Kenmore K90-125 User Manual Download

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Summary of Contents for K90-125

Page 1: ...lation Operation Maintenance 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 ...

Page 2: ... appliance is a gas fired direct vent cast aluminum hot water boiler A revolutionary cast aluminum heat exchanger means better heat transfer and thermal storage than similarly sized cast iron boilers which results in higher efficiency The heating system water absorbs large amounts of heat from the cast aluminum heat exchanger cooling the flue gases and causing condensation Sealed combustion premix...

Page 3: ... to the boiler prior to servicing 3 Inspect gas line for leaks VENT CONN CTI0_ 2 c_wc ______ may result in too much air for the pre mix bumer causing poor or loss of combustion 5 Never vent the products of combustion from this boiler to an enclosed space Always vent to the outdoors Never vent to another room or to inside a building 6 Be sure there is adequate outdoor air supply to boiler for compl...

Page 4: ...50 000 150 000 147 800 147 400 145 600 144 800 143 400 142 200 141 2001 139 600 139 000 137 000 136 800 134 400 134 600 131 800 132 400 129 200 130 200 126 600 128 000 124 000 Vent 125 000 123 500 122 000 120 500 119 000 117 500 114 500 113 000 111 500 110 000 125 000 123 000 121 000 119 000 117 000 115 000 113 000 111 000 109 000 107 000 105 000 Altitude 0 1 000 2 000 3 000 4 000 5 000 6 000 7 00...

Page 5: ...and pickup requirements Complete all of _e following prior to installing the boiler This boiler product is a gas fired direct vent con densing boiler and must be installed in accordance with all applicable federal state and local building codes including but not limited to the following United States Installation shall conform with National Fuel Gas Code NFPA 54 ANSI Z223 1 latest revision Canada ...

Page 6: ...ake passages free of obstruc tions Both the venting and combustion air intake piping systems connected to the outdoors must permit flow through the piping systems without restrictions for the boiler to operate 7 The boiler shall be installed such that the automatic gas ignition system components are protected from water dripping spraying rain etc during operation and service circulator re placemen...

Page 7: ......

Page 8: ...y 5 Test for spillage at the draft hood relief open ing after 5 minutes of main burner operation Use the flame of a match or candle or the smoke from a cigarette cigar or pipe Boiler must be placed on level surface Boiler is NOT to be installed on carpeting NOTES 1 Ifboiler is not level condensate drain lines will not function properly Adjustable feet are located on the boiler to make up for minor...

Page 9: ...er installed above radiation level must be equipped with a low water cut off device included with boiler A periodic inspection is necessary as is flushing of float type devices per low water cut off manufacturers specific instructions DIAPHRAGM TYPE EXPANSION TANK PIPING E_C_ T_f_ _VICE VAL_ _ _n VALOIS C_ FULL PORT B_ VAL _ _J TO_ATIC _R V_ _ _ X 8 _ F_t_i_O_J_ _i_ iN ST _ _1_4 FC_ F_ WA_R Figure...

Page 10: ...should be used as one of the zone pumps Each stripped end of the electrical wires for the circulator pump inside the junction box should be taped or wire nutted to prevent short circuits Unplug the circulator pump wiring at the integrated boiler control MULTIZONE BOILER PIPING WITH ZONE VALVES The packaged boiler unit is set up to receive 11 NPT supply and return piping from top access frNiOTE The...

Page 11: ...nt the chilled medium from entering the boiler The boiler piping system of a hot water boiler con nected to heating coils located in air handling units where they may be exposed to refrigerated air cir culation must be equipped with flow control valves or other automatic means to prevent gravity circu lation of the boiler water during the cooling cycle ibMPORTANT To prevent damage to the gas_ urne...

Page 12: ...or ter mination of combustion air and vent piping Comply with all clearances required as stated in paragraph 6 below Termination should be positioned where vent vapors will not damage plants shrubs air conditioning equipment or siding on the house Termination should be positioned so that it will not be effected by wind eddy air born leaves snow or recirculated flue gases Termination should be posi...

Page 13: ... et over primer Apply cement in light uniform coat on the inside of socket to prevent buildup of excess cement Apply second coat 8 While cement is still wet insert pipe into sock et with a 1 turn twist Be sure pipe is fully in serted into fitting socket 9 Wipe excess cement from joint A continuous bead of cement will be visible around perimeter of a properly made joint 10 Handle pipe joint careful...

Page 14: ...g rules apply 3 Use ground joint unions 4 Install a sediment trap upstream of gas con trols 5 Use two pipe wrenches when making the con nection to the gas valve to keep it from turning 6 Install a manual shutoff valve in the vertical pipe about 5 feet above floor outside the boiler jacket 7 Tighten all joints securely 8 Propane gas connections should only be made by a licensed propane installer 9 ...

Page 15: ...te screw on the service switch Connect the green ground lead from the power supply to the ground green screw on the service switch The recepta cle on the service switch is always powered regard less of whether the switch is on or off and could be used as a power supply for an external condensate pump if one is used The thermostat location has an important effect on the operation of your boiler sys...

Page 16: ...R COttOU_ORS ONLYI LADDER WIRING DIAGRAM 120 VOLT POWER SUPPLy NOTE USE COPPER COI_DUCTORS ONLy H TI C_N OF F 8LK SWITCH LWCO _ 1 CASTING TEMpERATLJR E SAFE_ SWITCH MANtJAL RESE_ tl 4K1 3K1 fl DIFFERENTIAL AIR PRESSLJRE O_ NWITCH NO S_T AT TNERMOSTAT 2 CIRCULATOR FIELD WIRED HOT SURFACE IGNITE R P12 2 p6 2 P7 2 _7 3 p4 3 p10 2 P5 3 J P10 3 5K2 I 120 VAC SFORM_R GAS VALVE II _ I I P3 5 I I P3 2 AIR...

Page 17: ...or protecting the boiler and heating system from unsafe operating conditions which could dam age the boiler The aquastat is mounted in the NPT control well and x bushing on the top of the front boiler section at the hot water outlet The aquastat is tied in with the IBC and is factory set at 180 F water temperature The high limit setpoint is field adjustable and may be set anywhere between 100 F an...

Page 18: ...eating system will increase The fur nished relief valve will automatically open at 30 psig pressure te relieve the strain on the boiler and heating system from the increasing pressure The pressure re lief valve discharge must be piped with the same size as the valve discharge opening to an open drain tub or sink or other suitable drainage point not subject to freezing in accordance with A S M E sp...

Page 19: ... manufacturer s in structions on determining proper ratio of an tifreeze to water for the expected low tem perature conditions and for maintaining the quality of the antifreeze solution from year to year Improperly maintained antifreeze solu tions will gradually lose their ability to protect the aluminum boiler from corrosion d The recommended premixed antifreeze solution is INTERCOOL NFP 50 This ...

Page 20: ...NOT use stop leak compounds Leaks in _ readed connections in the aluminum boiler sections mus _t I e repaired immediately Aluminum threads will not seal I emselves J _ READ BEFORE OPERATING APPLIANCE _ 1 This appliance does not have a pilot It is equipped with an ignition device which automat ically lights the burner Do NOT try to light this burner by hand 2 Before operating smell all around the a...

Page 21: ... be perpendicular to the gas pipe 7 Wait five minutes for any gas to clear Then smell for gas including near the floor If you smell gas STOP Follow instructions under What To Do If You Smell Gas previous page If you do not smell gas go to the next step 8 Turn the gas shut off valve to the On posi tion The handle on the valve should be parallel to the gas pipe 9 Replace the front jacket panel 10 Tu...

Page 22: ...rol energizes the gas valve initiating a 6 second trial for ignition mode which is indicated by the illumination of Lamp D Two seconds later Lamp C will extinguish when the integrated boiler control stops sending power to the hot surface igniter 7 A low level illumination of Lamp E indicates the initiation of flame proving During the last 2 seconds of the trial for ignition mode main burner flame ...

Page 23: ...mum high limit setting is 100 F Return high limit differen tial to original setting 20 F If the boiler is equipped with a low water cut off a manual reset high limit or additional safety controls For a single thermostat connected to the yellow thermostat lead wires in the furnished field wiring junction box the heat anticipator should be set at 0 7 amps For other wiring configurations refer to the...

Page 24: ...al completecycles to verify proper operation Reviewall instructionsshippedwiththis boilerwith ownerormaintenanceperson Instructions mustbe affixedonor adjacentto the boiler Thencomplete andsignthe Installation and Checkout Certificate at the end of this manual ...

Page 25: ...and cleaning instructions in paragraph F below b Visually inspect venting and air intake system for proper operation If the vent or air intake show any signs of deterioration or leakage repair or replace them immediately Insure proper reas sembly and resealing of the vent and air intake system c Check for and remove any obstruction to the flow of combustion air or venting of flue gases d Follow in...

Page 26: ... e Loosen but do not remove five nuts attaching blower adapter assembly to boiler f Remove two igniter screws and very carefully remove the igniter The igniter element is very sensitive Do not touch the igniter element with your fingers or hands as oils or debris will cause premature failure g Remove five nuts and blower adapter assem bly Remove burner and gaskets h Aluminum oxide deposits are wat...

Page 27: ...AT PURGE LIGHT 18ON AIRFLOW PROVED DRAFT INDUCER RUNS FOR 15 SEC PREPURGE MAIN BURNER BURNER PROVE FLAME WITHIN INITIAL TRIAL FOR IGNITION PERIOD J DURING THE LAST 2 SEC OF THE 6 SEC IGNITION TRIAL MAIN BURNER FLAME IS PROVED BY FLAME RECTIFICATION A FLAME SIGNAL TO IBC GAS VALVE REMAINS ENERGIZED BOILER RUNS 2 SEC INTO THE 6 SEC IGNITION TRIAL POWER IS TURNED OFF TO THE HOT SURFACE IGNITER IGNITE...

Page 28: ... PRESSURE SWITCH CONTACTS OPEN GAS VALVE WILL BE DE ENER GIZED VALVE AND FLAME LIGHTS GO OUT UTES FOR AIRFLOW TO BE RE ESTABLISHED iF AIRFLOW DOES NOT RE ESTABLISH CONTROL I I LOCKOUT PROBLEM WITH COMBUSTION AIR FLOW PURGE L GHT BL NKS CASTING TEMPERATURE SAFETY SWITCH IF BURNER OPERATES WHEN BOILER HAS NO WA i ER ALUMINUM BOILER SECTIONS HEAT UP RAPIDLY I CASTING TEMPERATURE SAFETY SWITCH CON TAC...

Page 29: ...ENDS CALL FOR HEAT I I GAS VALVE AND CIRCULATOR PUMP ARE DE ENER G ZED VALVE AND FLAME L GHTS GO OUT BLOWER RUNS FOR 30 SECONDS POST PURGE PURGE LIGHT IS ON BLOWER IS DE ENERGIZED AFTER 30 SECONDS PURGE LIGHT SHUTS OFF BOILER STAND BY FOR NEXT CALL FOR HEAT ...

Page 30: ...ap pening chances are that either there is nothing wrong with the control or it is being damaged by some other problem for example an electrical k_ hort burning out a transformer j 1 Before troubleshooting c Make sure that gas is on at the gas me ter at all appropriate manual shutoff valves and at the gas control valve d Make sure that the thermostat is calling for heat e Check that wire connector...

Page 31: ...ocations of the connection points required to check the differential air pressure DIFFERENTIAL AIR PRESSURE SWITCHES TRANSPARENT WHITE SILICONE HOSE SIGHT GLASS ESTING UNES MANOMETER OSE GAS VALVE Blockage in air intake or vent pipes Undersized air intake or vent pipes Loose blower wheel on motor shaft Incorrect pressure switch or pres sure switch setpoint Gas valve out of adjustment 6 When pressu...

Page 32: ...eceives more than 40 VAC IBC is energizing the draft inducer and air flow is proven Off during purge cycle draft inducer is not powered on or air flow is not proven Off during igniter and run cycle normal operation purge cycle complete IBC is locked out Problem could indicate false positive proof of air flow Blocked vent intake air pipe or flue way IBC is energizing igniter Igniter is not energize...

Page 33: ...CH CLOSED GREEN POWER INDICATOR LIGHT IS I _Np_ i_ ILLUMINATED OR THE IBC CHECK SYSTEM STATUS IF LOCKED OUTNOTE FAILURE MODE WHICH INDICATOR LIGHT IS BLINKING RESET SYSTEM BY TURNING SERVICE SWITCH OFFTHEN ON IF NOT LOCKED OUT SET THERMOSTAT TO CALL FOR HE_T CIRCULATOR STARTS YES IBC CHECKS NORMALLY OPEN AIR PRESSURE SWITCH CONTACTS OPEN CHART3 CHART 2 ...

Page 34: ...PLUG CN2 YES REPLACE IBC CHECK FOR 120 VAC BETWEEN TERMINALS 1 AND 3 AT CONNECTOR CN5 ON IBC YES CHECK FOR 120 VAC AT CIRCULATOR YES REPAIR REPLACE CIRCUL TOR I I IGPEN I l I I NO I NO r I L NO IN i J I t 1 I No J CHECK WATER LE VEL IN BOILER CHECK FOR AIR TRAPPED IN TOP OF BOILER CONTACTS WILL NOT STAY CLOSED UNT L SOILER COOLS OFF REPLACE REPAIR WIRING FROM SERVICE I SWITCH TO iSC I REPLACE IBC ...

Page 35: ...NSTRUCTIONS ON FOLLOWING PAGES ARE SAMPLING LINES CLEAR AND CONNECTED PROPERLY _YES CHECK FLUE PASSAGES IN BOILER PER MAINTENACE AND CLEANING ARE FLUE ___ CLEAN OUT VENT PIPE AND OR AIR INTAKE PIPE CHECK FOR SAGS OR LOW SPOTS WHERE CONDENSATE MAY PUDDLE AND BLOCK THE VENT t__ CLEAN OUT BAMPUNG LINES OR REPLACE DEFECTIVE SWITCH t__ CLEAN BOILER FLUE PASSAGES PER MAINTENANCE AND CLEANING INSTRUCTION...

Page 36: ...P YESI _ REPLACEIGNITER SENSOR I CHECK FOR 24 VAC ACROSS TERMINALS MV ON THE GAS CONTROL WHILE VALVE FLAME INDICATOR LIGHT IS ON YES CHECK FOR 24 VAC ACROSS TERMINALS CN6 2 AND CN6 5 ON ISC WHILE THE VALVE FLAME LED IS LIT YES REPAIR REPLACE WIRING BETWEEN IBC AND GAS CONTROL CHECK IF IGNITER SENSOR POSITION IS OK TiP SHOULD BE SLANTED TOWARDS BURNER YES CHECK GAS SUPPLY PRESSURE AT INLET PRESSURE...

Page 37: ...E TO USE CORRECT GASNENTURI VALVE SIZE CLEAN BOILER FLUE PASSAGES PER MAINTENANCE AND CLEANING INSTRUCTIONS CLEAN MIXER AND BURNER PER MAINTENANCE AND CLEANING INSTRUCTIONS REPLACE BURNER I DOES MAIN BURNER RUN UNTIL CALL FOR HEAT ENDS OR HI LIMIT AQUASTAT CONTACTS OPEN CHART6 NO 1 NO 2 NO 3 7 IF THE ANSWER IS NO CHOOSE THE APPROPRIATE PATH 1 2 OR 3 BASED ON SYMPTOMS SHOWN CHART 6 CHART 6 7 RUNS S...

Page 38: ...CE CLEAR OF BLOCKAGE rYES DOES THE UNIT USE LP GAS NO ADJUST RATE AS DESCRIBED IN THE CHECK OUT PROCEDURE AND ADJUSTMENT SECTION OF THE MANUAL REPLACE WITH CORRECT AIR BAFFLE _P BOILER SHUTS OFF BEFORE END OF CALL FOR HEAT ARE HI LIMIT AQUASTAT CONTACTS CLOSED YES SEE TROUBLESHOOTING PATH I I 2 ABOVE YES CHECK FLAME SIGNAL 0 6uA sO INI _ _ CONSULT BOILER MFGR FOR SPECIFIC INSTRUCTIONS REQUIRES SPE...

Page 39: ...tion instructions have been followed o Checkout procedure and adjustments performed o Maintenance and Service issues reviewed with owner maintenance person o Installation booklet affixed on or adjacent to boiler Installer Company Address Phone Installer s Name Signature ...

Page 40: ... MODELNUMBER NAMEOF ITEM All parts listed may be ordered from any Sears Service Center If the parts you need are not stocked locally your order will be electrically transmitted to a Sears Repair Parts Distribution Center for Handing When Sears arranges the installation you can be sure thejob is done right We will arrange for professional workmanship and we ll take care of the entire project What s...

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