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Kenmore 4EW.90 - page 1
[ Owner's Manual MODEL NO. 3E W. 65 3EW. 75 3EWI';O0 4EW.90 4EWl ;25 4EW1.50 5EWl.20 5EW1.75 5EW2.00 CAUTION Read aft instructions carefully before starting the installation. Save this manual for reference. Off-Fired Hot Water Boiler • Installation • Operation • Repair Parts ...
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Kenmore 4EW.90 - page 2
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 will repair defects in material or workmanship in the boiler, free of charge. LIMITED 12 YEAR WARRANTY ON STEAM CAST IR ...
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Kenmore 4EW.90 - page 3
INTRODUCTION The Empire Water boiler is a natural draft oil fired hot water boiler comprised of cast iron sections. The Empire Water boiler is available with 3, 4, or 5 cast iron sections. These sections are held together by cast iron push nipples. The Empire Water boiler is capable of firing #2 fuel oil from 0.65 gph up to 2.00 gph. Boilers may be ...
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Kenmore 4EW.90 - page 4
BOILER RATINGS AND CAPACITIES BOIIiR MOI)EI.NO Wlill WIIIIOU I IANK[ISS IANKIESS ('Oil ('OIl niw (_5I ¸ 3[!W65Z - 31,W 751 3EW 75Z 31!WI OttI ¸ 3EWI IRIZ 4[iw 90T 4EW 99Z 41!WI 251 4EWI 25Z 41LWl 501 4EWl 50Z 5EWI 20'I 5EWI 20Z 5EWI.75 I 5EWI 75Z 5[-W2 00"[ SEW200Z NO INPUI **llliA'[ ING Sli(' +M[_II ( APA('IIY ...
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Kenmore 4EW.90 - page 5
RULES FOR SAFE INSTALLATION AND OPEIL_TION 1. Read the Owner's Manual for Safe Operation carefidly. Failure to tbllow tile rules tbr sale operation and the instructions can cause a malflmction of the boiler and resuh in death, serious bodily injury, and/or property damage. 2. Check your local codes and utility requirements before installation. ...
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Kenmore 4EW.90 - page 6
BEFORE YOU START Complete all of the following prior to installing the boiler. A. Check to be sure you have selected the right size boiler with the proper capacity. The I=B=R rating of the boiler selected should be greater than or equal to the calculated peak heating load (heat loss) for the building or area(s) served by the boiler and associated h ...
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Kenmore 4EW.90 - page 7
ALWAYS KEEP TILE NL_NUAL FUEL SUPPLY VALVE SHUT OFF, IF THE BUI_NER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIa_clE. I_NSTALLATION REQUIRELMENTS 1 SHUT OFF VALVE OIL RLTER 2** FI LL PiPE MIN 2" VENT PIPE OIL TANK LINES TO OTHER APPLIANCES TO OUTSIDE ELECTRIC LINE AUTOMATIC FILL VALVE NOSHUTOFF EXPANSION TANK DRAFT REGULATO_ VENT PiPE RELIEF VAI ...
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Kenmore 4EW.90 - page 8
FRESH AIR FOR COMBUSTION WARNING I Be sure to provide enough fresh air for combustion. Enough air ensures proper combustion and assures that no hazard will develop due to the lack of oxygen. I NOTE [ If you use a fireplace or a kitchen or a bathroom exhaust fan, you should install an outside air intake. These devices will rob the boiler and water h ...
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Kenmore 4EW.90 - page 9
B. All Air from Outdoors: The confined space shall be provided with two permanent openings, one commencing within 12 inches of the top and commencing within 12 inches of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. 1. When d ...
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Kenmore 4EW.90 - page 10
SYSTEM PIPING I. When the installation of the boiler is for a new heating system, first instal! all of the radiation units (panels, radiators, baseboard, or tubing) and the supply and return mains. After all heating system piping and components have been installed, make final connection of the system piping to the boiler. It is recommended to mount ...
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Kenmore 4EW.90 - page 11
SYSTEM PIPING ARRANGEMENT ZONING WITH ZONE VALVES > CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANK > PIPING ARRANGED FOR "POWER P[VRGING" AIR OUT OF SYSTEM PIPING, REFER TO THIS MANUAL'S SECTION ON "FILLING THE SYSTEM _,VITH WATER" OPTION #1 BALANCINGVALVE ZONE VALVE RETURN FROM SYSTEM IT I RAIN VALVE FOR ...
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Kenmore 4EW.90 - page 12
SYSTEM PIPING ARRANGEMENT ZONING WITH CIRCULATORS CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANK PIPING ARRANGED FOR "POWER PURGING" AIR OUT OF SYSTEM PIPING, REFER TO THIS MANI_AL'S SECTION ON "FILLING THE SYSTEM WITH WATER" OPTION #1 RETURN FROM SYSTEM [ _ DRAIN VALVE FOR POWER PURGING MAIN SHUTOFF VALVE AUTOM ...
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Kenmore 4EW.90 - page 13
SYSTEM PIPING ARRANGEMENT ALTERNATE NEAR BOILER PIPING DIAPHRAGM EXPANSION TANK MOUNTED OFF THE BOILER > CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANK PER THIS MANUAL, USE OPTION #2 IN "FILLING THE SYSTEM WITH VATER" THIS PIPING ARRANGE_IENT CAN BE USED WITH ZONE VALVES OR ZONE CIRCULATORS RETURN FROM SYSTEM ISOLATION VAL ...
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Kenmore 4EW.90 - page 14
7. Boilers may be factory packaged with a tanMess heater coil see figure below. This coil provides instantaneous heating of water for domestic use - if proper burner and water supply line controls are used. Tankless coils are meant to provide domestic hot water for intermittent draws, no_J continuous flow. IMPORTANT Do not use a tankless coil if yo ...
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Kenmore 4EW.90 - page 15
8. Antifreeze addedto boilers must be non-toxic, and must be of a type specifically intended for use in closed b_ydronic heating systems. Under no circumstances should automotive antifreeze be used. Antifreeze used in any boiler may reduce capacity by 10% or more and increase fuel consumption. Tankless coil performance will fall as concentration of ...
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Kenmore 4EW.90 - page 16
I or oil-fired boilers for connections to vents or chimneys, vent installations shall be in accordance with applicable provisions of INSTALLATION OF OIL BURNING EQUIPMENT, NFPA-31 - latest revision, and applicable provisions of local building codes. CHIMNEY AND CHIMNEY CONNECTIONS This is a very important part of your heating system. No boiler, how ...
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Kenmore 4EW.90 - page 17
TYPICAL CHIMNEY CONNECTION MUST BE AT LEAST 4 INCHES THICK- AND BE TIGHT. MUST SLOPE UP AT LEAST 1/4 INCH PER FOOT OF HORIZONTAL RUN DRAWBAND LAST PIECE INSTALLED TIGHT, SMOOTH, CORRECTLY SIZED. I I ! • SEALED IN THIMBLE .TIGHT CLEAN-OUT DOOR MUST BE REQUIRED MIN- IMUM HEIGHT• MUST RE AT LEAST 3 FT. HIGHER THAN HIGHEST PART QF PASSAGE THROUGH R ...
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Kenmore 4EW.90 - page 18
ELECTRICAL CONNECTIONS Thermostat Install a 24-volt thermostat (not provided) in a proper location. The location of the thermostat has an important effect on boiler system operation. BE SURE TO FOLLOW THE INSTRUCTIONS INCLUDED WITH THE THERMOSTAT. Grounding Permanently ground the boiler according to local codes and the National Electrical Code. Run ...
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Kenmore 4EW.90 - page 19
SE_/ARS 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 will repair defects in material or workmanship in the boiler, free of charge. LIMITED 12 YEAR WARRANTY ON STEAM ...
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Kenmore 4EW.90 - page 20
MAIN AIR VENT: for down flow systems or diaphragm type expansion tanks (not provided) Before a system is filled with water, there is air in the pipes and radiation units• Some of the air will be trapped as the system is filled. It is possible to eliminate most of this air through the air vents on the radiation units• A main air vent will speed ...
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Kenmore 4EW.90 - page 21
FILLING THE BOILER HOW A HOT WATER SYSTEM OPERATES The entire heating system (boiler, piping, and radiation units) is filled with water. As the water in the boiler is heated, it is circulated from the top of the boiler through the supply main to the radiation units. The cooler water in the radiation units flows back through the return piping throug ...
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Kenmore 4EW.90 - page 22
BECKETT OIL BURNER, NOZZLE, AND AIR SETTINGS _BOILER MODEL 3EW 65* 3EW.75 3EW1.00 4EW.90 4EW1.25 4EW1.50 5EW1.20 5EW1.75 5EW2.00 DELEVAN OIL NOZZLE 0.50-80°B 0.65-70°B 0.85-70°B O.75-80OA 1.00-80°A 1.25-80°A 1.00-60°13 1.5045°B 1.65-60°B FIRING RATE (gph) 0.65 0.75 1.00 0.90 1.25 1.50 1.20 1.75 2.00 HEAD-ADJ. OR SETTING F0 - 1 1/8 F3 - 1 1/ ...
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Kenmore 4EW.90 - page 23
NOZZLES AND ELECTRODES: Use the proper size, spray angle, and spray pattern nozzle. Refer to the recommended nozzle selection charts at the end of this manual. To install a nozzle, remove the nozzle line electrode assembly, if necessary remove the retention ring assembly, and then install and tighten the nozzle. Be careful not to damage the electro ...
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Kenmore 4EW.90 - page 24
BECKETT AFG BURaNER ELECTRODE ADJUSTMENTS VARIABLE (VI) HEADS BOILER MODEL 5EW DIMENSION "'N" DIMENSION "H" (electrode to nozzle) (head to nozzle) 1/16" 7/32" to 9/32" lMENSION "}'1" SEE BELOW--_ 5132 ,,. .._.._CTROOE GAP " " _ ..,a LI or VI HEAD _.. _DIMEMBION -N" E B£LOW BECK ...
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Kenmore 4EW.90 - page 25
5/32" - 4 mm ,)- 5/64" to 7/64" or 2 to 2.5 m[__ "_ 5/32" or 4 mm 5/32" to 13/64" or 4 to 5 mm _ I _ i -- E E TO 23 ...
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Kenmore 4EW.90 - page 26
CHECKING AND ADJUSTING CONTROLS A boiler using a tankless coil is configured with a Honeywell L8124C Combination Hi/Low Limit Aquastat Relay (refer back to the SYSTEM PIPING section for more details). A boiler not using a tankless coil is configured with a Honeywell L8148A Hi Limit Aquastat Relay. Instructions for the control provided are included ...
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Kenmore 4EW.90 - page 27
MAINTENANCE ANUALLY: To assure trouble-free operation, it is recommended that the flue passages, combustion chamber area (target wall, fire door insulation, durablanket), burner adjustment, operation of the controls, and boiler seals (fire door gasket or silicone seal, cast iron sectional seals, flue collector) be checked once each year by a compet ...
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Kenmore 4EW.90 - page 28
OIL BOILER / BURNER CLEANING INSTRUCTIONS OIL BOILER CLEANING: I. Shut off all electrical power to the boiler / burner and shut off fuel oil supply. 2. Remove the vent pipe from the top of the boiler. Inspect the pipe and chimney for signs of corrosion and deterioration. Clean out the base of the chimney. If the vent pipe shows any signs of corrosi ...
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Kenmore 4EW.90 - page 29
OIL BURNER CLEANING: These are general instructions for cleaning an oil burner. For speci_'lcs, consult the buruer manufacturer's instructions. 1. Make sure all electrical power to the boiler / burner and the fuel supply to the burner are shut off. 2. With the swing door open, clean any soot accumulations from the end of the burner and if ...
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Kenmore 4EW.90 - page 30
SERVICE HINTS You may avoid inconvenience and service calls by checking these points before you call for service. Possible Cause Thermostat is not set correctly Boiler or Burner may be dirty Burner may not be firing at proper rate Burner may be short-cycling No power to boiler Controls out of adjustments Radiators not heating Circulating pump not r ...
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Kenmore 4EW.90 - page 31
ELECTRICAL WIRING BOILER WITH TANKLESS COIL AND HONEYWELL L8124C AQUASTAT CONTROL (BECKETT AFG BURNER SHOWN) BOILER WITHOUT TANKLESS COIL HONEYWELL L8 ! 48A AQUASTAT CONTROL (BECKETT AFG BURNER SHOWN) 24 VOLT THERMOSTAT 120V i I SUPPLY ? NEUTRAL I I HOT _ BK W : : PROTECTED OISCONNECT [_ ua12_c _ ® mUASTAT @j().@@ ,.___ W @ IGN. TRANN OIL VALVE CI ...
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Kenmore 4EW.90 - page 32
BOILER WITH TANKLESS COIL AND H ONEYWELL L8124C AQUASTAT CONTROL (CARLIN EZ BURNER SHOWN) BOILER WITHOUT TANKLESS COIL HONEYWELL L8148A AQUASTAT CONTROL (CARLIN EZ BURNER SHOWN) 24 VOLT THERMOSTAT 120V _ r _k POWER I i soP.LY _ N_UTRAL i i .oT _ eK w ] I L8124C _--_-'#'-(_@ AQUASTAT @J_'_(_ R W k CIRCULATOR 8K m IGN* TRAN$ OIL VALVE ...
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Kenmore 4EW.90 - page 33
BOILERWITH TANKLESS COIL AND HONEYWELL L8124C AQUASTAT CONTROL (RIELLO 40 BURNER SHOWN) BOILERWITHOUTTANKLESS COIL HONEYWELL L8148A AQUASTAT CONTROL (RIELLO 40 BURNER SHOWN) 120V pOWER SUPPLY 120/6O/I OVERCURREHT PROTECTED DISCONN[CT 24 VOLT THERMOSTAT @ COLO_ COOL BK- BLACX R- RED E_ - 8K'G_m B.- 8U_ L8124C AOUASTAT E w BK iI _ _CAPAC[TOR C T ...
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Kenmore 4EW.90 - page 34
SEQUENCE OF OPERATION BOILER WITH TANKLESS COIL: Aquastat hiI_h limit controller: The aquastat control's high limit contacts open and rum off the burner when the boiler water temperature reaches the control's high limit set point. The high limit contacts automatically reset alter the boiler water temperature drops past the set point by 10 ...
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Kenmore 4EW.90 - page 35
SEQUENCE OF OPERATION BOILER LESS TANKLESS COIL: Aquastat high limit controller: The aquastat control's high limit contacts open and turn offthe burner when the boiler water temperature reaches the control's high limit set point. The high limit contacts automatically reset after the boiler water temperature drops past the set point by 10? ...
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Kenmore 4EW.90 - page 36
REPAIR PARTS NOTES: _O0-F _CX _IUCQ_C _U88_R _or S_ewH i © ITEM DESCRIPTION 3EW I Water Boiler Back Section (EW-3) ¢03-00-008 2 Water Boiler Mddle Section EW-2) 403-00-007 3 Empire Water Front SeclJon IEW-1) 403`00-006 4 Cast Iron Machined Nipples 2" 433-00-976 5 1/4" Tie Rods 1464354302 6 Tie Rod 1/4"-20 Hex Head Nut 146-95-041 7 ...
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Kenmore 4EW.90 - page 37
REPAIR PARTS I I I I BALLOON SYMBOL KEY NO. &NTITY [_ ___1 I ITEM 1 2 3 4 5 6 7 8 9 10 11 12 DESCRIPTION Empire Water Front Section (EW-1 3/8"-16 x 2-1/4" stud 3/8" Whizlock Nut Swing Door Insulation Swing Door Hinge 1/4" x 2" Round Head Rivet 3/8" x 1" Hex Head Serrated Flange Bolt 3/8" x 48" Fiberf ...
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Kenmore 4EW.90 - page 38
% REPAIR PARTS BALLOON 5YMBOL KEY //--_TD4 _oI / / ITEM DESCRIPTION 1 Right Side iacket Panel 2 Back Jacket Panel 3 Top Jacket Panel 4 Left Side jacket Panel 5 Upper Front Jacket Panel 6 5/16" Acorn Nut 7 #10 x 1/2" Jacket Screw 8 Stand Off 9 Lower Front Jacket Panel {boiler w/swing door) XX Complete Jacket for Boiler with Swing Door 3EW ...
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Kenmore 4EW.90 - page 39
REPAIR PARTS 5a,5b 4 I (Without Tankle_= colt) Tankle== Coil) 8 FRONT VIEW WATER OUTLET 7 RIGHT SIDE VIEW j 3b 3a 3c 5 OPTIONAL TANKLESS COIL WATER HEATER WITH 1/2" NPT CONNECTIONS ITEM DESCRIPTION 1 Beckett AFG F-Head Oil Burner 1 Beckett AFG Variable Head Oil Burner ..... Beckett AFG F-Head Low Fire Kit (0.65 _ph) Beckett AFG F-Head Low Fire ...
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Kenmore 4EW.90 - page 40
BECKETT OIL BURNER_ NOZZLE, AND AIR SETTINGS BOILER DELEVAN FIRING HEAD-ADJ, LOW FIRE AIR STATIC OIL MODEL OIL NOZZLE RATE (gph) OR SETTING BAFFLE SHUTTER / BAND PLATE BURNER 3EW.65" 0.50-80°B 0 65 F0 - 1 1/8 YES 10 / 0 3-5/8 AFG F-HEAD 3EW 75 0.65-70°B 0.75 F3 - 1 1/8 YES 10 / 0 3-1/2 AFG F-HEAD 3EW1.00 0.85-70°B 1.00 F3 - 1 II8 NO 10 / 2 ...
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Kenmore 4EW.90 - page 41
Owner's Manual MODEL NO. 3EW.65 3EW.7+5 3EWI:00" 4EI/V.-90. 4EW.1_25 4EWI'_50 5EW1.20 5EWi".75 5EW2.00 HOW TO ORDER REPAIR PARTS TELL SEARS YOU WANT IT INSTALLED THEN RELAX F_4-t_9 Oi/-Fired Hot Water Boiler Now that you have purchased your Bo_ler should a need ever exist for repair parts or serwce, simply coHtact an,! Sears Ser ...
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