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OWNER'S MANUAL
CONTINUOUS PILOT
MODEL NO.
KWX - 3V
KWX - 4V
KWX - 5V
Gas- Fired
KWX - 6V
Cast Iron
KWX - 7V
KWX - 8V
HOT WATER
KWX - 9V
BOILER
• Installation
CAUTION
• Operation
Read all instructions
• Repair Parts
carefullybefore starting
the installation.
Save this manual
for future reference.
WAILING: Improper installation, adjustment, alteration, service or
These instructions must
maintenance can cause injury or property damage. Refer to this
manual. For assistance or additional information
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KENNMORE 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 willrepair 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 will furnish a replacement heat exchanger, if the heat exc
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FIG. 1 -ASME R[[J_¥ VALVE DAMPER TEMP./PRESS. GAUGE --A u C_ VI£NT hr_ l I I II l ENCLOSED ,-_ ..... -I, r--- SCOHTROL_ [_----- J I I I i<\/ I I i I;[ HPT , \ \ J I r' 'E'r'PPLE i I I I "_ i \.A • _AJN VALVE % _._L_ _.1__ _1__ _ GAS VALVE ® COH_OL ? 31 ? L ...... ,.Lr'--_l_ [ ! i LEFT S;DE RIGHT SIO[ BASIC BOILER MODEL NO. NATURAL GAS DIMENSIONS (INCHES) NO. OF HEATING NET ConUnuous Pilot AGA/CGA "A" FLUE With SECTIONS INPUT CAPACITY I=B=R DIAMETER WIDTH *MBH *MBH Ratin9*MBH Vent Damper 11 1/4 K
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Check Io besureyouhavetherightsizeboilerbefore startingtheinstallation. Whererequired bytheauthority havingjurisdiction, theinstallation mustcon- Seeratingandcapacitytable onpreviouspage. Alsobesurethenewboileris formto American Societyof Mechanical Engineers Safety Codefor Control_ forthetypeofgasyouareusing.Check theratingplateontherightsideof the andSaletyDevices for Automatically FiredBoilers,No.CSD-1. boiler. The installation mustconformto therequirements ol the authorityhaving Youmustseeth
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the National Fuel Gas Code, ANSI Z223.1-1atest revision, or applicable provisionsof the local building codes. I Provision for combustionand ventilation air must be in accordance with Section 5.3, Air for Combustionand Ventilation, of NOTE WARNING If you use a fireplace or a kitchen or bathroom exhaust Be sure to provide enough fresh air for combustion. fan, you should install an outside air intake. These devices will rob the boiler and water heater of combus- Enough air insures proper combustion
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installation instructions. 1.Place boiler inthe selecled Iocalion (as near chimney aspossible.) Your boiler isshipped assembled. You need only Ioinsfall theReliefValveand TheminimumdesignreturnwaterLemperature Io theboilerto prevenlcon- adrainlineto carryanywalerorsteamIo adrain. densation in theboilerandventingis 120° E Theminimumhigh limil set- ting is 140 ° F. 2. InstallRelielValveinto the3/,,-pipeonthetopol Iheboiler.SeeFigure5. Use¾" Pipeandanelbow(nolfurnished)to carrythewalerorsteamto ane
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CONNECTING THE VENT DAMPER AND VENT CONNECTOR Refer to Fig. 1 flue diagram for the size and location of the FLUE AREA IN INCHES Boiler Input vent (flue opening). Use a 28 gauge (minimum) galvanized Btuh "HT "HT. "HT pipe to connect to the chimney 10-15 Ft. 15-25 Ft. 25 Ft Up IMPORTANT - The damper blade on the furnished vent 6x6 6x5 5×5 Up to 100,000 damper has a !/2square inch hole (approximately 3/4"diame- 6x7 6x6 6×5 Up to 155,000 ter). On boilers equipped with standing pilot, the hole must 7
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7 Any _mproper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1 -latest revision. When res_ztng 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 Fue! Gas Code, ANSI Z2231-latest revision HT For boilers for connection to gas vents or chimneys, vent installations shall be in accord
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Forsafe,efficient operation, the vent damper and all flue For further information,and for a vent damper !roubleshooting product carrying areas of the appliance must be checked guide, refer to the Effikal manual that was packaged with the vent damper. annually by you, with particular attention given to deterioration from corrosion or other sources. If you see corrosion or other The vent damper must be inspected at least once a deterioration, contact your heating contractor tor repairs. year by a
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CHECK GASSUPP_ The gas pipe to your boiler must be the correct size for the length of the run and for the total Btu per hour input of all NATURAL GAS gas utilization equipment connected to it. See Fig. 12 for Pipe Capacity - BTU per Hour Input the proper size. Be sure your gas line complies with local Length of Includes Fittings Pipe - Ft. codes and gas company requirements. V2" 3/4" 1" 11/4" The boiler and its individual shutoff valve must be 20 92,000 190,000 350,000 625,000 disconnected from
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WARNING TURN OFF ELECTRICAL POWER AT FUSE BOX BEFORE MAKING ANY LINE VOLTAGE CONNECTIONS. FOLLOW LOCAL ELECTRICAL CODES. II I All electrical work must conform to local codes as well as the National Electrical Code, ANSI/NFPA-70, latest revision. In Canada, electrical wiring shall comply with the Canadian Electrical Codes, CSA-C22.1 and .2. ELECTRIC POWER SUPPLY Prior to making any line voltage connections, service switch at boiler should be in the offpnsition and the power turned offat the fuse
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Connect Circulator Pump Wiring See Fig.13-1 for line voltage, thermostat and circulator pump field wiring connections. A 5 foot wiring harness with flexible metal conduit is supplied to connect the circulator pump to the service switch junction box. If the two 120 volt circulator wire terminals inside the junction box are not used, please leave the two wire nuts to prevent the short circuit. FIG. 13-1 12
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THIS PAGE INTENTIONALLY LEFT BLANK I I 13
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THIS PAGE INTENTIONALLY LEFT BLANK J 14
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24 '_0LT TRANSFORMER AQUASTAT I 81 OR W XF._M R PRl_ / BU [3 Q BOILER SENSOR Y I _ SHUT OR= _ IFL_I LOCK_ VENT E ROLLOUT y SA,_L'IY SHUT OFF OR GROUNO ¢ OR POWER , -- suP_¥.OT......... --_ _H______ T w BK NELrmAL [ 115VAC __ ir ..... ii I I I I L BK l I GAS VR8200A/VR830OA VALVlE ClRCU_TOR _J'J_ BK PUMP 2€V _ERMOSrAT WIRE CODE COLOR COOE DAMPER CABLE BK-BLACK MAIN POWER STATUS LIGHT BIR-BROWN -- LINE VOLTAGE P -PINK CALL FOR HEAT/CIRCULATOR PUMP STATUS LIGHT .... LINE VOLTAGE Y -YELLOW FIELD WIR
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120/60/1 pOWIER SUPPLY NEUTRAL HOT OVERCURRENT PROTECTED DISCONNECT CIRCULATOR PUMP 120 V_C. PRIMARY 24 V_C. SECONDARY M3-1 P3-2 _LL /'_ M3--4 P3--, "7 r ; P2-04 ; P1-01 p2-01 K1A $2 S1B ,._>>---<<-_'D'-L-_'-I _ m-o4 RVGP-KS--BKF STAT P1--02 P2-OS Kle S1A $3 J VENT DAMPER _ - o- L .---- M3-5 E3 _/_ M3-2 E1 MICROPROCESSOR HIGH UMIT SOR_j 1 - 2 M3-3 _ /_ M3-6 Ji-I '-, GAS VALVE VR8200A/VR830OA NOTE: /_ MAIN POWER STATUS LIGHT SIA AND SID ARE THE AUTOMATIC OPERATION / HOLD DAMPER OPEN SWITCH. SWITC
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RELIEF VALVE You must have a relief 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 su
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CIRCULATING PUMP Every forced hot-water system requires a circulating pump. A separate 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 is connected into the return main just ahead of the boiler. It is also wired to the electrical system. VENT DAMPER This product is an automatic, motorized stack damper that has been developed to increase the efficiency of heating syst
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HOW A HOT-WATER SYSTEM OPERATES Your entire heating system (boiler, piping and radiation units) is filled with water. As the water in the boiler is heated, it is pumped from the top of the boiler through 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. FILLI"NG SYSTEM WITH WATER Close the air vents on all radiation units. Open the valves to these units. Make sure the boi
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I WARNING: If you do not follow these instructions exactly, a fire or explosion I may result causing property damage, personal injury or loss of life. I • Immediately call your gas supplier from a neighbor's A. Some boilers are equipped with an intermittent ignition phone. Follow the gas supplier's instructions. device which automatically lights the pilot. Do not try to *If you cannot reach your gas supplier, call the fire light the pilot by hand. department. Some boilers are equipped with a con
