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Kenmore ELITE 153.33262 User's Manual

1. 2 3 4 6 1 the COOLER button to the lowest setting AWARNING Explosion Hazard Replace view port if glass is missing or damaged Failure to do so can result in death explosion or fire FOR YOUR SAFETY READ BEFORE OPERATING BEFORE OPERATING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A This appliance does not have pilot It is equipped with an ignition device that will automatically light the burner Do not try to light the burner by hand BEFORE OPERATING 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 immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions ON OFF SWITCH GAS CONTROL STOP Read the safety information above on the label Turn on all electrical power to the appliance Set the ON OFF switch on the gas control to the ON position Set the Electronic Dis
2. 11 Installation Checklist x i de dent ue ie A ee 11 INSTALLATION INSTRUCTIONS 12 14 Removing the Old Water 12 Location Requirements 55 5 erre E EQ QNM RENTEN 13 sleep 13 Clearances andi ACCeSSIDIIIty c EYE RE EO Re 14 High Altitude Insta atom X 14 GAS SUPERI S A aR 15 Gas Req lrements xe oo m Seeds a Ni ema 15 GAS PIPING 15 Gas PIeSSUf e SAE HERR 15 Gas Pressute Testing ec eite octets dette eie eise e pide 15 COMBUSTION AIR SUPPLY amp VENTILATION 21 1 12 1 012 02 0 0 8 nennen nennen nnnm nen eee een nennen 17 20 Uncontitied Space rtt e e Temi p bee d ted E ERE e e tet ett tod bete PA n 17 Confined Spaces Em 17 AIAI tron 6 16 6 5 2 2 25 2525222 cie eere ee 17 e ejUje o a tI DP 18 1 12 2 1816 cim 18 Vent PIPE System ei Ge roo Hei NK cH ade lta
3. cre E dua Dev ao Y v e haa 26 Burner I II 27 EMe rgency Shut DOWD 27 Water Temperature Regulation ibt ER dad AE eer Td ERO 27 28 Powered Anode Rod Operation itr tr eer reiten ore oe EET Y Ene Pa a EBEN 28 SERVICE AND ADJUSTMENT 0 0020011111111 29 Draining and 111101 nnne nen nene nenne sn rrn esse sss 29 Routine Preventive 29 Temperature and Pressure Relief Valve 29 MAINTENANCE OF YOUR WATER HEATER 30 32 5 dent tte i NO dinde feta 30 Removing the Manifold Burner 30 Removing the Burner from the Manifold Burner Assembly 30 Replacing the Flame Sense Hot Surface Igniter 30 External Inspection amp Cleaning of the Air Intake Chamber 5 31 Cleaning the Combustion Chamber and Air Diverter 31 Replacing the Manifold Burner
4. Venting Gas Vent System With Type B Double Wail Vent Pipe FIGURE 21 Listed Vent Cap Maintain Manufacturer s Specified Minimum Clearance 4 Maintain Support Strap Specified Clearance Maintain Clearance e Vent Connector Unused Chimney Flue Or Masonry Enclosure Per Foot Minimum LII Venting Through Chimney With Type B Double Wall Vent Pipe FIGURE 22 Maintain vent pipe clearance requirements to local state and or the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition NFPA 211 Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances states that these chimneys are intended to be installed in accordance with the installation instructions provided with each chimney support assembly Minimum air space clearance to combustible materials should be maintained as marked on the chimney sections 21 WATER SYSTEM PIPING Piping Installation Piping fittings and valves should be installed according to the installation drawing Figure 23 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 should 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 pres
5. Relief Valve Drain Line T amp P Relief Valve Insulation FIGURE 26 ELECTRICAL Electrical Connections Before plugging in the water heater always make sure The Voltage and frequency correspond to that specified on the water heater The electrical outlet has the proper overload fuse or breaker protection Unit is to connect to a 120VAC electrical supply outlet extension cord is not allowed AWARNING Electric Shock Hazard Disconnect power before servicing Replace all parts and panels before operating Failure to do so can result in death or electrical shock Wiring Diagram FIGURE 27 Gas Control Air Intake Valve Thermostat Chamber Fan Pressure Switch Igniter Flame Sense Connector CAUTION LABEL IMPORTANT Do not use an extension cord to connect the water heater to an electrical outlet The water heater and the outlet are properly grounded Installed in accordance with prevailing provisions of local codes or in the absence of such National Electric Code ANSI NFPS 70 current edition Completely fill the tank with water and check all connections for leaks Open the nearest hot water faucet and let it run for three 3 minutes to purge the water lines of air and sediment and to ensure complete filling of the tank The electrical power may then be turned on Verify proper operation after servicing Solar Installation If this water heater is use
6. Replace the upper control if the error code does not clear cycle power to the water heater Off and On to reset Replace the lower control if the problem persists Turn the power off for 10 to 20 seconds then on again to clear the error code If the error code persists or cannot be cleared replace the lower control Gas supply is turned off pressure too low Ensure supply and manifold gas pressures are within requirements in the installation manual Manifold gas pressure is non adjustable if pressure is off by more than 0 3 W C 75 Pa replace the lower control Low supply voltage should be 115 125 VAC Ensure flame sensor is making good contact with the burner flame ensure flame is steady Ensure the flame sensor is clean use ultra fine steel wool or Scotch Brite pad to clean the flame sensor Ensure the hot surface ignitor is positioned to provide consistent ignition Check for any cracks in the ignitor assembly ceramic insulators replace ignitor assembly if damaged Check resistance of the ignitor at room temperature 77 F 25 C at the plug end Replace ignitor if the resistance is not within 1 72 to 2 4 ohms at room temperature Ensure flame sensor is making good contact with the burner flame ensure flame is steady Ensure the flame sensor is clean use ultra fine steel wool or Scotch Brite pad to clean the flame sens
7. Failure to follow these instructions can result in death explosion or carbon monoxide poisoning Table 1 Natural Gas Pipe Capacity Table Cu Ft Hr Capacity of gas pipe of different diameters and lengths in cu ft per hr with pressure drop of 0 3 in and specific gravity of 0 60 natural qas Nominal Iron Pipe Size in 10 20 Length of Pipe Feet 60 70 80 30 90 100 125 150 175 200 1 1 2 11600 11100 890 760 610 560 530 490 460 410 380 350 320 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 Min Cu Ft Per Hr Required Gas Input of Water Heater BTU HR Heating Value of Gas BTU FT The gas input of the water heater is marked on the water heater data plate The heating value of the gas BTU FT may be determined by consulting the local natural gas utility Table 2 LP Gas Capacity Table Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases at 11 inches water column pressure Based on a pressure drop of 0 5 inch water column Nominal Iron Pipe Length of Pipe Feet Size in t 34 40 114 237 217 448 409 913 834 Example Input BTU requirement of the water heater 100 000 BTUH Total pipe length 80 feet 3 4 IPS required Additional tables are availa
8. It is recommended that the tank be drained and flushed every 6 SS installed in opening provided months to remove sediment which may build up during operation E Y Can result in overheating The water heater should be drained if being shut down during and excessive tank pressure freezing temperatures To drain the tank perform the following Can cause serious injury steps death 1 Turn off the gas to the water heater at the manual gas shut off valve and turn off the electrical power to the gas control thermostat valve 2 Open nearby hot water faucet until the water is not longer hot 3 Close the cold water inlet valve Manually operate the temperature and pressure relief valve at least once a year to make sure it is working properly To prevent water damage the valve must be properly connected to a discharge line which terminates at an adequate drain Standing clear of the outlet discharged water may be hot slowly lift 4 Connect a hose to the drain valve and terminate it to an and release the lever handle on the temperature and pressure adequate drain or external to the building relief valve to allow the valve to operate freely and return to its 5 Open the water heater drain valve and allow all the water to closed position See Figure 34 If the valve fails to completely drain from the tank Flush the tank with water as needed to reset and continues to release water immediately shut off the remove sed
9. WATER HEATER COLD WATER INLET FITTING FLOOR CEILING JOIST ETC 3 PRESSURE REDUCING VALVE WITH BY PASS INLET COLD WATER SHUT OFF 1 EXPANSION TANK 2 PRESSURE GAUGE 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 depressurization 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 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 A water heater may appear to be leaking when in fact the water is condensation This usually happens when Anew water heater is filled with cold water for the first time Burning gas produces water vapor In water heaters
10. Use a pressure reducing valve and relief valve Lower the thermostat setting See CLOSED SYSTEM THERMAL EXPAN SION section ELECTRONIC CONTROL DISPLAY TROUBLESHOOTING POWER IGN HEATING CLEAN VAC LOCK CHECK SCREEN FV SENSE ECO LDO SW P ANODE P SW OPEN A SHORT ELECTRONIC CONTROL DISPLAY Please check guidelines below For your safety water heater service should be performed only by a qualified service person Read the GENERAL SAFETY INFORMATION supplied by the water heater manufacturer a CONTROL DISPLAY STATUS PROBLEM POWER Flashing HEATING and SHORT Flashing HEATING and OPEN Flashing HEATING OPEN and SHORT Flashing ECO and OPEN Flashing Communication Error The system has detected a communication error between the upper and lower controls The self diagnostic tests have found a problem with an internal circuit Ignition flame failure The water heater has reached the maximum number of retries and is currently locked out for one hour Cycle the power to the water heater off and on to reset Weak flame sensor current Water temperature in the tank has exceeded 185 F 85 C and has activated the ECO 38 SOLUTION Check the 5 conductor data cable that runs between the upper and lower controls Check that the wiring is not broken and the connectors on both ends are properly seated in the mating connectors
11. Water Heater Installation Kit em RE GEP you wil need to connect gt c LE 0200 0 Te i KC D 5 M JA 0 METAL DRAIN PANS AVAILABLE IN 20 508 mm DIAMETER FOR WATER HEATERS HAVING A DIAMETER 18 457 mm OR EXPANSION TANKS FOR THERMAL EXPANSION CONDITIONS AVAILABLE Hi IN 2 GALLONS LESS 24 610mm DIAMETER 7 6 LITERS AND FOR WATER HEATERS HAVING A esac DES PIERS DIAMETER 22 559 mm OR LESS AND AVAILABLE IN 28 711 mm LOCAL SEARS STORE WATER HEATER INSTALLATION KIT DIAMETER FOR OR SERVICE CENTER WITH FLEXIBLE CONNECTORS FOR 3 4 HAVING A DIAMETER 26 660 mm 19 05 mm COPPER PLUMBING AND FLEXIBLE OR LESS GAS CONNECTOR WITH FITTINGS BASIC TOOLS ADDITIONAL TOOLS NEEDED You may or may not need all these tools depending on your WHEN SWEAT SOLDERING type of installation These tools can be purchased at your local Tubing Cutters or Hacksaw Sears Store Propane Torch Soft Solder Pipe Wrenches 2 14 356 mm Solder Flux Screwdriver Emery Cloth Tin Snips 6 1 82 m Tape or Folding Ruler Garden Hose Drill Pipe Dope or Teflon Tape Wire Brushes 2 PROPANE CHi TUBING CUTTER TORCH SLOT HEAD SCREWDRIVER SS TIN SNIPS PHILLIPS SCR
12. before checking the water heater make sure the gas supply has been turned OFF and never turn the gas 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 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 35 Pressurized Combustion Chamber System Operational Checklist Manifold gasket properly sealed 5 No leaks at manifold connection Viewport not damaged or cracked 6 Manifold door screws securely tightened Combustion chamber free of debris and undamaged Manifold component block properly installed TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION Transformer unplugged Plug transformer back into 120 VAC outlet No power at outlet Repair service to outlet NO HOT WATER Thermostat defective Replace Thermostat Air Intake Chamber Fan defective Replace Air Intake Chamber Fan Assembly Pressure Switch defective Replace Pressure Switch Assembly Gas Valve Thermostat Switch in OFF Move Gas Valve Thermostat Switch to ON POSI POSITION TION Thermostat set too low Set temperature control higher Thermostat defectiv
13. level Reducer Flue D must be installed on 5 et 40 gallon unit f 4 Draft Hood Reduc r Flue R Legs instali The Draft Hood With The Four Screws Provided instali The Draft Hood With The Four Screws Provided FIGURE 19 40 Gal Water Heater Align the reducer flue over top of baffle shown in Figure 19 NOTE reducer flue must be installed on 40 gal water heater above elevation 5 400 Ft 1 646 m from sea level 40 amp 50 Gal Water Heaters 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 19 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 wall 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 wall vent pipe material may pass through walls or partitions constructed of combustible material if the minimum listed clearance is maintained Ma
14. 31 Removing and Replacing the Gas Control Valve Thermostat sse memes 32 TROUBLESHOOTING 2 2 02200 0 02 0 0 0 0000000 eE EE 33 35 Start Up 6161516 10 Cere o intime esee ede Go eR ERR a 33 Operational Conditions et urere tenete ec eee ee e Fio ue aE 34 ELE 34 Leakage CheCckpolnts 2 etes eite d reed e Pee e 35 Pressurized Combustion Chamber System Operational 36 TROUBLESHOOTING 36 37 ELECTRONIC CONTROL DISPLAY 38 40 TROUBLESHOOTING 41 PART S ORDER ISM 2 itum 42 PRODUCT WARRANTY 12 YEAR LIMITED WARRANTY WATER HEATER For twelve years from the 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 plumbing codes Sears will 1 Supply free water heater parts for those that are defective in material or workmanship 2 Supply a free water heater for one that develops a leak For the second through twelfth year from the purchase date you must pay the labor cost for installation of parts or water heater For
15. A or Canada call 1 800 4 MY HOME CUSTOMER RESPONSIBILITIES Thank You for purchasing a Kenmore water heater Properly installed and maintained it should give you years of trouble free service If you should decide that you want the new water heater professionally installed by Sears call 1 800 4 MY HOME They will arrange for prompt quality installation by Sears authorized contractors Abbreviations Found In This Instruction Manual CSA Canadian Standards Association ANSI American National Standards Institute NFPA 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 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 It 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
16. adequate drain or to the exterior of the building Open the drain valve and allow at least 5 gallons of water from the tank to drain Close drain and remove hose 6 Unplug the electrical connection on top of the powered anode by pulling the wire connector up and off of the powered anode rod electrical connector Figure 33 T Remove the powered anode rod by using a ratchet and a 1 146 socket turning counterclockwise Figure 33 Note Figure 33 is shown exploded If the socket used is short well you may have to remove the top male connector first before removing the powered anode rod 8 Use Teflon tape or an approved pipe sealant on threads of the new powered anode rod 9 Prior to installing it will be necessary to use pliers to bend up approximately 90 the electrical male connector on the top of the powered anode rod The electrical connector should be bent upward in order to allow the 1 1 16 deep well Socket to pass over the connector Note if using a short well socket the male connector must first be removed Figure 33 is shown exploded for clarity 10 Place the powered anode rod in the spud top of the tank and turn clockwise until the threads are hand tight Using a ratchet and 1 1 16 socket tighten down water tight Torque should be between 65 to 120 foot pounds 11 Open a nearby hot water faucet to purge air from the water line Fill water heater tank completely Note To assure the water heater tank is full ke
17. heater and its manual shut off valve must be disconnected from the gas supply piping system and the line capped fthe gas lines are to be tested at a pressure less than 14 W C the water heater must be isolated from 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 burner from lighting on initial start up The gas lines should be purged of air by a qualified technician after installation of the gas piping system While purging the gas piping system of air insure that the fuel is not spilled in the area of the water heater installation or any source of ignition NOTE spilled fuel may trip the FV Sensor preventing heater from starting 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 Gas Pipe Capacity Table WARNING 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 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 supply For more information contact your gas supplier Do not connect an L P gas water heater to a natural gas If a gas leak is detected follow the What to do if you supply smell gas instructions on the cover of this manual
18. location of this valve and how to shut off the water to the heater A temperature and pressure relief valve must be installed in the opening marked Temperature and Pressure T amp P Relief Valve on the water heater A discharge line must be added to the opening of the T amp 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 a closed system use a thermal expansion tank Cold Water 1 Pressure Reducing inlet Valve Valve with Bypass Hot Water Outlet r Dr Cold Water Supply to Fixture Water Supply Temperature and Pressure T amp P 7 Relief Valve Optional Relief Valve Not Shown Massachusetts 7 Install a vacuum relief in cold water line per section 19 MGL 142 Discharge line Do Not Cap or Plug 1 Min Drain line 3 4 ID Min 20 6 Min Depth Max Typical water piping installation FIGURE 23 Mixed Water To Fixtures Unmixed Hot Water 4 Em Cold Water Inlet Ho
19. near water heater Gas and carbon monoxide detectors are available water heater Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual CAUTION Improper installation and use may result in property damage Do not operate water heater if flood damaged Install in location with drainage Fill tank with water before operation Be alert for thermal expansion Refer to instruction manual for installation and service TABLE OF CONTENTS SAFE INSTALLATION USE AND SERVICE 2 Important DENNIT ONS RN LHP 2 SAFELY PRECAUTIONS ott 2 3 Table Of Contents f ee e e ds e eiat e te et 4 5 PRODUCT WARRANT Y 6 CUSTOMER RESPONSI BIEN ES wes at 7 PRODUGT SBPEGCIEIGATIONS eot eee ter tete te ertt e Endet Dette ei tei eit bd e dyes 8 MATERIALS AND BASIC TOOLS NEEDED tie De tree dee deis 9 TYPICALINSTAEBATION s esce pee Eee tt re hene it eee ice ces eto CE eme eet dee eta 10 Get to know your Water aee pe EG t E ER E CAFE E EUREN A UH ME gla dae dual 10 IMPORTANT INFORMATION ABOUT THIS WATER
20. of the total input rating of all gas utilization equipment in the confined area but not less than 100 square inches Figure 14 Confined Space 8 Permanent EE _ Openings qi 1 Square inch 1000 BTUH min 100 Sq in FIGURE 14 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 18 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 4 to calculate the minimum free area for each opening Figures 15 16 17 and 18 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 1 4 mesh If the free a
21. 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 talking owner s manual Power surge protection against electrical damage due to power fluctuations Leaks in pipes or fittings 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
22. 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 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 13 If flammable liquids or vapors have spilled or leaked in the area of the water heater leave the area immediately and call the fire department from a neighbor s home Do not attempt to clean the spill until all ignition sources have been extinguished WARNING Read instruction manual 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 a vertical position on a level surface DO NOT install in bathrooms bedrooms or any occupied room normally kept closed
23. terminals of the pressure switch Turn on power to the water heater and when the air intake fan comes on check for continuity across the pressure switch contacts If switch contacts remain open no continuity while the fan is in operation replace the pressure switch Turn off power to the water heater 25 P SW and SHORT Flashing The air pressure switch contacts T Locate the pressure switch wiring remain closed for more than 5 ensure pressure switch wiring is correct seconds when they should be open and not jumped Remove wires to both terminals on pressure switch Check pressure switch contacts with an ohmmeter for continuity A If pressure switch contacts show continuity closed circuit replace the pressure switch If pressure switch contacts show open circuit and all wiring is correct replace the lower control Check all wiring to the hot surface ignitor IGN Flashing Cpenoniter Check the 3 pin Molex ignitor assembly plug and receptacle on the lower control for a good connection Repair or replace parts if necessary Check resistance of the ignitor with an ohmmeter on the ignitor assembly plug Replace ignitor if resistance is not within 1 72 and 2 40 ohms If above checks are good turn off power for 10 seconds and then back on If this error code will not clear and the ignitor resistance is within specifications replace the lower control FV SENSE Flashing Flamm
24. the heater adjacent to the gas control valve thermostat of the water heater The water heater is certified for installation on a combustible floor e 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 five inches 127mm in any direction or if in an alcove or closet installa tion the entire floor must be covered by the panel Figure 11 may be used as a reference guide to locate the specific clearance locations A minimum of 5 inches of front clearance should be provided for inspection and service 6 min at Single Wall Vent Pipe 12 min Top to Ceiling 0 min Air Inlet Chamber A95 min Front Top View Minimum Clearance Locations FIGURE 11 High Altitude Installation This water heater should not be installed for operation at elevations above 10 100 ft 3 078 m GAS SUPPLY WARNING 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 p
25. 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 AWARNING 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 Flammable Vapors vicinity of this or any other appliance can result in serious injury or death Read and follow water heater warnings and instructions Sears Brands Management Corporation AWARNING 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 AWARNING Fire Hazard For continued protection against risk of fire Do not install water heater on carpeted floor Do not operate water heater i
26. 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 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 Thats 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
27. 5 Disconnect the the flame sense hot surface igniter wire power supply transformer pressure switch fan and display connector wires from the thermostat Figure 35 Disconnect the manifould tube at the thermostat Figure 35 6 Refer to Gas Piping section Figure 12 and disconnect the ground joint union in the gas piping Disconnect the remaining pipe from the gas control valve thermostat T To remove the gas control valve thermostat thread a correctly Sized pipe into the inlet and use it to turn the gas control valve thermostat counterclockwise Do not use pipe wrench or equivalent to grip body Damage may result causing leaks Do not insert any sharp objects into the inlet or outlet connections Damage to the gas control valve thermostat may result Replacing the Gas Valve 1 Toreplace the gas control valve thermostat reassemble in reverse order When replacing the gas control valve thermostat thread a correctly sized pipe into the inlet and use it to turn the gas valve clockwise DO NOT OVER TIGHTEN or damage may result NOTE Use an approved TEFLON tape or pipe compound only on the threaded section of the gas control valve thermostat that screws into the tank 2 Reconnect the gas piping to the gas control valve thermostat NOTE Use an approved Teflon tape or pipe compound on the gas piping connections 3 Reconnect the manifold tube flame sense hot surface igniter wire power supply transformer pressure s
28. CTIONS SEE PAGE 27 PRESSURE N SWITCH FAN FV SENSOR VACUUM RELIEF POWER SUPPLY IGNITERI HN CONNECTOR 22 VALVE TRANSFORMER FLAME INSTALL PER CONNECTOR 22 ISPLAY ANODE LOCAL CODES U NATURAL GAS BURNER ASSEMBLY MANIFOLD DOOR GASKET MANIFOLD COMPONENT MANIFOLD DOOR ASSEMBLY BLOCK W RETAINER CLIP BURNER 3 IGNITER FLAME SENSE CONNECTOR WIRE DISCHARGE PIPE DO NOT CAP OR PLUG IGNITER FLAME SENSE CONNECTOR WIRE 6 MAXIMUM AIR GAP BURNER FLOOR DRAIN dn VIEW PORT IMPORTANT DO NOT USE AN EXTENSION CORD TO CONNECT THE WATER HEATER TO AN ELECTRICAL OUTLET FIGURE 1 10 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 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 1 800 469 4663 Installation Checklist Water Heater Location Water heater location is important and can affect system performance Please check the following Installation area free of corrosive elements and flammable materials Centrally located w
29. 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 WARNING 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 PRODUCT SPECIFICATIONS MODEL TANK CAPACITY TYPE INPUT RECOVERY MINIMUM DIAMETER HEIGHT TO NUMBER IN GALS LTRS OF RATE RATE GALS VENT PIPE INCHES JACKET GAS Btu hr PER HOUR DIA INCHES mm INCHES mm 90 F RISE mm 153 332620 40 151 40000 426 6 4 102 20 508 58 1473 153 332640 50 189 40000 2426 6 4 102 22 559 57 13 1451 MATERIALS AND BASIC TOOLS NEEDED 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 Gas
30. EWDRIVER DES HACKSAW EMERY CLOTH PIPE DOPE ROLL OF TEFLON SQUEEZE TUBE TAPE USE ONLY ON USE FOR WATER AND GAS WATER CONNECTIONS CONNECTIONS 7777773 3 4 19 mm WIRE BRUSH Ss oo es ROLL OF LEAD FREE SOLDER GARDEN HOSE 6 FOOT TAPE PIPE WRENCH 1 2 13 mm WIRE BRUSH SOFT SOLDER FLUX TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER GAS MODELS A Vent Pipe K Outer door U Main Burner B Draft hood L Union V Flue C Anode Not Shown M Inlet Water Shut off Valve W Suitable Metal Drain Pan D Hot Water Outlet N Cold Water Inlet X Control Display E Insulation O Inlet Dip Tube Y Power Supply Transformer F GasSupply Piping P Temperature amp Pressure Relief Valve Shown detached from Heater G Manual Gas Shut off Valve Q Rating Plate YY Pressure Switch H Ground Joint Union R Flue Baffle Shown detached from Heater Drip Leg Sediment Trap S Gas Control Valve Thermostat Z Air Intake Chamber J Inner Door T Drain Valve ZZ FV Sensor Shown without Bracket INSTALL IN ACCORDANCE WITH LOCAL CODES DRIP LEG AS REQUIRED BY LOCAL CODES ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS S GAS CONTROL VALVE THERMOSTAT TO VENT TERMINATION ON ROOF INSTALL THERMAL EXPANSION TANK IF WATER HEATER 15 INSTALLED IN A CLOSED IMPORTANT WATER SYSTEM WHEN BRUSHING ONAN APPROVED NONCORROSIVE LEAK DETECTION SOLUTION DO NOT SPLASH SOLUTION ONTO ELECTRICAL CON NE
31. Locate the water heater as close to the chimney or gas vent as practical Consider the vent system piping and combus tion 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 water heater 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 af fect the proper operation of the water heater Special atten tion 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 10 The water heater is to be located as close as possible to a 120VAC outlet NOTE all electrical wiring should be in accordance to the NEC and all local state electrical codes extension cord is not allowed NOTE This water h
32. OMBUSTION FAN self diagnostic faults can be found on GAS VALVE OFF OFF AFTER POST PURGE DELAY pages 38 through 40 18 REQUEST FOR HEAT SATISFIED NO 41 PARTS ORDER LIST KENMORE ELITE HIGH EFFICIENCY Pressurized Combustion Chamber NATURAL GAS WATER HEATERS MODEL NUMBERS 153 332620 40 Gallon Tall Natural 153 332640 50 Gallon Tall Natural 1 e coeweermerue 7 e Conor bispe s e anifold Door Assembly Includes Manifold Door Burner Burner Orifice Hot Surface Igniter Manifold Door Gasket and anifold Component Block 2 Now that you have purchased your gas water heater WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE should a need ever exist for repair parts or service FOLLOWING INFORMATION simply contact any Sears Service Center or call MODEL NUMBER TYPE GAS NATURAL 1 800 4 MY HOME 1 800 469 4663 Be sure to SERIAL NUMBER PART DESCRIPTION provide all pertinent facts when you call or visit THIS IS A REPAIR PARTS LIST NOT A PACKING LIST NOTES 43 For troubleshooting product manuals and expert advice managemylife www managemylife com For repair in your home of all major brand appliances lawn and garden equipment or heating and cooling syste
33. Use amp Care Guide Model No 153 332620 40 Gallon Tall 153 332640 50 Gallon Tall LLC Kenmore Elite For potable water heating only Not suitable for space heating Not for use in mobile homes INSTALLER Affix these instructions to or near the water heater OWNER Retain these instructions for future reference FOR YOUR SAFETY An odorant is added to the gas used by this water heater ADVERTENCIA Si no puede leer o entender el ingl s 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 podr a originar lesiones graves o mortales P N 317997 000 0810 Sears Brands Management Corporation Hoffman Estates IL 60179 U S A www kenmore com www sears com WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT DO IF YOU SMELL GAS e Donottry to light any appliance e Do not touch any electrical switch do not use any phonein your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire d
34. WITCH TO OPEN PROVEN OPEN WITHIN DISPLAY ERROR 5 SECONDS NUMBER 7 YES COMBUSTION FAN ON is WAIT FOR PRESSURE PRESSURE SWITCH SWITCH TO OPEN PROVEN OPEN WITHIN DISPLAY ERROR 5 SECONDS NUMBER 7 Is PRESSURE SWITCH PROVEN CLOSED WITHIN 11 SECONDS NO WAIT FOR PRESSURE YES SWITCH TO CLOSE DISPLAY ERROR NUMBER 6 ONE HOUR AUTOMATIC RESTART YES TIME DELAY PREPURGE COMBUSTION FAN OFF NO TURN OFF COMBUSTION FAN 2 DISPLAY ERROR CODE 48 NUMBER 8 18 IGNITOR OKAY YES IGNITOR ON FOR WARM UP TIME TURN OFF COMBUSTION FAN COMBUSTION AFTER POST PURGE FAN OFF DISPLAY ERROR 3 GAS VALVE OPENS YES 15 PRESSURE SWITCH PROVEN CLOSED WITHIN 5 SECONDS WAIT FOR PRESSURE SWITCH TO CLOSE DISPLAY ERROR NUMBER 6 COMBUSTION FAN ON MAIN BURNER LIGHTS AND IS SENSED DURING TRIAL FOR IGNITION LESS YES THAN 3 TRIES OR IGNITION 7 NO GAS VALVE CLOSES INTERPURGE YES No IGNITOR TURNS OFF 5 LOST LESS THAN 4 TIMES YES GAS VALVE CLOSES NO Is PRESSURE SWITCH PROVEN CLOSED WITHIN 5 SECONDS NO WAIT FOR PRESSURE SWITCH TO CLOSE DISPLAY ERROR NUMBER 6 Please Note YES The control continually monitors internal circuits and external sensors Error codes noted above and those for YES C
35. able Vapor Sensor has Do not touch any electrical switch do not use detected the presence of any phone in the building and do not try to flammable vapors and is in lockout light any appliance Smell around the water heater to ensure there are no gas leaks at the gas control valve or in the supply gas line or for any other type of flammable vapors in the area Carefully inspect the area surrounding the water heater for any substances such as gas oline paint paint thinners varnish or cleaners that could emit flammable vapors Remove anything that can potentially emit flammable vapors from the area and store it properly in a different location continued next page 39 FV SENSE Flashing Continued from previous page LDO SW OPEN and CLEAN SCREEN Flashing FV SENSE and OPEN Flashing FV SENSE and SHORT Flashing THMSTR and OPEN Flashing THMSTR and SHORT Flashing All Segments Flashing P ANODE and OPEN Flashing P ANODE Flashing The air pressure switch contacts remain open longer than 5 seconds after the combustion fan is energized Flammable Vapor Sensor is open Flammable Vapor Sensor is shorted The self diagnostic test has detected the temperature sensor thermistor inside the immersion probe is open The self diagnostic test has detected the temperature sensor thermistor inside the immersion probe is shorted The self diagnostic check has d
36. ainage TONES FIGURE 9 Pipetoan adequate drain 1 3 4 max At least 2 greater than the water heater 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 metal 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 metal 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 metal drain pan that trigger an alarm or turn off the incoming water to the water heater when water is detected Sensors mounted in the metal drain pan that turn off the water supply to the entire home when water is detected in the metal 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 will turn off the gas supply to a gas water heater while at the same time shutting off its water supply EXHAUST FAN REVERSE FLOW OF GASES FIGURE 10 Clearances and Accessibility NOTE Minimum clearances from combustible materials are stated on the label on the front of
37. aterials as meeting the requirements for Relief Valves for Hot Water Supply Systems ANSI 221 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 amp 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 floor drain or external to the building In cold climates it is recommend ed that the discharge pipe be terminated at an adequate drain inside the building Must be capable of withstanding 250 F 121 C with
38. ay be present Keep all ignition sources away from faucet when turning on hot water 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 Do not remove the anode leaving the tank unprotected By doing so all warranty on the water heater tank is voided Safety Shut off and Thermal Switch This water heater is designed to automatically shut off in the event of the following 1 The burner flame is extinguished for any reason 2 The water temperature exceeds 195 F 91 C 3 Excessive build up of dust on the louvers of the air intake chamber See Maintenance of your Water Heater Section This unit is also equipped with a flammable vapor sensor FV Sensor designed to shut off the gas supply in the event the water heater has been exposed to flammable vapors e g spilled gasoline NOTE If th
39. b or shower NOTE A water 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 electronic control display temperature should be set at approximately 120 F 49 C and this is the preferred starting point see Table 5 Some states have a requirement for a lower setting If you need hotter water follow directions for temperature adjustment but beware of the warnings in this section Water Temperature 110 116 Time for Permanent Burns 2nd amp 3rd Degree Less Severe Burns Most Severe Burns normal shower temp Time for 1st Degree Burn E gentes TABLE 5 131 140 149 AR Pressing the COOLER button decreases temperature and pressing the HOTTER button increases the temperature To avoid any unintentional changes in water temperature settings the control has a tamper resistant feature for changing the temperature setting To change the temperature setting follow these instructions 1 Unlock the temperature indicators by holding down both COOLER and HOTTER temperature adjustment buttons at the same time for one second See Figure 32 The dis play will light up The display will only remain on for 30
40. ble in the latest edition of the National Fuel Gas Code ANSI 2223 1 16 COMBUSTION AIR amp VENTILATION A WARNING Carbon Monoxide Warning Water heater must be vented to outdoors Vent must be installed by a qualified technician using the installation instructions Examples of a qualified technican include gas technicians authorized gas company personel and authorized service persons Failure to so do can result in death 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 will 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 be free of acid forming chemicals such as sulfur fluorine and chlorine These elements are found in aerosol sprays detergents bleaches cleaning solvents air fresheners paint and varnish removers refrigerants and many other commercial and household products When burned vapors from these products form highly corrosive acid compounds These products should not be stored or u
41. bly A WARNING Explosion Hazard 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 Tighten both manifold door screws securely Failure to follow these instructions can result in death explosion or fire Check the door gasket for damage or imbedded debris prior to installation Inspect the view port for damage and replace as required Insert the manifold burner assembly into the burner compartment making sure that the tip of the manifold tube engages in the slot of the bracket inside the combustion chamber Figure 40 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 thermosta
42. burner to see if itis dirty or clogged The burner be cleaned with soap and hot water Gas Control Valve Thermostat Manifold Tube 88 m Pressure A Switch Fan FV Sensor Connector Power Supply ES 2 Transformer E Connector Igniter Flame Sense 2 lH Control Display Anode Rod Connector FIGURE 35 Removing the Burner from the Manifold Burner Assembly Natural Gas Burner 1 Take off the burner by removing the two 2 screws located underneath the burner 2 Check the burner to see if it is dirty or clogged The burner may be cleaned with soap and hot water Figure 36 Scoop side to be on the same side Igniter Flame Sense Connector Bottom View FIGURE 36 Replacing the Flame Sense Hot Surface igniter Assembly 1 Remove the manifold burner assembly See Removing the Manifold Burner Assembly 2 Liftthe retainer clip straight up from the back of the manifold component block using a flat blade screwdriver then remove the manifold component block from the manifold door Figure 37 3 Remove and keep the screw securing the flame sense hot surface igniter assembly Figure 37 4 Remove and discard the old flame sense hot surface igniter assembly 5 Route the new flame sense hot surface igniter connector wire through manifold burner door opening as shown in figure 37 Secure assembly to bracket using screw removed earlier ua
43. cn SE ee ee ed 19 Draft Hood Installation 2 tah Ee mere d e estes 19 20 2 TS 20 RET RE 20 Chimney COnMECUOM ELS 20 Vertical Exhaust Gas Vent S tentat dee RED qun ue Bana 20 WATER SYSTEM PIPING 5 tiere re eee cce b deeds 21 22 Piping Installation tbe diee dud 21 Closed System Thermal Expansion 5 ER e e ove e d a ER M ve Se RR eden 22 Temperature and Pressure Relief Valve ai uiii eed He P REP He eire eite reete 22 T amp P Relief Valve and Pipe Insul amp tion eee rer Pace Fo BEC des ose de MD nodes de 23 pM c 24 Electrical Connections et io et HU heh Dat ete eae erred 24 solariinstallationi c 4 514500 E 24 ud eite c uri tO ed e E y vest cu e deme eer eo M dude ES 24 OPERATING YOUR WATER HEATER ccccccecccccccececeeceeeeeeeeeceeeeeceeeeeeeceeeeeceseeeeeeeseeeeeeeeeeeseeeeeeeeeeeeeees 25 30 LIGHTING Instructions ie imde dre rer ue dee RE Rev qur M Ee A E A rer 25 Water Heater Operations nice eco ea 26 CHECKING Ihe ier
44. commercial institutional industrial or residential use by two or more families the above limited warranty is only for two years During the second year you must pay the labor cost for parts or water heater installation If governmental regulations prohibit Sears from furnishing a comparable model replacement water heater under this warranty Sears will furnish a new water heater of comparable output as permitted by such governmental regulations however the Owner will be charged for the additional cost associated with the changes made to comply with such governmental regulations Replacements furnished under this warranty do not carry a new warranty and are only covered by the unexpired portion of the original warranty 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 This warranty gives you specific legal rights and you may also have other rights which vary from state to state SEARS BRANDS MANAGEMENT CORPORATION Hoffman Estates IL 60179 WN ON NEN ANON ON ON NN ON ON OEE EEE 9 ACA ANA CA NT CA I CA NC The price of
45. 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 Location Requirements A WARNING Do not install in a mobile home Doing so can result in carbon monoxide poisoning and death The FVIR System is designed to reduce the risk of flammable vapor related fires Flammable liquids such as gasoline solvents propane etc emit flammable vapors which can be ignited by a gas water heater s hot surface igniter or main burner The resulting flashback and fire can cause death or serious burns to anyone in the area FIGURE 8 59 gt FV Sensor This heater is equipped with FV sensor for detecting the presence of flammable vapors When the sensor detects those vapors the unit will shut down and not operate Should this happen please refer to the troubleshooting guide on pages 38 40 numbers 9 11 12 Even though this water heater is a flammable vapors ignition resistant water heater and is designed to reduce the chances of flammable vapors being ignited gasoline and other flammable substances should never be stored or used in the same vicinity or area containing a gas water heater or other open flame or spark producing appliance WARNING FIRE AND EXPLOSION HAZARD A Can result in serious injury or death Do not
46. cted 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 21 and 22 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 22 Common combined venting is allowable with vertical tyoe B vent systems and lined masonry chimneys as long 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 20 22 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 2 FT Minimum Above 1 Any Object Within 10 FT Horizontally Minimum Support Strap Maintain 12224 B Double Clearance NU Wall Vent Pipe a y Maintain d ent Specified 2 Slope Up 1 4 Inch Per Foot Minimum
47. d 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 lack the necessary skills required to properly install this venting system you should not proceed but get help from a qualified technician Draft Hood Installation 50 GAL UNIT 40 GAL UNIT Flat Side Of Hood 5 Next To Water Connections Installation above _ elevation 5 400 ft m from sea Flat Side OF Hood S Next To Wat Connections
48. d as a solar storage heater or as a backup for the solar system the water supply temperatures to the water heater tank may be in excess of 120 F A mixing valve or other temperature limiting valve must be installed in the water supply line to limit the supply temperature to 120 F NOTE Solar water heating systems can often supply water with temperatures exceeding 180 F and may result in water heater malfunction CAUTION DO NOT USE AN EXTENSION CORD TO CONNECT THE TRANSFORMER TO AN ELECTRICAL OUTLET ALL WIRES PRIOR TO Power Supply DISCONNECTION WHEN SERVICING Transformer CONTROLS WIRING ERRORS CAN CAUSE S PER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING 24 OPERATING YOUR WATER HEATER Operating Instructions Read and understand these directions thoroughly before attempting to operate the water heater Make sure the view port is not missing or damaged See Figure 36 Make sure the tank is completely filled with water before operating the water heater The gas control valve thermostat has a On Off Switch and needs to be turned on before water heater is operational Check the label on the front of heater 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 label If you have any questions or doubts consult your gas supplier or gas utility company FIGURE 28
49. e Replace thermostat Heater undersized Reduce hot water use Low gas pressure Contact dealer Incoming water is unusually cold Allow more time for heater to reheat Leaking hot water pipes or fixtures Have plumber check and repair leaks INSUFFICIENT HOT WATER Low gas pressure Check with gas utility company Improper calibration Replace thermostat Thermostat set too low Turn temperature dial to desired setting SLOW HOT WATER Water heater too small Install adequate heater RECOVERY Wrong piping connections Correct piping dip tube must be in cold inlet Wasted hot water Advise customer WATER TOO HOT Thermostat set too high Settemperature control lower see WATER TEMPERATURE REGULATION section Turn off heater and gas clean burner head Check intake venting arrangements for obstruc tions Check intake venting arrangements for obsruc tions Clean locate source and correct Clean or replace orifice Check orifice and replace if necessary Replace thermostat Dirt in burner ports Combustion air path restricted BURNER FLAME YELLOW LAZY Not enough dilution air for proper com bustion Main burner line clogged Obstruction in main burner orifice Burner flame too high Flame burns at orifice thermostat not functioning properly Low gas pressure N gt N gt Check with gas utility company Orifice too large wrong orifice R
50. e FV Sense senses the presence of flammable vapors a special FV Sense reset sequence is required to be input into the Electronic Control Display in order to restore operation of the water heater A high temperature limit switch or ECO Energy Cut Off in the tank is used to shut off the unit if the water temperature exceeds 195 F 91 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 Service 1 800 4 MY HOME www sears com Service Before calling for repair service please read the Troubleshooting Guide 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 1 800 4 MY HOME 1 800 469 4663 Leakage Checkpoints B Condensation may be seen on pipes in humid weather or a pipe connections be leaking C The anode rod fitting may be leaking 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 fitt
51. e Retainer Clip Flame Sense Hot Surface Igniter Assembly Manifold Component Block FIGURE 37 6 7 Reposition the manifold component block in the mani fold door opening and secure it with the retainer clip See Replacing the Manifold Burner Assembly External Inspection amp Cleaning of the Air Intake Chamber Screen 1 At least twice annually inspect the air intake chamber screen Figure 38 for any dust or debris that may have accumulated on the louvers NOTE If the water heater is located in an area that is subjected to lint and dirt it may be necessary to check the air intake chamber screen more frequently Use a vacuum cleaner with a hose attachment to remove any dust or debris that may have accumulated on the screen Air Intake Chamber Screen FIGURE 38 Cleaning the Combustion Chamber and Air Diverter Assembly 1 2 Manifold Door Gasket 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 39 Use compressed air to clear any dust or debris that may have accumulated on the air diverter assembly Air Diverter Combustion s Assembly Chamber sy X 7225 I e ice 7 us a FIGURE 39 Reassemble following the procedure under Replacing the Manifold Burner Assembly 31 Replacing the Manifold Burner Assem
52. e fan and main burner will continue to operate until water temperature inside the tank reaches temperature set point Gas valve thermostat is de energized and air intake fan continues for a post purge time of approximately 5 seconds Water heater returns to standby mode 5 second pre purge then air intake fan will turn off Ignitor will start a 12 second warm up period IGN will show on display FIGURE 29 26 Checking the Draft AWARNING Burn Hazard Do not touch vent Doing so can result in burns 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 30 Make sure all other appliances in the area are operating and all doors windows are closed when performing the draft test Pass a match flame or smoke around the relief opening of the draft hood A steady flame or smoke drawn into the opening indicates proper draft Flue Products Vented to Ouside of Building Dilution Air Dilution Air Draft Hood Dilution Air Relief Opening Air is drawn in for combustion Keep area clean and free from combustibles and flammable vapors 6 Maximum Air Gap Floor Drain Outer Door The water heater must be installed according to all local and state codes or in the adsence of local and state codes the National Fuel Code ANSI Z223 1 NFPA 54 curr
53. e instruction manual before changing temperature 10 If the appliance will not operate follow the instruc tions TO TURN OFF GAS TO APPLIANCE and call technician or gas supplier TURN OFF ALL R BEFORE SERVICING TO TURN OFF GAS TO APPLIANCE ressing the COOLE ut Set the Electronic Display to the lowest setting by first Q and HOT ons together and holding for 1 second 2 3 Set the ON OFF switch on the gas control to the OFF postition Turn off all electrical power to the appliance if service is to be performed Water Heater Operation Figure 29 below shows the water heater s sequence of operation when a call for heat is initiated The ignition control module will attempt to light the burner three times If the ignition control does not detect ignition it will enter lockout mode indicated by display flashing status code see status code 3 page 38 and or status code 8 page 39 SEQUENCE OF OPERATION Call for heat indicated by flashing of display screen status codes Gas valve thermostat will open for 4 second trial for ignition and fan will turn on Gas valve thermostat will do a relay check relay clicks will be heard Display will show temperature set point during call for heat Draft Blower is energized System will verify pressure switch operation and start a Main burner flame is detected by flame sense rod Air intak
54. e rod The powered anode rod is non sacrificial and should not need to be replaced unless damaged If the powered anode rod has been damaged then the powered anode rod should be removed from the water heater tank and replaced IMPORTANT If the damaged powered anode rod has not been replaced but has been removed permanently this will void any warranties Powered Anode System To ensure a long trouble free operating life this water heater is equipped with a powered anode system The powered anode rod is of a permanent design and does not need replacing unless damaged FIGURE 33 NOTE Whether re installing or replacing the powered anode rod check for any leaks and immediately correct if found To replace the powered anode rod 1 Setthe gas control valve thermostat to its lowest setting by pressing the COOLER and HOTTER buttons together at the same time holding for 1 second Then press the COOLER button to the lowest setting Figure 32 2 Turn gas control switch to the OFF position located right side of the gas control valve thermostat Figure 28 and turn off the gas supply to the unit 3 Disconnect the electric connection by unplugging the water heater from the wall outlet 4 Shutoff the incoming water supply to the water heater and open a nearby hot water faucet to depressurize the water tank 5 Remove the manifold cover outer door and connect a hose to the drain valve and terminate it to
55. eater 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 and the National Electrical Code ANSI NFPS 70 current edition CAUTION Property Damage Hazard Allwater heaters eventually leak Donotinstall without adequate drainage IMPORTANT The water heater should be located in an area where eakage 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 will eventually eak after an extended period of time Also any external plumbing eak 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 a maximum depth of 1 3 4 and be two inches wider than the heater and piped to an adequate drain 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 dr
56. ent edition FIGURE 30 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 drawings in Figure 31 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 31 Emergency Shut Down IMPORTANT Should overheating occur or the gas supply fails to shut off turn off the heater s manual gas control valve and the electrical power Call a qualified technician Water Temperature Regulation Water temperature over 125 F 52 C can cause servere burns instantly resulting in severe injury or death ADANGER 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 situat
57. ep the hot water faucet open for 3 minutes after a constant flow of water is obtained 12 After turning off the hot water faucet check for water leaks around powered anode rod and immediately correct any if found 13 Upon determining there s no water leak at the newly installed powered anode rod reconnect the electrical plug connector to the top of the anode male terminal 14 Plug the electric transformer in the wall outlet and turn the gas supply back on to the gas control valve thermostat 15 Turn the gas control switch to the ON position located on the side of the gas control valve thermostat Figure 28 16 To restart the water heater follow the directions on the Lighting and Operating Instructions label located on the front of the water heater near the gas control valve thermostat Figure 28 17 Upon verifying proper operation of the water heater replace the manifold cover outer door TEFLON is a registered trademark of E I Du Pont De Nemours and Company SERVICE AND ADJUSTMENT Draining and Flushing Temperature and Pressure Relief Valve ADANGER Hotwater discharge burn hazard Keep clear of relief valve discharge unit AWARNING Temperature limiting valves are available Temperature pressure relief valve must comply with ANSI 221 22 5 4 4 and ASME Read instruction manual for safe code temperature setting Properly sized temperature pressure relief valve must be
58. epartment Installation and service must be performed by a qualified installer service agency or the gas supplier SAFE INSTALLATION USE AND SERVICE Your safety and the safety of others is extremely important in the installation use and servicing of this water heater Many safety related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard Read and obey all safety messages and instructions throughout this manual It is very important that the meaning of each safety message is understood by you and others who install use or service this water heater This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death gt DANGER indicates an imminently hazardous situation which if not avoided will result in death or injury WARNING indicates a potentially hazardous situation which if not avoided could result WARNING in death or injury CAUTION indicates a potentially hazardous situation which if not avoided could result CAUTION in minor or moderate injury CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided could result in property damage DANGER All safety messages will generally tell you about the type of hazard what can happen if you do not
59. eplace with correct orifice High gas pressure Check with gas utility company BURNER FLAME FLOATS Water heater flue or vent system Clean flue and burner locate source and correct AND LIFTS OFF PORTS blocked Cold drafts Locate source and correct Insufficient secondary air Provide ventilation to water heater Check flue Water heater flue or vent system Clean locate source and correct blocked Heater installed in a confined area Provide fresh air ventilation COMBUSTION ODORS 36 continued PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION WATER LEAKS LEAKING T amp P HOT WATER ODORS WATER HEATER SOUNDS SIZZLING RUMBLING SMOKING AND CARBON FORMATION SOOTING HIGH OPERATION COSTS THERMOSTAT FAILS TO SHUT OFF DRIP FROM RELIEF VALVE 0 090 0N Improperly sealed hot or cold supply connections relief valve drain valve or thermostat threads Leakage from other appliances or water lines Condensation of flue products Excessive water pressure Heater stacking Closed water system Thermal expansion in closed water system Improperly seated valve High sulfate or mineral content in water supply Bacteria in water supply Condensation dripping on burner Sediment at bottom of heater tank Insufficient secondary air Low gas pressure Water heater flue or vent system blocked Thermostat not functioning properly Heater installed in a confined area Burner f
60. etected one or both of the temperature adjustment buttons are stuck No current to Power Anode Power Anode circuit failure System must be manually reset by entering a special FVS reset sequence into the Electronic Control Display See Electronic Control Display FV Sense Reset Sequence in the Kenmore PCC Water Heater Service Handbook Clean the screen on the combustion air intake chamber retest If the problem persists Cycle power to the water heater OFF and ON to reset Check all wiring to the flammable vapor sensor Remove the connectors from the flammable vapor sensor and measure the resistance of the sensor with an ohmmeter A If thereading taken is more than 1 7 million ohms replace the flammable vapor sensor B If the reading taken is less than 1 7 million ohms and the wiring from the control to the sensor is good replace the lower control Check all wiring to the flammable vapor sensor Remove the connectors from the flammable vapor sensor and measure the resistance of the sensor with an ohmmeter A If thereading taken is less than 2000 ohms replace the flammable vapor sensor B If the reading taken is more than 2000 ohms and the wiring from the control to the sensor is good replace the lower control Turn power off for 10 to 20 seconds then on again to clear this error code This part of the control cannot be replaced or serviced If the e
61. f flood damaged ADANGER 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 risk forscald injury Feel water before bathing or showering Temperature limiting valves are available A WARNING Overheated water can cause watertank explosion Properly sized temperature and pressure relief valve must be installed in opening provided Read instruction manual for safe temperature setting AWARNING Fire or Explosion Hazard 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 Install vent system in accordance with codes Do not operate water heater if flood damaged Heater should not be installed for High Altitude operation above 10 100 feet 3 078 m Do not operate if soot buildup Do not obstruct water heater air intake with insulating jacket Do not place chemical vapor emitting products
62. 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
63. he absence of local and state codes the National Electrical Code ANSI NFPS 70 current edition INSTALLATION INSTRUCTIONS Removing the Old Water Heater Attach a hose to the water heater drain valve and put the other end in a floor drain or outdoors See Figures 2 and 5 Open the water 2 ga heater drain valve MANUAL GAS SHUT OFF VALVE 8 GROUND on JOINT UNION DISCHARGE PIPE DO NOT CAP CHECK WITH OR PLUG FIGURE 5 LOCAL UTILITY FOR MINIMUM HEIGHT 5 Disconnect the vent pipe from the draft hood where it connects C vwd TI to the water heater In most installations the vent pipe can um D be lifted off after any screw or other attached devices are GA 6 MAXIMUM removed Dispose of the draft hood The new water heater DRIP LEG ret AIR GAP SUITABLE gt V 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 until the water is no longer hot When the water has cooled turn OFF the water supply to the water heater at the water shut off valve o
64. iment electrial power manual gas control valve and the cold water 6 Close the drain valve refill the tank and restart the heater inlet valve and call a qualified technician Contact Sears Service as directed in this manual 1 800 4 MY HOME www sears com 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 RE UE AND PRESSURE and should not be confused with a tank leak MANUAL RELIEF VALVE Routine Preventive Maintenance At least annually a visual inspection should be made of the venting and air supply system piping systems and main burner Check the water heater for the following Obstructions damage or deterioration in the venting DISCHARGE LINE TO DRAIN system Make sure the ventilation and combustion air supplies are not obstructed Clean any dust or debris from the screen of the air intake chamber Soot and or carbon on the main burner Contact a qualified technician Leaking or damaged water and gas piping Presence of flammable or corrosive materials in the installation area Presence of combustible materials near the water heater After servicing this water heater check to make sure it is working properly See Operating Your Water Heater section of this manual IMPORTANT If you lack the necessary skills required to properly perform this visual inspection you should not
65. ing 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 Tocheck 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 in the Installation Instructions earlier in this manual 6 152 4 mm MAXIMUM AIR GAP FIGURE 42 AWA RN Teflon is a registered trademark of E I Du Pont De Numours and Company Read and understand instruction manual and safety messages before installing operating or servicingthis 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
66. intain a six inch minimum clearance from all combustible materials when using single wall vent pipe IMPORTANT Single wall 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 wall When installing a vent connector please note the following See Figures 20 22 nstall 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 Thelength of the vent connector cannot exceed 75 of the vertical vent height The vent connector must be accessible for cleaning inspection and replacement Vent connectors cannot pass through any ceiling floor firewall or fire partition tis recommended but not mandatory that a minimum 12 inches of vertical vent pipe be installed on the draft hood prior to any elbow in the 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 chi
67. ions 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 will 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 27 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 24 Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat see Table 5 and Figure 32 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 bathtu
68. ith the water piping system For new installations Located as close to the gas piping vent pipe system and 120VAC outlet 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 and Accessibility section of this manual O Water heater not located near an air moving device Sufficient room to service the water heater See Clearances Is the installed environment dirty excessive amounts of lint dirt dust etc If so the air intake chamber louvers located on the side of the water heater will need to be cleaned periodically Refer to the maintenance section of your water heater s manual for information on cleaning the Air Intake Chamber Screen Combustion Air Supply and Ventilation Check for sufficient combustion air supply Insufficient air for the combustion of gas will result in a inferior burner flame yellow lazy thereby allowing smoking and carbon formation sooting to build up in the combustion chamber 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
69. lame yellow lazy Thermostat set too high Sediment or lime in tank Water heater too small for job Wrong piping connections Leaking faucets Gas leaks Wasted hot water Long runs of exposed piping Hot water piping in exposed wall Thermostat not functioning properly Improper calibration Excessive water pressure Heater stacking Closed water system 37 Tighten threaded connections Inspect other appliances near water heater See START UP CONDITIONS section Use a pressure reducing valve and relief valve Lower the thermostat setting See Closed System Thermal Expansion Install thermal expansion tank DO NOT plug T amp P valve Check relief valve for proper operation DO NOT plug T amp P valve Drain and flushing heater thoroughly then refill Chlorinate water supply See START UP CONDITIONS section See DRAINING AND FLUSHING section Provide ventilation to water heater Check flue way flue baffle burner Check with gas utility company Clean locate source and correct Replace thermostat Provide fresh air ventilation See Burner Flame Yellow Lazy Set temperature to lower setting Drain flush provide water treatment if needed Install adequate heater Correct piping dip tube must be in cold inlet Repair faucets Check with utility repair at once Advise customer Insulate piping Insulate piping Replace thermostat Replace thermostat
70. late to be sure the water heater is made for the type of gas you will be using in your home This information will 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 Tables 1 and 2 on the following page provide a sizing reference for commonly used gas pipe materials Consult the National Fuel Gas Code for the recommended gas pipe size of other materials NOTE Use pipe joint compound or teflon tape marked as being resistant to the action of petroleum gases See Figure 12 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 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 long for the accumulation of dirt foreign material and water droplets Install a ground joint union between the gas control va
71. lve thermostat and the manual shut off valve This is to allow easy removal of the gas control valve thermostat 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 15 Manual Gas Shut Off Valve Ground Joint Union 1 Install readily acces sible manual shut off valve in the gas supply line as recommended by the local utility s Discharge Pipe Do Not plug or cap Check with local utility for minimum height 3 Minimum f Drip Leg T TERR FIGURE 12 Gas Pressure WARNING 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 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 Gas Pressure Testing IMPORTANT This water heater and its gas connection must be leak tested before placing the appliance in operation fthe code requires the gas lines to be tested at a pressure exceeding 14 W C the water
72. mney 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 20 2223 1 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 20 2 FT Minimum Above Any Object Within 10 FT Horizontally Support Strap Maintain ta Clearance F Do Not Extend Vent Beyond Edge Of Chimney Chimney Termination Vent System FIGURE 20 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 conne
73. ms no matter who made it no matter who sold it For the replacement parts accessories and owner s manuals that you need to do it yourself For Sears professional installation of home appliances and items like garage door openers and water heaters 1 800 4 MY HOME 1 800 469 4663 Call anytime day or night U S A and Canada www sears com www sears ca Our Home For repair of carry in items like vacuums lawn equipment and electronics call anytime for the location of your nearest Sears Parts amp Repair Service Center 1 800 488 1222 U S A 1 800 469 4663 Canada www sears com WWW Sears ca To purchase a protection agreement on a product serviced by Sears 1 800 827 6655 U S A 1 800 361 6665 Canada Para pedir servicio de reparaci n Au Canada pour service en francais a domicilio y para ordenar piezas 1 8004 1 888 SU HOGAR 1 800 533 6937 1 888 784 6427 WWNW Sears ca www sears com Sears Registered Trademark Trademark of KCD IP LLC in the United States or Sears Brands LLC in other countries Marca Registrada Marca de Fabrica de KCD IP LLC en Estados Unidos Sears Brands LLC in otros paises Marque de commerce P Marque d pos e de Sears Brands LLC
74. nal 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 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 Mixing 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 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 Electrical Supply Water heater to be located as close as possible to a 120VAC outlet extension cord is not allowed Electrical supply installed according to all local and state codes or in t
75. or Turn the power off for 10 20 seconds then on again to clear this error code Replace the lower control if the error code persists CONTROL DISPLAY STATUS PROBLEM SOLUTION 1 Clean the screen on the combustion air P SW OPEN and CLEAN SCREEN Flashing The air pressure switch contacts intake chamber Turn the power OFF for remain open longer than 11 10 to 20 seconds then ON again to clear seconds after the combustion fan the error code If the problem persists is energized Ensure the pressure switch sensing tube is in good condition and securely connected at both ends Ensure the inner door to the combustion chamber is secure and the gasket is properly sealing Check operation of the air intake chamber fan and pressure switch A Turn off power to the water heater B Remove the tubing from the pressure switch and the wires from both terminals of the pressure switch Connect a digital manometer to the open end of the tubing from the air intake chamber Turn on the power to the water heater and when the fan turns on measure the pressure reading in the tubing If the pressure reading reaches the 22 WC make point of the pressure switch turn off power to the water heater and reconnect tubing to the pressure switch If pressure reading does not reach the 22 WC make point check the system and tubing for restrictions and cleanliness Attach leads of ohmmeter or continuity tester to the
76. out dis tortion Mustbe installed to allow complete drainage of both the valve and discharge line T amp P Relief Valve and Pipe Insulation 1 Locate the temperature and relief valve on the water heater also known as a T amp P Relief Valve Figure 26 2 Locate the slit running the length of the insulation 3 Spreadthis slit open and slip it up under the T amp P Relief Valve See Figure 26 Apply gentle pressure to the insulation to ensure it is fully seated on the T amp P Relief Valve Once sealed secure the insulation with a section of duct tape electrical tape or equivalent IMPORTANT The insulation or tape must not block the discharge opening or hinder access to the manual relief lever Ensure a discharge pipe is installed into the T amp P valve discharge opening per the instructions manual 23 D Locate the hot water outlet amp cold water inlet pipes to the water heater Locate the slit running the length of a section of pipe insulation Spread the slit open and slip the insulation over the cold water inlet pipe Apply gentle pressure along the length of the insulation to ensure it is fully seated around the pipe Also ensure that the base of insulation is flush with the water heater Once seated secure the insulation with duct tape electrical tape or equivalent Repeat steps 5 through 6 for the hot water outlet pipe Add additional sections of pipe insulation as needed Manual Relief Lever 4a
77. 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 Code ANSI Z223 1 NFPA 54 This publication is available from the Canadian Standards Association 8501 East Pleasant Valley Rd Cleveland Ohio 44131 or The National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 f 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 putthe 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
78. 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 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 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 will disappear in a short while 34 Operational Conditions AIR In Hot Water Faucets AWARNING Flammable hydrogen gases m
79. play to the lowest setting by first pressing the COOLER and HOTTER e buttons together and holding for 1 second Then press the COOLER Q button to the lowest setting Set the ON OFF switch on the gas control to the OFF position This appliance is equipped with a device which automatically lights the burner DO NOT TRY TO LIGHT THE BURNER BY HAND 7 Wait five 5 minutes to clear out any gas If you then smell gas 5 Follow B the safety information above on this label If you don t smell gas go to the next step If you cannot reach your gas supplier call the fire department Use only your hand to push in the electronic displa buttons and gas control switch Never use tool If the control buttons will not push in don t try repair them call a qualified service technician Fort or attempted repair may result in a fire or explosio Do not use this appliance if any part has bee under water Immediately contact a qualified installer or service agency to replace a flooded water heater Do not attempt to repair the unit ELECTRONIC DISPLAY Set the ON OFF switch on the gas control to the risk sca A ON postition Set the Electronic Display to the desired setting by first pressing the COOLER and HOTTER e but tons together and holding for 1 second Then press the HOTTER button until the desired setting is reached Hotter water increases the injury Consult th
80. pplied 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 13 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 ermanen t openings to Closet the outside or or other additional confined rooms within space the building FIGURE 13 All Air from the Building 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 gas utilization equipment in the area If you are unsure that the structure meets this requirement contact your local gas utility company or other qualified agency for a safety inspection Each of the two openings shall have a minimum free area of 1 square inch per 1 000 BTUH
81. proceed but get help from a qualified technician FIGURE 34 29 MAINTENANCE OF YOUR WATER HEATER 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 typeofgas 3 item number 4 parts description See Parts Order List section for a list of available repair parts 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 Note the position of the shut off valve in the open on position then proceed to turn it off Figure 12 2 Disconnect power supply to the heater 3 Remove the outer door Remove the 2 screw securing the manifold door assembly to the skirt 4 Disconnect all wiring connectors from the gas control valve thermostat Figure 35 Disconnect the manifold tube at the gas control valve thermostat 5 Grasp the manifold tube and push down slightly to free the manifold from the gas control valve thermostat 6 Carefully remove the manifold assembly from the burner com partment NOTE Be sure not to damage internal parts Figure 39 7 Check the
82. r water meter Some installations require that the water be turned off to the entire house See Figures 2 and 4 FIGURE 4 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 ADANGER Burn hazard Hotwater discharge Keep hands clear of drain valve discharge 12 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 Disconnectthe 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 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 When the water heater is drained disconnect the hose from the drain valve Close the drain valve The water heater is now
83. rea 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 7596 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 4 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 Opening Source Per Opening sq in Reference Drawing Direct to outdoors 1 sq in per 4000 BTUH Figure 15 Vertical Ducts 1 sq in per 4000 BTUH Figure 16 Horizontal Ducts 1 sq in per 2000 BTUH Figure 17 Single Opening 1 sq in per 3000 BTUH Figure 18 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 venti lated attic a ventilated crawl space or through an outside wall Consult the local codes of your area for specific ventila
84. rror code cannot be cleared the lower control must be replaced Turn power off for 10 to 20 seconds then on again to clear this error code This part of the control cannot be replaced or serviced If the error code cannot be cleared the lower control must be replaced Press and release each of the temperature adjustment buttons If the above action does not clear the error the control will continue to regulate the water temperature at the last setting However settings will no longer be adjustable the upper control should be replaced Check the wire that runs from the power anode to the upper control Check the wire for damage and to ensure that the connectors are fully seated into the mating connectors on both ends Check that the tank is full of water 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 Cycle power to the water heater OFF and ON to reset Turn the power off for 10 to 20 seconds then on again to clear the error code If the error code persists or cannot be cleared replace the upper control TROUBLESHOOTING FLOWCHART APPLY POWER TO APPLIANCE No REQUEST FOR HEAT PRESENT 3 MINUTE AUTOMATIC RESET YES TIME DELAY 1s WAIT FOR PRESSURE PRESSURE SWITCH S
85. sec onds if no further buttons are pressed After 30 seconds the control will go back to Lock mode Lock mode indicates a temperature setting is locked into the control memory Release both of the temperature adjustment buttons A To decrease the temperature press and release the COOLER button until the desired setting is reached B To increase the temperature press and release the button until the desired setting is reached NOTE Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance NOTE During low demand periods when hot water is not being used a lower thermostat setting will 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 Set the electronic control display temperature COOLER button to its lowest setting This will maintain the water at low temperatures with minimum energy losses and prevent the tank from freezing during cold weather Gas Control Valve Thermostat Settings HOTTER COOLER Electronic Control Display FIGURE 32 Powered Anode Operation To protect the glass lined water tank from corrosion through electrolysis this water heater is equipped with a non sacrificial powered anod
86. sed 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 less 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 all gas appliances The table below shows a few examples of the minimum square footage area required for various BTUH inputs 17 TABLE 3 Minimum Square Feet with 8 Ceiling Typical Room with 8 Ceiling BTUH Input 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 un usually tight construction may still require outdoor air to func tion properly In this situation outside air openings should be sized the same as for a confined space Modern home construction usually requires supplying out side air into the water heater area Confined Space For the correct and proper operation of this water heater ample air must be su
87. 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 Location Requirements section of this water heater manual for specific requirements Fresh air 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 amp Refrigeration HVAC R authorized service provider Fresh air supply free of corrosive elements and flammable vapors Ductwork is the same cross sectional area as the openings 11 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 Natio
88. sures 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 23 Connect the cold water supply 3 4 NPT to the cold water inlet fitting Connect the hot water piping 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 Theinstallation of unions in both the hot and cold water supply lines is recommended for ease of removing the water heater for service or replacement 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 24 These valves reduce the point of use temperature of the water by mixing cold and hot water and are readily available for use 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 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
89. t Reconnect the flame sense hot surface igniter wire to the gas control valve thermostat Figure 35 Turn gas supply on and refer to the Lighting Instructions With the burner lit check the gas control valve thermostat supply line two piece wire connector and manifold tube connections for leaks Check for leaks by brushing on an approved noncorrosive leak detection solution IMPORTANT Do Not splash solution onto the electrical connections Bubbles forming indicate a leak Correct any leak found All leaks must be fixed immediately 10 Replace the outer door See item page 10 Door Gasket Burner a T Manifold Tab Viewport FIGURE 40 Removing and Replacing the Gas Control Valve Thermostat IMPORTANT Use only factory authorized replacement parts Removing the Gas Control Valve Thermostat 1 Setthe gas control valve thermostat to its lowest setting by first depressing the COOLER D and HOTTER D buttons together and hold for 1 second Then press the COOLER button until the VAC indicator light appears Figure 32 Unplug the water heater from the wall outlet 3 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 Note the position of the shut off valve in the open on position then proceed to turn it off Figure 12 4 Drain the water heater Refer to the section of Draining and Flushing section and follow the procedure
90. t Water Outlet ixing Valve Set To 120 F Follow The Mixing Valve Manufacturer s Instructions FIGURE 24 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 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 only 95 5 tin antimony or other equivalent solder ead 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 22 Closed System Thermal Expansion CAUTION Property Damage Hazard Allwater heaters eventually leak Do notinstall without adequate drainage 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 warrant
91. tion and combustion air requirements Gable Vent 2 Outdoors 4000 BTUH Install Above Ms Insulation Confined 1 Space Outlet Air to the Attic 1 sq in per 4000 BTUH Inlet Air from the Alternative Ere Space Air Inlet 1 ET ES 1 sq in per Open Foundation Vent All Air From Outdoors Inlet Air From Ventilated Crawl Space Outlet Air To Ventilated Attic FIGURE 15 Gable Vent z Outdoors install Above aimi Confined Space Outlet Air to the Attic 1 sq in per 4000 BTUH Inlet Air Duct 1 sq in per 4000 BTUH bre Max All Air from Outdoors Through Ventilated Attic FIGURE 16 1 sq in per 2000 BTUH Lc Ue EN TER 18 Outlet pace VA Outdoor Air Ducts 1 sq in per 2000 BTUH All Air From Outdoors Using Horizontal Ducts FIGURE 17 19 Alternative a pee Confined Space Vu Ys 1 sq in per 3000 BTUH gl All Air From Outdoors Using A Single Permanent Opening FIGURE 18 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 an
92. ure 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 Thermal Expansion Tank Specifications Tank Pipe Capacity in Inches Fitting In Gallons On Tank TABLE 6 Model Number Expansion Tank Sizing Chart Inlet Water Pressure Water Heater Capacity Gallons 30 40 50 66 82 Expansion Tank Capacity Needed TABLE 7 Highest recorded inlet water pressure in a 24 hour period or regulated water pressure 33 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 WATER HEATER COLD WATER INLET FITTING 3 PRESSURE REDUCING VALVE WITH BY PASS 2 F 2 INLET COLD WATER SHUT OFF HOT co COLD PRESSURE GAUGE RECOMMENDED INSTALLATION VERTICAL MOUNTING
93. witch fan and display connector wires Figure 35 4 Fill the tank completely with water NOTE 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 5 Turn on the gas supply and test the gas supply connections by brushing on an approved noncorrosive leak detection solution IMPORTANT Do Not splash solution onto the electrical connections Bubbles forming indicate a leak Correct any leak found 6 Checkthe 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 connections for leaks T Verify proper operation and then replace the outer door is a registered trademark of E l Du Pont De Nemours and Company TROUBLESHOOTING GUIDE Start Up Conditions Thermal Expansion CAUTION 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 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 press
94. y 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 Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank Temperature and Pressure Relief Valve AWARNING Temperature pressure relief valve must comply with ANSI 221 22 5 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 Relief Valve T amp P 125 Discharge line 3 4 Min Do not cap or plug N fe Max A drain FIGURE 25 Metal Drain Pan For protection against excessive pressures and temperatures a temperature and pressure relief valve must be installed in the opening marked T amp P RELIEF VALVE see Figure 25 This valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of listed equipment or m

Kenmore ELITE 153.33262 User's Manual

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