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Kenmore 6-Year Owner's Manual

1. 27 atiis teas ee iuba t de ARE MERE ERE PA UEM 28 30 Vent System Inspection ihe eT cedit enin 28 Burner diei ebd i ote tete i Miei Hasc 28 Burner Gleanings ceste modena veces f etie 28 Housekeeping n coop 29 Anode tete ei utut e adio tta 29 Temperature Pressure Relief Valve 29 Draining and Flushing ueber e 29 30 M laces 30 MAINTENANCE OF YOUR WATER 9 31 34 Replacement Parts ee eid ne eee ee ee ee 31 External Inspection amp Cleaning of the Base Ring 31 Removing the Manifold Burner 31 Removing the Burner from the Manifold Burner 31 Replacing the Pilot Igniter Flame Snesor 31 32 Cleaning the Combustion Chamber and 32 Replacing the Manifold Burner 32 33 ldni
2. Sears Installation Service For Sears professional installation of home appliances garage door openers water heaters and other major home items in the U S A or Canada call 1 800 4 MY HOME 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 e CSA Canadian Standards Association e ANSI American National Standards Institute e NFPA National Fire Protection Association ASME American Society of Mechanical Engineers e GAMA Gas Appliance Manufacturers Association Important Information About This Water Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation environments Please review the Installation Checklist found at the end of the installation instructions section and make any required installation upgrades or changes This manual contains instructions for the installation operation and maintenance of the gas fired water heater It also contains warnings th
3. Water heater will continue to operate normally until demand is satisfied Wait for flame lost 5 flash error code See Corrective gt Action Table pages 40 41 Damper closes displays 6 4 Flash Error Code and gas control valve goes into 20 minute lockout See Corrective Action Table pages 40 41 42 PARTSORDERLIST ORDER LIST KENMORE FLUE DAMPER GAS WATER HEATER MODEL NUMBERS 153 337021 40 Gallon Tall Natural 153 337041 50 Gallon Tall Natural Model Numbers 153 337021 153 337041 Anode Rod 9003944 9003944 Base Ring Filter 9006616 9006660 Burner Head 9006136 9006136 Burner Orifice 186016 034 186016 034 Draft Hood 9006647 9006647 Drain Valve 9000058 9000058 Gas Control Valve Thermostat 9007681 9007681 Inlet Tube w Gasket 9002059 9003473 Instruction Manual 319425 000 319425 000 Manifold Door Assembly Contains Manifold Tube Gasket Door Pilot Tube Pilot Igniter Flame Sensor assembly 9007682 9007683 Manifold Component Block w Clip Burner Head and Burner Orifice Nipple w Heat Trap 9003719 9003719 Outer Door 9006648 9006648 Pilot Assembly w Tubing and 9007684 9007684 Fittings T amp P Relief Valve 9000728 9000728 Manifold Component Block Clip 9007685 9007685 Damper 9007686 9007686 Transformer amp Cord 9007687 9007687 FV Sensor 9005968 9005968 Not Shown Now that you have purchased your g
4. 31 to remove the burner assembly Once the burner assembly has been removed inspect the manifold tube and burner see figure 36 for any obstructions If any clogs or obstructions are present clear them Inspect the electrode flame sense rod see figure 43 for corrosion buildup degradation or damage If there is evidence of any damage to the electrode flame sense rod replace the igniter pilot assembly Follow the directions on page 32 to re install the burner assembly into the combustion chamber Follow the instructions for lighting on page 24 If the problem persists contact a certified service representative Two Flash three second pause End Switch Failed Closed Look at the top of water heater to see if the damper is open see figure 27 If the damper is open insure there is no obstruction that would prevent the damper from closing If there are any obstructions turn the power switch on the gas valve to the OFF position remove the obstruction if the damper closes turn the power switch on the gas valve to the ON position If there are no obstructions present turn the power switch on the gas valve to the OFF position Observe the damper to see if the damper closes If the damper does not close unplug the power cord from the power outlet and proceed to step 1 If the damper closes turn the power switch on the gas valve to the ON position 4 Check all wiring connections to insure all harness and wire connections are seated f
5. 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 Water Heater Installation Kit 1 a 0 Ed EXPANSION TANKS FOR THERMAL EXPANSION CONDITIONS AVAILABLE IN 2 GALLONS 7 6 LITERS AND 5 GALLONS 18 9 LITERS RETREAT OR ORO d METAL DRAIN PANS AVAILABLE IN 20 508 mm DIAMETER FOR WATER HEATERS HAVING A DIAMETER 18 457 mm OR LESS 24 610mm DIAMETER FOR WATER HEATERS HAVING CAPACITY THROUGH A DIAMETER 22 559 mm LOCAL SEARS STORE WATER HEATER INSTALLATION KIT OR LESS AND AVAILABLE IN OR SERVICECENTER WITH FLEXIBLE CONNECTORS FOR 3 4 28 711 mm DIAMETER FOR 19 05 mm COPPER PLUMBING AND FLEXIBLE WATER HEATERS HAVING A GAS CONNECTOR WITH FITTINGS DIAMETER 26 660 mm OR LESS BASIC TOOLS You may or may not need all these tools depending on your type of installation These tools can be purchased at your local Sears Store Pipe Wrenches 2 14 356 mm e Screwdriver Tin Snips 6 1 82 m Tape or Folding Ruler Garden Hose Drill Pipe Dope or Teflon Tape CD SLOT HEAD SCREWDRIVER CE TIN SNIPS PHILLIPS SCREWDRIVER PIPE DOPE ROLL OF TEFLON SQUEEZE
6. be obtained from California s Office of the State Architect 1102 Q Street Suite 5100 Sacramento CA 95811 Instructions can also be downloaded to your computer at www dsa dgs ca gov Pubs Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248 CMR 2 00 State Plumbing Code and 248 CMR 5 00 Complies with 40 Ng J NOx requirements of Texas and most California AQM Districts 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 BATE RECOVERY MINIMUM DIAMETER DIMENSIONS OF GAS Btu hr NUMBER IN GALS LTRS RATE GALS VENT PIPE INCHES INCHES mm PER HOUR DIA INCHES mm HEIGHT TO 90 F RISE mm JACKET TOP 153 337021 40 151 Natural 40 000 3 76 or 4 102 20 508 58 13 1476 153 337041 50 189 Natural 40 000 3 76 or 4 102 22 558 57 28 1455 MATERIALS
7. death The Flammable Vapor FV Sensor 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 spark igniter or main burner The resulting flashback and fire can cause death or serious burns to anyone in the area This heater is equipped with an 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 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 In the event the FV Sensor does not prevent the ignition of flammable vapors the FVIR System is designed to reduce the risk of flammable vapor related fires FIGURE 8 The patented system protects your family by trapping the burning vapors within the water heater combustion chamber through the special flame arrestor The burning vapors literally burn themselves out without escaping back into the room In the event of a flammable vapor incident the FVIR System disables the water heater by shutting off the gas supply to the wat
8. detectors are available Install water heater in accordance with the instruction manual Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Should you choose to apply an insulation blanket to this heater you should follow these instructions See Figure 1 for identification of components mentioned below Failure to follow these instructions can restrict the air flow required for proper combustion potentially resulting in fire asphyxiation serious personal injury or death Do not apply insulation to the top of the water heater as this will interfere with safe operation of the draft hood and flue damper Do not cover the outer door thermostat or temperature amp pressure relief valve Do not allow insulation to come within 2 50 8 mm of the floor to prevent blockage of combustion air flow to the burner cover the instruction manual Keep it on the side of the water heater or nearby for future reference obtain new warning and instruction labels from Sears for placement on the blanket directly over the existing labels inspect the insulation blanket frequently to make certain it does not sag thereby obstructing combustion air flow Clearances and Accessibility NOTE Minimum clearances from combustible surfaces are stated on the label adjacent to the gas control valve thermostat of the water heate
9. 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 A new water heater is filled with cold water for the first time Burning gas produces water vapor In water heaters particularly high efficiency models where flue temperatures are lower Large amounts of hot water are used 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 Excessive condensation can cause pilot outage due to water running down the flue tube onto the main burner and putting out the pilot 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 wash
10. flushed every 6 months to remove sediment which may build up during operation The water heater should be drained if being shut down during freezing temperatures To drain the tank perform the following steps 1 Turn off the gas to the water heater at the manual gas shut off valve 2 Opena nearby hot water faucet until the water is no longer hot 3 Close the cold water inlet valve Connect a hose to the drain valve and terminate it to an adequate drain or external to the building 5 Open the water heater drain valve and allow all of the water to drain from the tank Flush the tank with water as needed to remove sediment 6 Close the drain valve refill the tank and restart the heater as directed in this manual 30 If the water heater is going to be shut down for an extended period the drain valve should be left open IMPORTANT Condensation may occur when refilling the tank and should not be confused with a tank leak Service Before calling for repair service please read the Troubleshooting 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 Center at 1 800 4 MY HOME 1 800 469 4663 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 Replacemen
11. for any other type of flammable vapors in the area Carefully inspect the area surrounding the water heater for any substances such as gasoline 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 Contact a qualified service representative for inspection and or replacement of the FV sensor Flash three second pause Flammable Vapor Sensor FVS Fault Detected Turn the power switch on the gas control valve to the OFF position wait 10 20 seconds then turn he power switch on the gas control valve to the ON position If the problem persists replace the gas valve Flash three second pause Temperature Sensor Fault Detected Turn the power switch on the gas control valve to the OFF position wait 10 20 seconds then turn the power switch on the gas control valve to the ON position If the problem persists replace the gas valve Three Flash three second pause Electronic Fault Detected switch on the gas control valve to the OFF position 10 20 seconds then turn ch on the gas control valve to the position If the problem persists replace the Four Flash three second pause Gas Control Valve Thermostat Fault Detected switch on the gas control valve to the OFF position 10 20 seconds
12. 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 the Installation Instructions earlier in this manual TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION BURNER WILL NOT IGNITE SMELLY WATER BURNER FLAME YELLOW LAZY PILOT WILL NOT LIGHT OR REMAIN LIT HIGH OPERATION COSTS INSUFFICIENT HOT WATER 3 4 5 6 7 8 9 1 1 12 13 1 2 3 4 0 0 1 Air for combustion obstructed Pilot will not light Thermostat set too low No gas Dirt in the gas lines Pilot line clogged Main burner line clogged Non functioning thermostat Heater installed in a confined area Flue Damper not functioning Insufficient secondary air Low gas pressure Flue clogged Main burner line clogged Heater installed in a confined area Obstruction in main burner orifice Non functioning Pilot lgniter Flame Sensor The thermal switch tripped Igniter wire connection loose Air in gas line Low gas pressure No gas Dirt in gas lines Cold drafts Thermostat ECO switch open Pilot line or orifice clogged FV Senor Lockout Flue Damper not functioning Thermostat set too high Sediment or lime in tank Water heater too small for job Wrong piping co
13. of this water heater manual for specific requirements NOTE This water heater utilizes an automatic flue damper that remains closed when the water heater is not operating Do not attempt to manually open operate the damper Damage to the flue damper may result 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 Propane L P 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 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
14. technician if the flame is not satisfactory H FIGURE 28 Water Heater Stacking Stacking occurs when a series of short draws of hot water 3 gallons or less are taken from the water heater tank This causes increased cycling of the burner and can result in increased water temperatures at the hot water outlet This water heater s temperature control has been designed to accurately regulate the water temperature However under certain operating conditions the water temperature may temporarily exceed the dial setting Consequently in addition to setting the temperature no higher than 120 F we recommend the installation of a mixing valve or an anti scald device in the hot water supply 25 line or at the point of use to further reduce the risk of scald injury These devices can be obtained from a plumbing service agency or your retail supplier Emergency Shut Down IMPORTANT Should overheating occur or the gas supply fails to shut off turn off the water heater s manual gas control valve and call a qualified technician Water Temperature 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 man
15. the water heater drain valve MANUAL GAS SHUT OFF VALVE GROUND JOINT UNION FIGURE 5 CHECK WITH DISCHARGE PIPE LOCAL UTILITY FOR MINIMUM HEIGHT Disconnect the vent pipe from the draft hood where it connects 3 MINIMUM DRIP ir B T MAXIMUM AIR GAP SUITABLE 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 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 or 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 Burnhazard Hot water discharge Keep hands clear of drain valve discharge DO NOT CAP OR PLUG 5 12 to water heater In most installations the vent pipe can be lifted off after any screw or other attached devices are removed Dispose of the draft hood
16. the water heater and its manual shut off valve must be disconnected from the gas supply piping system and the line capped e Ifthe gas lines are to be tested at a pressure less than 14 W C as given in the warning on the front page the water heater must be isolated from the gas supply piping system by closing its manual shut off valve When your L P tank runs out of fuel turn off the gas at all gas appliances including pilot lights After the tank is refilled all appliances must be re lit according to their manufacturer s instructions NOTE Air may be present in the gas lines and could prevent the pilot from lighting on initial start up The gas lines should be purged of air by a qualified technician after installation of the gas piping system While purging the gas piping system of air ensure that 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 gas Nominal Iron Pipe Length of Pipe Feet Size in 10 20 30 40 50 60 70 80 90 100 125 150 175 200 After the length of pipe has been determined select the pipe size which will provide the minimum cubic feet hour required for the gas input rating of the water heater By formula Gas Input of Water Heater BTU HR Cu Ft Per Hr Required 3 Heating Value of Gas BTU FT The gas input of the water heater is marked on th
17. 223 1 54 current edition connector must be installed above the extreme bottom of the chimney to prevent potentially blocking the flue gases connector must be firmly attached and sealed to prevent it from falling out Toaidin 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 LISTED LINED CHIMNEY 3 FT MINIMUM SUPPORT 2 FT MINIMUM ABOVE ANY OBJECT WITHIN 10FT HORIZONTALLY STRAP MAINTAIN CLEARANCE DO NOT EXTEND VENT BEYOND EDGE OF CHIMNEY UP 1 4 IN PER FT MINIMUM CONNECTOR 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 vent pipe according to the vent manufacturer s instructions and the terms of its listing It must be connected to the water heater s draft hood by a listed vent connector or by directly originating at the draft hood opening Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer s instructions Gas v
18. 3 See Closed System Thermal Expansion 1 1 2 2 THERMOSTAT FAILS TO Thermostat not functioning properly Replace thermostat SHUT OFF Improper calibration Replace thermostat COMBUSTION ODORS 1 Insufficient secondary air 1 Provide ventilation to water heater Check flue way flue baffle and burner 2 Flue clogged Clean locate source and correct 3 Heater installed in a confined area Provide fresh air ventilation SMOKING AND CARBON 1 Insufficient secondary air Provide ventilation to water heater Check FORMATION SOOTING flue way flue baffle burner 2 Low gas pressure 2 Check with gas utility company 3 Flue clogged 3 Clean locate source and correct 4 Thermostat not functioning properly 4 Replace thermostat 5 Heater installed in a confined area 5 Provide fresh air ventilation 6 Burner flame yellow lazy 6 See Burner Flame Yellow Lazy 1 1 CONDENSATION Temperature setting too low Increase the temperature setting BURNER FLAME FLOATS 1 Orifice too large 1 Replace with correct orifice AND LIFTS OFF PORTS 2 High gas pressure 2 Check with gas utility company 3 3 Flue clogged Clean flue and burner locate source and correct Cold drafts Locate source and correct BURNER FLAME TOO HIGH Orifice too large Replace with correct orifice FLAME BURNS AT ORIFICE 1 Thermostat not functioning properly 1 Replace thermostat Low gas pressure 2 Check with gas utility company PILOT FLAME Pilot line or
19. ACTURER 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 e Itis recommend that only full flow ball or gate valves are used in water piping installations The use of valves that may cause excessive restriction to water flow is not recommended Use only 95 5 tin antimony or other equivalent solder Any lead based solder must not be used Piping that has been treated with chromates boiler seal or other chemicals must not be used e Chemicals that may contaminate the potable water supply must not be added to the piping system Closed System Thermal Expansion CAUTION All water heaters eventually leak Donotinstall 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 warranty Thermal expansion can also cause intermittent temperature pressure relief valve operation water discharged from the valve due to excessive pre
20. B E R U MANIFOLD BURNER ASSEMBLY DISCHARGE PIPE DO NOT CAP OR PLUG 6 MAXIMUM AIR GAP FLOOR DRAIN ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS 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 4 MY HOME 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 with the water piping system For new installations Located as close to the gas piping and vent pipe system as possible Water heater must be located within 6 feet of 120VAC outlet Located indoors and in a vertical position Protected from freezing temperatures Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor Provisions made to protect the area from water damage Metal drain pan installed and piped to an adequate drain Sufficient ro
21. GEMENT CORPORATION Hoffman Estates IL 60179 9 956 205 66 5 AS ASA AS The price of your water heater does not include 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 That s when having a Master Protection Agreement can save you money and aggravation The Master Protection Agreement also helps extend the life of your new product Here s what the Agreement includes Parts and labor needed to 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 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 failur
22. Once seated secure the insulation with duct tape electrical tape or equivalent 7 Repeat steps 5 and 6 for the hot water outlet pipe 8 Add additional sections of pipe insulation as needed T amp P RELIEF VALVE INSULATION 7 MANUAL RELIEF wae LEVER T amp P RELIEF VALVE T amp P RELIEF VALVE DRAIN LINE FIGURE 26 OPERATING YOUR WATER HEATER Lighting Instructions Read and understand these directions thoroughly before attempting to light or re light the pilot Make sure the view port is not missing or damaged See Figure 35 Make sure the tank is completely filled with water before lighting the pilot Check the rating plate near the gas control valve thermostat for the correct gas Do not use this water heater with any gas other than the one listed on the rating plate If you have any questions or doubts consult your gas supplier or gas utility company injury or loss of life BEFORE LIGHTING ENTIRE SYSTEM MUST BE FILLE A This appliance is equipped with an ingnition device which automatically lights the pilot Do not open the inner door of the appliance and try to light the pilot by hand B BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor D because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS eDo not try to light any appliance eDo not touch any electric switch do not use any phone in your building elmmed
23. RT STRAP MAINTAIN CLEARANCE VENT VENT CONNECTOR CONNECTOR SLOPE UP 1 4 IN PERFT MINIMUM UNUSED CHIMNEY FLUE OR MASONRY ENCLOSURE VENTING THROUGH A 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 Buming 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 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 pressures IMPORTANT Heat cannot be applied to the water fittings on the heater as they may contain nonmetallic parts If solder connections are used solder the pipe to the adapter before attaching the adapter
24. STER CLEAN IF LINT ACCUMULATIONS ARE NOTICED INSTALLED IN SUITABLE AREA To ensure sufficient ventilation and combustion air supply proper clearances from the water heater must be maintained See Installation Instructions Combustible materials such as clothing cleaning materials or flammable liquids etc must not be placed against or adjacent to the water heater because they could catch on fire Anode Rod Inspection CAUTION Avoid water heater damage Inspection and replacement of anode rod required The anode rod is used to protect the tank from corrosion Most hot water tanks are equipped with an anode rod The submerged rod deteriorates to protect the tank Instead of corroding the tank water ions attack and eat away the anode rod This does not affect the water s taste or color The rod must be maintained to keep the tank in operating condition Exposed Pitted Exposed Support Anode Support Wire Rod Wire FIGURE 32 29 Anode deterioration depends on water conductivity not necessarily water condition A corroded or pitted anode rod indicates high water conductivity and should be checked and or replaced more often than an anode rod that appears to be intact Replacement of a depleted anode rod can extend the life of your water heater Inspection should be conducted by calling the Sears Service Center for an authorized contractor At a minimum the anode s should be checked annually after the
25. TUBE TAPE USE ONLY ON USE FOR WATER AND GAS WATER CONNECTIONS CONNECTIONS CWE L1 GARDEN HOSE 6 FOOT TAPE PIPE WRENCH ADDITIONAL TOOLS NEEDED WHEN SWEAT SOLDERING Tubing Cutters or Hacksaw Propane Torch Soft Solder Solder Flux Emery Cloth Wire Brushes PROPANE TUBING CUTTER TORCH ne 72 3 ROLL OF HACKSAW EMERY CLOTH C O 3 4 19 mm WIRE BRUSH ROLL OF LEAD FREE SOLDER 1 2 13 mm WIRE BRUSH SOFT SOLDER FLUX TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER GAS MODELS Vent Pipe J Inner Door S Gas Control Valve Thermostat B Draft Hood K Outer Door T Drain Valve C Anode Not Shown L Union U Pilot and Main Burner D Hot Water Outlet M Inlet Water Shut off Valve V Flue E Insulation N Cold Water Inlet W Metal Drain Pan Gas Supply Piping O Inlet Dip Tube X Igniter Wire G Manual Gas Shut off Valve P Temperature Pressure Relief Valve Y Base RingFilter H Ground Joint Union Q Rating Plate Z FVSensor Drip Leg Sediment Trap R Flue Baffle AA Transformer BB Flue Damper INSTALLINACCORDANCE WITH LOCAL CODES DRIP LEG AS REQUIRED BY LOCAL CODES TO VENT TERMINATION ON INSTALL THERMAL EXPANSION TANK IF WATER HEATER IS INSTALLED IN A CLOSED S GAS CONTROL VALVE WATER SYSTEM TH RMOSTAT STATUS N LIGHT VACUUM RELIEF VALVE INSTALL PER LOCAL CODES Y P GAS CONTROL TEMPERATURE KNO
26. The new water heater has a draft hood which must be used for proper operation If you have copper piping to the water heater the two copper water pipes can be cut with a hacksaw approximately four inches away from where they connect to the water heater See Figure 6 This will avoid cutting off pipes too short Additional cuts can be made later if necessary Disconnect the temperature pressure relief valve drain line When the water heater is drained disconnect the hose from the drain valve Close the drain valve The water heater is now completely disconnected and ready to be removed FIGURE 6 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 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
27. Use amp Care Guide Model No 153 337021 40 Gallon Tall 153 337041 50 Gallon Tall Kenmore ENERGY STAR Gas Water Heater 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 espa ol puede solicitarlo al 1 800 821 2017 NO TRATE DE INSTALAR U OPERAR ESTE CALENTADOR DE AGUA SI ENTIENDE LAS INSTRUCCIONES No hacer caso de esta advertencia podria originar lesiones graves o mortales P N 319425 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 TODOIF YOU SMELL GAS e Donottry tolightany appliance e Do not touch any electrical switch do notuse any phone in 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
28. anifold tube 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 Turn on the gas supply and test the gas supply connections by brushing on an approved noncorrosive leak detection solution Bubbles forming indicate a leak Correct any leak found Check the operation of the burner by following the lighting instructions on the front of the water heater With the burner lit check the gas control valve thermostat supply line manifold tube and pilot tube connections for leaks Verify proper operation and then replace the outer door If additional information is required contact Residential Technical Assistance by referencing the number on the water heater TEFLON is a registered trademark of E I Du Pont De Nemours and Company FVIR System Operational Checklist NO aA FON gt Manifold gasket properly sealed Viewport not damaged or cracked Flame arrestor free of debris and undamaged Manifold component block properly installed No leaks at pilot and manifold connection Manifold door screws securely tightened Depress the button on the thermal switch 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
29. 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 e Install the vent connector avoiding unnecessary bends which create resistance to the flow of vent gases Install without dips or sags with an upward slope of at least 1 4 inch per foot Joints must be fastened by sheet metal screws or other approved means It must be supported to maintain clearances and prevent separation of joints and damage The length of the vent connector cannot exceed 75 of the vertical vent height vent connector must be accessible for cleaning inspection and replacement e Vent connectors cannot pass through any ceiling floor firewall or fire partition Itis 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 chimney must be cleaned if previously used for venting solid fuel appliances or fireplaces Also consult local and state codes for proper chimney sizing and application or in the absence of local and state codes the National Fuel Gas Code ANSI 2
30. appropriate replacement After any connection problems are fixed restart the water heater by following the lighting instructions on page 24 If the problem persists proceed to step 3 Check condition of the base ring filter and flame arrestor If they are clogged follow the instructions for cleaning on page 32 If parts are not clogged proceed to step 4 After cleaning follow instructions for lighting on page 24 If problem persists proceed to step 4 Follow the instructions on page 31 to remove the burner assembly Once the burner assembly has been removed inspect the manifold tube and burner see figure 36 for any obstructions If any clogs or obstructions are present clear them Inspect the electrode flame sense rod see figure 43 for corrosion buildup degradation or damage If there is evidence of any damage to the electrode flame sense rod replace the igniter pilot assembly Follow the directions on page 32 to re install the burner assembly into the combustion chamber Follow the instructions for lighting on page 24 If the problem persists contact a qualified service representative Soft Lockout 20 minute wait before returning to normal mode 40 STATUS LIGHT TROUBLESHOOTING FLOWCHART LED FLASH SEQUENCE CONTROL STATUS CORRECTIVE ACTION Six Two Flash three second pause Soft Lockout Recycle Limit Flame Lost Turn the power switch on the gas control valve to the OFF position and unplug the power cord from th
31. as Control Valve Thermostat to the OFF position To clear any gas that may have accumulated wait ten 10 minutes If you then smell gas STOP Follow B in the safety warning above If you do not smell gas go to the next step Turn on all electric power to the appliance Connect to a grounded 110 120 volt power outlet Move the ON OFF switch on the Gas Control Valve Thermostat to the ON position Turn the gas control temperature knob to the LOW temperature setting As shown above This appliance is equipped with a device that automatically lights the pilot DO NOT TRY TO LIGHT THE PILOT BY HAND Electrode 9 When the pilot is lit the status light should blink a heartbeat bright dim bright dim etc If the status light does not start blinking repeat steps 3 7 The pilot can be located by looking through the glass view port If the pilot is lit you will see the pilot flame through the glass view port IMPORTANT If the appliance pilot fails to light after several tries follow the instructions To Turn Off Gas to Appliance and call a qualified service technician or gas supplier Record any status light flash codes Set the gas control temperature knob to the desired setting 11 Replace the outer door 12 Set thermostat to desired setting DANGER Hotter water increases the risk of scald injury consult the instruction manual before changing temperature 10 Turn off the gas to the water
32. as water heater should MODEL NUMBER a need ever exist for repair parts or service simply contact SERIAL NUMBER any Sears Service Center or call 1 800 4 MY HOME 1 800 469 4663 Be sure to provide all pertinent facts when GAS NATURAL OR PROPANE L P you call or visit PART DESCRIPTION WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE THIS IS A REPAIR PARTS LIST NOT A PACKING LIST FOLLOWING INFORMATION 43 Get it fixed at your home ours Your Home 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 systems 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 USA 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 re
33. at develops a leak For the second through sixth year from the purchase date you must pay the labor cost for installation of parts or water heater For 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 ue additional cost associated with the changes made to the replacement water heater design to comply with such governmental regulations Replacements and or repairs 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 MANA
34. bjected to a flammable vapors ignition will require replacement of the entire water heater 3 Reset the thermal switch by depressing the small button in the center of the thermal switch Follow the Lighting Instructions found on the front of your water heater Atemperature limit switch or ECO Energy Cut Off sensor located in the gas control valve thermostat is used to shut off the water heater if the water temperature exceeds 189 F 87 C The Diagnostic Status Light will flash a code indicating an Overheat Failure 4 Flashes See Status Light Troubleshooting Flowchart Section If the gas control valve thermostat has an ECO Lockout the gas control valve thermostat cannot be used until it is replaced by a qualified technician Contact Sears at 1 800 4 MY HOME 1 800 469 4663 to request service Leakage Checkpoints 6 MAXIMUM AIR GAP FIGURE 45 37 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 Read this manual first Then before checking the water heater make sure the gas supply has been turned OFF and never turn the gas ON before the tank is completely full of water Never use this water heater unless it is completely
35. ble installing using or servicing 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 Inspect and replace anode Install in location with drainage Fill tank with water before operation Be alert for thermal expansion Refer to instruction manual for installation and service TABLE OF CONTENTS SAFE INSTALLATION USE AND 2 00000 0 00000000 2 SAFETY PRECAUTIONS teet ed eed e a su ec aie Re ads 2 3 PRODUCT WARRANTY 31 3 p D ada rk S Rien as 6 CUSTOMER 5 7 PRODUCT SPECIFICATIONS 8 MATERIALS AND BASIC TOOLS 9 TYPIGAL INSTALEATION 5 6 dais een 10 IMPORTANT INFORMATION ABOUT THIS WATER 11 Installation Checklist t de fede Pea ides 11 INSTALEATION INSTRUGTIQONS t ote Re tiae n ta ee e E E ESTRENO 12 15 Removing the Old Water Heater icit pret iE ete La e EP e en 12 Location Requireme
36. d water pressure 35 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 3 COLD WATER PRESSURE INLET FITTING REDUCING VALVE WITH BY PASS 07 EXPANSION TANK INLET COLD WATER SHUT OFF 2 PRESSURE GAUGE RECOMMENDED INSTALLATION VERTICAL MOUNTING WATER HEATER COLD WATER INLET FITTING FLOOR CEILING JOIST ETC STRAPPING 3 PRESSURE REDUCING VALVE WITH 1 BY PASS EXPANSION TANK 2 zt PRESSURE GAUGE INLET COLD WATER SHUT OFF ALTERNATE RECOMMENDED INSTALLATION HORIZONTAL MOUNTING FIGURE 44 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
37. e 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 Figures 41 amp 42 10 Inspect the door gasket and make sure there is fiberglass insulation between the gasket and the combustion chamber Replace the two screws which secure the manifold burner assembly door to the combustion chamber and tighten securely Once the manifold burner assembly door is tightened visually inspect the door gasket between the manifold burner assembly door and the combustion chamber for spaces or gaps that would prevent a seal IMPORTANT Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber During the following procedure do not cross thread or apply any thread sealant to any of the fittings listed below First reconnect the manifold tubing to the gas control valve thermostat NOTE L P gas systems use reverse left hand threads on the manifold tube NOTE If a ferrule nut needs to be installed for the pilot tube locate the one provided with your parts kit Install it in the gas control valve thermostat at the pilot location hand tight only Next insert the pilot tube into the ferrule nut until it bottoms out NOTE Hold the tube in this position Tighten the ferrule nut with a wrench until the crimp connection seals to the pilo
38. e found to be damaged consult the replacement parts list on page 43 for the appropriate replacement After any connection problems are fixed restart the water heater by following the lighting instructions on page 24 If the problem persists replace the damper Four Flash three second pause ECO Limit Lockout the power switch the gas control valve to the OFF position 10 20 seconds then turn the power switch on the gas control valve to the ON position If the problem persists replace the gas control valve Five Flash three second pause Flame Out of Sequence Turn the power switch on the gas control valve to the OFF position Wait 10 minutes then follow the lighting instructions on page 24 If the problem persists replace the gas control valve Six One Flash three second pause Soft Lockout Retry Limit Turn the power switch on the gas control valve to the OFF position and unplug the power cord Failed TFI Trial for Ignition from the power outlet KE Check the incoming gas line pressure to ensure adequate supply to the water heater If incoming gas supply pressure is adequate proceed to step 2 Check all wiring connections and insure all harness and wires connections are seated firmly and provide proper electrical contact If no connection problems are found proceed to step 3 Firmly seat any loose connections found If any connections are found to be damaged consult the replacement parts list for the
39. e power outlet END Switch Fails 1 Check all wiring connections to insure all harness and wire connections are seated firmly and provide proper electrical contact If no connection problems are found replace the damper Firmly seat any loose connections found If any connections are found to be damaged consult the replacement parts list on page 43 for the appropriate replacement After any connection problems are fixed restart the water heater by following the lighting instructions on page 24 If the problem persists replace the damper Six Three Flash three second pause Soft Lockout Recycle Limit Flame Lost Turn the power switch on the gas control valve to the OFF position and unplug the power cord from the power outlet 1 Check the incoming gas line pressure to ensure adequate supply to water heater If incoming gas supply pressure is adequate proceed to step 2 Check all wiring connections and insure all harness and wires connections are seated firmly and provide proper electrical contact If no connection problems are found proceed to step 3 Firmly seat any loose connections found If any connections are found to be damaged consult the replacement parts list for the appropriate replacement After any connection problems are fixed restart the water heater by following the lighting instructions on page 24 If the problem persists proceed to step 3 Check condition of the base ring filter and flame arrestor If they are clogged
40. e 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 60 0 Example Input BTU requirement of the water heater 100 000 BTUH Total pipe length 80 feet 3 4 IPS required Additional tables are available in the latest edition of the National Fuel Gas Code ANSI 2223 1 17 Carbon Monoxide Warning Follow all the local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI 2223 1 NFPA 54 current edition to properly install vent system Failure to do so can result in death explosion or carbon monoxide poisoning IMPORTANT Air for combustion and ventilation must not come from a corrosive atmosphere Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage The following types of installation not limited to the following will require outdoor air for combustion due to chemical exposure and may reduce but not eliminate the presence of corrosive chemicals in the air e beauty shops photo processing labs buildings with indoor pools e water heaters installed in laundry hobby or craf
41. eads on the manifold tube 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 To remove the gas control valve thermostat thread a 4 section of 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 To replace the gas control valve thermostat reassemble in reverse order When replacing the gas control valve thermostat thread a 4 section of pipe into the inlet and use it to turn the gas control valve thermostat 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 Reconnect the gas piping to the gas control valve thermostat NOTE Use an approved Teflon tape or pipe compound on the gas piping connections Do not use the pilot ferrule nut supplied with the new gas control valve thermostat unless the existing nut is not usable Reconnect the manifold tube pilot tube igniter wire 34 wiring harness and thermal switch wires NOTE L P gas systems use reverse left hand threads on the m
42. ectric utility requirements when you install this wiring This appliance must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA No 70 current edition and or THE CSA C22 1 ELECTRICAL CODE LATEST EDITION Note If any of the original wire as supplied with the appliance must be replaced it must be replaced with 105 C wire or its equivalent FIGURE 30 27 SERVICE AND ADJUSTMENT Vent System Inspection WARNING Flue gases may escape if vent pipe is not connected Be alert for obstructed sooted or deteriorated vent system to avoid serious injury or death Do not store corrosive chemicals in vicinity of water heater Chemical corrosion of flue and vent can cause serious injury death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual At least once a year a visual inspection should be made of the venting system You should look for e Obstructions which could cause improper venting The combustion and ventilation air flow must not be obstructed Damage or deterioration which could cause improper venting or leakage of combustion products Rusted flakes around top of water heater Be sure the vent piping is properly connected to prevent escape of dangerous flue gasses which could cause deadly asphyxiation Obstructions and deteriorated vent syste
43. ements to the water heater Areas that are being used for storage or contain large objects may not be suitable for water heater installation e Water heaters installed in open spaces in buildings with unusually tight construction may still require outdoor air to function properly In this situation outside air openings should be sized the same as for a confined space Modern home construction usually requires supplying outside air into the water heater area Confined Space For the correct and proper operation of this water heater ample air must be supplied for the combustion ventilation and dilution of flue gases Small enclosures and confined areas must have two permanent openings so that sufficient fresh air can be drawn from outside of the enclosure One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure as shown in Figure 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 12 MAXIMUM CLOSET OR PERMANENT OTHER OPENINGS TO CONFINED THE OUTSIDE OR SPACE ADDITIONAL ROOMS WITHIN THE BUILDING 12 MAXIMUM FIGURE 13 All Air fro
44. ents must be supported to prevent damage joint 21 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 type 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 2223 1 current edition and the guidelines set forth by prevailing local codes oar LISTED VENT CAP 2 FT MINIMUM ABOVE ANY OBJECT WITHIN 10 FT HORIZONTALLY TYPE DOUBLE WALL VENT PIPE 3 FT MINIMUM A SUPPORT STRAP MAINTAIN CLEARANCE MAINTAIN SPECIFIED CLEARANCE SLOPE UP 1 4 VERTICAL GAS VENT SYSTEM WITH TYPE B DOUBLE WALL VENT PIPE FIGURE 21 5 LISTED VENT CAP MAINTAIN MANUFACTURER S SPECIFIED MINIMUM CLEARANCE M MAINTAIN SPECIFIED CLEARANCE SUPPO
45. eplacing the Pilot Igniter Flame Sensor Assembly 1 Remove the manifold assembly as directed previously 2 the retainer clip straight up from the back of the manifold component block using flat blade screwdriver then remove the manifold component block from the manifold door Figure 37 3 Using a 7 16 wrench loosen the nut securing the pilot tube to assembly NOTE To prevent any bending of the pilot bracket use pliers to hold the pilot assembly bracket while loosening the pilot nut Pilot Igniter Flame Sensor Assembly Pilot Tube Igniter Wire Manifold Component Block Manifold Door FIGURE 37 Pull the pilot tube from the pilot assembly Figure 37 IMPORTANT Be careful not to bend or alter the position of the pilot assembly components Use a screwdriver to remove the screws securing the Pilot Igniter Flame Sensor Assembly Keep the screws for reattachement Using the old pilot pilot tube assembly as a guide bend the new pilot tube to match the old one Make only the bends closest to the pilot before going to the next step OLD PILOT IGNITER FLAME SENSOR ASSEMBLY ma D SCREWS OTHER FITTINGS NOT SHOWN 9 FOR CLARITY PILOT TUBE_ po n FIRST BEND S FIGURE 38 Push the new pilot tube and igniter wire through the hole in the manifold door See Figure 37 Reconnect the pilot tube and tighten the nut securing i
46. er heater s burner and pilot preventing re ignition of any remaining flammable vapors in the area This will not prevent a possible fire explosion if the igniter activates and flammable vapors have accumulated in the combustion chamber with the pilot light off If you suspect a flammable vapor incident has occurred do not use this appliance Do not attempt to light this appliance if you suspect flammable vapors have accumulated inside or outside the appliance Immediately call a qualified technician to inspect the appliance Water heaters subjected to a flammable vapors incident will show a discoloration on the flame arrestor and require replacement of the entire water heater 13 AWARNING 9 7 Flammable Vapors FIRE AND EXPLOSION HAZARD Can result in serious injury or death A Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Storage of or use of gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance can result in serious injury or death Read and follow water heater warnings and instructions 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 sub
47. er 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 Water Temperature Adjustment The water temperature setting can be adjusted from 70 F to 160 F Turn the Gas Control Temperature Knob to the desired setting temperature NOTE The temperatures indicated are approximates The actual temperature of the heated water may vary Status Light Code demand When leaving your home for extended periods vacations etc turn the temperature dial 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 Operating Modes and Settings Standard Mode The controller adjusts the water heater to maintain the temperature set by the user e Vacation Setting The Vacation Setting VAC sets the controller at approximately 70 F This setting is recommended when the water heater is not in use for a long period of time This effectively turns the controller temperature setting down to a temperature that prevents the water in the water heater from freezing while still conserving energy Table 5 LED FLASH SEQUENCE Short flash once every four second Heartbeat alternates bright dim One Flash three second pause Two Flash three second pause Three Flash three
48. es it is recommended that the discharge line be terminated at an adequate drain inside the building Must be capable of withstanding 250 F 121 C without distortion Must be installed to allow complete drainage of both the valve and discharge line T amp P Relief Valve and Pipe Insulation The 1 Locate the temperature and pressure relief valve on the water heater also known as a T amp P relief valve See Figure 26 2 Locate the slit running the length of the T amp P relief valve insulation 3 Spread the slit open and fit the insulation over the T amp P relief valve See Figure 26 Apply gentle pressure to the insulation to ensure that it is fully seated on the T amp P Relief Valve Once seated secure the insulation with duct tape electrical tape or equivalent IMPORTANT The insulation and tape must not block the discharge opening or hinder access to the manual relief lever Figure 26 Ensure a discharge pipe is installed into the T amp P valve discharge opening per the instructions in this manual Locate the hot water outlet amp cold water inlet pipes to the water heater 5 Locate the slit running the length of a section of pipe insulation 6 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 that it is fully seated around the pipe Also ensure that the base of the insulation is flush with the water heater
49. es occur within twelve months Product replacement if your covered product can t be fixed e Annual Preventive Maintenance Check at your request no extra charge Fast by phone 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 6 c 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
50. ete M Ote ud at Dod Mte EE dete M EEEE 20 Draft Hood Installation cette ent d o data ote Di alites 20 Ment Pipe SIZe vivitar pedem Hane ee Pe Veo dd a d 20 Vent CGonnectolS E EE 20 21 Chimney Corinectlon 2 coniicere eee eiie ce eee ee n e da naive deae dme de aga een aep ieu ed eda 21 Vertical Exhaust 22 5 a ee e cb 21 WATER SYSTEM PIPING tette ine testet ales EE Ya E Pei p ae 22 23 Piping Installation ott i e o oe td re a 22 Glosed System Thermal Expansion 15i etit ce diee cited esee eode nt a eec eae tq 23 Temperature and Pressure Relief 23 T amp P Relief Valve and Pipe 23 OPERATING YOUR WATER HEATER 24 26 Lighting Instr ctlOris iine et Red ene eh emat UEM 24 Checking the 25 adc 25 Emergency Shut DWM iar teet ee c ttti qd ee tees 25 Water Temperature Regulatlori 3 1 eerte dite pe dta ete nad iet 25 26 Water Temperature Adjustment 2 rero reb e E e nette 26 Operating Modes and Settings ee doe Rata ea eee 26 Electrical Connections Wiring
51. expansion In a closed system the volume of water will grow As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent temperature pressure relief valve operation water discharged from the valve due to excessive pressure build up The temperature pressure relief valve is not intended for the constant relief of thermal expansion This condition is not covered under the limited warranty A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion Thermal expansion tanks are available from Sears stores and through the Sears Service Centers Contact the local plumbing inspector water supplier and or the Sears Service Center for assistance in controlling these situations See Figure 44 Table 6 Thermal Expansion Tank Specifications Model Number Tank Dimensions Capacity in Inches Fitting In Gallons Length On Tank 153 331020 8 203 mm 12 3 4 323 3 4 Male 153 331050 5 m 279 mm 14 3 4 375 3 4 Male Table 7 Expansion Tank Sizing Chart Inlet Water Pressure Water Heater Capacity Gallons Expansion Tank Capacity Needed Highest recorded inlet water pressure in a 24 hour period or regulate
52. f problem persists replace the flue Set temperature dial to lower setting Drain flush provide water treatment if needed Install adequate heater 3 4 Correct piping dip tube must be in cold inlet 5 Repair faucets 6 Check with utility repair at once 7 customer 8 Insulate piping 9 Insulate piping 10 Replace the flue damper 1 2 Turn temperature dial to desired setting Drain flush provide water treatment if needed Install adequate heater 3 4 Correct piping dip tube must be in cold inlet 5 gt faucets 6 Advise customer 7 Insulate piping 8 Insulate piping 9 Check with gas utility company TROUBLESHOOTING CHART CONTINUED PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION SLOW HOT WATER 1 Insufficient secondary air 1 Provide ventilation to water heater Check RECOVERY flue way flue baffle and burner 2 Flue clogged 2 Clean flue locate source and correct 3 Low gas pressure 3 Check with gas utility company 4 Improper calibration 4 Replace thermostat 5 Thermostat set too low 5 Turn temperature dial to desired setting 6 Water heater too small 6 Install adequate heater 7 7 Wrong piping connections Correct piping dip tube must be in cold inlet 8 Wasted hot water 8 Advise customer DRIP FROM RELIEF VALVE 1 Excessive water pressure 1 Use a pressure reducing valve and relief valve 2 Heater stacking 2 Lower the thermostat setting 3 Closed water system
53. f 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 ADANGER Water temperature over 125 F 52 can cause severe burns instantly resulting in severe injury or death Children the elderly and the
54. filled with water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater A Water at the draft hood is water vapor which has condensed out of the combustion products This is caused by a problem in the vent Contact a qualified technician Condensation may be seen on pipes in humid weather or pipe connections may be leaking C The anode rod fitting may be leaking D Small amounts of water from temperature pressure relief valve may be due to thermal expansion or high water pressure in your area E The temperature pressure relief valve may be leaking at the tank fitting F Water from a drain valve may be due to the valve being slightly opened The drain valve may be leaking at the tank fitting 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 the water heater bottom or on the floor may be from condensation loose connections or the relief valve DO NOT replace the water heater until a full inspection of all possible water sources is made and necessary corrective steps taken Leakage from other appliances water lines or ground seepage should also be checked To check where threaded portion enters tank
55. fire department 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 n
56. follow the instructions for cleaning on page 32 If parts are not clogged proceed to step 4 After cleaning follow instructions for lighting on page 24 If problem persists proceed to step 4 Follow the instructions on page 31 to remove the burner assembly Once the burner assembly has been removed inspect the manifold tube and burner see figure 36 for any obstructions If any clogs or obstructions are present clear them Inspect the electrode flame sense rod see figure 43 for corrosion buildup degradation or damage If there is evidence of any damage to the electrode flame sense rod replace the igniter pilot assembly Follow the directions on page 32 to re install the burner assembly into the combustion chamber Follow the instructions for lighting on page 24 If the problem persists contact a qualified service representative Six Four Flash three second pause Soft Lockout Flame out of Sequence Sensed Turn the power switch on the gas control valve to the OFF position and unplug the power cord from the power outlet Wait 10 minutes then follow the lighting instructions on page 24 If the problem persists replace the gas control valve Seven Flash three second pause Flammable Vapor Sensor FVS Lockout A Do not touch any electrical switch do not use any phone in the building and do not try to 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
57. gure 25 This valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of listed equipment or materials as meeting the requirements for Relief Valves for Hot Water Supply Systems ANSI Z21 22 The function of the temperature and pressure relief valve is to discharge water in large quantities in the event of excessive temperature or pressure developing in the water heater The valve s relief pressure must not exceed the working pressure of the water heater as stated on the rating plate IMPORTANT Only a new temperature and pressure relief valve should be used with your water heater Do not use an old or existing valve as it may be damaged or not adequate for the working pressure of the new water heater Do not place any valve between the relief valve and the tank The Temperature 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 Discharge Line Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line Must not be capped blocked plugged or contain any valve between the relief valve and the end of the discharge line Must terminate a maximum of six inches above a floor drain or external to the building In cold climat
58. heater at the manual shut off valve Move the ON OFF switch on the Gas Control Valve Thermostat to the OFF position 3 Turn off all electric power to the appliance Disconnect from grounded 110 120 volt power outlet 24 Checking the Draft Do 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 27 Make sure all other appliances in the area are operating and all doors are closed when performing the draft test Pass a match flame around the relief opening of the draft hood A steady flame drawn into the opening indicates proper draft FIGURE 27 If the flame flutters or is blown out combustion products are escaping from the relief opening If this occurs do not operate the water heater until proper adjustments or repairs are made to the vent pipe system and or air supply requirements Burner Flames Inspect the burner flames through the viewport and compare them to the drawing in Figure 28 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
59. iately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions elf you cannot reach your gas supplier call the fire department WARNING if you do not follow these instructions exactly a fire or explosion may result causing property damage personal C Use only your hand to turn the gas control knob E Explosion Hazard Replace view port if glass is missing or damaged Failure to do so can result in death explosion or fire FLAMMABLE D WITH WATER AND AIR PURGED FROM ALL LINES Never use tools If the knob will not turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately contact a qualified installer or service agency to replace a flooded water heater Do not attempt to repair the unit It must be replaced DO NOT USE THIS APPLIANCE IF THERE HAS BEEN AN IGNITION OF VAPORS Immediately call a qualified service technician to inspect the appliance Water heaters subjected to a flammable vapors ignition will show a discoloration on the air intake grid and require replacement of the entire water heater On Off Switch x e C Status Light 59 rol Temperature Knob STOP It is imperative that you read ll the safety warnings above on abel Remove the outer door Move the ON OFF switch on the G
60. igure 34 Igniter dal Manifold Wire Tube Wiring Harness FIGURE 34 3 Remove the outer door 4 Remove the two screws 1 4 nut driver securing the manifold door assembly to the combustion chamber Figure 35 Gas Control Thermostat Wiring Pilot Tube Vi rt Manifold Tube iewpo FV Sensor Thermal Switch J g Manifold Door Manifold t Block Manifold Screw fh FIGURE 35 5 Disconnect the pilot tube 7 16 wrench the igniter wire and manifold tube 3 4 wrench at the gas control valve thermostat Also use needle nose pliers to disconnect the yellow TCO wire leads from the thermal switch on the manifold door NOTE L P Gas systems use reverse left hand threads on the manifold tube 6 Grasp the manifold tube and push down slightly to free the manifold and pilot tube 7 Carefully remove the manifold assembly from the burner compartment NOTE Be sure not to damage internal parts Removing the Burner from the Manifold Burner Assembly Natural Gas Low Nox amp L P 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 BURNER BOTTOM VIEW FIGURE 36 R
61. ing 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 in These openings connect directly with the outdoors through a ventilated attic a ventilated crawl space or through an outside wall Consult the local codes of your area for specific ventilation and combustion air requirements GABLE VENT TO OUTDOORS INSTALL ABOVE P INSULATION CONFINED ATTIC 1 SQ INCH PER 4000 BTUH ALTERNATE AIR INLET 1 INCH PER OPEN 4000 FOUNDATION VENT ALL AIR FROM OUTDOORS INLET AIR FROM VENTILATED CRAWL SPACE OUTLET AIR TO VENTILATED ATTIC FIGURE 15 GABLE VENT xm TO OUTDOORS INSTALL ABOVE a INSULATION J OUTLET AIR 5 CONFINED 1 SQ INCH SPACE PER 4000 BTUH INLET AIR DUCT 1 SQ INCH PER 4000 BTUH 12 MAXIMUM ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC FIGURE 16 19 1 INCH PER 2000 BTUH TOI AY OUTLET OUTDOOR AIR DUCTS CONFINED SPACE 1 SQ INCH PER 2000 BTUH ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS FIGURE 17 ALTERNATIVE OPENING LOCATION 1 SQ INCH E PER 3000 BTUH CONFINED SPACE ALL AIR FROM OUTDOORS USING A SINGLE PERMANENT OPENING FIGURE 18 Vent Pipe Sy
62. ing 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 Operational Conditions Smelly Odor In each water heater there is installed at least one anode rod see parts section for corrosion protection of the tank Certain water conditions will cause a reaction between this rod and the water The most common complaint associated with the anode rod is one of a rotten egg smell This odor is derived from hydrogen sulfide gas dissolved in the water The smell is the result of four factors which must all be present for the odor to develop 36 e aconcentration of sulfate in the supply water little or no dissolved oxygen in the water e sulfate reducing bacteria within the water heater This harmless bacteria is non toxic to humans anexcess of active hydrogen in the tank This is caused by the corrosion protective action of the anode Smelly water may be eliminated or reduced in some water heater models by replacing the anode s with one of less active material and then chlorinat
63. ing the water heater tank and all hot water lines Contact Sears Service for further information concerning this chlorination treatment and an anode replacement kit 49001453 For short heaters use anode replacement kit 9006299 Anode replacement and chlorination of the tank are not covered by the water heater s limited warranty If the smelly water persists after the anode replacement and chlorination treatment it may be necessary to chlorinate or aerate your water supply to eliminate the problem Do not remove the anode leaving the tank unprotected By doing so all warranty on the water heater tank is voided AIR In Hot Water Faucets A WARNING Explosion Hazard Flammable hydrogen gases may 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 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 o
64. inimum 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 area through a particular design of louver or grille is known it should be used in calculating the specified free area of the opening If the design and free area are not known it can be assumed that most wood louvers will allow 20 2590 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 Reference Opening Source Per Opening sq in 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 Open
65. irmly and provide proper electrical contact If no connection problems are found replace the damper Firmly seat any loose connections found If any connections are found to be damaged consult the replacement parts list on page 43 for the appropriate replacement After any connection problems are fixed restart the water heater by following the lighting instructions on page 24 If the problem persists replace the damper Three Flash three second pause End Switch Failed Open or TCO Limit Lockout Turn the power switch on the gas control valve to the OFF position and unplug the power cord from the power outlet 1 Attempt to depress the TCO door switch button see figure 35 If the TCO door switch button depresses follow the instructions for cleaning the filter and flame arrestor on page 24 After cleaning is completed follow the lighting instructions on page 24 If the TCO door switch button does not depress proceed to step 2 Follow the lighting instructions on page 24 Observe the damper during initial startup If there is a call for heat and the damper opens allow the unit to continue to perform and monitor any change in status If there is a call for heat and the damper does not open proceed to step 3 Check all wiring connections to insure all harness and wire connections are seated firmly and provide proper electrical contact If no connection problems are found replace the damper Firmly seat any loose connections found If any connections ar
66. m Inside 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 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 PERMANENT OPENINGS 1 SQUARE INCH 1000 BTUH MINIMUM 100 SQ IN FIGURE 14 Air from Outdoors Outdoor fresh air can be provided to a confined area either directly or by the use of vertical and horizontal ducts The fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors Attic or crawl spaces cannot be closed and must be properly ventilated to the outside Ductwork must be of the same cross sectional area as the free area of the opening to which they connect The minimum dimension of rectangular air ducts cannot be less than three inches The size of each of the two openings is determined by the method in which the air is to be provided Refer to Table 4 to calculate the m
67. mp 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 7 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 22 IN A CLOSED SYSTEM USE A gc THERMAL EXPANSION TANK COLD WATER SUPPLY TO FIXTURES PRESSURE REDUCING VALVE a WITH BYPASS COLD WATER INLET COLD WATER INLET VALVE SHUT OFF VALVE RE HOT WATER OUTLET TEMPERATURE AND PRESSURE T amp P RELIEF VALVE OPTIONAL TOP T amp P RELIEF VALVE NOT SHOWN DISCHARGE PIPE DO NOT CAP OR PLUG MASSACHUSETTS INSTALL A VACUUM RELIEF IN COLD WATER LINE PER SECTION 19 MGL 142 DRAIN LINE 3 4 ID MINIMUM 1 MINIMUM SEED DRAIN gt F SUITABLE DRAIN 6 MAXIMUM AIR GAP FIGURE 23 F TEMPERED WATER FIXTURES UNTEMPERED HOT WATER COLD WATER ware OUTLET MIXING VALVE SET TO 120 F 3 FOLLOW THE MIXING VALVE MANUF
68. ms may present serious health risk or asphyxiation Chemical vapor corrosion of the flue and vent system may occur if air for combustion contains certain chemical vapors Spray can propellants cleaning solvents refrigerator and air conditioner refrigerants swimming pool chemicals calcium and sodium chloride waxes bleach and process chemicals are typical compounds which are potentially corrosive If when inspecting the vent system you find sooting or deterioration something is wrong Call the local gas supplier to correct the problem and clean or replace the flue and venting before resuming operation of the water heater Burner Inspection Flood damage to a water heater may not be readily visible or immediately detectable However over a period of time a flooded water heater will create dangerous conditions which can cause DEATH SERIOUS BODILY INJURY OR PROPERTY DAMAGE Contact a Sears Service Center to replace a flooded water heater Do not attempt to repair the unit It must be replaced 28 At least once a year a visual inspection should be made of the main burner and pilot burner See Figure 31 You should check for sooting Soot is not normal and will impair proper combustion Soot build up indicates a problem that requires correction before further use Turn OFF gas to water heater and leave off until repairs are made because failure to correct the cause of the sooting can result in a fire causing death serious inju
69. n 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 e 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 drain pan e 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 e Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply Insulation Blankets Insulation blankets available to the general public for external use on gas water heaters are not necessary with Kenmore products The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters Your Kenmore water heater meets or exceeds the National Appliance Energy Conservation Act standards with respect to insulation and standby loss requirements making an insulation blanket unnecessary A WARNING Do not obstruct water heater air intake with insulating blanket Gas and carbon monoxide
70. nnections Leaking faucets Gas leaks Wasted hot water Long runs of exposed piping Hot water piping in exposed wall Flue Damper seal not functioning Thermostat set too low Sediment or lime in tank Water heater too small Wrong piping connections Leaking faucets Wasted hot water Long runs of exposed piping Hot water piping in outside wall Low gas pressure 38 See PILOT WILL NOT LIGHT OR REMAIN LIT Turn temp dial to desired temperature Check with gas utility company Notify utility install trap in gas line Clean locate source and correct Clean locate source and correct Replace thermostat Provide fresh air ventilation Cycle power to the water heater off and on If problem persists replace the flue Provide ventilation to water heater Check with gas utility company Clean locate source and correct Clean locate source and correct Proper fresh air ventilation Clean or replace orifice See Status Light Code Troubleshooting Table section 2 See Pilot Light Troubleshooting Flowchart section Seat connector firmly in socket Bleed the air from the gas line Check with gas utility company Check with gas utility company Notify utility install dirt trap in gas line Locate source and correct Replace thermostat Clean locate source and correct See maintenance section for inspection and cleaning of flame trap Contact a qualified person to reset the sensor Cycle power to the water heater off and on I
71. nts eie Ua et deed iit e las a a niga id 13 cue 13 Insulation Blankets n tem idit tpm diee 14 Clearances Accessibility 5 ee ee etd dde Uae ec eet ed de e de pede 15 Filling Water Heater cire ait Dee eb 15 GAS SUPPLY T iret et a aie 16 5 taba aioe e Dee pee Leda 16 eee ee 16 as Pressure iui o tito e ie tec fe 17 Gas Pressure n en eee eee ee Lee a awe eg deed 17 Gas Only cese od eeu IA 17 COMBUSTION AIR SUPPLY amp VENTILATION ccccccccceesseceeeeeeceeseeseaseuceceeeesseseaeeuceeeeeessesaeaeseeeeees 18 23 Wncontined Space m mede im e p ber t e PEEL Ee t aded 18 Confinied Space uaa te etia de ce Janie os eee dae dap eee dot uten 18 All Ait from Inside the Bullding io coe Pe t eee ma etit 18 19 from OUtdoOrs i terit Pero eet aa 19 the tw te tenen a ett tetendit ees 19 20 Ment Plpe System ad ic dee ee LU e bete ti P
72. of the water piping and drain piping to protect against freezing The drain and controls must be easily accessible for operation and service Maintain proper clearances as specified on the rating plate Do not locate the water heater near an air moving device The operation of air moving devices such as exhaust fans ventilation systems clothes dryers fireplaces etc can affect the proper operation of the water heater Special attention must be given to conditions these devices may create Flow reversal of flue gases may cause an increase of carbon monoxide inside of the dwelling Figure 9 If the water heater is located in an area that is subjected to lint and dirt it may be necessary to periodically clean the base ring filter and flame arrestor see External Inspection amp Cleaning of the Flame arrestor This water heater is not for use in manufactured mobile homes or outdoor installation NOTE This water heater must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition EXHAUST FAN REVERSE FLOW OF GASES FIGURE 9 CAUTION All water heaters eventually leak Do notinstall without adequate drainage IMPORTANT The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower fl
73. of this manual LP Gas Only AWARNING 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 Explosion Hazard For more information contact your gas supplier PP Have a qualified person make sure L P gas pressure If a gas leak is detected follow the What to do if you does not exceed 13 water column smell gas instructions on the cover of this manual Examples of a qualified person include licensed plumbers authorized gas company personnel and IMPORTANT The gas supply pressure must not exceed the maximum authorized service personnel supply pressure as stated on the water heater s rating plate The minimum supply pressure is for the purpose of input adjustment Failure to do so can result in death explosion or fire Gas Pressure Testing IMPORTANT This water heater and its gas connection must be leak tested before placing the appliance in operation Liquefied petroleum gas is over 5096 heavier than air and in the occurrence of a leak in the system the gas will settle at floor level Basements crawl spaces closets and areas below ground level will serve as pockets for the accumulation of gas Before lighting an L P gas water heater smell all around the appliance at floor level If you smell gas follow the instructions e If the code requires the gas lines to be tested at a pressure exceeding 14 W C
74. om to service the water heater See Clearances and Accessibility section of this manual Water heater not located near an air moving device Is the installed environment dirty excessive amounts of lint dirt dust etc If so the base ring filter located on the bottom of the water heater will need to be cleaned periodically Refer to the Maintenance of your Water Heater section of this manual for information on cleaning the base ring filter Combustion Air Supply and Ventilation Check for sufficient combustion air supply Insufficient air for the combustion of gas will result in the flame becoming lazy thereby allowing heat to build up in the combustion chamber This excessive heat will cause a thermal switch on the door assembly to trip 15 the water heater installed in a closet or other small enclosed space If so Are there openings for make up air to enter and exit the room area Are the openings of sufficient size Remember if there are other gas fired or air consuming appliances in the same room you need more make up air Refer to the Installation Instructions and Combustion Air Supply and Ventilation sections for specific requirements Make sure that fresh air is not taken from areas that contain negative pressure producing devices such as exhaust fans dryers fireplaces etc Is there a furnace air handler in the same room space as the wate
75. oors of the structure Due to the normal corrosive action of water the tank will eventually leak after an extended period of time Also any external plumbing leak including those from improper installation may cause early failure of the tank due to corrosion if not repaired If the homeowner is uncomfortable with making the repair a qualified technician should be contacted A suitable metal drain pan should be installed under the water heater as shown below to help protect the property from damage which may occur from condensate formation or leaks in the piping connections or tank The pan must limit the water level to a maximum depth of 1 3 4 and be two inches wider than the heater and piped to an adequate drain NOTE The pan must not restrict combustion air flow Locate the water heater near a suitable indoor drain Outside drains are subject to freezing temperatures which can obstruct the drain line The piping should be at least 3 4 ID and pitched for proper drainage DISCHARGE PIPE DO NOT CAP OR PLUG METAL DRAIN PAN 172 AT LEAST 2 GREATER THAN THE DIAMETER OF THE WATER HEATER TO AN ADEQUATE DRAIN 6 MAXIMUM AIR GAP FIGURE 10 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 eve
76. orifice clogged 1 Clean locate source and correct TOO SMALL Low gas pressure 2 Check with gas utility company 39 STATUS LIGHT TROUBLESHOOTING FLOWCHART Status Light Code LED FLASH SEQUENCE CONTROL STATUS CORRECTIVE ACTION OLE One Flash three second pause Low Flame Signal control continues to Turn the power switch on the gas control valve to the OFF position and unplug the power cord from operate the power outlet 1 Check the incoming gas line pressure to ensure adequate supply to the water heater If incoming gas supply pressure is adequate proceed to step 2 Check all wiring connections and insure all harness and wires connections are seated firmly and provide proper electrical contact If no connection problems are found proceed to step 3 Firmly seat any loose connections found If any connections are found to be damaged consult the replacement parts list for the appropriate replacement After any connection problems are fixed restart the water heater by following the lighting instructions on page 24 If the problem persists proceed to step 3 Check condition of the base ring filter and flame arrestor If they are clogged follow the instructions for cleaning on page 32 If parts are not clogged proceed to step 4 After cleaning follow instructions for lighting on page 24 If problem persists proceed to step 4 Follow the instructions on page
77. ot 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 o
78. ound or teflon tape marked as being resistant to the action of petroleum Propane L P 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 2 Install a drip leg if not already incorporated as part of the water heater as shown The drip leg must be no less than three inches long for the accumulation of dirt foreign material and water droplets 3 Install a ground joint union between the gas control valve thermostat and the manual shut off valve This is to allow easy removal of the gas control valve thermostat 4 Turn the gas supply on and check for leaks Test all connections by brushing on an approved noncorrosive leak detection solution Bubbles will show a leak Correct any leak found 1 MANUAL GAS SHUT OFF GROUND gt 4 JOINT UNION CHECK WITH T DISCHARGE PIPE LOCAL UTILITY DO NOT CAP FOR MINIMUM HEIGHT OR PLUG 37 MINIMUM Lg MINE 6 MAXIMUM DRIP LEG PLU SUITABLE DRAIN V FIGURE 12 fuel is not spilled in area of the water heater installation ee or any source of ignition If the fuel is spilled while purging the piping system of air follow the WHAT TO DO IF YOU SMELL A WARN G GAS instructions on the cover
79. paracion a domicilio y para ordenar piezas 1 888 SU HOGAR 1 888 784 6427 www sears com Au Canada pour service en francais 1 800 LE FOYER 1 800 533 6937 WWW Sears ca Sears Registered Trademark Trademark of KCD IP LLC in the United States or Sears Brands LLC in other countries Marca Registrada Marca de F brica de IP LLC en Estados Unidos o Sears Brands LLC in otros pa ses MC Marque de commerce 0 Marque d pos e de Sears Brands LLC
80. pen flame near the faucet at the time it is open Safety Shut off and Thermal Switch This water heater is designed to automatically shut off in the event of the following 1 The water temperature exceeds 189 F 87 C for 160 F models 2 Excessive combustion chamber temperatures 3 The presence of flammable vapors This unit is equipped with a flammable vapor sensor designed to shut off the gas supply in the event the heater has been exposed to flammable vapors spilled gasoline or paint fumes for example IMPORTANT If the flammable vapor sensor activates a qualified technician must be contacted Reference Seven Flash Error code in the Status Light Troubleshooting Flowchart Section This unit is also equipped with a thermal switch designed to shut off the gas control valve thermostat in the event the water heater has poor combustion caused by a blocked vent or insufficient combustion air If the switch opens 1 Check the flame arrestor for signs of high temperature blue or black discoloration See Figure 41 2 If there are signs of high temperature or that the thermal switch has opened inspect your installation for problems with venting combustion air supply or a possible flammable vapor event Correct any issues prior to resetting the thermal switch If you suspect a flammable vapor incident has occurred do not use this appliance Immediately call a qualified technician to inspect the appliance Water heaters su
81. physically er mentally disabled are at highest riskforscald injury Feel water before bathing or showering Temperature limiting valves are available AWARNING Fire Hazard For continued protection against risk of fire not install water heater carpeted floor Do not operate water heater if flood damaged AWARNING Overheated water can cause water tank explosion Properly sized temperature and pressure relief valve must be installed in opening provided Read instruction manual for safe temperature setting Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and Do A WARNING AWARNING Install vent system in accordance with codes not operate water heater if flood liquids in the vicinity of this or any other appliance damaged Avoid all ignition sources if you smell Natural or LP gas High altitude orifice must be installed for Do not expose water heater control to excessive gas E operation above 10 100 feet 3 048m pressure Do not operate if soot is present Use only gas shown on rating plate UV Do not obstruct water heater air intake Maintain required clearances to combustibles with insulating jacket Keep ignition sources away from faucets after extended Do not place chemical vapor emitting period of non use products near water heater Ea Gas and carbon monoxide detectors Read instruction manual before are availa
82. r 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 three inches 76 2mm in any direction or if in an alcove or closet installation the entire floor must be covered by the panel e Figure 11 may be used as a reference guide to locate the specific clearance locations A minimum of 24 inches of front clearance should be provided for inspection and service 15 SIDES FIGURE 11 Filling the Water Heater Never use this water heater unless it is completely full of water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater To fill the water heater with water e Close the water heater drain valve by turning the handle to the right clockwise The drain valve is on the lower front of the water heater e Open the cold water supply valve to the water heater NOTE The cold water supply valve must be left open when the water heater is in use To ensure complete filling of the tank allow air to exit by opening the nearest hot water faucet Allow water to run until a constant flow is obtained This will let air out of the water heater and the piping e Check all water piping and connection
83. r 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 11 Use a fresh air supply that is free of corrosive elements and flammable vapors Fresh air openings must be sized correctly with consideration given to the blocking effect of louvers and grilles Ductwork must be the same cross sectional area as the openings Vent Pipe System Check for proper drafting at the water heater draft hood Refer to the Checking the Draft section of this manual for the test procedure If the procedure shows insufficient draft is present please check the following Draft hood properly installed Vent connectors securely fastened with screws supported properly to maintain six inch clearance Vent connector made of approved material and sized correctly Vent pipe system installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition Flue baffle properly positioned in the flue tube Check the vent system for restrictions obstructions and check the vent termination height Refer to the Air Supply and Ventilation section
84. r pilot assembly If no spark is visible check the wire connections and make sure the electrode is not broken Replace the igniter if defective Dirt and rust on the pilot or electrode tip can prevent the igniter spark Wipe clean with a damp cloth and dry completely Rust can be removed from the electrode tip and metal surfaces by lightly sanding with an emery cloth or fine grit sandpaper Removing and Replacing the Gas Control Valve Thermostat IMPORTANT This water heater has a resettable thermal switch installed Do not attempt to disable or modify this feature in any way Use only factory authorized replacement parts Removing the Gas Valve 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 Move the ON OFF switch on the gas control valve thermostat to the OFF position to turn off the water heater and unplug from the wall outlet Figure 34 3 Drain the water heater Refer to the section of Draining and Flushing section and follow the procedure Disconnect the wire harness flammable vapor sensor wires and igniter wire from the gas control valve thermostat Disconnect pilot tube 7 16 wrench and manifold tube 3 4 wrench at the gas control valve thermostat Figure 34 NOTE L P Gas systems use reverse left hand thr
85. roughout the manual that you must read and be aware of All warnings and all instructions are essential to the proper operation of the water heater and your safety Since we cannot put everything on the first few pages READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER The installation must conform with these instructions and the local code authority having jurisdiction In the absence of local codes installations shall comply with the following In the United States The National Fuel Gas 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 e Carefully plan the place where you are going to put the water heater Correct combustion vent action and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and fires See Figure 1 Examine the location to ensure the water heater complies with the nstallation 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
86. ry or property damage Wn AAA MV UU 1112 FIGURE 31 Burner Cleaning A DANGER Failure to properly reseal the combustion chamber will disable the flammable vapor ignition resistance feature of this water heater which could result in death or serious local Sears Service Center injury Contact your for assistance A Read instruction manual before installing using or servicing water heater If inspection of the burner shows that cleaning is required move the ON OFF switch on the gas control valve thermostat to the OFF position to turn off the water heater The burner needs to be removed for cleaning Call the Sears Service Center to remove and clean the burner and correct the problem that required the burner to be cleaned Housekeeping Vacuum around base of water heater for dust dirt and lint on a regular basis ADANGER Do not obstruct combustion air openings at the bottom of the water heater Do not use or store flammable vapor products such as gasoline solvents or adhesives in the same room or area near water heater or other appliance At least annually check the base ring filter and flame arrester for any dust lint or debris that may have accumulated Clean as necessary Can cause serious injury or death AT LEAST ANNUALLY A VISUAL INSPECTION SHOULD BE MADE OF THE BASE RING FILTERAND FLAME ARRE
87. s for leaks Repair as needed CAUTION Avoid water heater damage Fill tank with water before operating GAS SUPPLY AWARNING Explosion Hazard Use a new CSA approved gas supply line Install a shut off valve Do not connect a natural gas water heater to an L P gas supply Do not connect an L P gas water heater to a natural gas supply Failure to follow these instructions can result in death explosion or carbon monoxide poisoning Gas Requirements IMPORTANT Read the rating plate to be sure the water heater is made for the type of gas you 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 16 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 comp
88. second pause Four Flash three second pause Five Flash three second pause Six One Flash three second pause Six Two Flash three second pause Six Three Flash three second pause Six Four Flash three second pause Seven Flash three second pause Eight One Flash three second pause Eight Two Flash three second pause Eight Three Flash three second pause Eight Four Flash three second pause Soft Lockout Retry Limit Failed TFI Trial for Ignition Soft Lockout Recycle Limit Flame Lost END Switch Fails Soft Lockout Recycle Limit Flame Lost Soft Lockout 20 minute wait before returning to normal mode ELECTRICAL CONNECTIONS WIRING DIAGRAM Electrical Connections Before plugging in the water heater always make sure AWARN G The Voltage and frequency correspond to that specified on the water heater The electrical outlet has the proper overload fuse or breaker protection Plug into a 3 prong outlet e Water heater to be located within 6 feet of 120VAC outlet Unitis to connect to a 120VAC electrical supply outlet extension cord is not allowed Do not use an adapter 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 Failure to follow these ANSI NFPS 70 current edition instructions can result in Completely fill the tank with water and check all connections for dea
89. ssure build up The temperature pressure relief valve is not intended for the constant relief of thermal expansion This condition is not covered under the limited warranty A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion Thermal expansion tanks are available from Sears stores and through the Sears Service Centers Contact the local plumbing inspector water supplier and or the Sears Service Center for assistance in controlling these situations For additional information see the Troubleshooting Guide later in this manual Temperature and Pressure Relief Valve AWARNING Temperature pressure relief valve must comply with ANSI Z21 22 CSA 4 4 and ASME code Properly sized temperature pressure relief valve must be installed in opening provided Can result in overheating and excessive tank pressure Can cause serious injury or death TEMPERATURE AND PRESSURE T amp P RELIEF VALVE OPTIONAL TOP T amp P RELIEF VALVE NOT SHOWN DISCHARGE PIPE DO NOT CAP OR PLUG DRAIN LINE 3 4 ID MINIMUM FIGURE 25 1 MINIMUM METAL DRAIN PAN gt 6 MAXIMUM AIR GAP DRAIN 23 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 Fi
90. stances are in use If flammable liquids or vapors have spilled or leaked in the area of the water heater leave the area immediately and call the fire department from a neighbor s home Do not attempt to clean the spill until all ignition sources have been extinguished A WARNING Read instruction manual before installing using or servicing water heater 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 e Selectalocation 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 Locate the water heater as close to the chimney or gas vent as practical Consider the vent system piping and combustion air supply requirements when selecting the water heater location The venting system must be able to run from the water heater to termination with minimal length and elbows e Locate 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 an area not subject to freezing temperatures Water heaters located in unconditioned spaces i e attics basements etc may require insulation
91. stem This water heater uses a non direct single pipe vent system to remove exhaust gases created by the burning of fossil fuels Air for combustion is taken from the immediate water heater location or is ducted in from the outside see Combustion Air Supply and Ventilation This water heater must be properly vented for the removal of exhaust gases to the outside atmosphere Correct installation of the vent pipe system is mandatory for the proper and efficient operation of this water heater and is an important factor in the life of the unit The vent pipe must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition The vent pipe installation must not be obstructed so as to prevent the removal of exhaust gases to the outside atmosphere IMPORTANT The use of vent dampers is not recommended by the manufacturer of this water heater Although some vent dampers are certified by CSA International this certification applies to the vent damper device only and does not mean they are certified for use on this water heater U L recognized fuel gas and carbon monoxide CO detectors are recommended in all applications and should be installed using the manufacturer s instructions and local codes rules or regulations 20 IMPORTANT f you lack the necessary skills required to properly install this venting system you should no
92. t parts may be ordered from Sears Parts and Service Centers or by calling 1 800 4 MY HOME 1 800 469 4663 When ordering replacement parts always have the following information ready 1 model serial and product number 2 type of gas 3 item number 4 parts description See the Parts Order List section for a list of available repair parts External Inspection amp Cleaning of the Base Ring Filter 1 Atleast annually check the base ring filter Figure 40 for any dust or debris that may have accumulated on the filter screen NOTE If the water heater is located in an area that is subjected to lint and dirt it may be necessary to check the base ring filter more frequently 2 Follow the Lighting Instructions to turn off the water heater and allow it to cool for 10 minutes before attempting to clean the base ring filter 3 Use a vacuum cleaner with a hose attachment to remove any dust or debris that may have accumulated on the filter NOTE If unable to inspect or clean the base ring filter follow the Cleaning the Combustion Chamber and Flame arrestor instructions 4 After the base ring filter has been cleaned follow the Lighting Instructions to return the water heater to service Removing the Manifold Burner Assembly 1 1 Turn off the gas to the water heater at the manual shut off valve Figure 11 2 Move the ON OFF switch on the gas control valve thermostat to the OFF position to turn off the water heater F
93. t proceed but get help from a qualified technician Draft Hood Installation Draft hood Twist or bend the leg tips to secure the draft hood to the flue damper FIGURE 19 Align the legs of the draft hood with the slots provided Insert the draft hood leg tips into slots on the flue damper s flange as shown in Figure 19 Secure the draft hood by twisting or bending the leg tips See Figure 19 Do not alter the draft hood in any way If you are replacing an existing water heater be sure to use the new draft hood supplied with the 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 Maintain 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
94. t rooms e 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 used near the water heater or air inlet Combustion and ventilation air requirements are determined by the location of the water heater The water heater may be located in either an open unconfined area or in a confined area or small enclosure such as a closet or small room Confined spaces are areas with 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 TABLE 3 Minimum Square Feet with 8 Ceiling 188 281 375 469 Typical Room with 8 Ceiling BTUH Input 30 000 45 000 60 000 75 000 9 x21 14 x 20 15x25 15 x 31 18 IMPORTANT area must be open and be able to provide the proper air requir
95. t to the pilot assembly IMPORTANT Keep the pilot orifice in the pilot when making the connection DO NOT operate the water heater without the pilot orifice installed Reattach the pilot assembly to the manifold Be sure the igniter wire is positioned through the bottom opening of the manifold component block See Replacing Manifold Assembly section PILOT TUBE IGNITER WIRE MANIFOLD COMPONENT BLOCK FIGURE 39 32 Cleaning the Combustion Chamber and Flame arrestor 1 3 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 40 Use compressed air to clear any dust or debris that may have accumulated in the flame arrestor FLAME ARRESTOR COMBUSTION CHAMBER FILTER FIGURE 40 Reassemble by following the procedure under Replacing the Manifold Burner Assembly Replacing the Manifold Burner Assembly 1 2 3 AWARNING Explosion Hazard Tighten both manifold door screws securely Remove any fiberglass between gasket and combustion chamber Replace viewport if glass is missing or damaged Replace manifold component block if missing or removed Replace door gasket if damaged 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 replac
96. t tube Continue to tighten until the nut is tight in the gas control valve thermostat When you are finished connect the two wire leads that go to the thermal switch Reconnect the igniter wire Turn gas supply on and refer to the Lighting Instructions With the burner lit check the gas control valve thermostat supply line manifold component block manifold tube and pilot tube connections for leaks Check for leaks by brushing on an approved noncorrosive leak detection solution Bubbles forming indicate a leak Correct any leak found IMPORTANT All leaks must be fixed immediately Replace the outer door FLAME ARRESTOR BRACKET DOOR GASKET BASE RING FILTER FIGURE 41 33 CLOSE UP INSIDE VIEW OF THE COMBUSTION CHAMBER MANIFOLD TUBE BRACKET FIGURE 42 Igniter System The STP Spark to Pilot igniter system consists of the pilot electrode and wire The pilot is ignited by an electric spark generated when the gas control valve thermostat sends an electrical signal to the electrode Use only factory authorized STP igniter parts for replacement Igniter Wire Connection Point Pilot Igniter Flame Sensor Bracket FIGURE 43 Testing the Igniter System Turn off the gas to the water heater at the manual gas shut off valve Watch the electrode tip while activating the igniter A visible spark should jump from the electrode To avoid shock do not touch the burner or any metal part on the pilot o
97. ter a ea hee idet ut ima cata 33 Testing the Igniter Systelni fetch tind e deno imde tut dt ae las ede ee tee ee 33 Removing and Replacing the Gas Control 33 34 FVIR System Operational Checklist ettet edenda nha nn Rau ne una 34 TROUBLESHOOTING aie ee eR EE ee Ree 35 37 Start Up amp alates an dae Ssh vee 35 36 Operational CONdILIONS a nie eee De a ene ocd dace 36 37 TROUBLESHOOTING 38 39 STATUS LIGHT TROUBLESHOOTING FLOWCHART 2 40 41 SEQUENCE OF OPERATION 42 PARTS ORDER EIST ma heu MORE a dr ie dcs hee 43 PRODUCT WARRANTY 6 YEAR LIMITED WARRANTY ON WATER HEATER For six 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 th
98. th fire or electrical shock 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 AWARNING Electric Shock Hazard Electric Shock Hazard Do not remove ground prong Do not use an extension cord Disconnect power before servicing Replacing all parts and panels before operating Failure to do socan result in death or electrical shock YL 24VAC FLUE DAMPER BK 24 HOT WH 24VAC NEUTRAL 1 2 3 YL HAA oo END SWITCH 4 120 120 1 YL 24 YL 24VAC TRANSFORMER BL RD TRANSFORMER 24 vac vi 24 YL YE cus WH 24VAC NEUTRAL DAMPER TEMPERATURE CUT OFF SWITCH BK 120VAC me 120 BK 24VAC HOT tke gt SENSOR TEMPERATURE CUT OFF SWITCH BK 24 YL H WH 24 a 5 GAS CONTROL VALVE r1 THERMOSTAT Au eE I IGNITER FLAME SENSOR oe ON OFE SWITCH FLAME SENSOR IGNITER You must provide all wiring of the proper size outside of the water heater You must obey local codes and el
99. then turn ch on the gas control valve to the ON position If the problem persists replace the Soft Lockout 20 minute wait before returning to normal mode 41 SEQUENCE OF OPERATION CHART Apply Power to Appliance Is there Call for Heat 15 Damper Closed Damper Energizes 15 Damper Open Pilot Valve Energizes Does Pilot Valve Open Spark Electrode is Energized Is Pilot Flame Sensed Within 1 5 min Main Valve Energized Does Main Valve Open Is Main Flame Sensed 15 Demand for Heat Satisfied Pilot amp Main Valve De Energize Is Flame Sensed Damper Energizes and Closes Will not attempt to light 2 flash error code See Corrective Action Table on pages 40 41 Gas Valve attempts to open damper for 30 seconds displays 3 flash error code and then waits 2 mintues before attempting to open damper again See Corrective Action Table pages 40 41 Will not light 8 4 flash error code See Corrective Action Table on pages 40 41 Will not light 8 4 flash error code See Corrective Action Table on pages 40 41 Will not light 8 4 flash error code See Corrective Action Table on pages 40 41 Will not light 8 4 flash error code See Corrective Action Table on pages 40 41
100. 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 supply 3 4 NPT to the hot water outlet fitting IMPORTANT Some models may contain energy saving heat traps to prevent the circulation of hot water within the pipes Do not remove the inserts within the heat traps 2 The installation of unions in both the hot and cold water supply lines is recommended for ease of removing the water heater for service or replacement 3 The manufacturer of this water heater recommends installing a mixing valve or an anti scald device in the domestic hot water line as shown in Figure 24 These valves reduce the point of use temperature of the water by mixing cold and hot water and are readily available for use 4 f installing the water heater a closed water system install an expansion tank in the cold water line as specified under Closed System Thermal Expansion 5 Install shut off valve in the cold water inlet line It should be located close to the water heater and be easily accessible Know the location of this valve and how to shut off the water to the heater 6 temperature and pressure relief valve must be installed in the opening marked Temperature and Pressure T a
101. ual for safe temperature setting Due to the nature of the typical gas water heater the water temperature in certain situations may vary up to 30 F 16 7 C higher or lower at the point of use such as bathtubs showers sink etc HOTTER WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which 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 means such as a mixing valve should be used at the hot water taps used by these people or at the water heater Mixing valves are available at plumbing supply or hardware stores See Figure 24 Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat see Figure 29 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
102. warranty period Temperature Pressure Relief Valve Operation The temperature pressure relief valve must be manually operated at least once a year A DANGER Burn hazard e Hot water discharge e Keep clear of relief valve discharge outlet When checking the temperature pressure relief valve operation make sure that 1 no one is in front of or around the outlet of the temperature pressure relief valve discharge line and 2 that the water discharge will not cause any property damage as the water may be extremely hot See Figure 33 TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE FIGURE 33 If after manually operating the valve it fails to completely reset and continues to release water immediately close the manual gas shut off valve and the cold water inlet valve and call the Sears Service Center If the temperature pressure relief valve on the appliance weeps or discharges periodically this may be due to thermal expansion You may have a check valve installed in the water line or a water meter with a check valve Consult the Sears Service Center for further information Do not plug the temperature pressure relief valve Draining and Flushing ADANGER Hotwater discharge burn hazard Keep clear of relief valve discharge unit Temperature limiting valves are available Read instruction manual for safe temperature setting It is recommended that the tank be drained and
103. water tap or to draw their own bath water Never leave a child or handicapped person unattended in a bathtub 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 the pilot position It is adjustable and must be reset to the desired temperature setting to reduce the risk of scald injury The HOT mark is indicative of approximately 120 F 49 C and is the preferred starting point See Figure 29 on the next page Some states have a requirement for a lower setting Turn the water temperature dial clockwise to increase the temperature or counterclockwise to decrease the temperature Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance Water Time for Permanent Burns Time for 1st 160 F Approx Temperature Degree Burn 2nd amp 3rd Degree A dp Less Severe Burns Most Severe Burns BSE iomarsoweriemo normal shower temp 120 F KO ode pentes 1 2 HOT 2 5 T oO Gas Control Temperature Knob vic HO F Approx TO F Approx U S Government Memorandum C P S C Peter L Armstrong Sept 15 1978 TEMPERATURES SHOWN ARE APPROXIMATES AND MAY VARY FIGURE 29 NOTE During low demand periods when hot wat

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