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Start Up Conditions
Condensate
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 condensate. This usually happens
when:
a. A new water heater is filled with cold water for
the first time.
b. Burning gas produces water vapor in water
heaters, particularly high efficiency models
where flue temperatures are lower.
c. 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.
Because of the suddenness and amount of water,
condensate water maybe diagnosed as a "tank
leak". After the water in the tank warms up (about 1
hour), 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.
Excessive condensate maybe 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 (see also
"Condensate" in "Venting" section).
Thermal Expansion
As water is heated, it expands (thermal expansion).
In a closed system, the volume of water will grow.
As the volume of water grows, there will 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 54).
Thermal Expansion Tank Specifications are shown
in Table 5.
Diameter Length
2 8 12-3/4 314" Male
153.331021
(203 mm) (323 mm)
5 11 14-3/4 314" Male
153.331051
(279 mm) (375 mm)
Table 5
An Expansion Tank Sizing Chart is shown in Table
6.
" 30 40 so 66 82
E_i in.......
40ps 2 2 2 5 5
50psi 2 2 2 5 5
oupsl 2 2 5 5 5
70ps 2 2 5 5 5
80psi 2 5 5 5 5
*Highest recorded inlet water pressure in a 24 hour
or regulated water
Table 6
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.
54
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