050

730-06-1170

146-86-005

425-01-499

425-01-738

146-14-020

146-14-117

146-14-127

433-01-976

730-00-1040

730-06-1037

146-05-005

146-95-041

410-01-019

416-01-018

736-00-1017

425-01-541

736-00-3007

410-01-017

730-00-1027

730-06-1007

146-95-074

410-01-712

146-14-032

SEARSINDUCED DRAFT BOILERS

229.965520, 229.965530, 229.965540, 229.965550, 229.965560, 229.966570

229.965320, 229.965330, 229.965340, 229.965350, 229.965360, 229.965370

BOILERS CONTROL AND PIPING

5 S

Key

No.

Description

/4"ASME Relief Valve

/4"x 5½" Nipple

Temperature Pessure Gauge - (3½" Stem)

1¼" x 5½" Nipple

1¼" x ¾" x 1¼" Tee

L8148A Comb Hi Limit & Relay Control

Grundfos Pump UP15-42F

Taco Pump 007

1¼" Return Nipple

Intermittent Pilot Control

Induced Draft Blower and Gasket

Pressure Switch - 2,3,4,5, Section

Pressure Switch -6,7, Section

Isolation Ball Valve

Rubber Tube (Blower to Pressure Switch)

Part

No.

146-22-011

146-07-040

146-23-007

146-07-019

146-93-049

433-00-521

CI-006,01

Cl-001.03

146-07-004

146-62-070

433-00-511

146-55-006

146-55-005

146-26-043

146-29-003

Rollout Switch

1¼" x_" Bushing

AT 140C 24 V. Transformer

/_"Close Nipple

¼" Coupling

3" x 4" Increaser Fitting -Galvanized

400° F Black Silicone Rubber Adhesive

Sealant (10,3 oz. Cartridge)

500° F Black Silicone Rubber Adhesive

Sealant (10.3 oz. Cartridge)

146-29-002

146-93-006

146-62-O80

146-07-031

146-93-054

146-28-012

146-06-020

139-50-03

146-06-023

:1:Not illustrated

NOTE: The circulator and ball valves do not

come pre-installed.

Electronic Ignition

Gas-Fired

Hot Water

Induced Draft

Boiler

Now thatyou have purchased your Boiler, should a need

ever exist for repair parts or service, simply contact any

Sears service Center. Be sure to provide all pertinent

facts when you call or visit.

The model number of your Boiler will be found on the

model plate on the side of the Boiler.

WHEN ORDERING REPAIR PARTS, ALWAYS GIVE

THE FOLLOWING INFORMATION:

• PART NUMBER

• MODEL NUMBER • PART DESCRIPTION

• NAME OF ITEM

All parts listed may be order from any Sears Service

Center.

Ifthe 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.

14683601 Rev 1, August 2003

Kenmore 229965320 Gas-Fired Hot Water Induced Draft Boiler

Product's Documents

Owner 's Manual

Specifications

Kenmore 229965320 Questions and Answers