Kenmore K90-150 Owner's Manual
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Kenmore K90-150 Owner's Manual

Kenmore K90-150 Owner's Manual

Gas-fired direct vent condensing hot water boiler
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Gas-FiredDirectVent
Condensing
HOT WATER BOILER
• Installation
• 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.

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Summary of Contents for Kenmore K90-150

  • Page 1 Gas-FiredDirectVent Condensing HOT WATER BOILER • Installation • 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: Installation

    INSTALLATION MANUALAND OPERATING INSTRUCTIONS PIN# 240004826K, Rev. 1.1 [08/05] • Printed in USA • Made In USA forces the resulting flue gases from the boiler unit and provides a positive removal of the flue gases I. Introduction ............from the building through inexpensive and readily...
  • Page 3 WARNING O_Pt'NING FOR AIR YENT OPENING FOR REIJI_ VALVE AND EXPANSION TANK STANDARD OISCHARG£ PIPE _CONNECTIOH SUPPLY _ RL'TURNOFTNINGS 1 1 4 NPT CONNECTIONS VENT CONN(CTI0_(2" c_wc)- JU_1_q FOR 120V._ --__BIN_. ----" '______ _'-- "'-_ C:::::l '1/4 _tl/' (2" C_C) DRAIN' (1/2"...
  • Page 4 112.5 2" CPVC & 3" PVC 2" CPVC & 3" PVC 157.5 2" CPVC & 3" PVC 2" CPVC & 3" PVC c_)1MBH = 1,000 Btuh(British ThermalUnits PerHour) (2) AFUE (Annual Fuel Utilization Efficiency) and Heating Capacity is based on Department of Energy test procedure. Ratings shown are for sea level applications.
  • Page 5 These low pressure gas-fired hot water boilers are design certified by CSA International, for use with natural and propane gases. The boilers are constructed and hydrostatically tested for a maximum work- ing pressure of 50 psig (pounds per square inch gauge) in accordance with A.S.M.E.
  • Page 6 • Connectedto a suitable hot water heating the front where passage is required for cleaning or system. servicing, inspection or replacement of any parts that normally may require such attention. Allow at • Suppliedwith a suitableelectricalsupplyfor least 24" at the front and left side and 8" at the top all boiler motorsand controls.
  • Page 8 remaining connected to it. At the time of removal CONCENTRIC VENT ROOF INSTALLATION an existing boiler, the following steps shall be fol- lowed with each appliance remaining connected , AIIOv_E _6NEST the common venting system placed in operation, while the other appliances remaining connected the common...
  • Page 9 The boiler should be placed to provide the most ly or 2-wheelhand truck. The dolly or hand truck directconnectionsto the combustionair, vent and should be insertedunder the right hand side of systempipingas possible. the boiler.It is possibleto slidethe boilerfor a short distanceon a smoothfloor or surface.

  • Page 10: Drain Piping

    but leave an air gap between piping and drain. MULTIZONE BOILER PIPING No shutoffof any descriptionshall be placed be- WITH ZONE VALVES tween safety relief valve and the boiler, or on the dischargepipes betweensuchsafetyvalveandthe atmosphere. Installationof the safety relief valve shall conformto ANSl/ASME Boiler and Pressure VesselCode, Section IV.The manufactureris not responsiblefor anywater damage.
  • Page 11 NOTES ON INITIAL START UP THE CONDENSATE TRAP 1. Condensate trap is to be built in the field per Figure 10 MUST BE MANUALLY FILLED WITH WATER. 2. Wood frame or blocks may be used to raise the boiler to maintain drain pitch or to be above external condensate The following are the steps required...

  • Page 12: Combustion Air And Vent Piping

    Reduce the maximum vent length 5 feet per • D2665 (PVC-DWV) each additional elbow. • D2241 (SDR-21 and SDR-26 PVC) 4. Combustion air and vent piping to be pitched back to boiler at minimum 1/,,, per foot from intake • D2661 (ABS-DWV) and vent terminals so that all moisture in com-...
  • Page 13 above grade. Terminationof the vent shall be 6. Check dry fit of pipe and mark insertion depth not less than 7 feet above an adjacent public on pipe. walkway. T he vent terminalshall not beinstalled closerthan 3 feetfrom the insidecornerof an L (_OTE: It is recommended that all pipes be cut, prepared, and_ shapedstructure.Termination of the ventshould...

  • Page 14: Gas Piping

    requirements, by the National Fuel Gas Code, ANSI Z223.1- latest revision. In Canada, follow the CAN/CGA B149.1 and .2 Installation Codes for Gas Buming Appliances and Equipment. 92,000 190,000 350,000 625,000 63,000 130,000 245,000 445,000 2. Use pipe joint compound suitable for liquefied 50,000 105,000...
  • Page 15 WARNING boiler, when installed, must be electrically grounded in accordance with the requirements the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code, ANSI/NFPA-70, latest revision. In Canada, electrical wiring shall comply with the Canadian All electrical work must conform to local codes as...

  • Page 16: Ladder Wiring Diagram

    SCHEMATIC WIRING CONNECTIONS NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°C Thermoplastic wire or its equivalent. PC_3 l _Ct _SFORM_R SECONE_RY 24 VA¢ BK P_ I_N_ORM_R F_J_RY pURCta (NOTE: USE COP_ER COttOU_ORS...

  • Page 17: Indicator Lights

    This section provides a brief description of the key the failure mode as a lack of flame signal. The IBC is controls and accessories found in this boiler. manually reset from lockout by either removing reestablishing the thermostat's call for heat, or by See Section XVII, "Troubleshooting,"...
  • Page 18 burner/boiler sections. If there is no place for the water WARNING to expand its volume, (i.e., a properly sized and prop- erly functioning expansion tank) pressure on the inside of the boiler and heating system will increase. The fur- nished relief valve will automatically open at 30 psig pressure te relieve the strain on the boiler and heating...
  • Page 19 c. Follow the antifreeze manufacturer's structions on determining proper ratio of an- tifreeze to water for the expected low tem- 1. Consult localwater treatmentspecialistfor wa- perature conditions, and for maintaining ter treatmentrecomendations if your waterpH lev- quality of the antifreeze solution from year to els are belowof 7.0 or hardnessis above 7 grains year.

  • Page 20: Operating Appliance

    4. Open the expansion tank service valve the tank vent. Fill the tank to the proper level and close the tank vent. Remove handle from the expansion tank service valve so the homeowner doesn't accidentally close Refer to the appropriate diagrams in Section VII,...
  • Page 21 Safe lighting and other performance criteria were replace any part of the control system and any gas control which has been under water. met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in ANSI Z21.13-latest revision.
  • Page 22 The sequencecan be followedvia the diagnosticindicatorlampson the UT 1013-10integratedboiler controlin Figure 16(SectionXI), This is the normalsequenceofoperation.A moredetailedsequence of operationcontainingpotentialfaults can be found in the servicehintssection. • (1) Lamp A is illuminated,indicating that the integrated control is receiving 24 volts and is in standby waiting for the thermostat to call for heat. (2) Thermostat calls for heat, energizing the system circulator.
  • Page 23 test for operation as outlined by the control manu- facturer. Burner should be operating and should go off when controls are tested. When safety controls Operate the boiler and verify that all vent/air intake are restored, burner should reignite. connections are gastight watertight.
  • Page 24 Reviewall instructionsshippedwith this boilerwith owneror maintenanceperson.Instructions mustbe Set thermostat to desired room temperatureand affixedon or adjacentto the boiler.Then complete observe several complete cycles to verify proper andsignthe operation. "Installation and Checkout Certificate" at the end of this manual.
  • Page 25 Maintenance as outlined below can be performed tings. Repair, if found. DO NOT use stop leak by the owner unless otherwise noted. compounds. 2. Check that boiler area is free from combustible The acidic nature of flue gasses condensing on the aluminum boiler sections...
  • Page 26 i. Use a flexible handle nylon brush to loosen sediment and aluminum oxide on all exposed heating surfaces of boiler (see "Repair Parts 1. Follow the instructions in "To Turn Off Gas To Ap- Manual" for diagram). Be sure that brush does pliance"...
  • Page 27 STAND BY POWER ON CALLS FOR HEAT THERMOSTAT IF MAIN BURNER DOES NOT PROVE FL&ME IN 3 TRIALS, CONTROL CIRCULATOR LOCKOUT, VALVE/FLAME LIGHT BLINKS, RESET IS REQUIRED THIS PROBLEM IS A ENERGIZES THRU RESULT OF NOT ESTABLISHING A FLAME SIGNAL. 2K1 CONTACTS IBC SELF CHECK OF CONTROL...

  • Page 28: During Operation

    SAFETY SEQUENCES DURING OPERATION DRAFT INDUCER TEMPERATURE SAFETY SWITCH CASTING TEMPERATURE SAFETY SWITCH IF DRAFT INDUCER TEMPERATURE REACHES IF BURNER OPERATES WHEN BOILER HAS NO WA- i TEMPERATURE SAFETY SWITCH SETPOINT, ER, ALUMINUM BOILER SECTIONS HEAT UP RAPIDLY. I ÷ SAFETY SWITCH CONTACTS OPEN IMMEDIATEL_ CLOSING GAS VALVE (LIGHT GOES OUT).
  • Page 29 END OF NORMAL SEQUENCE OF OPERATION THERMOSTAT ENDS CALL FOR HEAT. 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...
  • Page 30 SERVICE HINTS WARNING IMPORTANT c. Make sure that gas is on at the gas me- ter, at all appropriate manual shutoff valves, 1. In a reset from lockout condition, all electri- and at the gas control valve. cal meter readings at the gas control valve (24 VAC) must be taken within the trial for ignition...
  • Page 31 SERVICE HINTS The differential air pressure switch is a This diagram indicates the locations of the connection safetydevicewhich will preventthe boiler points required to check the differential air pressure. from firing if there is an air intake, boiler heatexchangeror vent blockage. DIFFERENTIAL AIR PRESSURE S WITCHES 1.Turn off serviceswitch,or lowerther-...
  • Page 32 SYSTEM STATUS The indicator lights track the operating sequence. If the system locks out, the lights indicate the point in the sequence of operation were lockout occurs. If this table does not readily provide the reason for boiler malfunction or non-operation, refer to the following pages for more detailed troubleshooting...

  • Page 33: Troubleshooting

    TROUBLESHOOTING CHART #1 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 CALL FOR HE_T, CIRCULATOR STARTS?
  • Page 34 TROUBLESHOOTING CHART #2 CHECK THAT CIRCUIT BREAKER IS ON OR FUSES ARE OK AT THE ELECTRICAL PANEL CHECK THAT SERVICE SWITCH IS ON ,_DE CHECK CASTING TEMPERATURE SAFETY CHECK WATER LE'VEL IN BOILER. CHECK SWITCH. PUSH RESET BUTFON ON SWITCH. FOR AIR TRAPPED IN TOP OF BOILER.
  • Page 35 TROUBLESHOOTING CHART #3 CHART OPEN BLOWER STARTS BETWEEN TERMINALS 1 AND 3 REPLACE CHECK FOR VAC N___ AT CONNECTOR CN4 ON 18C REPAIR/REPLCE I-'1 BLOWER LEADS ON WIRING WIRING FROM CHECK FOR 120 VAC AT HARNESS TO BLOWER REPAIR/REPLACE BLOWER PRESSURE SWITCH OPEN...
  • Page 36 TROUBLESHOOTING CHART #4 CHART 3 BETWEEN TERMINALS 1 UP AND GLOWS YELLOW/ORANGE AND 2 AT CONNECTOR REPLACE tBC DURING 20 SECOND CN1 ON IBC (DURING IGNITER/SENSOR WARMS CHECK FOR 120 VAC WARM UP IGNITER WARM UP) CHECK FOR 120 VAC AT ON WIRING HARNESS FROM IBC (DURING IGNITER...
  • Page 37 TROUBLESHOOTING CHART #5 CHART4 CHART4 POSSIBLY MIXTURE TOO LEAN! CHECK GAS LINES DOWNSTREAM OF GAS VALVE FOR BLOCKAGE. CLEAN/REPLACE GAS LINES. ARE GAS LINES CLEAR? BE SURE TO USE CORRECT GASNENTURI VALVE SIZE. IS GASNENTURI VALVE CORRECT SIZE? SEE REPAIR PARTS DIAGRAM. POSSIBLY MITURE TOO RICH!
  • Page 38 TROUBLESHOOTING CHART #6 CHART 5 CHART5 CHART5 NO #3 REPLACE GAS CONTROL. CHECK GAS ORFICICE SIZE. IS GAS ORIFICE SIZE CORRECT CHECK REPAIR PARTS LIST NO #2 FOR CORRECT SIZE, IS GAS ORIFICE CLEAR OF BLOCKAGE, RUNS FOR 25-_ SECONDS, THEN TURNS OFF.
  • Page 39 Boiler Model Serial # Date Installed Measured BTU/HR Input Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner/maintenance person Installation booklet affixed on or adjacent to boiler Installer (Company) Address Phone Installer's Name Signature...

  • Page 40: Hot Water Boiler

    Gas-FiredDirectVent Condensing HOT WATER BOILER Now that you have purchased your boiler, should a need ever existfor repair parts or service, simply contact any SearsService Center. Be sureto 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.

This manual is also suitable for:

K90-125K90-200K90-175

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