Owner's Manual
HydroSense
Gas Water Heater
FOR POTABLE WATER HEATING ONLY.
NOT SUITABLE FOR SPACE HEATING.
NOT FOR USE IN MOBILE HOMES.
MODEL NO.
153.331492 40 Gallon
153.331592 50 Gallon
• Safety Instructions
• Installation
• Operation
• Care and Maintenance
• Troubleshooting
• Parts List
I =i_,I=1:{Ct'd,,,it'=_,"
For Your Safety
AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER.
This water heater complies with ANSI Z21.10.1-
current edition regarding the accidental or
unintended ignition of flammable vapors, such
as those emitted by gasoline.
Read and understand instruction
manual and safety messages
before installing, operating or
servicing this water heater.
Failure to follow instructions and
safety messages could result in
death or serious injury.
Instruction manual must remain
with water heater.
Si no puede leer o entender el ingles y necesita el manual de
instrucciones en espa_ol, puede solicitarlo al 1-800-821-2017. NO
TRATE DE INSTALAR U OPERAR ESTE CALENTADOR DE AGUA
SI NO ENTIENDE LAS INSTRUCCIONES. No hacer caso de esta
advertencia podria originar lesiones graves o mortales.
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
m Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
-- WHAT TO DO IFYOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do
not use any phone in your building.
• Immediately call your gas supplier
from a neighbor's phone. Follow the
gas supplier's instructions.
• If you cannot reach your gas supplier,
call the fire department.
m lnstallation and service must be
performed by a qualified installer,
service agency orthe gas supplier.
PRINTED IN U.S.A. 1208
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A
www.sears.com PART NO. 186422-001
SUPERSEDES 186422-000
Yoursafetyandthesafetyofothersisextremelyimportantintheinstallation,useandservicingofthiswaterheater.
Manysafety-relatedmessagesandinstructionshavebeenprovidedinthismanualandonyourownwaterheatertowarnyouandothersof
apotentialinjuryhazard.Readandobeyallsafetymessagesandinstructionsthroughoutthismanual.Itisveryimportantthatthemeaning
ofeachsafetymessageisunderstoodbyyouandotherswhoinstall,useorservicethiswaterheater.
,_ I This is the safety alert symbol, it is used to alert you to potential personal injury hazards.
n
I
Obey all safety messages that follow this symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, could result
in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous
situation which, if not avoided, could result in property damage.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and
how to avoid the risk of injury.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to
the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure
to such substances. WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other
reproductive harm. This appliance can cause low-level exposure to some of the substances included in the Act.
IMPORTANT DEFINITIONS
• Qualified Technician: A qualified technician must have ability equivalent to a licensed tradesman in the fields of plumbing, air supply,
venting, and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the
installation of gas fired water heaters The qualified technician must also be familiar with the design features and use of flammable vapor
ignition resistant water heaters, and have a thorough understanding of this instruction manual
• Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing, air supply, venting
and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of
gas fired water heaters The service agency must also have a thorough understanding of this instruction manual, and be able to perform
repairs strictly in accordance with the service guidelines provided by the manufacturer
• Gas Supplier: The natural gas or propane utility or service who supplies gas for utilization by the gas burning appliances within this
application The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the natural
gas meter or propane storage tank of a building Many gas suppliers also offer service and inspection of appliances within the building
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity of this
or any other appliance. Storage of or use of
gasoline or other flammable vapors or liquids in the
vicinity of this or any other appliance can result in
serious injury or death.
Read and follow water heater warnings and instructions.
© Sears, Roebuck and Co.
Read and understand instruction
manual and safety messages
before installing, operating or
servicing this water heater.
Failure to follow instructions and
safety messages could result in
death or serious injury.
Instruction manual must remain
with water heater.
Fire Hazard
For continued protection against
riskof fire:
• Do not install water heater on
carpeted floor.
• Do not operate water heater if
flood damaged.
Water temperature over 125°F
(52°C) can cause severe burns
instantly resulting in severe injury
or death.
Children, the elderly, and the
physically or mentally disabled
are at highest riskforscald injury.
Feel water before bathing or
showering.
Temperature limiting valves are
available.
Read instruction manual for safe
temperature setting
Fire or Explosion Harzard
• Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
• Avoid all ignition sources if you smell Natural or LP gas.
• Do not expose water heater control to excessive gas
pressure.
• Use only gas shown on rating plate.
• Maintain required clearances to combustibles.
• Keep ignition sources away from faucets after extended
period of non-use.
Read instruction manual before
installing, using or servicing
water heater.
Explosion Hazard
• Overheated water can cause
watertank explosion.
• Properly sized temperature
and pressure relief valve must
be installed in opening
provided.
Breathing Hazard - Carbon Monoxide Gas
• Instaii vent system in accordance with
cedes.
- Do not operate water heater if flood
damaged.
• High altitude orifice must be installed for
opera, on above 7.700 feet (2.347m).
, Do not operate if s_t is present.
• Do not obstru_ water hea_er air intake
with insulating jacket
, Do not place chemical vapor emi_Jng
produc_s near water heater.
, Gas and carbon monoxide detectors
are available
Breathing carbon monoxide car cause brain damage or
death Always read and understand instruction manual_
Improper installation and use may result
in property damage.
• Do not operate water heater if flood damaged.
• Inspect and replace anode.
• Install in location with drainage.
• Fill tank with water before operation.
• Be alert for thermal expansion.
Refer to instruction manual for installation and service.
SAFE INSTALLATION, USE AND SERVICE ................................................................................................. 2
SAFETY PRECAUTIONS ........................................................................................................................... 2-3
PRODUCT WARRANTY ................................................................................................................................ 6
CUSTOMER RESPONSIBILITIES ................................................................................................................. 7
PRODUCT SPECIFICATIONS ...................................................................................................................... 7
MATERIALS AND BASIC TOOLS NEEDED .................................................................................................. 8
TYPICAL INSTALLATION .............................................................................................................................. 9
IMPORTANT INFORMATION ABOUT THIS WATER HEATER ................................................................... 10
Installation Checklist ............................................................................................................................................... 10
INSTALLATION INSTRUCTIONS ........................................................................................................... 11-14
Removing the Old Water Heater .............................................................................................................................. 11
Location Requirements ........................................................................................................................................... 12
Site Location ........................................................................................................................................................... 12
Insulation Blankets .................................................................................................................................................. 13
Clearances and Accessibility ............................................................................................................................. 13-14
Filling the Water Heater .......................................................................................................................................... 14
GAS SUPPLY .......................................................................................................................................... 14-15
Gas Requirements .................................................................................................................................................. 14
Gas Piping .............................................................................................................................................................. 14
Gas Pressure .......................................................................................................................................................... 15
Gas Pressure Testing .............................................................................................................................................. 15
COMBUSTION AIR SUPPLY & VENTILATION ...................................................................................... 16-19
Unconfined Space ................................................................................................................................................... 16
Confined Space ...................................................................................................................................................... 16
All Air from Inside the Building ........................................................................................................................... 16-17
All Air from Outdoors ............................................................................................................................................... 17
Louvers and Grilles ................................................................................................................................................. 17
Vent Pipe System ................................................................................................................................................... 18
Draft Hood Installation ............................................................................................................................................ 18
Vent Pipe Size ........................................................................................................................................................ 18
Vent Connectors ................................................................................................................................................ 18-19
Chimney Connection ............................................................................................................................................... 19
Vertical Exhaust Gas Vent ...................................................................................................................................... 19
WATER SYSTEM PIPING ....................................................................................................................... 20-21
Piping Installation .................................................................................................................................................... 20
Closed System/Thermal Expansion ........................................................................................................................ 21
Temperature and Pressure Relief Valve ................................................................................................................. 21
T&P Relief Valve and Pipe Insulation ........................................................................................................................ 21
OPERATINGYOURWATERHEATER...................................................................................................22-24
LightingInstructions................................................................................................................................................22
CheckingtheDraft..................................................................................................................................................23
BurnerFlames........................................................................................................................................................23
EmergencyShutDown...........................................................................................................................................23
WaterTemperatureRegulation..........................................................................................................................23-24
SERVICEANDADJUSTMENT...............................................................................................................25-27
Tank(Sediment)Cleaning......................................................................................................................................25
VentSystemInspection..........................................................................................................................................25
BurnerInspection....................................................................................................................................................25
BurnerCleaning......................................................................................................................................................25
Housekeeping.........................................................................................................................................................26
AnodeRodInspection............................................................................................................................................26
Temperature-PressureReliefValveOperation.......................................................................................................26
DrainingandFlushing........................................................................................................................................26-27
Service....................................................................................................................................................................27
SERVICEINSTRUCTIONSFORTHEGASCONTROLVALVE/THERMOSTAT...................................28-29
MAINTENANCEOFYOURWATERHEATER........................................................................................30-32
ReplacementParts.................................................................................................................................................30
ExternalInspection&CleaningoftheBase-RingFilter.........................................................................................30
RemovingtheManifold/BurnerAssembly...............................................................................................................30
RemovingtheBurnerfromtheManifold/BurnerAssembly....................................................................................30
ReplacingthePilot/PilotTubeAssembly..........................................................................................................30-31
CleaningtheCombustionChamberandFlame-arrestor........................................................................................31
ReplacingtheManifold/BurnerAssembly..........................................................................................................31-32
PiezoelectricIgniterSystem...................................................................................................................................32
TestingtheIgniterSystem......................................................................................................................................32
FVlRSystemOperationalChecklist.......................................................................................................................32
TROUBLESHOOTINGGUIDE................................................................................................................33-35
StartUpConditions............................................................................................................................................33-34
OperationalConditions......................................................................................................................................34-35
TROUBLESHOOTINGCHART...............................................................................................................36-38
PILOTLIGHTTROUBLESHOOTINGFLOWCHART...................................................................................39
PARTSORDERLIST...................................................................................................................................40
12 YEAR LIMITED WARRANTY ON WATER HEATER
For twelve years from date of purchase, if this water heater is installed and operated ina single family home in accordance with the owner's
manual instructions and all local applicable codes, Sears will supply a free water heater for one that develops a leak.
For the second through twelfth year from purchase date, you must pay the labor cost for installation of the water heater.
3 YEAR LIMITED WARRANTY ON PARTS
For three years from date of purchase, if this water heater is installed and operated in a single family home in accordance with the owner's manual
instructions and all local applicable codes, if a part fails due to materials or workmanship, Sears will supply a free replacement part.
After one year from purchase date, you must pay the labor cost for installation of the part.
1 YEAR EXCLUSIVE KENMORE LABOR WARRANTY
For the first year from the date of purchase, Sears will, free of charge, supply and install new water heater parts for defective ones or a
new water heater for one that develops a leak.
WARRANTY SERVICE
To obtain warranty service, call 1-800-4-MY-HOME ® (1-800-469-4663). This warranty applies only while this product is in use in the United
States.
For commercial, institutional, industrial or residential use by two or more families, the above limited warranty for tanks that leak is effective for
two years from the date of purchase and the above limited parts warranty is effective for one year from the date of purchase.
This warranty gives you specific legal rights and you may also have other rights which vary from state to state.
Sears, Roebuck and Co., Dept. 817 WA, Hoffman Estates, IL 60179
The price of your water heater does not include a free checkup service call. On water heater installations arranged by Sears, Sears
warrants the installation.
A charge will be made on service calls due to poor or incomplete installation. These include:
a. Adjusting thermostat b. Condensation c. Leaks in pipes or fittings
Master Protection Agreements
Congratulations on making a smart purchase. Your new
Kenmore ® product is designed and manufactured for years
of dependable operation. But like all products, it may require
preventive maintenance or repair from time to time. That's when
having a Master Protection Agreement can save you money and
aggravation.
The Master Protection Agreement also helps extend the life of your
new product. Here's what the Agreement* includes:
• Parts and labor needed to help keep products operating
properly under normal use, not just defects. Our coverage
goes well beyond the product warranty. No deductibles, no
functional failure excluded from coverage-- real protection.
• Expert service by a force of more than 10,000 authorized
Sears service technicians, which means someone you can
trust will be working on your product.
• Unlimited service calls and nationwide service, as often as
you want us, whenever you want us.
• "No-lemon" guarantee - replacement of your covered product
if four or more product failures occur within twelve months.
• Product replacement if your covered product can't be fixed.
• Annual Preventive Maintenance Check at your request - no
extra charge.
• Fast help by phone - we call it Rapid Resolution - phone
support from a Sears representative on all products. Think of
us as a "talking owner's manual."
• Power surge protection against electrical damage due to
power fluctuations.
• $250 Food Loss Protection annually for any food spoilage
that is the result of mechanical failure of any covered
refrigerator or freezer.
• Rental reimbursement if repair of your covered product takes
longer than promised.
• 10% discount off the regular price of any non-covered repair
service and related installed parts.
Once you purchase the Agreement, a simple phone call is all that it
takes for you to schedule service. You can call anytime day or night,
or schedule a service appointment online.
The Master Protection Agreement is a risk free purchase. If you
cancel for any reason during the product warranty period, we
will provide a full refund. Or, a prorated refund anytime after the
product warranty period expires. Purchase your Master Protection
Agreement today!
Some limitations and exclusions apply. For prices and additional
information in the U.S.A. call 1-800-827-6655.
* Coverage in Canada varies on some items. For full details,
call Sears Canada at 1-800-361-6665.
Sears Installation Service
For Sears professional installation of home appliances, garage door
openers, water heaters, and other major home items, in the U.S.A.
or Canada call 1-800-4-MY-HOME ®.
ThankYouforpurchasingaKenmorewaterheater.Properlyinstalled
andmaintained,itshouldgiveyouyearsoftroublefreeservice.If
youshoulddecidethatyouwantthenewwaterheaterprofessionally
installedbySearscall1-800-4-MY-HOME®.Theywillarrangefor
prompt,qualityinstallationbySearsauthorizedcontractors.
Abbreviations Found In This Instruction Manual:
• CSA- Canadian Standards Association
• ANSI- American National Standards Institute
• N FPA- National Fire Protection Association
• ASME - American Society of Mechanical Engineers
• GAMA- Gas Appliance Manufacturers Association
Important Information About This Water Heater:
This gas water heater was manufactured to voluntary safety
standards to reduce the likelihood of a flammable vapor ignition
incident. New technology used in meeting these standards makes this
product more sensitive to installation errors or improper installation
environments. Please review the Installation Checklist found at the
end of the installation instructions section and make any required
installation upgrades or changes.
This manual contains instructions for the installation, operation,
and maintenance of the gas-fired water heater, tt also contains
warnings through out the manual that you must read and be aware
of. All warnings and all instructions are essential to the proper
operation of the water heater and your safety. Since we cannot put
everything on the first few pages, READ THE ENTIRE MANUAL
BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER
HEATER.
The installation must conform with these instructions and the
local code authority having jurisdiction. In the absence of local
codes, installations shall comply with the following:
In the United States: The National Fuel Gas CodeANSI Z223.1/
NFPA 54. This publication is available from the Canadian
StandardsAssociation, 8501 East Pleasant Valley Rd, Cleveland
Ohio 44131, or The National Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02269.
• If after reading this manual you have any questions or do not
understand any portion of the instructions, call the Sears Service
Center.
Carefully plan the place where you are going to put the water heater.
Correct combustion, vent action, and vent pipe installation are
very important in preventing death from possible carbon monoxide
poisoning and fires. See Figure 1.
Examine the location to ensure the water heater complies with
the Installation Instructions section in this manual.
For California installation, this water heater must be braced,
anchored, or strapped to avoid falling or moving during an
earthquake. See instructions for correct installation procedures.
Instructions may be obtained from California's Office of the
State Architect, 1102 Q Street, Suite 5100, Sacramento, CA
95811. Instructions can also be downloaded to your computer
at www.dsa.dgs.ca.gov/Pubs.
Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5.00.
Complies with 40 Ng/J NOx requirements of Texas and most
California AQM Districts.
Excessive Weight Hazard
Use two or more people to move and install the water heater.
Failure to do so can result in injury (including back injury).
IMPORTANT: Do not remove any permanent instructions, labels, or
the data label from either the outside of the water heater or on the
inside of water heater panels.
• Remove exterior packaging and place installation components
aside.
• Inspect all parts for damage prior to installation and
start-up.
• Completely read all instructions before attempting to assemble
and install this product.
• After installation, dispose of/recycle all packaging materials.
MODEL TANK CAPACITY TYPE INPUT RECOVERY MINIMUM DIAMETER DIMENSIONS
NUMBER IN GALS (LTRS) OF RATE
RATE GALS. VENT PIPE INCHES INCHES (mm)
GAS (Btu/hr) PER HOUR DIA. INCHES (mm) HEIGHT TO
@ 90°F RISE (mm) JACKET TOP
153.331492 40 (151) Natural 40,000 42.0 3 (76) OR 4 (102) 20 (508) 58.14 (1477)
153.331592 50 (189) Natural 40,000 42.0 3 (76) OR 4 (102) 22 (559) 57.28 (1455)
MATERIALS NEEDED
To simplify the installation Sears has available the installation parts shown below. You may or may not need all of these materials,
depending on your type of installation.
EXPANSION TANKS FOR
THERMAL EXPANSION
CONDITIONS AVAILABLE
IN 2 GALLONS
(7.6 LITERS) AND
5 GALLONS (18.9 LITERS)
CAPACITY THROUGH
LOCAL SEARS STORE
OR SERVICE CENTER.
WATER HEATER INSTALLATION KIT WITH
FLEXIBLE CONNECTORS FOR 3/4"
(19.05 ram) OR 1/2" (12.7 mm) THREADED OR
COPPER PLUMBING AND FLEXIBLE WATER
HEATER GAS CONNECTOR WITH FITTINGS.
METAL DRAIN PANS AVAILABLE
IN 20" (508 mm) DIAMETER
FOR WATER HEATERS HAVING
A DIAMETER 18" (457 mm) OR
LESS, 24" (610mm) DIAMETER
FOR WATER HEATERS HAVING
A DIAMETER 22" (559 mm) OR
LESS AND AVAILABLE IN 28"
(711 mm) DIAMETER FOR WATER
HEATERS HAVING A DIAMETER
26" (660 mm) OR LESS.
BASIC TOOLS
You may or may not need all these tools, depending on your
type of installation. These tools can be purchased at your local
Sears Store.
• Pipe Wrenches (2) 14" (356 mm)
• Screwdriver
• Tin Snips
• 6' (1.82 m) Tape or Folding Ruler
• Garden Hose
• Drill
• Pipe Dope or Teflon Tape
DRILL
SLOT-HEAD SCREWDRIVER
PHILLIPS SCREWDRIVER
TIN SNIPS
ROLL OF TEFLON
TAPE (USE ONLY ON
WATER CONNECTIONS)
PIPE DOPE
(SQUEEZE TUBE)
USE FOR WATER AND GAS
CONNECTIONS
GARDEN HOSE
6 FOOT TAPE
PIPE WRENCH
ADDITIONAL TOOLS NEEDED
WHEN SWEAT SOLDERING
• Tubing Cutters or Hacksaw
• Propane Tank
• Soft Solder
• Solder Flux
• Emery Cloth
• Wire Brushes
TUBING CUTTER
HACKSAW
3/4" (19 mm) WIRE BRUSH
1/2" (13 mm)WIRE BRUSH
ROLL OF LEAD-FREE
SOFT SOLDER
PROPANE
TORCH
ROLLOF
EMERY CLOTH
G
SOLDER
FLUX
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A Vent Pipe
B Draft Hood
C Anode (Not Shown)
D Hot Water Outlet
E Insulation
F Gas Supply Piping
G Manual Gas Shut-off Valve
H Ground Joint Union
I Drip Leg (Sediment Trap)
J Inner Door
K Outer Door
L Union
M Inlet Water Shut-off Valve
N Cold Water Inlet
O Inlet Dip Tube
P Temperature-Pressure Relief Valve
Q Rating Plate
R Flue Baffle
S Gas Control Valve/Thermostat
T Drain Valve
U Pilot and Main Burner
V Flue
W Metal Drain Pan
X Piezo Igniter
Y Base-Ring Filter
* INSTALL INACCORDANCE
WITH LOCAL CODES.
* DRIP LEG AS REQUIRED
BY LOCAL CODES.
TO VENT
TERMINATION ON
ROOF
/ /
R/ E
F
G
H\
v s
W j /
X
INSTALL THERMAL EXPANSION
TANK OR DEVICE IF WATER
HEATER IS INSTALLED IN A
CLOSED WATER SYSTEM
(S) GAS CONTROL VALVE/
THERMOSTAT
GAS CONTROL\THERMOSTAT KNOB
GAS VALVE
ASSEMBLY
ELECTRONIC CONTROL
MODULE
(U) MANIFOLD/BURNER ASSEMBLY
MAIN BURNER
_\\ PILOT TUBE
IGNITER RoD _ :IT_'_'_ JUBE
MANIFOLD O__ IGNITER WIRE
* ALL PIPING MATERIALS TO BE
SUPPLIED BY CUSTOMERS.
FIGURE 1.
This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident.
The new technology used in meeting these standards makes this product more sensitive to installation errors. Please review the
following checklist and make any required installation upgrades or changes.
Questions? Contact Sears at 1-800-4-MY-HOME (1-800-469-4663).
Installation Checklist
Water Heater Location
Water heater location is important and
performance. Please check the following:
[]
can affect system
Installation area free of corrosive elements and flammable
materials.
[] Centrally located with the water piping system (For new
installations). Located as close to the gas piping and vent
pipe system as possible.
[] Located indoors and in a vertical position. Protected from
freezing temperatures.
[] Proper clearances from combustible surfaces
maintained and not installed directly on a carpeted floor.
[] Provisions made to protect the area from water damage.
Metal drain pan installed and piped to an adequate drain.
[] Sufficient room to service the water heater. See Clearances
and Accessibility section of this manual.
[] Water heater not located near an air moving device.
[] Is the installed environment dirty (excessive amounts of
lint, dirt, dust, etc.)? If so, the base-ring filter located on
the bottom of the water heater will need to be cleaned
periodically. Refer to the "Maintenance of your Water
Heater" section of this manual for information on cleaning
the base-ring filter.
Combustion Air Supply and Ventilation
[]
[]
Check for sufficient combustion air supply. Insufficient air for
the combustion of gas wilt result in the flame becoming "lazy",
thereby allowing heat to build up in the combustion chamber.
This excessive heat wilt cause a thermal switch on the door
assembly to trip. Is the water heater installed in a closet or other
small, enclosed space? If so:
Are there openings for make-up air to enter and exit the
room/area?
[]
[]
[]
Are the openings of sufficient size? Remember, if there
are other gas-fired or air-consuming appliances in the
same room, you need more make-up air. Refer to the
"Installation Instructions" and "Combustion Air Supply and
Ventilation" sections for specific requirements.
Make sure that fresh air is not taken from areas that contain
negative pressure producing devices such as exhaust fans,
dryers, fireplaces, etc.
Is there a furnace/air handler in the same room space as
the water heater? If so, has a return air duct system been
attached that exits the room? If so, check for leaks on the
air duct system. If no air duct system is present, correct
immediately by contacting a local Heating, Ventilation, Air-
Conditioning & Refrigeration (HVAC-R) authorized service
provider.
Use a fresh air supply that is free of corrosive elements and
flammable vapors.
[]
[]
Fresh air openings must be sized correctly with consideration
given to the blocking effect of louvers and grilles.
Ductwork must be the same cross-sectional area as the
openings.
Vent Pipe System
Check for proper drafting at the water heater draft hood. Refer
to the "Checking the Draft" section of this manual for the test
procedure. If the procedure shows insufficient draft is present,
please check the following:
Draft hood properly installed.
[]
[]
[]
[]
Vent connectors securely fastened with screws and
supported properly to maintain six inch clearance.
Vent connector made of approved material and sized
correctly.
Vent pipe system installed according to all local and state
codes or, in the absence of local and state codes, the
"National Fuel Gas Code", ANSI Z223.1(NFPA 54)-current
edition.
[] Flue baffle properly positioned in the flue tube.
[] Check the vent system for restrictions/obstructions and
check the vent termination height. Refer to the "Combustion
Air Supply and Ventilation" section of this water heater
manual for specific requirements.
[] Recheck for sufficient combustion air supply.
Water System Piping
[] Temperature and pressure relief valve properly installed with
a discharge line run to an open drain and protected from
freezing.
[] All piping properly installed and free of leaks.
[] Heater completely filled with water.
[] Closed system pressure build-up devices installed.
[] Tempering valve (when applicable) installed per
manufacturer's instructions (See "Water Temperature
Regulation" section).
Gas Supply and Piping
[] Gas type is the same as that listed on the water heater rating
plate.
[] Gas line equipped with shut-off valve, union, and drip leg.
[] Use pipe joint compound or teflon tape marked as being
resistant to the action of petroleum [Propane (L.R)] gases.
[]
[]
Adequate pipe size and approved pipe material.
An approved noncorrosive leak detection solution used
to check all connections and fittings for possible gas leaks.
Correct any leak found.
10
Removing the Old Water Heater C)
Q
MANUALGAS
SHUT-OFFVALVE---.....
GROUND-----=
JOINT
UNION
CHECK WITH
LOCAL UTILITY
FOR MINIMUM HEIGHT
3" MINIMUM
, DRIP LEG_
@
DISCHARGE PIPE
(DO NOT CAP
OR PLUG)
//_ GAS CONTROL
VALVE/
THERMOSTAT
_) DRAINVALVE
6" MAXIMUM
_ T AIRGAP
SUITABLE"_"_f
DRAIN
FIGURE 2.
©
Turn "OFF" the gas supply to the
water heater.
If the main gas line shutoff valve
serving all gas appliances is used,
also shut "OFF" the gas at each
appliance. Leave all gas appliances
shut "OFF" until the water heater
installation is completed. See
Figures 2 and 3.
FIGURE 3.
®
®
Open a nearby hot water faucet
and leave it open to allow for
draining. Allow the hot water
to run until water flowing from
the faucet is 100 ° F or less.
Connect a hose to the drain valve
and terminate to an adequate
drain or outdoors. (Make sure all
connections are tight and that the
water flow is directed away from
people.) Open the drain valve
and allow the tank to drain. (See
Figures 2 and 5.)
FIGURE 5.
Disconnect the vent pipe from the draft hood where it connects
to the water heater. In most installations the vent pipe can
be lifted off after any screw or other attached devices are
removed. Dispose of the draft hood. The new water heater
has a draft hood which must be used for proper operation.
If you have copper piping to the water heater, the two copper
water pipes can be cut with a hacksaw approximately four
inches away from where they connect to the water heater.
See Figure 6. This will avoid cutting off pipes too short.
Additional cuts can be made later if necessary. Disconnect the
temperature-pressure relief valve drain line. When the water
heater is drained, disconnect the hose from the drain valve.
Close the drain valve. The water heater is now completely
disconnected and ready to be removed.
FIGURE 6.
®
Turn "OFF" the water supply to
the water heater at the water
shut off valve or water meter.
Some installations require that
the water be turned off to the
entire house. See Figures 2
and 4.
FIGURE 4.
If you have galvanized pipes to the water heater, loosen
the two galvanized pipes with a pipe wrench at the union in
each line. Also disconnect the piping remaining to the water
heater. See Figure 7. These pieces should be saved since
they may be needed when reconnecting the new water heater.
Disconnect the temperature-pressure relief valve drain line.
®
Check again to make sure the gas supply is "OFF" to the water
heater. Then disconnect the gas supply connection from the
gas control valve.
Ir I,7:1 [€']:1;I
• Burn hazard
• Hotwater discharge.
• Keep hands clear of drain
valve discharge.
When the water heater is drained, disconnect the hose from
the drain valve. Close the drain valve. The water heater
is now completely disconnected and ready to be removed.
Mineral buildup or sediment may have accumulated in the
old water heater. This causes the water heater to be much
heavier than normal and this residue, if spilled out, could
cause staining.
FIGURE 7.
11
Location Requirements
Carbon Monoxide Poisoning Hazard
Do not install in a mobile home.
Do ng so can resu t n carbon monox de poson ng and death.
the fire department from a neighbor's home. Do not attempt to
clean the spill until all ignition sources have been extinguished.
The FVIR System is designed to reduce the risk of flammable
vapor-related fires. The patented system protects your family by
trapping the burning vapors within the water heater combustion
chamber through the special flame-arrestor. The burning vapors
literally "burn themselves out" without escaping back into the
room. In the event of a flammable vapor incident, the FVIR
System disables the water heater by shutting off the gas supply
to the water heater's burner and pilot, preventing re-ignition
of any remaining flammable vapors in the area. This will not
prevent a possible fire/explosion if the igniter is depressed
and flammable vapors have accumulated in the combustion
chamber with the pilot light off. If you suspect a flammable
vapor incident has occurred, do not use this appliance. Do not
attempt to light this appliance, or depress the igniter button
if you suspect flammable vapors have accumulated inside or
outside the appliance. Immediately call a qualified technician to
inspect the appliance. Water heaters subjected to a flammable
vapors incident will show a discoloration on the flame-arrestor
and require replacement of the entire water heater.
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
_Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other
appliance. Storage of or use of gasoline or other
flammable vapors or liquids in the vicinity of this or any
other appliance can result in serious injury or death.
Read and follow water heater warnings and instructions.
Fire or Explosion Hazard
• Read instructionmanual before installing, using or
servicing water heater.
• Improper use may result in fire or explosion.
• Maintain required clearances to combustibles.
Keep combustibles such as boxes, magazines, clothes, etc.
away from the water heater area.
Site Location
• Select a location near the center of the water piping system.
The water heater must be installed indoors and in avertical
position on a level surface. DO NOT install in bathrooms,
bedrooms, or any occupied room normally kept closed.
• Locate the water heater as close to the chimney or gas
vent as practical. Consider the vent system piping and
combustion air supply requirements when selecting the
water heater location. The venting system must be able
to run from the water heater to termination with minimal
length and elbows.
• Locate the water heater near the existing gas piping. If
installing a new gas line, locate the water heater to minimize
the pipe length and elbows.
• The water heater should be located in an area not subject
to freezing temperatures. Water heaters located in
unconditioned spaces (i.e., attics, basements, etc.) may
require insulation of the water piping and drain piping
to protect against freezing. The drain and controls must
be easily accessible for operation and service. Maintain
proper clearances as specified on the rating plate.
• Do not locate the water heater near an air-moving device.
The operation of air-moving devices such as exhaust fans,
ventilation systems, clothes dryers, fireplaces, etc., can
affect the proper operation of the water heater. Special
attention must be given to conditions these devices may
create. Flow reversal of flue gases may cause an increase
of carbon monoxide inside of the dwelling (Figure 8).
• If the water heater is located in an area that is subjected to
lint and dirt, it may be necessary to periodically clean the
base-ring filter and flame-arrestor (see External Inspection
& Cleaning of the Base-Ring Filter; also see Cleaning the
Combustion Chamber and Flame-Arrestor).
• This water heater is not for use in manufactured (mobile)
homes or outdoor installation.
NOTE: This water heater must be installed according to all local
and state codes or, in the absence of local and state codes, the
"National Fuel Gas Code", ANSI Z223.1(NFPA 54)-current edition.
Do not use or store flammable products such as gasoline,
solvents, or adhesives in the same room or area near the
water heater. If such flammables must be used, all gas burning
appliances in the vicinity must be shut off and their pilot lights
extinguished. Open the doors and windows for ventilation while
flammable substances are in use.
If flammable liquids or vapors have spilled or leaked in the
area of the water heater, leave the area immediately and call
12
!
REVERSE FLOW
/-- OF GASES
FIGURE 8
Property Damage Hazard
• AJlwater heaters eventually leak
• Do notinstall without adequate drainage.
IMPORTANT: The water heater should be located in an area
where leakage of the tank or connections will not result in damage
to the area adjacent to the water heater or to lower floors of the
structure. Due to the normal corrosive action of water, the tank wilt
eventually leak after an extended period of time. Also any external
plumbing leak, including those from improper installation, may
cause early failure of the tank due to corrosion if not repaired. If
the homeowner is uncomfortable with making the repair a qualified
technician should be contacted. A suitable metal drain pan should
be installed under the water heater as shown below, to help protect
the property from damage which may occur from condensate
formation or leaks in the piping connections or tank. The pan must
limit the water level to amaximum depth of 1-3/4" and be two inches
wider than the heater and piped to an adequate drain. NOTE: The
pan must not restrict combustion air flow. Locate the water heater
near a suitable indoor drain. Outside drains are subject to freezing
temperatures which can obstruct the drain line. The piping should
be at least 3/4" ID and pitched for proper drainage.
METAL
DRAIN
PAN
0
ATLEAST2"GREATERTHA.TH;'
DIAMETER OF THE WATER HEATER.
PIPED TO AN
ADEQUATE DRAIN
FIGURE 9.
Water heater life depends upon water quality, water usage,
water temperature and the environment in which the water
heater is installed. Water heaters are sometimes installed
in locations where leakage may result in property damage,
even with the use of a drain pan piped to a drain. However,
unanticipated damage can be reduced or prevented by a leak
detector or water shut-off device used in conjunction with
a piped drain pan. These devices are available from some
plumbing supply wholesalers and retailers, and detect and react
to leakage in various ways:
• Sensors mounted in the drain pan that trigger an alarm or
turn off the incoming water to the water heater when water
is detected.
• Sensors mounted in the drain pan that turn off the water
supply to the entire home when water is detected in the
drain pan.
• Water supply shut-off devices that activate based on the
water pressure differential between the cold water and hot
water pipes connected to the water heater.
• Devices that wilt turn off the gas supply to a gas water
heater while at the same time shutting off its water supply.
Insulation Blankets
Insulation blankets available to the general public for external
use on gas water heaters are not necessary with Kenmore
products. The purpose of an insulation blanket is to reduce the
standby heat toss encountered with storage tank heaters. Your
Kenmore water heater meets or exceeds the National Appliance
Energy Conservation Act standards with respect to insulation
and standby loss requirements, making an insulation blanket
unnecessary.
13
Breathing Hazard -
I
Carbon Monoxide Gas
i o not obstruct water heater air
intakewith insulating blanket.
Gas and carbon monoxide detectors
are available.
• Install water heater in accordance
with the instruction manual.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
_k, WARNING
Should you choose to apply an insulation blanket to this
heater, you should follow these instructions (See Figure 1
for identification of components mentioned below). Failure to
follow these instructions can restrict the air flow required for
proper combustion, potentially resulting in fire, asphyxiation,
serious personal injury or death.
• Do not apply insulation to the top of the water heater, as
this will interfere with safe operation of the draft hood.
• Do not cover the outer door, thermostat or temperature &
pressure relief valve.
• Do not allow insulation to come within 2" (50.8 mm) of
the floor to prevent blockage of combustion air flow to the
burner.
Do not cover the instruction manual. Keep it on the side of
the water heater or nearby for future reference.
Do obtain new warning and instruction labels from Sears
for placement on the blanket directly over the existing
labels.
• Do inspect the insulation blanket frequently to make
certain it does not sag, thereby obstructing combustion air
flow.
Clearances and Accessibility
NOTE: Minimum clearances from combustible materials are
stated on the label adjacent to the gas control valve/thermostat
of the water heater. The water heater is certified for installation
on a combustible floor.
• IMPORTANT: If installing over carpeting, the carpeting
must be protected by a metal or wood panel beneath the
water heater. The protective panel must extend beyond the
full width and depth of the water heater by at least three
inches (76.2mm) in any direction; or if in an alcove or closet
installation, the entire floor must be covered by the panel.
• Figure 10 may be used as a reference guide to locate the
specific clearance locations. A minimum of 24 inches of
front clearance should be provided for inspection and
service.
TF- BACK SIDES
TOP --
VIEW l
TOP
SIDESII f
-_._VENT
li
FIGURE 10.
Open the cold water supply valve to the water heater.
NOTE: The cold water supply valve must be left open
when the water heater is in use.
To ensure complete filling of the tank, allow air to exit by
opening the nearest hot water faucet. Allow water to run until
a constant flow is obtained. This will let air out of the water
heater and the piping.
Check all water piping and connections for leaks. Repair as
needed.
Filling the Water Heater
Never use this water heater unless it is completely full of water.
To prevent damage to the tank, the tank must be filled with water.
Water must flow from the hot water faucet before turning "ON" gas
to the water heater. To fill the water heater with water:
• Close the water heater drain valve by turning the handle to
the right (clockwise). The drain valve is on the lower front of
the water heater.
Property Damage Hazard
• Avoid water heater damage.
• Fill tank with water before operating.
Explosion Hazard
Use a new CSA approved gas supply line.
Install a shut-off valve.
Do not connect a natural gas water heater to an
L.P. gas supply.
Do not connect an L.P. gas water heater to a
natural gas supply.
Failure to follow these instructions can result in
death, explosion, or carbon monoxide poisoning.
Gas Requirements
IMPORTANT: Read the rating plate to be sure the water heater
is made for the type of gas you wilt be using in your home. This
information wilt be found on the rating plate located near the
gas control valve/thermostat. If the information does not agree
with the type of gas available, do not install or light. Call your
dealer.
NOTE: An odorant is added by the gas supplier to the gas used
by this water heater. This odorant may fade over an extended
period of time. Do not depend upon this odorant as an indication
of leaking gas.
Gas Piping
The gas piping must be installed according to all local and state
codes or, in the absence of local and state codes, the "National
Fuel Gas Code", ANSI Z223.1(NFPA 54)-current edition.
Table 1 on the following page provides a sizing reference for
commonly used gas pipe materials. Consult the "National
Fuel Gas Code" for the recommended gas pipe size of other
materials.
Refer to Figure 11 for the items below.
1. Install a readily accessible manual shut-off valve in the gas
supply line as recommended by the local utility. Know the
location of this valve and how to turn off the gas to this unit.
2. Install a drip leg (if not already incorporated as part of
the water heater) as shown. The drip leg must be no less
than three inches tong for the accumulation of dirt, foreign
material, and water droplets.
3. Install a ground joint union between the gas control valve/
thermostat and the manual shut-off valve. This is to allow
easy removal of the gas control valve/thermostat.
4. Turn the gas supply on and check for leaks. Test all
connections by brushing on an approved noncorrosive
leak-detection solution. Bubbles will show a leak. Correct
any leak found.
MANUAL GAS _
SHUT-OFF VALVE---...._._
GROUND------_
JOINT
UNION
CHECK WITH
LOCAL UTILITY
FOR MINIMUM HEIGHT
3" MINIMUM
DRIP LEG--_'
SUITABLE DRAIN
-_ 6" MAXIMUM
AIR GAP
FIGURE 11.
14
Gas Pressure
Explosion Hazard
• Gas leaks can not always be detected by smell.
• Gas suppliers recommend that you use a gas
detector approved by UL or CSA.
• For more information, contact your gas supplier.
• If a gas leak is detected, follow the "What to do if you
smell gas" instructions on the cover of this manual.
Gas Pressure Testing
IMPORTANT: This water heater and its gas connection must be
leak tested before placing the appliance inoperation.
• If the code requires the gas lines to be tested at a pressure
exceeding 14" W.C., the water heater and its manual shut-off
valve must be disconnected from the gas supply piping system
and the line capped.
• Ifthe gas lines are to be tested at apressure tess than 14"W.C.,
the water heater must be isolatedfrom the gas supply piping
system by closing its manual shut-off valve.
NOTE: Air may be present in the gas lines and could prevent the
pilot from lighting on initial start-up. The gas lines should be purged
of air by a qualified technician after installationof the gas piping
system. While purging the gas piping system of air, ensure that
the fuel is not spilled in the area of the water heater installation,
or any source of ignition. If the fuel is spilled while purging the
piping system of air follow the "WHAT TO DO IF YOU SMELL
GAS" instructions on the cover of this manual.
IMPORTANT:The gas supply pressure must not exceed the maximum
supply pressure as stated on the water heater's rating plate. The
minimum supply pressure is for the purpose of input adjustment.
Table 1
Natural Gas Pipe Capacity Table (Cu. Ft./Hr.)
Capacityof gaspipe of differentdiametersandlengthsincu.ft. perhr.withpressuredrop of 0.3 in. and specificgravity
of0.60 (naturalgas).
Nominal Iron Pipe Length of Pipe,Feet
Size,in. 10 20 30 40 50 60 70 80 90 100 125 150 175 200
1/2 132 92 73 63 56 50 46 43 40 38 34 31 28 26
3/4 278 190 152 130 115 105 96 90 84 79 72 64 59 55
1 520 350 285 245 215 195 180 170 160 150 130 120 110 100
1-1/4 1050 730 590 500 440 400 370 350 320 305 275 250 225 210
1-1/2 1600 1100 890 760 670 610 560 530 490 460 410 380 350 320
After the length of pipe has been determined, select the pipe size which will provide the minimum cubic feet per hour
required for the gas input rating of the water heater. By formula:
Gas Input of Water Heater (BTU/HR)
Cu. Ft. Per Hr. Required=
Heating Value of Gas (BTU/FT 3)
The gas input of the water heater is marked on the water heater data plate. The heating value of the gas (BTU/FT 3)
may be determined by consulting the local natural gas utility.
15
Carbon Monoxide Warning
Follow all the local and state codes or, in the absence of
local and state codes, the "National Fuel Gas Code",
ANSI Z223.1 (NFPA 54)- current edition to properly
install vent system.
Failure to do so can result in death, explosion, or
carbon monoxide poisoning.
IMPORTANT: Air for combustion and ventilation must not
come from a corrosive atmosphere. Any failure due to corrosive
elements in the atmosphere is excluded from warranty
coverage.
The following types of installation (not limited to the following)
wilt require outdoor air for combustion due to chemical exposure
and may reduce but not eliminate the presence of corrosive
chemicals in the air:
• beauty shops
• photo processing labs
• buildings with indoor pools
• water heaters installed in laundry, hobby, or craft rooms
• water heaters installed near chemical storage areas
Combustion air must befree ofacid-forming chemicals such assulfur,
fluorine, and chlorine. These elements are found in aerosol sprays,
detergents, bleaches, cleaning solvents, air fresheners, paint, and
vamish removers, refrigerants, and many other commercial and
household products. When bumed, vapors from these products
form highly corrosive acid compounds. These products should not
be stored or used near the water heater or air inlet.
Combustion and ventilation air requirements are determined by
the location of the water heater. The water heater may be located
in either an open (unconfined) area or in a confined area or small
enclosure such as a closet or small room. Confined spaces are
areas with tess than 50 cubic feet for each 1,000 BTUH of the total
input for all gas-using appliances.
Unconfined Space
A water heater in an unconfined space uses indoor air for
combustion and requires at least 50 cubic feet for each 1,000
BTUH of the total input for alt gas appliances. The table below
shows a few examples of the minimum square footage (area)
required for various BTUH inputs.
TABLE 2
Minimum Square Typical Room
BTUH Input Feet with
with 8' Ceiling
8' Ceiling
30,000 188 9 x 21
45,000 281 14 x 20
60,000 375 15 x 25
75,000 469 15 x 31
90,000 563 20 x 28
105,000 657 20 x 33
TABLE 2
Minimum Square Typical Room
Feet with 8'
BTUH Input 8' Ceiling with Ceiling
120,000 750 25 x 30
135,000 844 28 x 30
IMPORTANT:
The area must be open and be able to provide the proper
air requirements to the water heater. Areas that are being
used for storage or contain large objects may not be
suitable for water heater installation.
Water heaters installed in open spaces in buildings with
unusually tight construction may still require outdoor air
to function properly. In this situation, outside air openings
should be sized the same as for a confined space.
• Modern home construction usually requires supplying
outside air into the water heater area.
Confined Space
For the correct and proper operation of this water heater,
ample air must be supplied for the combustion, ventilation, and
dilution of flue gases. Small enclosures and confined areas
must have two permanent openings so that sufficient fresh air
can be drawn from outside of the enclosure. One opening shall
be within 12 inches of the top and one within 12 inches of the
bottom of the enclosure as shown in Figure 12.
The size of each opening (free area) is determined by the total
BTUH input of all gas utilization equipment (i.e., water heaters,
furnaces, clothes dryers, etc.) and the method by which the air
is provided. The BTUH input can be found on the water heater
rating plate. Additional air can be provided by two methods:
1. All air from inside the building.
2. All air from outdoors.
12" MAXIMUM
PERMANENT
OPENINGS TO
THE OUTSIDE OR
ADDITIONAL
ROOMS WITHIN
THE BUILDING
I
12" MAXIMUM J
CLOSET
4: OR
-- OTHER
CONFINED
SPACE
FIGURE 12.
All Air from Inside the Building
16
When additional air is to be provided to the confined area
from additional room(s) within the building, the total volume of
the room(s) must be of sufficient size to properly provide the
necessary amount of fresh air to the water heater and other
gasutilizationequipmentinthearea.Ifyouareunsurethatthe
structuremeetsthisrequirement,contactyourlocalgasutility
companyorotherqualifiedagencyforasafetyinspection.
Eachofthetwoopeningsshallhaveaminimumfreeareaof1
squareinchper1,000BTUHofthetotalinputratingofallgas
utilizationequipmentintheconfinedarea,butnotlessthan100
squareinches(Figure13).
CONFINED
SPACE
PERMANENT
OPENINGS
_ 1 SQUARE
INCH/1000
BTUH
(MINIMUM
100 SQ. IN.)
FIGURE 13.
All Air from Outdoors
Outdoor fresh air can be provided to a confined area either
directly or by the use of vertical and horizontal ducts. The
fresh air can be taken from the outdoors or from crawl or attic
spaces that freely communicate with the outdoors. Attic or crawl
spaces cannot be closed and must be properly ventilated to the
outside.
Ductwork must be of the same cross-sectional area as the
free area of the opening to which they connect. The minimum
dimension of rectangular air ducts cannot be less than three
inches.
The size of each of the two openings is determined by the
method in which the air is to be provided. Refer to Table 3 to
calculate the minimum free area for each opening. Figures 14,
15, 16 and 17 are typical examples of each method.
Louvers and Grilles
In calculating free area for ventilation and combustion air supply
openings, consideration must be given to the blocking effect
of protection louvers, grilles, and screens. These devices can
reduce airflow, which in turn may require larger openings to
achieve the required minimum free area. Screens must not be
smaller than 114" mesh. If the free area through a particular
design of louver or grille is known, it should be used in
calculating the specified free area of the opening. If the design
and free area are not known, it can be assumed that most wood
louvers will allow 20 - 25% of free area while metal louvers and
grilles will allow 60 - 75% of free area.
Louvers and grilles must be locked open or interconnected with
the equipment so that they are opened automatically during
equipment operation.
Keep louvers and grilles clean and free of debris or other
obstructions.
TABLE 3
Minimum Free Area of Permanent Openings for Ventilation
and Combustion Air Supply - All Air from Outdoors Only.
Based on total BTUH input rating for all utilizing equipment
within the confined space.
Minimum Free Area Reference
Opening Source Per Opening (sq. in.) Drawing
*Direct to outdoors 1sq. in, per 4000 BTUH Figure 14
Vertical Ducts 1sq. in, per 4000 BTUH Figure 15
Horizontal Ducts 1sq. in, per 2000 BTUH Figure 16
Single Opening 1sq. in, per 3000 BTUH Figure 17
Example: A water heater with an input rating of 50,000 BTUH using
horizontal ducts would require each opening to have a minimum free
area of 25 square inches.
Minimum free area = 50,000 BTUH x 1 sq. in. ! 2000 BTUH = 25 sq.
in.
* These openings connect directly with the outdoors through a
ventilated attic, a ventilated crawl space, or through an outside
walt.
Consult the local codes of your area for specific ventilation and
combustion air requirements.
GABLE VENT
j TO OUTDOORS
INSTALLABOVE
INSULATION
CONFINED
AIR TO
ATTIC 1 SQ.
INCH PER
4000 BTUH
ALTERNATE INLET AIR FROM
AIR INLET
1 SQ. INCH PER OPEN
4000 BTUH FOUNDATION '_
VENT
ALL AIR FROM OUTDOORS: INLET AIR FROM VENTILATED
CRAWL SPACE/OUTLET AIR TO VENTILATED ATTIC
FIGURE 14.
,GABLE VENT
TO OUTDOORS
• INSTALL ABOVE
INSULATION
-.-,...
OUTLET AIR
1SQ. INCH
PER4000
BTUH
INLET AIR DUCT
1 SQ. INCH PER
4000 BTUH
17
12" MAXIMUM
ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC
FIGURE 15.
CONFINED
SPACE
2000 BTUH
1 SQ. INCH PER
2000 BTUH
ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS
FIGURE 16.
ALTERNATIVE
OPENING
LOCATION
CONFINED
SPACE
1SQ. INCH
PER3OOOBTUH
ALL AIR FROM OUTDOORS - USING A SINGLE PERMANENT OPENING
FIGURE 17.
Vent Pipe System
This water heater uses a non-direct, single-pipe vent system
to remove exhaust gases created by the burning of fossil fuels.
Air for combustion is taken from the immediate water heater
location or is ducted in from the outside (see "Combustion Air
Supply and Ventilation").
This water heater must be properly vented for the removal of
exhaust gases to the outside atmosphere. Correct installation
of the vent pipe system is mandatory for the proper and efficient
operation of this water heater and is an important factor in the
life of the unit.
The vent pipe must be installed according to all local and state
codes or, in the absence of local and state codes, the "National
Fuel Gas Code", ANSI Z223.1(NFPA 54)-current edition. The
vent pipe installation must not be obstructed so as to prevent
the removal of exhaust gases to the outside atmosphere.
IMPORTANT: The use of vent dampers is not recommended
by the manufacturer of this water heater. Although some vent
dampers are certified by CSA International, this certification
applies to the vent damper device only and does not mean they
are certified for use on this water heater.
U.L. recognized fuel gas and carbon monoxide (CO) detectors
are recommended in all applications and should be installed
using the manufacturer's instructions and local codes, rules, or
regulations.
IMPORTANT: If you tack the necessary skills required to
properly install this venting system, you should not proceed, but
get help from a qualified technician.
Draft Hood Installation
ETAL SCREWS (FOUR PROVIDED)
_ _k,P'--'DRAFT HOOD
SLOTJ \ _JACKET TOP p" LSLOT
INSTALL THE DRAFT HOOD WITH
THE FOUR SCREWS PROVIDED.
FIGURE 18.
Align the legs of the draft hood with the slots provided. Insert
the legs and secure the draft hood to the water heater's top
with the four screws provided as shown in Figure 18. Do not
alter the draft hood in any way. If you are replacing an existing
water heater, be sure to use the draft hood supplied with this
water heater.
Vent Pipe Size
It is important that you follow the guidelines in these instructions
for sizing a vent pipe system. If a transition to a larger vent size
is required, the vent transition connection must be made at the
draft hood outlet.
Vent Connectors
1. Type B, Double wall, U.L. Listed Vent Pipe.
2. Single walt Vent Pipe.
Maintain the manufacturer's specified minimum clearance from
combustible materials when using type B double wall vent
pipe.
Vent connectors made of type B, double walt vent pipe material
may pass through walls or partitions constructed of combustible
material if the minimum listed clearance is maintained.
Maintain a six inch minimum clearance from all combustible
materials when using single walt vent pipe.
IMPORTANT: Single walt vent pipe cannot be used for water
heaters located in attics and may not pass through attic spaces,
crawl spaces or any confined or inaccessible location. A single
wall metal vent connector cannot pass through any interior
walt.
When installing a vent connector, please note the following
(See Figures 19-21):
• Install the vent connector avoiding unnecessary bends,
which create resistance to the flow of vent gases.
• Install without dips or sags with an upward slope of at least
1/4-inch per foot.
• Joints must be fastened by sheet metal screws or other
approved means. It must be supported to maintain
clearances and prevent separation of joints and damage.
• The length of the vent connector cannot exceed 75% of the
vertical vent height.
18
• The vent connector must be accessible for cleaning,
inspection, and replacement.
• Vent connectors cannot pass through any ceiling, floor,
firewall, or fire partition.
• It is recommended (but not mandatory) that a minimum 12
inches of vertical vent pipe be installed on the draft hood
prior to any elbow inthe vent system.
IMPORTANT: Existing vent systems must be inspected for
obstructions, corrosion, and proper installation.
Chimney Connection
IMPORTANT: Before connecting a vent to a chimney, make sure
the chimney passageway is clear and free of obstructions. The
chimney must be cleaned if previously used for venting solid
fuel appliances or fireplaces. Also consult local and state codes
for proper chimney sizing and application or, in the absence
of local and state codes, the "National Fuel Gas Code", ANSI
Z223.1 (NFPA 54)-current edition.
• The connector must be installed above the extreme bottom
of the chimney to prevent potentially blocking the flue
gases.
• The connector must be firmly attached and sealed to
prevent it from falling out.
• To aid in removing the connector, a thimble or slip joint may
be used.
• The connector must not extend beyond the inner edge of
the chimney as it may restrict the space between it and the
opposite wall of the chimney (Figure 19).
3 FT. MINIMUM
SUPPORT
MAINTAIN
CLEARANCE*
€_
f
LISTED LINED
CHIMNEY
2 FT. MINtMUM ABOVE ANY OBJECT
WITHIN 10FT. HORIZONTALLY
DO NOT EXTEND
BEYOND EDGE
OF CHIMNEY
CONNECTOR
CHIMNEY TERMINATION VENT SYSTEM
FIGURE 19.
Do not terminate the vent connector in a chimney that has not
been certified for this purpose. Some local codes may prohibit
the termination of vent connectors in a masonry chimney.
Vertical Exhaust Gas Vent
Vertical exhaust gas vents must be installed with U.L. listed type B
vent pipe according to the vent manufacturer's instructions and the
terms of its listing.
It must be connected to the water heater's draft hood by a
listed vent connector or by directly originating at the draft hood
opening.
Vertical gas vents must terminate with a listed cap or other roof
assembly and be installed according to their manufacturer's
instructions.
Gas vents must be supported to prevent damage, joint
separation, and maintain clearances to combustible materials
(Figures 20 and 21).
IMPORTANT: This gas vent must be terminated in a vertical
position to facilitate the removal of the burnt gases.
An unused chimney flue or masonry enclosure may be used as a
passageway for the installation of a gas vent (Figure 21).
Common (combined) venting is allowable with vertical type B
vent systems and lined masonry chimneys as tong as proper
draft for the water heater is established under all conditions of
operation. CAUTION: DO NOT common vent this water heater
with any power vented appliance.
Figures 19-21 are examples of vent pipe system installations
and may or may not be typical for your specific application.
Consult the "National Fuel Gas Code", NFPA 54, ANSI Z223.1-
current edition and the guidelines set forth by prevailing local
codes.
SUPPORT
STRAP
*MAINTAIN
CLEARANCE
±
t
-- LISTED VENT CAP
L!__
1
_' FT. MINIMUM ABOVE ANY OBJECT
3 FT. MINIMUM WITHIN 10 FT. HORIZONTALLY
TYPE B DOUBLE
WALL VENT PIPE
_**MAtNTAIN
VENT
l
VERTICAL GAS VENT SYSTEM WITH
TYPE B DOUBLE WALL VENT PIPE.
FIGURE 20.
SUPPORT
*MAINTAIN
CLEARANCE
3_
-.,w_LISTED VENT CAP
5 FT. MINIMUM
"MAINTAIN
T SPECIFIED
CLEARANCE
VENT
CONNECTOR
1/4 IN. PER FT.
MINIMUM
CONNECTOR
UNUSED CHIMNEY
-.,F--_FLUE OR MASONRY
ENCLOSURE
19
VENTING THROUGH A CHIMNEY WITH
TYPE B DOUBLE WALL VENT PIPE.
FIGURE 21.
, Maintain vent pipe clearance requirements to local, state and/or the
"National FuelGas Code",ANSI Z223.1(NFPA 54)-current edition.
** NFPA 211, Standard for Chimneys, Fireplaces, Vents, and Solid
Fuel-Buming Appliances states that these chimneys are intended to
be installed in accordance with the installation instructions provided
with each chimney support assembly. Minimum airspace clearance to
combustible materialsshould be maintained as marked on the chimney
sections.
Piping Installation
Piping, fittings, and valves should be installed according to the
installation drawing (Figure 22). If the indoor installation area
is subject to freezing temperatures, the water piping must be
protected by insulation.
The water supply pressure should not exceed 80 psi. If this
occurs, a pressure reducing valve with a bypass may need to
be installed in the cold water inlet line. This should be placed
on the supply to the entire house in order to maintain equal hot
and cold water pressures.
IMPORTANT: Heat cannot be applied to the water fittings on
the heater as they may contain nonmetallic parts. If solder
connections are used, solder the pipe to the adapter before
attaching the adapter to the hot and cold water fittings.
IMPORTANT: Always use a good grade of joint compound and
be certain that all fittings are drawn up tight.
1. Install the water piping and fittings as shown in Figure 22.
Connect the cold water supply (3/4" NPT) to the cold water
inlet fitting. Connect the hot water supply (3/4" NPT) to the
hot water outlet fitting.
IMPORTANT: Some models may contain energy saving heat
traps to prevent the circulation of hot water within the pipes. Do
not remove the inserts within the heat traps.
2. The installation of unions in both the hot and cold water
supply lines is recommended for ease of removing the
water heater for service or replacement.
3. The manufacturer of this water heater recommends
installing a mixing valve or an anti-scald device in the
domestic hot water line as shown in Figure 23. These
valves reduce the point-of-use temperature of the water
by mixing cold and hot water and are readily available
for use.
4. If installing the water heater in a closed water system,
install an expansion tank in the cold water line as specified
under "Closed System/Thermal Expansion."
5. Install a shut-off valve in the cold water inlet line. It
should be located close to the water heater and be easily
accessible. Know the location of this valve and how to shut
off the water to the heater.
6,
A temperature and pressure relief valve must be installed
in the opening marked "Temperature and Pressure
(T & P) Relief Valve" on the water heater. A discharge line
must be added to the opening of the T&P Relief Valve.
Follow the instructions under "Temperature and Pressure
Relief Valve."
After piping has been properly connected to the water
heater, remove the aerator at the nearest hot water faucet.
Open the hot water faucet and allow the tank to completely
fill with water. To purge the lines of any excess air, keep
the hot water faucet open for 3 minutes after a constant
flow of water is obtained. Close the faucet and check all
connections for leaks.
Please note the following:
• The system should be installed only with piping that is
suitable for potable (drinkable) water such as copper,
CPVC, or polybutylene. This water heater must not be
installed using iron piping or PVC water piping.
• Use only pumps, valves, or fittings that are compatible with
potable water.
2O
IN A CLOSED SYSTEM, USE A
_THERMAL EXPANSIONTANK../COLD WATER SUPPLY TO FIXTURES
J_ _ r_ PRESSURE REDUCING VALVE
]_ _'T'_ U A.,_W_THEYPASS
HOT WATER COLD WATER
OUTLET ER _ _ INLET
\ TvALvE
TEMPERATURE AND PRESSURE (T&P)
RELIEF VALVE (OPTIONAL TOP T&P
RELIEF VALVE NOT SHOWN)
1" MINtMUM --_
METAL
DRAIN PAN --_
_---_ DISCHARGE PIPE
(DO NOT CAP OR PLUG)
DRAIN LINE MASSACHUSETTS: INSTALL
"0_ 3/4" ID AVACUUM RELIEF IN COLD
MINIMUM WATER LINE PER SECTION
_'-_ I /_ _19 MGL 142.
6" MAXIMUM
T AIR GAP
DRAIN /
FIGURE 22.
UNTEMPERED
HOT WATER
TO FIXTURES
COLD
WATER
INLET
HOT
OUTLET
\
MIXING VALVE
(SET TO 120°F)
FOLLOW THE MIXING
VALVE MANUFACTURER'S
INSTRUCTIONS
FIGURE 23.
Itis recommend that only full flow ball or gate valves are used
in water piping installations. The use of valves that may cause
excessive restriction to water flow is not recommended.
Use only 95/5 tin-antimony or other equivalent solder. Any
lead based solder must not be used.
Piping that has been treated with chromates, boiler seal, or
other chemicals must not be used.
Chemicals that may contaminate the potable water supply
must not be added to the piping system.
To protect against untimely corrosion of hot and cold water
fittings, it is strongly recommended that dielectric unions or
couplings be installed on this water heater when connected
to copper pipe.
Closed System/Thermal Expansion
. All water heaters eventually leak
• Do notinstallwithout adequate drainage,
As water is heated, it expands (thermal expansion). In a closed
system, the volume of water wilt grow. As the volume of water
grows, there wilt be a corresponding increase in water pressure
due to thermal expansion. Thermal expansion can cause
premature tank failure (leakage). This type of failure is not covered
under the limited warranty. Thermal expansion can also cause
intermittent temperature-pressure relief valve operation: water
discharged from the valve due to excessive pressure build up. The
temperature-pressure relief valve is not intended for the constant
relief of thermal expansion. This condition is not covered under
the limited warranty.
A properly sized thermal expansion tank should be installed
on all closed systems to control the harmful effects of thermal
expansion. Thermal expansion tanks are available from Sears
stores and through the Sears Service Centers. Contact the
local plumbing inspector, water supplier and/or the Sears
Service Center for assistance in controlling these situations.
(For additional information, see the Troubleshooting Guide later
in this manual.)
Temperature and Pressure Relief Valve
Explosion Harzard
Temperature-pressure relief
valve must comply with ANSI
Z21.22-CSA 4.4 and ASME
code.
• Properly sized temperature-
pressure relief valve must be
installed in opening provided.
• Can result in overheating
and excessive tank pressure.
• Can cause serious injury or
death.
\
TEMPERATURE AND PRESSURE (T&P)
RELIEF VALVE (OPTIONAL TOP T&P
RELIEF VALVE NOT SHOWN)
DISCHARGE PIPE
(DO NOT CAP OR PLUG)
DRAIN LINE
3/4" ID
i INIMuM
I"METALMINIMUM--=._ _
& 6" MAXIMUM
DRAIN PAN --_-_ __ AIR GAP
DRAIN _
FIGURE 24.
For protection against excessive pressures and temperatures,
a temperature and pressure relief valve must be installed in the
opening marked "T & P RELIEF VALVE." (See Figure 24). This
valve must be design certified by a nationally recognized testing
laboratory that maintains periodic inspection of the production
of listed equipment or materials as meeting the requirements
for Relief Valves for Hot Water Supply Systems, ANSI Z21.22.
The function of the temperature and pressure relief valve is to
discharge water in large quantities in the event of excessive
temperature or pressure developing in the water heater. The
valve's relief pressure must not exceed the working pressure of
the water heater as stated on the rating plate.
IMPORTANT: Only a new temperature and pressure relief valve
should be used with your water heater. Do not use an old or
existing valve as it may be damaged or not adequate for the
working pressure of the new water heater. Do not place any
valve between the relief valve and the tank.
The Temperature & Pressure Relief Valve:
• Must not be in contact with any electrical part
• Must be connected to an adequate discharge line
• Must not be rated higher than the working pressure shown
on the rating plate of the water heater
The Discharge Line:
• Must not be smaller than the pipe size of the relief valve or
have any reducing coupling installed in the discharge line
• Must not be capped, blocked, plugged or contain any valve
between the relief valve and the end of the discharge line
• Must terminate a maximum of six inches above a floor
drain or external to the building
• Must be capable ofwithstanding 250°F (121°C)without distortion
• Must be installed to allow complete drainage of both the
valve and discharge line
T&P Relief Valve and Pipe Insulation
1. Locate the T&P Relief Valve on the water heater.
2. Locate the slit running the length of the insulation.
3 Spread this slit open and slip it up under the T&P Relief
Valve. See Figure 25. Apply gentle pressure to the insulation
to ensure it is fully seated on the T&P Relief Valve. Once
sealed secure the insulation with a section of tape.
IMPORTANT: The insulation or tape should not block or
cover the T&P Relief Valve drain opening. Also the insulation
or tape should not block or hinder access to the T&P Relief
Valve manual relief lever.
4. Next locate the hot water (outlet) & cold water (inlet) pipes to
the water heater.
5. Select one of the sections of pipe insulation and locate the slit
that runs the length of the insulation.
6. Spread the slit open at the base of the insulation and slip it
over the cold water (inlet) pipe. Apply gentle pressure along
the length of the insulation to ensure it is fully seated around
the cold water pipe. Also ensure that the base of insulation is
flush with the water heater. Once seated, secure the insulation
with a section of tape.
7. Repeat steps 5through 6 for the hot water (outlet) pipe.
T&P RELIEF VALVE INSULATION
MANUAL RELIEF LEVER
©
DRAIN LINE
FIGURE 25.
21
Lighting Instructions
Read and understand these directions thoroughly before
attempting to light or re-light the pilot. Make sure the view port
is not missing or damaged. (See Figure 33.) Make sure the
tank is completely filled with water before lighting the pilot.
Check the rating plate near the gas control valve/thermostat for
the correct gas. Do not use this water heater with any gas other
than the one listed on the rating plate. If you have any questions
or doubts, consult your gas supplier or gas utility company.
Explosion Hazard
Replace view port if glass is missing
or damaged.
Failure to do so can result in death,
explosion or fire.
BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES
A. T,hisappliance has.a .pi.lotwhich is litby a piezo-
etec[rlc spark gas ignluon ,sys[em. uo n_,.o_open
the inner aoor of tiSeappliance and try [o light
the pilot by hand.
B.BEFORE LIGHTING 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.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any
phone in your building.
elmmediately call your gas supplier from a neighbor's
phone. Follow the gas supplier's instructions.
°If you cannot reach your gas supplier, call the fire
department.
C.Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or
turn by hand, don't try to repair it, call a qualified
service technician. Force or attempted repair may
result in a fire or explosion.
D. Do not use this appliance if any part has been under
water, immediately contact a qualified installer or
service agency to replace a flooded water heater.
Do not attempt to repair the unit! It must be replaced!
Pl_
tGNITOR STATUS_"
LED.
GAS CONTROL
_GAS CONTROL FIGUREIA' FIGURE'B' FIGURE'C' MAINBURNER
KNOB \
"_ .... _,to__ "PILOT
"OFF" POSITION "PILOT" POSITION "ON" POSITION
CONTROL KNOB FIGURE 'D'
1.
2.
3.
4.
5.
6.
7.
8.
STOP! Read the safety information
above on this label.
Turn gas control knob fully counterclockwise
to "OFF". SEE FIGURE 'A'.
Remove the outer burner door located below
the gas control.
Wait five (5) minutes to clear out any gas. If you
then smell gas, STOP! Follow "B" in the
above on this label. If
youdon'tsmellgas, go to next step.
This unit is equipped with a push button pilot ignitor,
which is used to light the pilot. Locate the ignitor
onthe gas control.
Turn gas control knob clockwise
Cto "PILOT". SEE FIGURE 'B'.
The pilotis locatedonthe left sideoftheburner. It
can be locatedby lookingthroughthe glassview port
while pressingthepiezoignitorbutton severaltimes.
Lookfora sparkat thepilotlocation,Figure'D'.
Oncethe pilothas beenfound, push thegas control
knoballthewayin(towardthewaterheater.)Immediately
10.
11.
press the piezo ignitor button rapidly (4) or(5) times.
Ifthe pilotwill notlight,repeatedsteps(2) through (8).
Continuetohold _e gas controlknob infor about
(30) seconds after the pilotis lit untilthe statusLE.D.
isflashing (oneflash everythree secondsis normal.)
Releasethegascontrolknobandthepilotshould
remain lit.If itgoes out,repeatsteps (2)through (8).
It may take several minutes for air to clear the lines
before the pilot will light.
If the pilot will not stay lit after several tries,
turn the gas control knob counterclockwise
to "OFF"and call your service technician or gas
supplier. SEE FIGURE 'A'.
Once the pilot flame is established replace the
outer burner door.
At arm's length away, turn gas control
knob clockwise C to desired temperature setting.
SEE FIGURE 'C'.
DANGER: Hotter water increases the risk
of scald injury. Consult the instruction
manual before changing temperature.
1. Turn control/thermostat knob fully counterclockwise _ to "OFF".
SEE FIGURE 'A'.
22
Checking the Draft Water Temperature Regulation
r:lmT_,l2[.=t=1;11
• Burn harzard
• Hot water discharge.
• Keep clear of relief valve
discharge outlet.
After successfully lighting the water heater, allow the unit to operate
for 15 minutes and check the draft hood relief opening for proper
draft (Figure 26). Make sure all other appliances in the area are
operating and all doors are closed when performing the draft test.
Pass a match flame around the relief opening of the draft hood. A
steady flame drawn into the opening indicates proper draft.
DRAFT HOOD
"" /Y'1J
MATCH_
FIGURE 26.
If the flame flutters or is blown out, combustion products are
escaping from the relief opening. If this occurs, do not operate the
water heater until proper adjustments or repairs are made to the
vent pipe system and/or air supply requirements.
Burner Flames
Inspect the burner flames through the viewport and compare
them to the drawing in Figure 27. A properly operating burner
should produce a soft blue flame. Blue tips with yellow inner
cones are satisfactory. The tips of the flame may have a slight
yellow tint. The flame should not be all yellow or have a sharp
blue-orange color. Contaminated air may cause an orange
colored flame. Contact a qualified technician if the flame is not
satisfactory.
FIGURE 27.
Emergency Shut Down
IMPORTANT: Should overheating occur or the gas supply fails
to shut off, turn off the water heater's manual gas control valve
and call a qualified technician.
Water temperature over 125°F (52°C)
can cause servere burns instantly
resulting in severe injury or death.
Children, the elderly, and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting valves are
available.
Read instruction manual for safe
temperature setting.
Due to the nature of the typical gas water heater, the water
temperature in certain situations may vary up to 30°F (16.7 °C)
higher or lower at the point of use such as, bathtubs, showers,
sink, etc.
HOTTER WATER CAN SCALD: Water heaters are intended to
produce hot water. Water heated to a temperature which wilt
satisfy space heating, clothes washing, dish washing, and other
sanitizing needs can scald and permanently injure you upon
contact. Some people are more likely to be permanently injured
by hot water than others. These include the elderly, children, the
infirm, or physically/mentally handicapped. If anyone using hot
water in your home fits into one of these groups or if there is
a local code or state law requiring a certain temperature water
at the hot water tap, then you must take special precautions.
In addition to using the lowest possible temperature setting
that satisfies your hot water needs, a means such as a mixing
valve should be used at the hot water taps used by these
people or at the water heater. Mixing valves are available at
plumbing supply or hardware stores. See Figure 23. Follow
manufacturer's instructions for installation of the valves. Before
changing the factory setting on the thermostat, see Figure 28.
Using the lowest hot water temperature that meets your needs
will also provide the most energy efficient operation of the water
heater.
Never allow small children to use a hot water tap, or to draw
their own bath water. Never leave a child or handicapped
person unattended in a bathtub or shower.
NOTE: Awater temperature range of 120°F-140°F (49°C-60°C)
is recommended by most dishwasher manufacturers.
The thermostat of this water heater has been factory set at its
lowest position. It is adjustable and must be reset to the desired
temperature setting to reduce the risk of scald injury. The 120°F
(49°C) mark is the preferred starting point. (See Figure 28 on
the next page.) Some states have a requirement for a lower
setting.
Turn the water temperature dial clockwise ( f'_ ) to increase
the temperature, or counterclockwise ( _ ) to decrease the
temperature.
Should overheating occur or the gas supply fail to shut off, turn
off the manual gas control valve to the appliance.
23
GASCONTROUTEMPERATUREKNOB
©
160°F (71°C) About 1/2 second
About 1-1/2 seconds
Less than 5 seconds
About 30 seconds
More than 5 minutes
150°F (66°C)
140°F (60°C)
130°F (54°C)
120°F (49°C)
VAC = approx. 80°F (27°C)
FIGURE 28.
NOTE: During tow demand periods when hot water is not
being used, a lower thermostat setting wilt reduce energy
losses and may satisfy your normal hot water needs. If hot
water use is expected to be more than normal, a higher
thermostat setting may be required to meet the increased
demand. When leaving your home for extended periods
(vacations, etc.) turn the temperature dial to its lowest
setting. This wilt maintain the water at tow temperatures with
minimum energy losses and prevent the tank from freezing
during cold weather.
24
Tank (Sediment) Cleaning
Sediment build-up on the tank bottom may create varying amount of
noise, and if left in the tank will cause permanent tank failure. In some
water areas, you may not be able to drain all sediment deposits by
simply draining the tank. In these cases, Mag-Erad (part no. 23600)
can be used to help remove the sediment deposits. This may be
ordered from the Sears Service Center. For ordering, refer to the
"Parts Order List" section.
Vent System Inspection
Ca_on Monoxide and Fire Hazard
, Fiue gases may escape if vent pipe
is not connected
* Be alert for obs.tructed, sooted or
deteriorated vent system to avoid
sedous injury or death.
• Do not store corrosive chemicals
in vicinity of water heater.
• Chemical corrosion of flue and vent
system can cause serious injury or
death
Breathing carbon monoxide can cause brain damage or
death. A(ways read and understand instruction manual
At least once a year, a visual inspection should be made of the
venting system. You should look for:
• Obstructions which could cause improper venting. The
combustion and ventilation air flow must not be obstructed.
• Damage or deterioration which could cause improper venting
or leakage of combustion products.
• Rusted flakes around top of water heater.
Be sure the vent piping is properly connected to prevent escape of
dangerous flue gasses which could cause deadly asphyxiation.
Obstructions and deteriorated vent systems may present serious
health risk or asphyxiation.
Chemical vapor corrosion of the flue and vent system may occur
if air for combustion contains certain chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants, swimming pool chemicals, calcium and sodium chloride,
waxes, bleach and process chemicals are typical compounds which
are potentially corrosive.
If when inspecting the vent system you find sooting or deterioration,
something is wrong. Call the local gas supplier to correct the problem
and clean or replace the flue and venting before resuming operation
of the water heater.
Burner Inspection
Flood damage to a water heater may not be readily visible or
immediately detectable. However, over a period of time a flooded
water heater will create dangerous conditions which can cause
DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.
Contact a Sears Service Center to replace a flooded water heater.
Do not attempt to repair the unit! tt must be replaced!
At least once a year, a visual inspection should be made of the main
burner and pilot burner. See Figure 29.
You should check for sooting. Soot is not normal and will impair
proper combustion.
Soot build-up indicates a problem that requires correction before
further use. Turn "OFF" gas to water heater and leave off until repairs
are made, because failure to correct the cause of the sooting can
result in a fire causing death, serious injury, or property damage.
FIGURE 29.
Burner Cleaning
Fire or Explosion Hazard
Failure to properly reseal the combustion chamber will
disable the flammable vapor ignition resistance feature
of this water heater, which could result in death or serious
injury. Contact your local Sears Service Center
for assistance.
Read instruction manual before
installing, using or servicing
water heater.
In the event your burner needs cleaning, follow these instructions:
If inspection of the burner shows that cleaning is required, turn the
gas control knob counterclockwise ( _ ) to the "OFF" position,
depressing slightly.
NOTE: The knob cannot be turned from "PILOT" to "OFF" unless
knob is depressed slightly. DO NOT FORCE.
The burner needs to be removed for cleaning. Call the Sears Service
Center to remove and clean the burner and correct the problem that
required the burner to be cleaned.
25
Housekeeping
Vacuum around base of water heater for dust, dirt, and lint on
a regular basis.
Fire and Explosion Hazard
Temperature-Pressure Relief Valve Operation
The temperature-pressure relief valve must be manually
operated at least once a year.
,7,_I =4
/
Do not obstruct combustion air
openings at the bottom of the
water heater.
Do not use or store flammable
vapor products such as gasoline,
solvents or adhesives in the
same room or area near water
heater or other appliance.
At least annually, check the
base-ring filter and flame arrestor
for any dust, lint, or debris that
may have accumulated. Clean
as necessary.
Can cause serious injury or death.
AT LEAST ANNUALLY, A VISUAL INSPECTION SHOULD BE
MADE OF THE BASE-RING FILTER AND FLAME ARRESTOR.
CLEAN IF LINT ACCUMULATIONS ARE NOTICED.
INSTALLED IN SUITABLEAREA: Toensure sufficient ventilation
and combustion air supply, proper clearances from the water
heater must be maintained. See "Installation Instructions."
Combustible materials such as clothing, cleaning materials, or
flammable liquids, etc. must not be placed against or adjacent
to the water heater because they could catch on fire.
Anode Rod Inspection
Property Damage Hazard
• Avoid water heater damage.
• Inspection and replacement of anode rod required.
The anode rod is used to protect the tank from corrosion.
Most hot water tanks are equipped with an anode rod. The
submerged rod deteriorates to protect the tank. Instead of
corroding the tank, water ions attack and eat away the anode
rod. This does not affect the water's taste or color. The rod
must be maintained to keep the tank in operating condition.
m7.'1
Anode deterioration depends on water conductivity, not
necessarily water condition. A corroded or pitted anode rod
indicates high water conductivity and should be checked and/
or replaced more often than an anode rod that appears to be
intact. Replacement of a depleted anode rod can extend the
life of your water heater. Inspection should be conducted by
calling the Sears Service Center for an authorized contractor.
At a minimum, the anode(s) should be checked annually after
the warranty period.
• Burn harzard
• Hot water discharge.
• Keep clear of relief valve
discharge outlet.
When checking the temperature-pressure relief valve operation,
make sure that (1) no one is in front of or around the outlet of
the temperature-pressure relief valve discharge line, and (2)
that the water discharge will not cause any property damage, as
the water may be extremely hot. See Figure 30.
TEMPERATURE-PRESSURE
DISCHARGE PIPE
FIGURE 30.
If after manually operating the valve, it fails to completely reset
and continues to release water, immediately close the cold
water inlet to the water heater, follow the draining instructions,
and replace the temperature-pressure relief valve with a new
one.
If the temperature-pressure relief valve on the appliance
weeps or discharges periodically, this may be due to thermal
expansion. You may have a check valve installed in the
water line or a water meter with a check valve. Consult the
Sears Service Center for further information. Do not plug the
temperature-pressure relief valve.
Draining and Flushing
• Hotwaterdischarge burn hazard.
• Keep clear of relief valve discharge
unit.
• Temperature limiting valves are
available.
• Read instruction manual for safe
temperature setting.
It is recommended that the tank be drained and flushed
every 6 months to remove sediment which may build up during
operation. The water heater should be drained if being shut
26
down during freezing temperatures. To drain the tank, perform
the following steps:
1. Turn the thermostat dial to the "OFF" position. (This dial is
located on the gas control valve/thermostat.)
2. Turn off the gas to the water heater at the manual gas shut-
off valve.
3. Open nearby hot water faucets and leave them open to
allow for draining. Allow the hot water to run until water
flowing from the faucets is 100 ° F or less.
4. Close the cold water inlet valve.
5. Connect a hose to the drain valve and terminate it to an
adequate drain or outdoors. (Make sure all connections
are tight and that the water flow is directed away from
people.)
6. Open the water heater drain valve and allow all the water
to drain from the tank. Flush the tank with water as needed
to remove sediment.
7. Close the drain valve, refill the tank, and restart the heater as
directed under the "Operating Your Water Heater" section.
If the water heater is going to be shut down for an extended
period, the drain valve should be left open.
IMPORTANT: Condensation may occur when refilling the tank
and should not be confused with a tank leak.
Service
Before calling for repair service, please read the troubleshooting
section in this manual.
If a condition persists or you are uncertain about the operation
of the water heater, let the Sears Service Center check it out.
Contact Sears Service Center at:
1-800-4-MY-HOME® (1-800-469-4663).
27
A. Tools required:
1. T15 Torx Screwdriver
2. 3/16" slotted screwdriver.
3. Open-end wrenches 7/16", and 3/4".
For these instructions, please see Figure 31.
B. Removing the Electronic Control Module:
1. Turn the gas control/temperature knob to the "OFF"
position.
2. Turn off the gas at the manual shut-off valve on the gas
supply line (Figure 11).
3. Disconnect the wire connectors from the piezo igniter, tank
sensors, and thermopile mounted on the lower front of the
gas control valve assembly.
4. Remove the torx screw located beside the pilot tube on the
lower front of the electronic control module with a T15 torx
screwdriver.
5. Depress the two plastic locking tabs on the top surface
of the electronic control module with a 3/16" slotted
screwdriver.
6. Grasp the sides of the electronic control module and pull
outward to remove.
C. Removing the Gas Valve Assembly:
IMPORTANT: This water heater has a resettable thermal switch
installed. Do not attempt to disable or modify this feature in any
way. Use only factory authorized replacement parts.
1. Follow steps 1 to 6 in B above to remove the electronic
control module.
2. Refer to the "Gas Piping" section (Figure 11)and disconnect
the ground joint union in the gas piping. Next, disconnect
the inlet gas supply to the gas valve.
3. Loosen the flare nut that connects the pilot tube to the
bottom of the gas control valve assembly with a 7/16" open-
end wrench. Pull down on the pilot tube to separate the tube
from the gas valve.
4. Loosen the flange nut that connects the burner tube to
bottom of gas control valve with a 314" open-end wrench.
Pull down on the burner tube to separate the tube from the
gas valve.
5. Unscrew and remove the gas valve assembly and backplate
by turning it to the left. Continue until it separates from the
gas valve nipple that is threaded into the tank. (The gas
valve nipple remains attached to the tank.)
6. Check for water leaks around the threads of the gas valve
nipple (which is still attached the tank). If leaks appear,
drain the tank and contact a qualified service technician.
(Refer to the "Draining and Flushing" section.)
D: Installing a Gas Control Valve/Thermostat
(Full Assembly)
NOTE: If the electronic control module, gas valve, and backptate
are not assembled, assemble them before proceeding.
1. If it is not needed, remove the metal gas valve nipple from
the gas control valve/thermostat. (It is screwed onto the
threaded plastic nipple of the gas control valve/thermostat's
backplate.)
IMPORTANT: You can use the metal gas valve nipple that
is already installed in the tank. However, if you need to
install a new gas valve nipple, drain the water heater before
removing the old one from the tank.
2. Screw the new gas control valve into the tank opening, then
hand tighten it. DO NOT OVER TIGHTEN or damage may
result. Check for water leaks when you are finished.
3. Reconnect the manifold tube, pilot tube, and inlet gas supply
line to the gas valve. Tighten securely. NOTE: Use an
approved Teflon ®tape or pipe compound on the gas piping
connections.
4. Connect the thermopile, tank sensor, and igniter wire
plugs.
5. Turn on the gas supply and test the gas supply connections
by brushing on an approved noncorrosive leak detection
solution. Bubbles forming indicate a leak. Correct any leak
found.
6. Check the operation of the burner by following the lighting
instructions on the front of the water heater. With the burner
lit, check the gas control valve/thermostat supply line,
manifold tube and pilot tube connections for leaks.
E: Installing the Electronic Control Module:
1. Align the two plastic locking tabs on the top surface of the
electronic control module with the openings of the gas valve
back-plate. Press on the front of the control module until it
locks into position.
2. Reinstall the torx screw on the lower front of the electronic
control module (beside pilot tube) with a T15 torx screwdriver.
Tighten securely.
3. Reconnect the wire connectors from the piezo igniter, tank
sensors, and thermopile to the electronic control module.
4. Light the heater following the lighting and operating
instructions on the front surface of the heater.
TEFLON®is a registered trademark of E.I. Du Pont De Nemours
and Company.
28
LOCKING
TAB
IGNITER
ELECTRONIC CONTROL MODULE
O
\
THERMOPILE
TORX
SCREW
\
LOCKING
TAB
"TANK
SENSOR
GAS VALVE ASSEMBLY
GAS VALVE NIPPLE
GAS VALVE ASSEMBLY
(FRONT VIEW WITH ELECTRONIC
CONTROL MODULE REMOVED)
INLET
GAS
SUPPLY
LOCKING LOCKING
TAB TORX PILOT BURNER TAB
SCREW TUBE TUBE
\
\
\
\
\
\
\
\
\
\
FIGURE 31.
29
Replacement Parts
IMPORTANT: The following maintenance procedures are for
the FVIR System components and should be performed by a
qualified technician.
Replacement parts may be ordered from Sears Parts and
Service Centers or by calling 1-800-4-MY-HOME (1-800-469-
4663). When ordering replacement parts, always have the
following information ready:
1. model, serial, and product number
2. type of gas
3. item number
4. parts description
See the Parts Order List section for a list of available repair parts.
External Inspection & Cleaning of the
Base-Ring Filter
1. At least annually, check the base-ring filter (Figure 37) for
any dust or debris that may have accumulated on the filter
screen. NOTE: If the water heater is located in an area that
is subjected to tint and dirt, it may be necessary to check
the base-ring filter more frequently.
2. Follow the Lighting Instructions to turn off the water heater
and allow it to coot for 10 minutes before attempting to clean
the base-ring filter.
3. Use a vacuum cleaner with a hose attachment to remove
any dust or debris that may have accumulated on the filter.
NOTE: Ifunable to inspect or clean the base-ring filter, follow
the "Cleaning the Combustion Chamber and Flame-arrestor"
instructions.
4,
After the base-ring filter has been cleaned, follow the
Lighting Instructions to return the water heater to service.
Removing the Manifold/Burner Assembly
1. Turn off the gas supply to the water heater at the manual
gas shut-off valve. This valve is typically located beside the
water heater (Figure 11). Note the position of the shut-off
valve in the open/on position then proceed to turn it off.
2. Turn the temperature dial to the "OFF" position.
ELECTRONIC CONTROL MODULE
IGNITER , _ 'TANK SENSOR
THERMOPiLE _ \
PLUG PILOT MANIFOLD
TUBE TUBE
FIGURE 32.
3. Remove the outer door.
4. Remove the two screws securing the manifold door
assembly to the combustion chamber (Figure 33).
GAS CONTROL VALVE/
THERMOSTAT
THERMOPILE
I
%_gR _&.,FOLD
MANIFOLD PIECE
SCREWS (2) WIRE CONNECTOR
FIGURE 33.
5. Disconnect the following from the gas control valve/thermostat:
thermopite plug, tank sensor plug, igniter wire plug, pilot tube,
and manifold tube. (See Figures 32 & 33.)
6. Grasp the manifold tube and push down slightly to free the
manifold and pilot tubes.
7. Carefully remove the manifold/burner assembly from the
burner compartment. NOTE: Be sure not to damage internal
parts.
Removing the Burner from the Manifold/
Burner Assembly
1,
2.
Take off the burner by removing the two (2) screws located
underneath the burner.
Check the burner to see if it is dirty or clogged. The burner
may be cleaned with soap and hot water (Figure 34).
(BOTTOM VIEW)
SCREW_
BURNER
(BOTTOM VIEW)
FIGURE 34.
Replacing the Pilot/Pilot Tube Assembly
1. Remove the manifold assembly. See "Removing the
Manifold/Burner Assembly."
2. Remove the retainer clip from the back of the two piece
wire connector (using a flat blade screw driver), then
remove the two piece wire connector from the manifold
door (Figure 35).
IMPORTANT: Be careful not to bend or alter the position of
the pilot tube. It will be used as a bending template for the
new pilot assembly.
3. Remove the burner by removing the two (2) screws located
beneath it. Keep the screws for future use.
3O
4. Remove the screw that secures the pilot shield and pilot
assembly to the pilot bracket (Figure 35). Keep the screw
for future use.
5. Loosen the nut securing the pilot tube to the pilot assembly.
NOTE: To prevent any bending of the pilot bracket, use
pliers to hold the pilot assembly bracket while loosening
the pilot nut.
6. Pull the pilot tube from the pilot assembly (Figure 35).
IMPORTANT: Be careful not to bend or alter the position of
the pilot assembly components.
7. Using the old pilot/pilot tube assembly as a guide, bend
the new pilot tube to match the old one. NOTE: Make only
the bends closest to the pilot before going to the next step.
DO NOT crimp or crease the pilot tube.
8. Push the new pilot assembly connectors through the hole
in the manifold door where the two piece wire connector
wilt be seated (See Figure 35). Reconnect the pilot tube
and tighten the nut securing it to the pilot assembly.
IMPORTANT: Keep the pilot orifice in the pilot when making
the connection. Do not operate the water heater without
the pilot orifice installed.
9. Reattach the pilotshield and pilot assembly to the pilot bracket.
10. Reattach the burner and secure with the screws
removed earlier. NOTE: See Figure 34 for correct burner
orientation.
11. Position the new pilot tube through the largest opening of
the two piece wire connector. NOTE: The largest opening
should be located at the top position. The igniter wire
should be located in the middle opening and thermopile
wires in the bottom opening.
12. Reposition the two piece wire connector in the manifold
door opening and secure it with the retainer clip.
13. Before you proceed to the next step, install the new brass
ferrule nut in the gas control valve/thermostat's pilot tube
opening. HAND TIGHTEN ONLY.
14. See "Replacing the Manifold/Burner Assembly."
Thermopile
Connector
Wire
Pilot Tube _ _
Two Piece / _
Wire Connector
Burner and other fittings
not shown for clarity.
_tainer Clip
FIGURE 35.
Pilot
Thermopile
Cleaning the Combustion Chamber and
Flame-arrestor
1.
2.
Follow procedure outlined in "Removing the Manifold/
Burner Assembly."
Use a vacuum cleaner/shop vac to remove all loose debris
in the combustion chamber (Figure 37). Use compressed
air to clear any dust or debris that may have accumulated
in the flame-arrestor.
COMBUSTION CHAMBER
FLAME ARRESTOR
DOOR GASKET
BASE-RING
FIGURE 37.
3. Reassemble by following the procedure under "Replacing
the Manifold/Burner Assembly."
Replacing the Manifold/Burner Assembly
Explosion Hazard
Tighten both manifold door screws securely.
Remove any fiberglass between gasket
and combustion chamber.
Replace viewport if glass is missing or
damaged.
Replace two piece wire connector if missing or
removed.
• Replace door gasket if damaged.
• Failure to follow these instructions can result
in death, explosion, or fire.
Thermopile
Connector
Thermal
Connectors
1. Check the door gasket for damage or imbedded debris
prior to installation.
2. Inspect the view port for damage and replace as required.
3. Insert the manifold/burner assembly into the burner
FIGURE 36.
31
4,
5,
6,
7,
8,
9.
10.
compartment, making sure that the tip of the manifold tube
engages in the slot of the bracket inside the combustion
chamber (Figures 38 & 39).
Inspect the door gasket and make sure there is no
fiberglass insulation between the gasket and the
combustion chamber.
Replace the two screws, which secure the manifold/
burner assembly door to the combustion chamber and
tighten securely. Once the manifold/burner assembly door
is tightened, visually inspect the door gasket between
the manifold/burner assembly door and the combustion
chamber for spaces or gaps that would prevent a seal.
IMPORTANT: Do not operate the water heater if the door
gasket does not create a seal between the manifold door
and the combustion chamber.
During the following procedure, do not cross-thread or
apply any thread sealant to any of the fittings listed below.
First, reconnect the manifold tubing to the gas control valve/
thermostat.
NOTE: If a ferrule nut needs to be installed for the pilot
tube, locate the one provided with your parts kit. Install it in
the gas control valve/thermostat at the pilot location, hand
tight only.
Next, insert the pilot tube into the ferrule nut until it bottoms
out. NOTE: Hold the tube in this position. Tighten the ferrule
nut with a wrench until the crimp connection seals to the
pilot tube. Continue to tighten until the nut is tight in the gas
control valve/thermostat.
Plug the thermopile plug into the gas control valve/
thermostat. Also, connect the two wire leads that go to the
thermal switch if they had been removed.
Reconnect the igniter wire and tank sensor plugs.
Turn gas supply on and refer to the Lighting Instructions.
With the burner tit, check the gas control valve/thermostat
supply line, two piece wire connector, manifold tube,
and pilot tube connections for leaks. Check for leaks by
brushing on an approved noncorrosive leak detection
solution. Bubbles forming indicate a leak. Correct any leak
found. IMPORTANT: All leaks must be fixed immediately.
11. Replace the outer door.
MANIFOLD TUBE
CLOSE-UP INSIDE VIEW OF
THE COMBUSTION CHAMBER.
__ SLOT
TIP BRACKET
FIGURE 39.
Piezoelectric Igniter System
The piezoelectric igniter system consists of the igniter button,
electrode, and wire. The pilot is ignited by an electric spark
generated when the igniter button is pressed. The spark gap
of 0.125 inch is set when the electrode is installed at the factory.
(Figure 40). Use only factory authorized piezoelectric igniter
parts for replacement.
ELECTRONIC CONTROL MODULE
IGNITER
BUTTON
PILOT ASSEMBLY
PILOT
THERMOPILE
PILOT BRACKET
* NOTE: SPARK GAP DISTANCE MEASURED FROM ELECTRODE TIP TO PILOT.
FIGURE 40.
Testing the Igniter System
Turn off the gas to the water heater at the manual gas shut-off
valve. Watch the electrode tip while activating the igniter. A
visible spark should jump from the electrode. To avoid shock,
do not touch the burner or any metal part on the pilot or pilot
assembly. If no spark is visible, check the wire connections
and make sure the electrode is not broken. Replace the igniter
if defective. Dirt and rust on the pilot or electrode tip can
prevent the igniter spark. Wipe clean with a damp cloth and dry
completely. Rust can be removed from the electrode tip and
metal surfaces by lightly sanding with an emery cloth or fine
grit sandpaper.
FLAMEARRESTOR BRACKET
FVIR System Operational Checklist
1. Manifold gasket properly sealed.
2. Viewport not damaged or cracked.
3. Flame-arrestor free of debris and undamaged.
4. Two piece wire connector properly installed.
5. No leaks at pilot and manifold connection.
6. Manifold door screws securely tightened.
7. Depress the button on the thermal switch.
TiP
FIGURE 38.
32
Start Up Conditions
Thermal Expansion
Property Damage Hazard
• Avoid water heater damage.
• install thermal expansion tank or device if necessary.
• Contact qualified installer or service agency.
As water is heated, it expands (thermal expansion). In a closed
system, the volume of water wilt grow. As the volume of water
grows, there wilt be a corresponding increase in water pressure
due to thermal expansion. Thermal expansion can cause
premature tank failure (leakage). This type of failure is not
covered under the limited warranty. Thermal expansion can also
cause intermittent temperature-pressure relief valve operation:
water discharged from the valve due to excessive pressure
build up. The temperature-pressure relief valve is not intended
for the constant relief of thermal expansion. This condition is not
covered under the limited warranty.
A properly sized thermal expansion tank should be installed
on all closed systems to control the harmful effects of thermal
expansion. Thermal expansion tanks are available from Sears
stores and through the Sears Service Centers. Contact the local
plumbing inspector, water supplier and/or the Sears Service
Center for assistance in controlling these situations. See
Figure 41.
TABLE 4
Thermal Expansion Tank Specifications
Model
Number
153.331020
153.331050
Tank Dimensions Pipe
Capacity in Inches Fitting
In Gallons Diameter Len£1th On Tank
2 8 (203 mm) 12-3/4 (323 mm) 3/4" Male
5 11 (279 mm) 14-3/4 (375 mm) 3/4" Male
TABLE 5
Expansion Tank Sizing Chart
Expansion
Tank
Capacity
Needed
Inlet*
Water
Pressure
40psi
50psi
60psi
70psi
80psi
Water Heater Capacity (Gallons)
30 40 50 66 82
2 2 2 5 5
2 2 2 5 5
2 2 5 5 5
2 2 5 5 5
2 5 5 5 5
*Highest recorded inlet water pressure in a 24 hour period or regulated
water pressure.
NOTE: Expansion tanks are pre-charged with a 40 psi air
charge. If the inlet water pressure is higher than 40 psi, the
expansion tank's air pressure must be adjusted to match
that pressure, but must not be higher than 80 psi.
HOT
I I
WATER HEATER (3)
../ COLD WATER PRESSURE
INLET FITTING REDUCING
VALVE WITH
BY-PASS
(2)
PRESSURE GAUGE INLET COLD
WATER SHUT-OFF
RECOMMENDED INSTALLATION
(VERTICAL MOUNTING)
WATER HEATER
COLD WATER
INLET FITTING
FLOOR, CEILING JOIST, ETC.
HOT COLD
(3)
PRESSURE
REDUCING
VALVE WITH
(1) BY-PASS
EXPANSION /
.,I t
PRESSURE GAUGE-- INLET COLD
WATER SHUT-OFF
ALTERNATE RECOMMENDED INSTALLATION
(HORIZONTAL MOUNTING)
FIGURE 41.
Strange Sounds
Possible noises due to expansion and contraction of some
metal parts during periods of heat-up and cool-down do not
represent harmful or dangerous conditions.
Condensation causes sizzling and popping within the burner
area during heating and cooling periods and should be
considered normal. See "Condensation" section.
Draft Hood Operation
Check draft hood operation by performing a worst case
depressurJzation of the building. With all doors and windows
closed, and with all air handling equipment and exhaust fans
operating such as furnaces, clothes dryers, range hoods and
bathroom fans, a match flame should still be drawn into the draft
hood of the water heater with its burner firing. If the flame is not
33
drawn toward the draft hood, shut off water heater and make
necessary air supply changes to correct.
Condensation
Whenever the water heater is filled with cold water, some
condensate will form while the burner is on. Awater heater may
appear to be leaking when in fact the water is condensation.
This usually happens when:
• A new water heater is filled with cold water for the first
time.
• Burning gas produces water vapor In water heaters,
particularly high efficiency models where flue temperatures
are lower.
• Large amounts of hot water are used in a short time and the
refill water in the tank is very cold.
Moisture from the products of combustion condense on the
cooler tank surfaces and form drops of water which may fall
onto the burner or other hot surfaces to produce a "sizzling" or
"frying" noise.
result of four factors which must all be present for the odor to
develop:
• a concentration of sulfate in the supply water.
• little or no dissolved oxygen in the water.
• a sulfate reducing bacteria within the water heater. (This
harmless bacteria is non-toxic to humans.)
• an excess of active hydrogen in the tank. This is caused by
the corrosion protective action of the anode.
Smelly water may be eliminated or reduced in some water
heater models by replacing the anode(s) with one of tess active
material, and then chlorinating the water heater tank and all
hot water lines. Contact Sears Service for further information
concerning this chlorination treatment and an anode replacement
kit #9001453. (For short heaters, use anode replacement
kit #9006299.) Anode replacement and chlorination of the tank
are not covered by the water heater's limited warranty.
If the smelly water persists after the anode replacement and
chlorination treatment, it may be necessary to chlorinate or
aerate your water supply to eliminate the problem.
Do not remove the anode, leaving the tank unprotected. By
doing so, all warranty on the water heater tank is voided.
Excessive condensation can cause pilot outage due to water
running down the flue tube onto the main burner and putting
out the pilot.
"AIR" In Hot Water Faucets
Because of the suddenness and amount of water, condensation
water may be diagnosed as a "tank leak". After the water in
the tank warms up (about 1-2 hours), the condition should
disappear.
Do not assume the water heater is leaking until there has been
enough time for the water in the tank to warm up.
An undersized water heater will cause more condensation.
The water heater must be sized properly to meet the family's
demands for hot water including dishwashers, washing machines
and shower heads.
Explosion Hazard
• Flammable hydrogen
gases may be present.
• Keep all ignition sources
away from faucet when
turning on hot water.
Excessive condensation may be noticed during the winter and
early spring months when incoming water temperatures are at
their lowest.
Good venting is essential for a gas fired water heater to operate
properly as well as to carry away products of combustion and
water vapor.
Smoke Odor
It is not uncommon to experience a small amount of smoke and
odor during the initial start-up. This is due to burning off of oil
from metal parts, and wilt disappear in a short while.
Operational Conditions
Smelly Odor
In each water heater there is installed at least one anode rod
(see parts section) for corrosion protection of the tank. Certain
water conditions will cause a reaction between this rod and the
water. The most common complaint associated with the anode
rod is one of a "rotten egg smell". This odor is derived from
hydrogen sulfide gas dissolved in the water. The smell is the
HYDROGEN GAS: Hydrogen gas can be produced in a hot water
system that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely flammable and
explosive. To prevent the possibility of injury under these conditions,
we recommend the hot water faucet, located farthest away, be
opened for several minutes before any electrical appliances which are
connected to the hot water system are used (such as a dishwasher
or washing machine). If hydrogen gas is present, there will probably
be an unusual sound similar to air escaping through the pipe as the
hot water faucet is opened. There must be no smoking or open flame
near the faucet at the time it is open.
Safety Shut-off and Thermal Switch
This water heater is designed to automatically shut-off in the
event of the following:
1. The pilot flame is extinguished for any reason.
2. The water temperature exceeds 195°F (91°C).
3. Excessive build up of dust on the base ring filter or flame
arrestor. See Maintenance of your Water Heater Section.
4. The ignition of flammable vapors.
A thermocouple is used to determine if a pilot flame is present,
and will shut off the gas supply to the main burner and the pilot
34
if the flame is absent. This unit is also equipped with a thermal
switch, designed to shut off the gas supply in the event the
water heater has been exposed to flammable vapors (e.g.,
spilled gasoline), poor combustion caused by a blocked vent or
insufficient combustion air. If the thermal switch opens:
1. Check the flame-arrestor for signs of high temperature (blue
or black discoloration). See Figure 37.
2. Ifthere are signs of high temperature or that the thermal switch
has opened, inspect your installation for problems with venting,
combustion air supply, or a possible flammable vapor event.
(See "Pilot Light Troubleshooting Flowchart" section.) Correct
any issues prior to resetting the thermal switch. Ifyou suspect
a flammable vapor incident has occurred, do not use this
appliance. Immediately call a qualified technician to inspect
the appliance. Water heaters subjected to a flammable vapors
ignition will require replacement of the entire water heater.
3. Reset the thermal switch by depressing the small button in the
center of the thermal switch. Follow the Lighting Instructions
found on the front of your water heater. Ahigh temperature limit
switch or ECO (Energy Cut Off) in the tank is used to shut offthe
unit if the water temperature exceeds 195°F (91°C). The ECO
is a single-use switch, which, if activated, requires complete
replacement of the entire gas control valve/thermostat. If the
ECO should activate, the water heater cannot be used until
the gas control valve/thermostat is replaced by a qualified
technician. Contact Sears at 1-800-4-MY-HOME (1-800-469-
4663) to request service.
Leakage Checkpoints
6" MAXIMUM
AIR GAP
f
DRAIN VALVE IS PARTIALLY HIDDEN BY DISCHARGE PIPE.
FIGURE 42.
Read and understand instruction
manual and safety messages
before installing, operating or
servicing this water heater.
Failure to follow instructions and
safety messages could result in
death or serious injury.
Instruction Manual must remain
with water heater.
Read this manual first. Then, before checking the water heater,
make sure the gas supply has been turned "OFF", and never
turn the gas "ON" before the tank is completely full of water.
Never use this water heater unless it is completely filled with
water. To prevent damage to the tank, the tank must be filled
with water. Water must flow from the hot water faucet before
turning "ON" gas to the water heater.
A. Water at the draft hood is water vapor which has condensed
out of the combustion products. This is caused by a
problem in the vent. Contact a qualified technician.
B. *Condensation may be seen on pipes in humid weather or
pipe connections may be leaking.
C. *The anode rod fitting may be leaking.
D. Small amounts of water from temperature-pressure relief
valve may be due to thermal expansion or high water
pressure in your area.
E. *The temperature-pressure relief valve may be leaking at
the tank fitting.
F. Water from a drain valve may be due to the valve being
slightly opened.
G. *The drain valve may be leaking at the tank fitting.
H,
Combustion products contain water vapor which can
condense on the cooler surfaces of the tank. Droplets form
and drip onto the burner or run on the floor. This is common
at the time of start-up after installation and when incoming
water is cold.
Water in the water heater bottom or on the floor may be
from condensation, loose connections, or the relief valve.
DO NOT replace the water heater until a full inspection
of all possible water sources is made and necessary
corrective steps taken.
Leakage from other appliances, water lines, or ground seepage
should also be checked.
To check where threaded portion enters tank, insert cotton
swab between jacket opening and fitting. If cotton is wet, follow
draining instructions in the "Draining and Flushing" section and
then remove fitting. Put pipe dope or teflon tape on the threads
and replace. When you are finished, follow the steps in "Filling
the Water Heater" inthe Installation Instructions earlier in this
manual.
35
PROBLEM
GAS CONTROL
VALVE/
THERMOSTAT
LED STATUS
OFF
1flash *
2 flashes *
3flashes *
POSSIBLE CAUSE(S)
Electronic control module off or pilot
flame off.
Electronic control module is powered
and pilot lit.
Thermopile voltage low.
Gas valve or tank sensor failure.
Gas control valve overheat failure
4 flashes *
(pilot off or burner off).
5flashes *
6 flashes *
Lower tank sensor failure (pilot on
and burner off).
Upper tank sensor failure (pilot on
and burner off).
CORRECTIVE ACTION
Check wiring harness for proper connection.
Ignite pilot flame.
Normal operation. No action required.
Inspect thermopite connection to gas control
valve/thermostat.
Inspect flame coverage on thermopile.
Check inlet gas pressure.
Run open circuit thermopite output test and
replace pilot assembly if output is below 350 mV.
Restart gas control valve.
If main burner turns on after restart, replace
tank sensor.
If main burner does not turn on after restart,
replace gas valve assembly.
Replace gas control valve/thermostat.
Verify tank sensor is connected to electronic
control module.
Verify tank sensor is connected to the heater
tank.
Run tank sensor calibration check.
Replace tank sensor and electronic control
module.
Verify tank sensor is connected to electronic
control module.
Verify tank sensor is connected to the heater
tank.
Run tank sensor calibration check.
Replace tank sensor and electronic control
module.
Replace electronic control module.
Electronic control module failure
7flashes *
(pilot on or off and burner off).
Gas control valve failure (pilot off Replace gas control valve/thermostat.
8flashes *
and burner off).
6 second solid light Pilot stays tit only when control knob Overheat failure. Replace gas control valve/
followed by 4flashes * is depressed in PILOT position, thermostat.
6 second solid light Pilot stays tit onlywhen control knob Electronic control module failure. Replace
followed by 7flashes * is depressed in PILOT position, module.
6 second solid light Pilot stays tit only when control knob Gas control valve failure. Replace gas control
followed by 8flashes * is depressed in PILOT position, valve/thermostat.
Overheat failure and electronic control module
6combinationsSeCondsolidoflight4+with7 Pilot stays tit only when control knob failure. Replace gas control valve/thermostat.
flashes * is depressed in PILOT position.
6 second solid light with Pilot stays tit only when control knob Overheat failure and gas control valve failure.
combinations of 4+ 8 Replace gas control valve/thermostat.
flashes * is depressed in PILOT position.
6 second solid lightwith Pilot stays tit onlywhen control knob Electronic control module failure and gas
combinations of 7 + 8 is depressed in PILOT position, control valve failure. Replace gas control valve/
flashes * thermostat.
Overheat failure, electronic control module
6combinationsSeCondsolid light with Pilot stays tit only when control knob failure, and gas control valve failure. Replace
of 4 + 7+ 8 flashes * is depressed in PILOT position, gas control valve/thermostat.
Wait until light goes outto restart the gas control
Continuous solid light System shutdown/safety interlock, valve/thermostat.
• Flashes are approximately 1/10 second in duration with approximately three seconds between groups of flashes.
36
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION
BURNER WILL NOT IGNITE 1. Pilot not tit
2. Thermostat set too low
3. No gas
4. Dirt in the gas lines
5. Pilot line clogged
6. Main burner line clogged
7. Non-functioning thermopile
8. Non-functioning thermostat
9. Heater installed in a confined area
1. Light pilot
2. Turn temp. dial to desired temperature
3. Check with gas utility company
4. Notify utility-install trap in gas line
5. Clean, locate source and correct
6. Clean, locate source and correct
7. Replace thermopile
8. Replace thermostat
9. Provide fresh air ventilation
SMELLY WATER 1. Sulfides in the water 1.
BURNER FLAME YELLOW-
LAZY
PILOT WILL NOT LIGHT OR
REMAIN LIT
1. Insufficient secondary air
2. Low gas pressure
3. Water heater flue or vent
blocked
4. Main burner line clogged
5. Heater installed in a confined area
6. Obstruction in main burner orifice
HIGH OPERATION COSTS
1,
2.
3.
1,
2.
system
3.
4.
5,
6.
Replace the anode with a special anode
Provide ventilation to water heater
Check with gas utility company
INSUFFICIENT HOT WATER
Clean, locate source and correct
Clean, locate source and correct
Proper fresh air ventilation
Clean or replace orifice
Non-functioning igniter 1.
The thermal switch tripped 2.
Wire lead connection at thermal switch 3.
loose thermal
and not
Replace igniter pilot assembly
See Pilot LightTroubleshooting Flowchart section
Remove and reconnect the wire leads at
switch, confirm connections are tight
loose
4. Thermopite connection loose
5. Air in gas line
6. Low gas pressure
7. No gas
8. Dirt in gas lines
9. Cold drafts
10. Thermostat ECO switch open
11. Pilot line or orifice clogged
12. Non-functioning thermopite
13. Air for combustion obstructed
14. Flammable vapors incident, FVIR
4. Correct the connection(s)
5. Bleed the air from the gas line
6. Check with gas utility company
7. Check with gas utility company
8. Notify utility-install dirt trap in gas line
9. Locate source and correct
10. Replace thermostat
11. Clean, locate source and correct
12. Replace thermopite
13. See maintenance section for inspection and
cleaning of flame arrester
14. Replace water heater, eliminate flammable
SLOW HOT WATER
RECOVERY
DRIP FROM RELIEF VALVE
15.
function actuated
Base-ring filter obstructed
1. Thermostat set too high
2. Sediment or time in tank
3. Water heater too small for job
4. Wrong piping connections
5. Leaking faucets
6. Gas leaks
7. Wasted hot water
8. Long runs of exposed piping
9. Hot water piping in exposed wall
1. Thermostat set too tow
2. Sediment or time in tank
3. Water heater too small
4. Wrong piping connections
5. Leaking faucets
6. Wasted hot water
7. Long runs of exposed piping
8. Hot water piping in outside wall
9. Low gas pressure
1. Insufficient secondary air
2. Water heater flue or vent
blocked
3. Low gas pressure
4. Improper calibration
5. Thermostat set too tow
6. Water heater too small
7. Wrong piping connections
8. Wasted hot water
1. Excessive water pressure
2. Heater stacking
3. Closed water system
15.
vapors source. Contact Sears Service.
Inspect and clean base-ring filter. See "External
Cleaning & Inspection of the Base-Ring Filter."
1. Set temperature dial to lower setting
2. Drain/flush-provide water treatment if needed
3. Install adequate heater
4. Correct piping-dip tube must be in cold inlet
5. Repair faucets
6. Check with utility-repair at once
7. Advise customer
8. Insulate piping
9. Insulate piping
1. Turn temperature dial to desired setting
2. Drain/flush-provide water treatment if needed
3. Install adequate heater
4. Correct piping-dip tube must be in cold inlet
5 Repair faucets
6. Advise customer
7. Insulate piping
8. Insulate piping
9. Check with gas utility company
1,
system 2.
3.
4.
5.
6.
7.
8.
1.
2.
3.
Provide ventilation to water heater. Check flue
way, flue baffle, and burner
Clean flue, locate source and correct
Check with gas utility company
Replace thermostat
Turn temperature dial to desired setting
Install adequate heater
Correct piping-dip tube must be in cold inlet
Advise customer
Use a pressure reducing valve and relief
valve
Lower the thermostat setting
See "Closed System/Thermal Expansion"
37
