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Kenmore 30 gal. Mobile Home Natural Gas Water Heater Installation Guide

1. eve Pot tt eder ande cete tee eO seed eed OU Re ex qae dede et ee e gunt DU Ta 36 37 TROUBLESHOOTING CHECKLIST arerp eon er cele ea eec e encore teer curte lena Fe Uu et aede ven ete Sats 38 39 PILOT LIGHT TROUBLESHOOTING FLOWCHART c ccecceccceceeeeeeaeeaaeeaaeeaaeeaaeeaeceaeeeaeeeaeceaeeeaeenaeeees 40 STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART 41 42 PARTS ORDER HUS Torli rhet Ee rie td ter HERE ieee E ETERNI EN D EHE CERES 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 in a single family home in accordance with the owner s manual instructions and all local applicable plumbing codes Sears will 1 Supply free water heater parts for those that are defective in material or workmanship 2 Supply a free water heater for one that develops a tank leak See notes below also 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 S
2. GAS CONVERSION AWARNING For your safety the following procedures should be performed by a qualified technician as it involves disconnection of gas piping and leak testing 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 A Remove the Manifold Burner Assembly 1 Turn off the gas supply to the water heater at the manual gas shut off valve This valve is typically located beside the water heater Note the position of the shut off valve in the open on position then proceed to turn it off 2 Onthe lower front of the water heater locate the gas control valve thermostat 3 Turn the gas control temperature knob to the OFF position With the unit shut off allow sufficient time for the water heater to cool before performing any maintenance 4 Remove the outer door 5 Remove the two screws securing the installed manifold door assembly to the combustion chamber Figure 11 6 Disconnect the following from the gas control valve thermostat pilot tube igniter wire and manifold tube See Figure 11 7 Using needle nose pliers disconnect the white and red thermopile wires from the gas control valve thermostat Figure 11 8 Grasp the manifold tube and push down slightly to free the manifold tube and pilot tube 9 Carefully remove the manifold burner assembly from the bumer compartment NOTE Be sure not to damage interna
3. It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during operation The water heater should be drained if being shut down during freezing temperatures To drain the tank perform the following steps 30 1 Turn off the gas to the water heater at the manual gas shut off valve 2 Open a 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 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 shoul
4. FIGURE 2 e 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 FIGURE 4 to the entire house See Figures 2 and 4 3 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 12 Attach a hose to the water heater drain valve and put the other end in a floor drain or outdoors See Figures 2 and 5 Open the water heater drain valve The water passing out of the drain valve may be extremely hot To avoid being scalded make sure all connections are tight and that the water flow is directed away from any person FIGURE 5 Disconnect the vent pipe from the draft hood where it connects to the water heater In most installations the vent pipe can be lifted off after any screw or other attached devices are removed Dispose of the draft hood The new water heater has a draft ho
5. Enclosure Installation Air for combustion and ventilation must not be supplied from the occupied spaces of the manufactured mobile home IMPORTANT The opening that provides outside air to your water heater must have a minimum free area of 20 square inches Also ensure that your installation complies with all applicable code requirements The following methods may be used to provide sufficient combustion and ventilation air to the water heater when it is installed in the enclosure Method Figure 15 Provide a single air opening in the exterior door of the enclosure The opening must have a minimum free area of 20 square inches The bottom of the opening must be within 6 inches from the bottom edge of the door Cover the opening with 1 4 inch wire mesh screen or louvers Method II Figure 16 For enclosures with a solid exterior door provide an air opening in the floor The opening must have a minimum diameter of 5 inches 20 square inches minimum free area and be covered with 1 4 inch wire mesh screen Method I Door Opening Also if the manufactured home is skirted an air intake opening with a minimum free area of 32 square inches must be provided in the skirt Other gas fired appliances in the home may require additional free air openings Consult the manufacturers for correct sizing IMPORTANT When using M
6. Manifold Component Block w Clip Not Shown Contains Manifold Tube Gasket Door Pilot Tube Thermopile Manifold Component Block w Clip Thermal Switch Burner Head Burner Orifice and Pilot Assembly Now that you have purchased your gas water heater should a need ever exist for repair parts or service simply contact any Sears Service Center or call 1 800 4 MY HOME 1 800 469 4663 Be sure to provide all pertinent facts when you call or visit 43 9006449 9006449 WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE FOLLOWING INFORMATION e MODEL NUMBER e SERIAL NUMBER e GAS NATURAL OR PROPANE L P PART DESCRIPTION THIS IS A REPAIR PARTS LIST NOT A PACKING LIST Get it fixed at your home or ours Your Home For troubleshooting product manuals and expert advice 6 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 loc
7. 1 Read and follow the lighting instructions on the water heater s label 2 the Control Knob to Pilot Press the Knob in fully and hold it in The knob will travel in about 1 4 inch if it is set to Pilot correctly 3 Click the Igniter button continuously for up to 90 seconds or until the Status Light begins to blink If the Status Light does not begin to blink after 90 seconds STOP Wait 10 minutes before attempting to relight the Pilot Repeat these steps 2 3 times if necessary The circuitry in this gas valve requires that you wait 10 minutes between lighting attempts If the Status Light blinks release the Control Knob and turn it to the desired setting Hot is approximately 120 F If the Status Light Does Not Blink 1 Wait 10 minutes before another lighting attempt 2 Ifthe Status Light did not blink repeat the lighting procedure by following the lighting instructions on the water heater s label Remove the outer door The Control Knob must be set to Pilot and held in continuously while clicking the igniter button about once per second for up to 90 seconds To observe the Pilot remove the outer door and look through the view port sight glass See Figure 29 Continue clicking the Igniter button for up to 90 seconds until Pilot lights Once the Pilot is lit continue to hold the Control Knob in until the Status Light begins to blink Release Control Knob and set Knob to desired temperatu
8. Title 24 CFR Part 3280 CAUTION All water heaters eventually leak Donotinstall without adequate drainage IMPORTANT The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure Due to the normal corrosive action of water the tank 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 an adequate drain Figure 1 In cold climates it is recommended that the drain pipe be terminated at an adequate drain inside the building The piping should be at least 3 4 ID and pitched for proper drainage METAL DRAIN PIPED TO AN PAN ADEQUATE DRAIN 1 SEE FIGURE 1 AT LEAST 2 GREATER THAN THE
9. DIAMETER OF THE WATER HEATER FIGURE 8 Water heater life depends upon water quality water usage water temperature and the environment in which the water heater is installed Water heaters are sometimes installed in locations where leakage may result in property damage even with the use of a metal drain pan piped to a drain However unanticipated damage can be reduced or prevented by a leak detector or water shut off device used in conjunction with a piped metal drain pan These devices are available from some plumbing supply wholesalers and retailers and detect and react to leakage in various ways 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 e 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 Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply Securing Water Heater to Floor and Wall The water heater must be secured to the floor and to the wall of the enclosure as described below See also Enclosure Installation 1 After properly locating the water heater fasten it to the floor with the brackets and screws that were prov
10. For continued protection against risk of fire Do not install water heater on carpeted floor Do not operate water heater if flood damaged AWARNING Overheated water can cause watertank explosion Properly sized temperature and pressure relief valve must be installed in opening provided A WARNING Breathing Hazard Carbon Monoxide Gas Install vent system in accordance with codes Do not operate water heater if flood damaged High altitude orifice must be installed for operation above 10 100 feet 3 078 m Do not operate if soot is present Do not obstruct water heater air intake with insulating jacket Do not place chemical vapor emitting products near water heater Gas and carbon monoxide detectors are available Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual AWARNING Hydrogen gas can be produced in a hot water system after a period of non use generally two or more weeks Hydrogen gas is extremely flammable and can ignite After an extended period of non use purge gases from hot water system To return hot water system to service open a hot water faucet in kitchen for several minutes before using electrical appliances Do not smoke or have open flame near faucet while it is open Leave hot water faucet open until the sound of escaping air stops TABLE OF CONTENTS SAFE I
11. This appliance has a pilot which is lit by a piezo electric spark gas ignition system 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 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 immediately 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 120 F Mark OFF POSITION igniter GAS CONTROL STOP It is imperative that you read all safety warnings before lighting the pilot Turn the gas control temperature knob counterclockwise 5 to the OFF setting Wait ten 10 minutes to clear out any gas If you then smell gas STOP O B in the safety information above on this label If you do not smell gas go to the next step Turn the gas control temperature knob clockwise to PILOT See Figure B Press the gas control temperature knob all the way in and hold it in The knob should travel in about 1 4 inch 6 35 mm if it is set to PILOT correctly While holding the gas control temperature knob in click the igniter button continuously about once a second for up to 90 seconds or until Status Light be
12. lead based solder must not be used Piping that has been treated with chromates boiler seal or other chemicals must not be used Chemicals that may contaminate the potable water supply must not be added to the piping system Water Piping Pressure Test WARNING If the water piping system is to be air pressure tested the water heater must be disconnected from the water piping system Failure to disconnect the water heater during air pressure testing of the water piping system could result in DEATH SERIOUS BODILY INJURY OR PROPERTY DAMAGE This section is only for the manufacturer installing the water heater when the installation is to comply with H U D Standards When testing the water ways H U D standards state Water distribution system All water piping in the water distribution system shall be subjected to a pressure test The test shall be made by subjecting the system to air or water at 100 psi for 15 minutes without loss of pressure When air pressure is used the water heater shall not be connected during the test AIR PRESSURE TESTING HOT WATER OUTLET WHEN AIR TESTING REMOVE THE WATER LINES FROM THE WATER HEATER COLD WATER 7 In INLET FIGURE 19 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 increase As the volu
13. models or 199 F 93 C for 180 F models See the data plate for your model Should the water temperature get too high the diagnostic status light will flash a code 4 flashes indicating an over temperature condition and the main burner will be shut off If a high temperature condition occurs turn the main gas supply OFF and have the water heater repaired by a qualified service technician Contact Sears at 1 800 4 MY HOME 1 800 469 4663 to request service Leakage Checkpoints FIGURE 38 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 filled with water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater A Water at the draft hood is water vapor which has condensed out of the combustion products This is caused by a problem in the vent Contact a qualified technician B Condensation may be seen on pipes in humid w
14. AIR INTAKE FLOOR OPENING 5 IN MIN DIA 1 4 IN WIRE MESH PROTECTION FREE AREA FOR AIR OPENING 20 SQ IN MIN FIGURE 16 WATER SYSTEM PIPING Piping Installation Piping fittings and valves should be installed according to the installation drawing Figure 17 If the indoor installation area is subject to freezing temperatures the water piping must be protected by insulation The water supply pressure should not exceed 80 psi If this occurs a pressure reducing valve with a bypass may need to be installed in the cold water inlet line This should be placed on the supply to the entire house in order to maintain equal hot and cold water pressures IMPORTANT Heat cannot be applied to the water fittings on the heater as they may contain nonmetallic parts If solder connections are used solder the pipe to the adapter before attaching the adapter to the hot and cold water fittings IMPORTANT Always use a good grade of joint compound and be certain that all fittings are drawn up tight 1 Install the water piping and fittings as shown in Figure 17 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
15. DANGER All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances WARNING This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances included in the act This product is certified to comply with a maximum weighted average of 0 2596 lead content as required in some areas 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 e Service Agency A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing air supply
16. Loss Protection annually for any food spoilage that is the result of mechanical failure of any covered refrigerator or freezer Rental reimbursement if repair of your covered product takes longer than promised 10 discount off the regular price of any non covered repair service and related installed parts Once you purchase the Agreement a simple phone call is all that it takes for you to schedule service You can call anytime day or night or schedule a service appointment online The Master Protection Agreement is a risk free purchase If you cancel for any reason during the product warranty period we will provide a full refund Or a prorated refund anytime after the product warranty period expires Purchase your Master Protection Agreement today Some limitations and exclusions apply For prices and additional information in the U S A call 1 800 827 6655 Coverage in Canada varies on some items For full details call Sears Canada at 1 800 361 6665 Sears Installation Service For Sears professional installation of home appliances garage door openers water heaters and other major home items in the U S A or Canada call 1 800 4 MY HOME 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 HOMES Th
17. Piping Temperature and pressure relief valve properly installed with a discharge line run to an adequate 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 unless the water heater has been properly converted Refer to the Gas Conversion section of this manual 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 MANUAL GAS SHUT OFF SS E 64 1 0 GROUND e amp JOINT UNION M DISCHARGE PIPE DO NOT CAP CHECK WITH OR PLUG LOCAL UTILITY FOR MINIMUM HEIGHT fa DRIP LEG DRAIN LINE MUST PASS THROUGH FLOOR 77 AND TERMINATE EXTERNAL TO BUILDING
18. Settemperature dial to lower setting 2 3 4 5 6 Wasted hot water 7 Advise customer 8 9 1 2 3 4 5 Drain flush provide water treatment if needed Install adequate heater Correct piping inlet tube must be in cold inlet Long runs of exposed piping Insulate piping Hot water piping in exposed wall Insulate piping INSUFFICIENT HOT WATER 1 Thermostat set too low Sediment or lime in tank Water heater too small Turn temperature dial to desired setting Drain flush provide water treatment if needed Install adequate heater Wrong piping connections Correct piping inlet tube must be in cold inlet Leaking faucets Repair faucets Wasted hot water 6 Advise customer Long runs of exposed piping 7T Insulate piping Hot water piping in outside wall 8 Insulate piping Low gas pressure 9 Check with gas utility company 0 Incorrect gas conversion if unit was 10 Contact a qualified technician converted to use a different type of gas 38 TROUBLESHOOTING CHECKLIST CONTINUED PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION SLOW HOT WATER 1 RECOVERY Insufficient combustion air 2 Water heater flue or vent system blocked 3 Low gas pressure 4 Improper calibration 5 Base Ring Filter blocked with lint dust 6 T FVIR Flame Arrestor blocked with lint dust Incorrect gas conversion if unit was converted to use a different type of gas Excessive water pressure Heater stacking Closed water
19. all hot water lines Contact Sears Service for further information concerning this chlorination treatment and an anode replacement kit 449001453005 For short heaters use anode replacement kit 449006299005 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 36 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 AWARNING 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 for several minutes before any electrical appliances which are connected to the hot water system are used such as a dishwasher or washing machine If hydrogen gas is present there will probably be an unusual sound similar to air escaping through the pipe as the hot water faucet is opened There must be no smoking or open flame near the faucet at the tim
20. and understand instruction manual A WARNING Should you choose to apply an insulation blanket to this heater you should follow these instructions See Figure 1 for identification of components mentioned below Failure to follow these instructions can restrict the air flow required for proper combustion potentially resulting in fire asphyxiation serious personal injury or death Do not apply insulation to the top of the water heater as this will interfere with safe operation of the draft hood Do not cover the outer door thermostat or temperature 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 Do not cover the instruction manual Keep it on the side of the water heater or nearby for future reference Doobtain new warning and instruction labels from Sears for placement on the blanket directly over the existing labels Doinspect 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 heater The water heater is certified for installation on a combustible floor IMPORTANT If installing over carpeting the carpeting must be protected by a metal or wood panel beneath the water
21. 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 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 29 The anode rod should be inspected after a maximum of three years and annually thereafter until the condition of the anode rod dictates its replacement NOTE Artificially softened water requires the anode rod to be inspected annually Anode Rod Deple
22. home This information will be found on the rating plate located near the gas control valve thermostat If the information does not agree with the type of gas available do not install or light Call your dealer NOTE An odorant is added by the gas supplier to the gas used by this water heater This odorant may fade over an extended period of time Do not depend upon this odorant as an indication of leaking gas Gas Piping The gas piping must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition Manufactured home manufacturers must conform with The Manufactured Home Construction and Safety Standard Title 24 CFR Part 3280 Tables 1 and 2 on the following page provide a sizing reference for commonly used gas pipe materials Consult the National Fuel Gas Code for the recommended gas pipe size of other materials NOTE Use pipe joint compound or teflon tape marked as being resistant to the action of petroleum Propane L P gases See Figure 13 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
23. monoxide poisoning and death The FVIR System is designed to reduce the risk of flammable vapor related fires The patented system protects your family by trapping the burning vapors within the water heater combustion chamber through the special flame arrestor The burning vapors literally burn themselves out without escaping back into the room In the event of a flammable vapor incident the FVIR System disables the water heater by shutting off the gas supply to the water heater s burner and pilot preventing re ignition of any remaining flammable vapors in the area This will not prevent a possible fire explosion if the igniter is depressed and flammable vapors have accumulated in the combustion chamber with the pilot light off If you suspect a flammable vapor incident has occurred do not use this appliance Do not attempt to light this appliance or depress the igniter button if you suspect flammable vapors have accumulated inside or outside the appliance Immediately call a qualified technician to inspect the appliance Water heaters subjected to a flammable vapors incident will show a discoloration on the flame arrestor and require replacement of the entire water heater AWARNING J Flammable Vapors FIRE AND EXPLOSION HAZARD Can result in serious injury or death A vapors and liquids in the vicinity of this or any other appliance Storage of or use of gasoline or other flammable vapors or liquid
24. 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 Z223 1 18 COMBUSTION AIR SUPPLY amp VENTILATION AWARNING Carbon Monoxide Warning The vent system 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 2223 1 54 current edition Manufactured home manufacturers must comply with the Manufactured Home Construction and Safety Standard Title 24 CFR Part 3280 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 water heaters installed in laundry hobby or craft rooms water heaters installed near chemical storage areas Combustion air must be free of acid forming chemicals such as sulfur fluorine and chlorine These elements are found in aerosol sprays detergents bleaches cleaning solvents air freshe
25. or serious injury Instruction manual must remain with water heater A DANGER Water temperature over 125 F 52 C can cause servere burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting AWARNING Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Avoid all ignition sources if you smell Natural or LP gas Do not expose water heater control to excessive gas pressure Use only gas shown on rating plate unless the water heater has been properly converted Follow conversion instructions listed in manual when converting to opposite gas e Maintain required clearances to combustibles Keep ignition sources away from faucets after extended period of non use Read instruction manual before installing using or servicing water heater 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 AWARNING Fire Hazard
26. pilot tube location hand tight only 2 Insert the pilot tube into the ferrule nut until the tube bottoms out then tighten the nut with a 7 16 wrench until the crimp connection seals to the pilot tube 3 Continue to tighten until the nut is tight in the gas valve Connect the white and red wires to the gas control valve thermostat as shown in Figure 28 Also ensure that the red thermal switch wires are connected to the thermal Switch on the manifold door Figure 33 Reconnect the igniter wire Figure 28 Turn on the gas supply to the water heater at the manual gas shut off valve Figure 2 Follow the lighting instructions on the front of the water heater With the main burner lit check for leaks at the manifold and pilot connections by brushing on an approved noncorrosive leak detection solution If such a solution is not available use a mixture of hand dish washing soap and water one part soap to 15 parts water or childrens soap bubble solution Bubbles forming indicate a leak Correct any leak found Verify proper operation then replace the outer door CLOSE UP INSIDE VIEW OF THE COMBUSTION CHAMBER SLOT TIP BRACKET MANIFOLD TUBE FIGURE 35 Piezoelectric Igniter System The piezoelectric igniter system consists of the igniter button electrode and wire The pilot is ignited by an electric spark generated when the igniter button is pressed See Figure 36 Y T
27. pressure in 24 hour period or regulated 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 MASSACHUSETTS INSTALL A VACUUM RELIEF IN COLD WATER LINE PER SECTION 19 MGL 142 r HOT WATER amp THERMAL OUT EXPANSION TANK COLD WATER SUPPLY TO FIXTURES PRESSURE PRESSURE GAUGE REDUCING VALVE WITH BYPASS A O CA 8 Hp G3 T COLD WATER INLET VALVE COLD WATER LE SHUT OFF VALVE IN FIGURE 37 Strange Sounds Possible noises due to expansion and contraction of some metal parts during periods of heat up and cool down do not represent harmful or dangerous conditions Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal See Condensation section Draft Hood Operation Check draft hood operation by performing a worst case depressurization of the building With all doors and windows closed and with all air handling equipment and exhaust fans operating such as furnaces clothes dryers range hoods and bathroom fans a match flame should still be drawn into the draft hood of the water heater with its burner firing If the flame is no
28. requirements Burner Flames Inspect the burner flames through the viewport and compare them to the drawing in Figure 23 A properly operating burner should produce a soft blue flame Blue tips with yellow inner cones are satisfactory The tips of the flame may have a slight yellow tint The flame should not be all yellow or have a sharp blue orange color Contaminated air may cause an orange colored flame Contact a qualified technician if the flame is not satisfactory FIGURE 23 26 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 manual for safe temperature setting Due to the nature of the typical gas water heater the water temperature in certain situations may vary up to 30 F 16 7 C higher or lower at the point of use such as bathtubs showers sink etc HOTTER WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes washing dish washing and
29. the connector s IMPORTANT Grip the connector carefully to prevent damage Do not grip or pull the wires themselves 7 Grasp the manifold tube and push down slightly to free the manifold tube and pilot tube 8 Remove the screws 1 4 nut driver securing the manifold burner assembly to the combustion chamber See Figure 29 9 Carefully remove the manifold burner assembly from the combustion chamber BE SURE NOT TO DAMAGE ANY INTERNAL PARTS 31 GAS CONTROL VALVE THERMOSTAT THERMOPILE AND X SWITCH WIRE GAS CONTROL BN CONNECTIONS TEMPERATURE KNOB PIEZO IGNITER BUTTON L E 4 lie PILOT TUBE 9 MANIFOLD TUBE VIEWPORT ib THERMAL SWITCH OUTER DOOR MANIFOLD DOOR NOT SHOWN MANIFOLD SCREW 2 2 MANIFOLD COMPONENT BLOCK FIGURE 29 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 30 IMPORTANT DO NOT remove the orifice BURNER BOTTOM VIEW FIGURE 30 Replacing the Pilot Thermopile Assembly 1 Remove the manifold door assembly as described in Removing the Manifold Burner Assembly section 2 Remove the burner to
30. then tighten the nut with a 7 16 wrench until the crimp connection seals to the pilot tube C Continue to tighten until the nut is tight in the gas valve Connect the white and red thermopile wires to the gas control valve thermostat See Figure 11 Reconnect the igniter wire Turn the gas supply on and follow the Lighting Instructions With the main burner lit check for leaks at the manifold and pilot connections by brushing on an approved non corrosive leak detection solution If such a solution is not available use a mixture of hand dish washing soap and water one part soap to 15 parts water Bubbles forming indicate a leak Correct any leak found Verify proper operation replace outer door GAS CONTROL VALVE THERMOSTAT m CONVERSION FITTING 09 09 NATURAL GAS NAT FACES OUTWARD TOWARD YOU LP GAS LP FACES OUTWARD TOWARD YOU ORIENTATION MAY VARY FITTING TO BE TIGHT FIGURE 12 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
31. thermal switch tripped SeePilot Light Troubleshooting Flowchart section Wire lead connection at thermal switch 3 Remove and reconnect the wire leads at loose thermal switch confirm connections are tight and not loose Thermopile connection loose Seatconnector firmly in socket Air in gas line Bleed the air from the gas line Low gas pressure Check with gas utility company No gas Check with gas utility company Dirt in gas lines Notify utility install dirt trap in gas line Cold drafts Locate source and correct Thermostat temperature limit Replace thermostat exceeded Status light will blink 4 flashes Pilot line or orifice clogged Clean locate source and correct Non functioning thermopile Replace thermopile Air for combustion obstructed 13 See maintenance section for inspection and cleaning of flame arrester FVIR Flame Arrestor blocked with lint 14 Clean filter See Cleaning the Combustion dust Chamber and Flame Arrestor section Flammable vapors incident FVIR 15 Replace water heater eliminate flammable function actuated vapors source Contact Technical Assistance Base Ring Filter blocked with lint dust Clean filter See External Inspection amp Cleaning of the Base Ring Filter section HIGH OPERATION COSTS Thermostat set too high Sediment or lime in tank Water heater too small for job Wrong piping connections Leaking faucets Repair faucets Gas leaks Check with utility repair at once 1
32. venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters The service agency must also have a thorough understanding of this instruction manual and be able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer Gas Supplier The natural gas or propane utility or service who supplies gas for utilization by the gas burning appliances within this application The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the natural gas meter or propane storage tank of a building Many gas suppliers also offer service and inspection of appliances within the building 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
33. water supply lines is recommended for ease of removing the water heater for service or replacement The manufacturer of this water heater recommends installing a mixing valve or an anti scald device in the domestic hot water line as shown in Figure 18 These valves reduce the point of use temperature of the water by mixing cold and hot water and are readily available for use If installing the water heater in a closed water system install an expansion tank in the cold water line as specified under Closed System Thermal Expansion Install a shut off valve in the cold water inlet line It should be located close to the water heater and be easily accessible Know the location of this valve and how to shut off the water to the heater A temperature and pressure relief valve must be installed in the opening marked Temperature and Pressure T amp P Relief Valve on the water heater A discharge line must be added to the opening of the T amp P Relief Valve Follow the instructions under Temperature and Pressure Relief Valve After piping has been properly connected to the water heater remove the aerator at the nearest hot water faucet Open the hot water faucet and allow the tank to completely fill with water To purge the lines of any excess air keep the hot water faucet open for 3 minutes after a constant flow of water is obtained Close the faucet and check all connections for leaks 21 MASSACHUSETTS INSTALL A VACUUM R
34. 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 17 MANUAL GAS SHUT OFF VALVE el i I y GROUND JOINT UNION CHECK WITH LOCAL UTILITY FOR MINIMUM HEIGHT 3 T e Y DRIP LEG FIGURE 13 Gas Pressure WARNING Explosion Hazard Gas leaks can not always be detected by smell Gas suppliers recommend that you use a gas detector approved by UL or CSA For more information contact your gas supplier If a gas leak is detected follow the What to do if you smell gas instructions on the cover of this manual IMPORTANT The gas supply pressure must not exceed the maximum supply pressure as stated on the water heater s rating plate The minimum supply pressure is for the purpose of input adjustment Gas Pressure Testing IMPORTANT This water heater and its gas connection must be leak tested before placing the appliance in operation e Ifthe code requires the gas lines to be tested at a pressure exceeding 14 W C the water heater and its manual shut off valve must be disconnec
35. water heater s label NOTE This gas control valve thermostat has built in circuitry that requires waiting 10 minutes between lighting attempts Until the Thermopile reaches its normal operating temperature the Status Light will not blink even if the Pilot is lit It may take up to 90 seconds of continuous Pilot operation before the Thermopile reaches normal operating temperature and the Status Light starts to blink 1 FLASH EVERY 3 SECONDS Normal operation No corrective action necessary 2 FLASHES Pilot is lit but the Thermopile is Turn Gas Control Valve Thermostat knob to OFF not producing the required output The Thermopile is probably defective but loose voltage wiring connections or a weak Pilot flame can also cause this symptom 41 STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART Continued LED STATUS PROBLEM CORRECTIVE ACTION 4 FLASHES 5 FLASHES 7 FLASHES 8 FLASHES The Gas Control Valve s temperature sensor has detected that the water temperature was too high Once this condition occurs the Main Burner and the Pilot Light will be shut off Since the Pilot light will be off should this condition occur this Flash Code will only be displayed immediately after the Pilot has been relit Turn Gas Control Valve Thermostat knob to OFF The temperature thermistor is defective sensor Gas Control Valve failure This condition only appears if the gas control temperature knob has be
36. 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 Mustnot be capped blocked plugged or contain any valve between the relief valve and the end of the discharge line Must pass through the structural floor and terminate external to the building In cold climates it is recommended that the discharge pipe be terminated at an adequate drain inside the building The 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 Some Models 1 2 Locate the temperature and pressure relief valve on the water heater also known as a T amp P relief valve See Figure 21 Locate the slit running the length of the T amp P relief valve insulation Spread the slit open and fit the insulation over the T amp P relief valve See Figure 21 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 21 Ensure a discharge pipe is installed into the T amp P valve discharge opening per the instructions in this m
37. 32 At least annually check the base ring filter Figure 34 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 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 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 After the base ring filter has been cleaned follow the Lighting Instructions to return the water heater to service CONNECTIONS AT MANIFOLD DOOR Cleaning the Combustion Chamber and Flame arrestor 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 34 Use compressed air to clear any dust or debris that may have accumulated in the flame arrestor COMBUSTION CHAMBER FLAME ARRESTOR aee FIGURE 34 Reassemble following the procedure under Replacing the Manifold Burner Assembly Replacing the Manifold Burner Assembly A WARNING Explosion Hazard Tighten both manifold door screws securely Remove any fiberglass between
38. ALS TO BE INSTALLATION SECTION OF THIS SUPPLIED BY CUSTOMERS MANUAL ROOF JACK NOT FURNISHED 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 Located indoors and in a vertical position Protected from freezing temperatures Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor Provisions made to protect the area from water damage Metal drain pan installed and piped to an adequate drain Sufficient room to service the water heater See Clearances and Accessibility section of this manual Water heater not located near an air moving device Is the installed environment dir
39. As water is heated it expands thermal expansion In a closed system the volume of water will grow As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent temperature pressure relief valve operation water discharged from the valve due to excessive pressure build up The temperature pressure relief valve is not intended for the constant relief of thermal expansion This condition is not covered under the limited warranty A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion Thermal expansion tanks are available from Sears stores and through the Sears Service Centers Contact the local plumbing inspector water supplier and or the Sears Service Center for assistance in controlling these situations See Figure 37 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 mm 3 4 153 331050 5 n 279 mm 14 3 4 375 mm 3 4 Male Pipe Expansion Tank Sizing Chart Inlet Water Pressure Water Heater Capacity Gallons Expansion Tank Capacity Needed Les 2 2 mosi 2 2_ Highest recorded inlet water
40. Be sure to remove the pilot ferrule nut from the new gas control valve thermostat Turn the main gas supply on and check the gas supply connections for leaks Correct any leak found Next light the pilot and main burner then check the manifold tube and pilot tube connections for leaks Correct any leak found Use an approved noncorrosive leak detection solution If such a solution is not available use a mixture of hand dish washing soap and water one part soap to 15 parts water or childrens soap bubble solution Bubbles forming indicate a leak Be sure tank is completely filled with water before lighting and activating the water heater Follow the Lighting Instructions on the front of the water heater If additional information is required contact Sears Service at 1 800 4 MY HOME 1 800 469 4663 TEFLON is a registered trademark of E I Du Pont De Nemours and Company FVIR System Operational Checklist 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 NOaRWN gt 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
41. Check with gas utility company Clean flue and burner locate source and correct Locate source and correct Contact a qualified technician Replace with correct orifice Contact a qualified technician Replace thermostat Check with gas utility company Contact a qualified technician Clean locate source and correct Check with gas utility company PILOT LIGHT TROUBLESHOOTING FLOWCHART Section A Pilot light will not light new installation Is the manual gas shut off valve located in the supply line to the water heater in the on position Turn the manual gas shut off valve to the on position and follow the lighting While repeatedly depressing the igniter NO button push in and hold the gas control temperature knob until the pilot is lit and maintains a stable flame status light will YES blink It may take up to 90 seconds of pilot operation before status light blinks Once status light blinks release the gas control temperature knob Have you bled all the air from the pilot tube and gas supply line o Is the igniter producing a YE spark NO Follow the Testing the Igniter System section in this manual Section B Pilot light repeatedly goes out Check the Base Ring Filter and Flame Arrestor for blockage due to lint or dust Are both the Air Filter and Flame Arrestor clean Refer to the Maintenance of your Water Heater section of this manual for information on cleaning t
42. DD oeste tdt ii s 30 MAINTENANCE OF YOUR WATER HEATER sssssssssesseeseener ener nn nnne nene nnn nnns nn nn sess 31 33 Replacement o oer itte n tte eode ide tx sca daro cattle ux dade x ted aeterno te 31 Removing the Manifold Burner Assembly sssssssesssesene eene eene rne nnns 31 Removing the Burner from the Manifold Burner Assembly ssessseeeeenemeen 31 Replacing the Pilot Thermopile Assembly nennen enn 31 32 External Inspection 4 Cleaning of the Base Ring Filter sss mem eem 32 Cleaning the Combustion Chamber and Flame arrestor sssssssssseeeeeen eene enne 33 Replacing the Manifold Burner Assembly sssssssssesseeene een 33 Piezoelectric Igniter iiss dete cete m reb aen ona 34 Testing ihe dedi bt re rest e diee Lebe 34 Removing and Replacing the Gas Control Valve Thermostat sssssssseee eene 34 FVIR System Operational Checklist armin een enne nem nnnm nennen nnne inen nnne nennen 34 TROUBLESHOOTING GUIDE otis eee en diea teen ed eva Tua Pea d 35 37 StartUp Conditions tics oe ER e eee edd ene en RR va e Rip dee dee een aa 35 36 Operational
43. ELIEF IN COLD WATER LINE PER SECTION 19 MGL 142 TEMPERATURE AND PRESSURE T amp P c t J KOT NATER RELIEF VALVE OPTIONAL TOP T amp P OUTLET RELIEF VALVE NOT SHOWN IN A CLOSED SYSTEM COLD WATER USE A THERMAL INLET VALVE EXPANSION TANK SHUT OFF VALVE DISCHARGE PIPE DO NOT CAP COLD WATER PRESSURE OR PLUG SUPPLY REDUCING e TO VALVE WITH FIXTURES BYPASS o C ES 1 T MINIMUM E es e PAN DRAIN LINE 3 4 ID MINIMUM METAL PRAN LINE TERMINATES COLD WATER DRAINPAN gt J EXTERNAL TO BUILDING INLET FIGURE 17 4 TEMPERED WATER TO FIXTURES UNTEMPERED HOT WATER FROM HOT WATER OUTLET FROM COLD WATER INLET Cae VALVE SET TO 120 F FOLLOW THE MIXING VALVE MANUFACTURER S INSTRUCTIONS FIGURE 18 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 It is 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
44. HERMOPILE BRACKET WIRE TO ELECTRODE IGNITER BUTTON FIGURE 36 Testing the Igniter System Turn off the gas to the water heater at the manual gas shut off valve Watch the electrode tip while activating the igniter A visible spark should jump from the electrode To avoid shock do not touch the burner or any metal part on the pilot or pilot assembly If no spark is visible check the wire connections and make sure the electrode is not broken Replace the igniter if defective Dirt and rust on the pilot or electrode tip can prevent the igniter spark Wipe clean with a damp cloth and dry completely Rust can be removed from the electrode tip and metal surfaces by lightly sanding with an emery cloth or fine grit sandpaper 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 IMPORTANT This gas control valve thermostat is shipped from the factory as a natural gas unit However it may be converted to use LP gas Before installing this gas control valve thermostat make sure that it is configured for the type of gas that you are using Refer to the Gas Conversion section Removing the Gas Control Valve Thermostat 1 Turn the gas control temperature knob to the OFF position Figure 24B 2 Turn off the gas at the manual shut
45. Hazard 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 Have a qualified technician make sure that the L P gas operating pressure does not exceed 13 water column Failure to do so can result in death explosion or fire 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 per hour required for the gas input rating of the water heater By formula Gas Input of Water Heater BTU HR Cu Ft Per Hr Required eating Value of Gas The gas input of the water heater is marked on the water heater data plate The heating value of the gas BTU FT may be determined by consulting the local natural gas utility Table 2 LP Gas Capacity Table Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases at 11 inches water column pressure Based on a pressure drop of 0 5 inch water column Nominal Iron Pipe Length of Pipe Feet Size in Example Input BTU requirement
46. I pe li METAL DRAIN PANS AVAILABLE IN THE FOLLOWING SIZES 20 508 mm DIAMETER FOR WATER HEATERS HAVING A DIAMETER OF 18 457 mm OR LESS 24 610mm DIAMETER FOR WATER ANU c CAPACITY THROUGH HEATERS HAVING A DIAMETER 22 LOCAL SEARS STORE WATER HEATER INSTALLATION KIT 559 mm OR LESS OR SERVICE CENTER WITH FLEXIBLE CONNECTORS FOR 3 4 19 05 mm COPPER PLUMBING AND FLEXIBLE GAS CONNECTOR WITH FITTINGS BASIC TOOLS You may or may not need all these tools depending on your type of installation These tools can be purchased at your local Sears Store Pipe Wrenches 2 14 356 mm Screwdriver Tin Snips 6 1 82 m Tape or Folding Ruler Garden Hose Drill Pipe Dope or Teflon Tape CD SLOT HEAD SCREWDRIVER CE TIN SNIPS PHILLIPS SCREWDRIVER PIPE DOPE ROLL OF TEFLON SQUEEZE 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 amans 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 A VentPipe J Inn
47. ITE 1 Pilot not lit 1 Light pilot Thermostat set too low 2 Turn temp dial to desired temperature Main burner line clogged 3 Clean locate source and correct Non functioning thermostat 4 Test Gas Control Valve Thermostat Base Ring Filter blocked with lint dust 5 Clean filter See External Inspection amp Cleaning of the Base Ring Filter section Heater installed in a confined area FVIR Flame Arrestor blocked with lint 6 Provide fresh air ventilation 7 Clean filter See Cleaning the Combustion Chamber and Flame Arrestor section SMELLY WATER BURNER FLAME YELLOW Insufficient combustion air 1 Provide ventilation to water heater LAZY Low gas pressure 2 Check with gas utility company Water heater flue or vent system 3 Clean locate source and correct blocked Main burner line clogged 4 Clean locate source and correct Base Ring Filter blocked with lint dust 5 Clean filter See External Inspection amp Cleaning of the Base Ring Filter section Heater installed in a confined area 6 Proper fresh air ventilation FVIR Flame Arrestor blocked with lint 7 Clean filter See Cleaning the Combustion Chamber and Flame Arrestor section Obstruction in main burner orifice 8 Clean or replace orifice Incorrect gas conversion if unit was 9 Contact a qualified technician converted to use a different type of gas PILOT WILL NOT LIGHT OR 1 Non functioning igniter Replace igniter pilot assembly REMAIN LIT The
48. NSTALLATION USE AND SERVICE sss ener erre nnns 2 SAFETY PRECAUTIONS eer dne d eoe on eu oU Y PER ERE Te RE e FORE e ER PU Rad 2 3 PRODUCT WARRANTY 3 RE I EE HERE 6 CUSTOMER RESPONSIBILITIES esses ener ea rrr rrr rennen nnne nnns 7 PRODUCT SPECIFICATIONS ix rnt rh hr HR RH RR RE REEL Re RR ERR ED ERREUR S ERE PR re X FIRES KV EPA ER ERES 8 MATERIALS AND BASIC TOOLS 9 TYPICAL INSTALLAT O N eaves dee aa REIN ERE RA ERES RETE RR NR ER e Oe ERR eR MEER Mu n VR TRE MA A AERIS RR EIER 10 IMPORTANT INFORMATION ABOUT THIS WATER HEATER ssssse Hee 11 Installation Checklist etcetera pautas n doe ene ae 11 INSTALLATION INSTRUCTIONS sssssessesseeneeerree en nn nn nn nnne ne nn nnns nnn nsns sensn nsns sse 12 15 Removing the Old Water Hetero urairi asa plate rote oe e b tege een aeter ct dete ee ere dne redet ed 12 Location Requirements et ete een edet ve eedem t dette e eM tede od 13 Site 1 m 13 14 Securing Water Heater to Floor and Wall ssssssssseeeeeee een nenne 14 Insulation Blankets ic iiber a 14 15 Clearances and Accessib
49. Use amp Care Guide Model No 153 336930 30 Gallon Tall 153 336940 40 Gallon Tall Kenmore LOW LEAD CONTENT Gas Water Heater For potable water heating only Not suitable for space heating For use only in mobile homes This water heater shall not be installed in the occupied space of the manufactured mobile home INSTALLER Affix these instructions to or near the water heater OWNER Retain these instructions for future reference FOR YOUR SAFETY An odorant is added to the gas used by this water heater ADVERTENCIA Si no puede leer o entender el ingl s y necesita el manual de instrucciones en espafol puede solicitarlo al 1 800 821 2017 NO TRATE DE INSTALAR U OPERAR ESTE CALENTADOR DE AGUA SI NO ENTIENDE LAS INSTRUCCIONES No hacer caso de esta advertencia podr a originar lesiones graves o mortales P N 321634 001 0512 Sears Brands Management Corporation Hoffman Estates IL 60179 U S A ww w 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 to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighb
50. access the pilot thermopile assembly Remove and keep the screws securing the burner to the manifold Figure 30 IMPORTANT DO NOT remove the orifice 3 Remove the screw securing the pilot thermopile assembly to the pilot bracket and keep for reuse later Figure 31 4 Lift the retainer clip straight up from the back of the manifold component block using a flat blade screwdriver then remove the manifold component block from the manifold door Figure 31 IMPORTANT Be careful not to bend or alter the position of the pilot tube It will be used as a bending template for the new pilot assembly Note the placement order of the wires in the manifold component block 5 Lift the pilot thermopile assembly including the igniter wire from the manifold assembly 10 11 12 PILOT THERMOPILE 27 ASSEMBLY SCREW CONNECTORS P BURNER AND OTHER FITTINGS NOT SHOW FOR CLARITY IGNITER WIRE RED WIRES TO THERMAL SWITCH 2 BLOCK PILOT TUBE MANIFOLD DOOR FIGURE 31 6 Read this step carefully before proceeding 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 PILOT THERMOPILE ASSEMBLY CONNECT AT GAS CONTROL VALVE THERMOSTAT FOR CLARITY PILOT TUBE NOT SHOWN THERMAL SWITCH CONNECTORS RED WIRES FIGURE 32 Route the new pilot tube and wi
51. anual Locate the hot water outlet amp cold water inlet pipes to the water heater Locate the slit running the length of a section of pipe insulation 23 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 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 Manual Relief Lever T amp P Relief Valve T amp P Relief Valve Drain Line FIGURE 21 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 29 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 unless the water heater has been properly converted Refer to the Gas Conversion section of this manual If you have any questions or doubts consult your gas supplier or gas utility company Lighting the Pilot
52. ation of your nearest Sears Parts amp Repair Service Center 1 800 488 1222 U S A 1 800 469 4663 Canada www sears com www sears ca To purchase a protection agreement on a product serviced by Sears 1 800 827 6655 U S A 1 800 361 6665 Canada Para pedir servicio de reparacion a domicilio y para ordenar piezas 1 888 SU HOGAR 1 888 784 6427 777 eeare 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 KCD IP LLC en Estados Unidos o Sears Brands LLC in otros pa ses MC Marque de commerce Marque d pos e de Sears Brands LLC Au Canada pour service en francais 1 800 LE FOYER 1 800 533 6937 WWW Sears ca
53. bly Check the door gasket for damage or imbedded debris prior to installation Inspect the view port for damage and replace as required Insert the conversion 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 NOTE For 30 gallon models the LP manifold burner assembly is identified by a yellow square label on the packaging For 40 gallon models the LP manifold burner assembly is identified by a green square on the packaging Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion chamber Replace the two screws that secure the manifold burner assembly door to the combustion chamber then tighten them securely There should be no space between the gasket part of the manifold door and the combustion chamber IMPORTANT Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber Reconnect the manifold tube and pilot tube to the gas control valve thermostat Figure 11 Do not cross thread or apply any thread sealant to the fittings IMPORTANT If you were supplied with a new ferrule nut in a parts kit follow these steps to connect the pilot tube A Install the ferrule nut into the gas valve at the pilot tube location hand tight only B Insert the pilot tube into the ferrule nut until the tube bottoms out
54. d be performed by a qualified technician Replacement parts may be ordered from Sears Parts and Service Centers or by calling 1 800 4 MY HOME 1 800 469 4663 When ordering replacement parts always have the following information ready 1 model serial and product number 2 type of gas 3 item number 4 parts description See the Parts Order List section for a list of available repair parts Removing the Manifold Burner Assembly 1 Turn the gas control temperature knob to the OFF position Figure 28 2 Before performing any maintenance it is important to 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 2 3 With the unit shut off allow sufficient time for the water heater to cool before performing any maintenance GAS CONTROL TEMPERATURE KNOB IGNITER BUTTON IGNITER gt LEAD WIRE PILOT RED WIRE IGNITER gt TUBE IONIT LEFT SIDE MANIFOLD TUBE FIGURE 28 Remove the outer door Disconnect the following from the gas control valve thermostat pilot tube 7 16 wrench igniter wire from the igniter lead wire and manifold tube 3 4 wrench See Figure 28 6 Disconnect the white and red wires from the gas control valve thermostat Figure 28 Use needle nose pliers to grip
55. e failure to correct the cause of the sooting can result in a fire causing death serious injury or property damage FIGURE 25 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 4 Read instruction manual before installing using or servicing water heater The burner must be removed for cleaning If inspection of the burner shows that cleaning is required 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 A DANGER 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 FILTER AND FLAME ARRESTER CLEAN IF LINT ACCUMULATIONS ARE NOTICED INSTALLED IN SUITABLE AREA To ensure sufficient ventilation and
56. e it is open Safety Shut off and Thermal Switch This water heater is designed to automatically shut off in the event of the following 1 The pilot flame is extinguished for any reason 2 The water temperature exceeds 189 F 87 C for 155 F models or 199 F 93 C for 180 F models See the data plate for your model 3 Excessive combustion chamber temperatures 4 The ignition of flammable vapors A thermopile is used to determine if a pilot flame is present and will shut off the gas supply to the main burner and the pilot if the flame is absent This unit is also equipped with a thermal switch designed to shut off the gas supply in the event the heater has been exposed to flammable vapors spilled gasoline or paint fumes for example poor combustion caused by insufficient combustion air or improper venting If the switch opens check the flame arrestor for signs of high temperature blue or black discoloration and inspect your installation for any problems with venting or combustion air See Pilot Light Troubleshooting Flowchart Reset the switch by depressing the small button in the center of the switch IMPORTANT Correct any issues prior to resetting the switch Contact Sears at 1 800 4 MY HOME 1 800 469 4663 to request service The gas control valve thermostat includes a temperature limiting ECO Energy Cut Off system that will shut off the water heater if the water temperature exceeds 189 F 87 C for 155 F
57. e vent system for restrictions obstructions and check the vent termination height Refer to the Installation Instructions section of this manual for specific requirements Contact a Heating and Air Conditioning service technician to relocate the return air duct The water heater s pilot can be extinguished when the heating or cooling system is turned on if the return air duct is in the same location If you are still having difficulty keeping the pilot lit contact Sears Service at 1 800 4 MY HOME 1 800 469 4663 NOTE If you are still experiencing difficulties after following the steps in sections A B and C please contact Sears Service at 1 800 4 MY HOME 1 800 469 4663 THERMAL SWITCH LOCATION Re a ee L9 Ones 0 THERMAL SWITCH FIGURE 39 STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART LED STATUS PROBLEM CORRECTIVE ACTION 0 FLASHES LED NOT LIT Pilot light is not lit or Thermopile Turn Gas Control Valve Thermostat knob to OFF has not yet reached normal Wait 10 minutes then attempt to relight Pilot by operating temperature following the lighting instructions on the water heater s label Until the Thermopile reaches its normal operating temperature the Status Light will not blink even if the Pilot is lit It may take up to 90 seconds of continuous Pilot operation before the Thermopile reaches normal operating temperature and the Status Lig
58. ears will furnish a new water heater of comparable output as permitted by such governmental regulations however the Owner will be charged for the additional cost associated with the changes made to 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 MANAGEMENT CORPORATION Hoffman Estates IL 60179 S SS AS ORONO NINN SOK SOS SPY COORG ROG ROD RR RRR RDA GEG RRO RRR RIL DAD The price of your water heater does not include a free checkup service call On water heater installations arranged by Sears Sears warrants the installation A charge will be made on service calls due to poor or incomplete installation These include a Adjusting thermostat b Condensation Master Protection Agreements Congratulations on ma
59. eather or pipe connections may be leaking The anode rod fitting may be leaking Small amounts of water from temperature pressure relief valve may be due to thermal expansion or high water pressure in your area E The temperature pressure relief valve may be leaking at the tank fitting F Water from a drain valve may be due to the valve being slightly opened 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 in the water heater bottom or on the floor may be from condensation loose connections or the relief valve DO NOT replace the water heater until a full inspection of all possible water sources is made and necessary corrective steps taken Leakage from other appliances water lines or ground seepage should also be checked To check where threaded portion enters tank insert cotton swab between jacket opening and fitting If cotton is wet follow draining instructions in the Draining and Flushing section and then remove fitting Put pipe dope or teflon tape on the threads and replace When you are finished follow the steps in Filling the Water Heater the Installation Instructions earlier in this manual TROUBLESHOOTING CHECKLIST BURNER WILL NOT IGN
60. ed room normally kept closed Locate the water heater near the existing gas piping If installing a new gas line locate the water heater to minimize the pipe length and elbows The water heater should be located in an area not subject to freezing temperatures Water heaters located in unconditioned spaces may require insulation of the water piping and drain piping to protect against freezing The drain and controls must be easily accessible for operation and service Maintain proper clearances as specified on the water heater labeling Do notlocate 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 Ifthe 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 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 Manufactured home manufacturers must conform with The Manufactured Home Construction and Safety Standard
61. eeaeeees 22 T amp P Relief Valve and Pipe em emere nennen nennen nent n nnns n nennen nenne 23 OPERATING YOUR WATER HEATER nnn 24 27 Lighting e 24 25 Checking teet d 26 Burner Elames eee redet E et aM eM 26 Emergency hut DOWLIS ote e tte bea tet tbe bei ced n AE P E Eo o LU S erba tuas 26 Water Temperature Regulation e da i nail t rA e na tr Rio dehet ra rad 26 27 Operating the Temperature Control System een enne nnne nennen enne nennen nennen nens 27 SERVIGE AND ADJUSTMENT ntn Rae rta unit ii on 28 30 Vent System Inspectlon s os coe eee ble Ae eta ee i Pede ee De RE ta dee tul oe etae seu ett 28 mec 28 Burner Cleaning eon Wie ee ao ae d eio E eti te 28 Housekeeping ee eatem etica debel pa cede eden 29 Anode Rod Inspection e a es lati T Tee ote eee e ae oo db e oed ud eva A et eoe le 29 Temperature Pressure Relief Valve Operation eren ntn nnn nnne nennen 29 Draining arid El sFhing erede et hoe bent bubo atu eid 30 EA
62. en turned off and the thermopile continued to produce electric power This condition can occur if the thermopile does not cool down as quickly as expected when the unit is shut off This condition can also occur if the gas control temperature knob has been turned off and the pilot continues to operate because the pilot valve is stuck in the open position 42 Relight pilot and verify 4 flashes If 4 flashes are observed turn Gas Control Valve Thermostat knob to OFF Turn Main Gas Supply OFF Replace the Gas Control Valve Thermostat See Removing and Replacing the Gas Control Valve Thermostat Turn Gas Control Valve Thermostat knob to OFF Replace the temperature sensor thermistor Turn Gas Control Valve Thermostat knob to OFF Turn Main Gas Supply OFF Replace the Gas Control Valve Thermostat See Removing and Replacing the Gas Control Valve Thermostat Make sure that the gas control valve thermostat knob is set to OFF Wait one minute Remove the outer door Look through the sight glass for a pilot flame If a pilot flame is observed with the gas control valve thermostat knob set to the OFF position the pilot valve is stuck open Turn the main gas supply OFF Replace the gas control valve thermostat For instructions see Removing and Replacing the Gas Control Valve Thermostat If the pilot flame is not observed when the gas control valve thermostat knob is set to the OFF position wait 10 minutes for the t
63. er Door S Gas Control Valve Thermostat B Draft Hood K Outer Door T Drain Valve C Anode Not Shown L Union U Manifold Burner Assembly D Hot Water Outlet M Inlet Water Shut off Valve V Flue E Insulation N Cold Water Inlet W Metal Drain Pan F Gas Supply Piping O Inlet Dip Tube Not Shown X Piezo Igniter bottom Left hand G Manual Gas Shut off Valve P Temperature Pressure Relief Valve Side of Gas Control Valve Thermostat H Ground Joint Union Q Rating Plate Y Base RingFilter Drip Leg Sediment Trap R Flue Baffle Z Roof Jack Z ROOF JACK S GAS CONTROL VALVE THERMOSTAT Gas Control Temperature Knob TO VENT TERMINATION ROOF JACK Conversion Fitting W Status Light 7 VAC P OFF o Igniter Temperatures shown are approximates and may vary U MANIFOLD BURNER ASSEMBLY MAIN BURNER DISCHARGE PIPE Y DO NOT CAP WU MANIFOLD OR PLUG INSTALL THERMAL THERMOPILE Sx TUBE EXPANSION TANK f IF WATER HEATER IS INSTALLED IN A CLOSED WATER SYSTEM V IGNITER WIRE VACUUM RELIEF VALVE INSTALL PER LOCAL CODES INSTALL IN ACCORDANCE WITH LOCAL CODES DRIP LEG AS REQUIRED BY LOCAL CODES DRAIN LINE MUST PASS THROUGH THE STRUCTURAL SECURE WATER HEATER TO FLOOR AND DISCHARGE FLOOR AND WALL AS DESCRIBED EXTERNAL TO THE BUILDING IN THIS MANUAL INSTALLATION SHOULD COMPLY WITH THE ENCLOSURE ALL PIPING MATERI
64. ethod ll ensure that the drain pan does not cover the air intake opening in the floor A discharge line must be installed as described in the Temperature and Pressure Relief Valve section e Do not obstruct the combustion and ventilation air openings Do not use the enclosure as a storage area Secure the water heater as described in Securing Water Heater to Floor and Wall Method II Floor Opening ROOF JACK ROOF JACK NOT INCLUDED NOT INCLUDED ROOF t ROOF CEILING gt CEILING MAINTAIN MIN CEILING Nj MAINTAIN MIN CEILING CLEARANCE PER LABEL CLEARANCE PER LABEL ON WATER HEATER ON WATER HEATER MAINTAIN MIN METAL MAINTAIN MIN CLEARANCE PER CODE DRAIN PAN CLEARANCE PER CODE SECURE TOP SECURE TOP TO WALL WITH TO WALL WITH STRAP AND STRAP AND SCREWS ONE GPENING SCREWS IN DOOR MAINTAIN MIN MAINTAIN MIN E PROTECTION CLEARANCES 1 4 IN WIRE CLEARANCES N OUTSIDE SECURE WATER HEATER FOUVERS FRESH SECURE WATER HEATER METRI TO FLOOR WITH BRACKETS AIR TO FLOOR WITH BRACKETS DRAIN B N AND SHEET METAL AND SHEET METAL SCREWS PROVIDED SCREWS PROVIDED AIRINTAKE EI __ 6 INCHES MAX Na e FLOOR Above sorrow FLOOR e EDGE OF DOOR FREE AREA FOR AIR OPENING 20 SQ IN MIN FIGURE 15 IMPORTANT DRAIN PAN MUST NOT BLOCK OR COVER
65. ey 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 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 and make any required installation upgrades or changes IMPORTANT This water heater is shipped from the factory as a natural gas unit However it may be converted to use LP gas See the Gas Conversion section for more information This manual contains instructions for the installation operation and maintenance of the gas fired water heater It also contains warnings through out the manual that you must read and be aware of All warnings and all instructions are essential to the proper operation of the water heater and your safety Since we cannot put everything on the first few pages READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER Theinstallation must conform with these instructio
66. 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 Figure 34 Inspect the viewport for damage and replace as required Figure 29 Insert the new manifold burner assembly into the burner compartment making sure that the tab of the manifold 33 tube engages the slot of the bracket inside the combustion chamber Figure 35 Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion chamber Figure 34 Tighten the two screws that secure the manifold burner assembly to the combustion chamber Use a 1 4 nut driver There should be no space between the gasket part of the manifold door and combustion chamber IMPORTANT Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber Reconnect the manifold tube 3 4 wrench and pilot tube 7 16 wrench to the gas control valve thermostat Figure 28 Do not cross thread or apply any thread sealant to the fittings IMPORTANT If you were supplied with a new ferrule nut in a parts kit follow these steps to connect the pilot tube 1 Install the ferrule nut into the gas valve at the
67. gins to blink When the status light starts blinking release the gas control temperature knob Set the gas control D E FIGURE B PILOT POSITION CONTROL FLAMMABLE knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion 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 MAIN BURNER THERMOPILE E FIGURE D temperature knob to the desired setting See Figure C If the status light does not start blinking within 90 seconds repeat steps 2 through 5 up to THREE 3 times waiting 10 minutes between lighting attempts The circuitry in this advanced gas valve requires that you wait 10 minutes between lighting attempts If the status light turns solid red release the gas control temperature knob and repeat steps 2 through 5 waiting 10 minutes before attempting to relight the pilot If the status light does not star
68. he flame arrestor and burner Does the flame arrestor show signs No Reassemble the water heater press the of discoloration thermal switch and attempt to return the water heater to service Does the pilot remain lit YES N Set to desired temperature YES Shut off the gas supply to the water heater at the manual gas shut off valve Contact Sears Service at 1 800 4 MY HOME 1 800 469 4663 Does the diagnostic status light on the gas control valve thermostat give a two flash error code NO Go to section C Refer to the Replacing the Pilot Assembly instructions in the manual Reassemble and restore to service instructions on the front of the water heater Set thermostat to desired temperature Section C Pilot light will not remain lit Complete this section after completing Section B Check for insufficient combustion air YES Are the combustion air supply and ventilation openings of sufficient size See Combustion Air Supply and Ventilation section in this manual for requirements Correct size of openings to allow sufficient air Does the return air duct for the furnace air handler air conditioner draw its air from the same location as Checking the Draft the water heater See the section in this manual Location Requirements YES section and the Combustion Air Supply section Is there proper drafting at the drafthood See Check th
69. he preferred starting point is 120 F at the HOT setting Align the knob with the desired water temperature as shown in Figure 24A There is a hot water scald potential if the thermostat is set too high NOTE Temperatures shown on the gas control valve thermostat are approximates The actual temperature of the heated water may vary IMPORTANT Adjusting the thermostat past the 120 F mark on the temperature dial will increase the risk of scald injury Hot water can produce first degree burns within Time for Permanent Burns 2nd amp 3rd Degree Most Severe Burns Time for 1st Degree Burn Less Severe Bums Water Temperature F 110 116 116 122 131 140 normal shower temp pain threshold 35 minutes 1 minute 5 seconds 2 seconds 45 minutes 5 minutes 25 seconds 5 seconds 149 1 second 2 seconds 154 Instantaneous 1 second U S Government Memorandum C P S C Peter L Armstrong Sept 15 1978 GAS CONTROL VALVE THERMOSTAT SETTINGS GAS CONTROL TEMPERATURE KNOB 120 F A sou STATUS 0 A 5 LIGHT VAC pior OFF IGNITER FIGURE 24A Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance NOTE During low demand periods when hot water is not being used a lower thermostat setting will reduce energy losses and may satisfy your normal hot water needs If hot water use is expected to be more than norma
70. 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 e a concentration of sulfate in the supply water e little or no dissolved oxygen in the water sulfate reducing bacteria within the water heater This harmless bacteria is non toxic to humans e 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 chlorinating the water heater tank and
71. 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 10 may be used as a reference guide to locate the specific clearance locations A minimum of 24 inches of front clearance should be provided for inspection and service BACK V SIDES gt FRONT C 24 MINIMUM S FOR SERVICE TOP VIEW FIGURE 10 15 Filling the Water Heater Never use this water heater unless it is completely full of water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater To fill the water heater with water Close the water heater drain valve by turning the handle to the right clockwise The drain valve is on the lower front of the water heater 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 ensure complete filling of the tank allow air to exit by opening the nearest hot water faucet Allow water to run until a constant flow is obtained This will let air out of the water heater and the piping Check all water piping and connections for leaks Repair as needed CAUTION Avoid water heater damage Fill tank with water before operating
72. hermopile to cool then attempt to relight the pilot by following the lighting instructions on the water heater s label If this condition returns replace the gas control valve thermostat See Removing and Replacing the Gas Control Valve Thermostat for instructions PARTS ORDER LIST KENMORE MOBILE HOME GAS WATER HEATER MODEL NUMBERS 153 336930 30 Gallon Tall 153 336940 40 Gallon Tall Key No Part Description 153 336930 153 336940 Anode Rod 9003944 9003944 Base Ring Filter 9006616 9006616 Burner Head Natural Gas 9006136 9006136 Burner Head LP Gas 9006651 9006603 Burner Orifice Natural Gas Burner Orifice LP Gas 9001886 9001886 186056 052 9006700 Draft Hood 9006647 9006647 Drain Valve 9000058 9000058 Gas Control Valve Thermostat 9008101 9008101 Inlet Tube 9008232 9008233 Inner Door Gasket 9006141 9006141 Instruction Manual 321634 001 321634 001 Manifold Door Assembly Natural Gas 9008105 9008108 Manifold Door Assembly LP Gas 9008106 9008107 Mounting Bracket Kit Nipple w Heat Trap 9006388 9006388 9003719 9003719 Outer Door 9006648 9006648 Pilot Assembly w Tubing and Fittings Natural Gas 9007876 9007876 Pilot Assembly w Tubing and Fittings LP Gas 9007877 9007877 T amp P Relief Valve 9000728 9000728 Thermopile 9007872 9007872
73. ht starts to blink If the Status Light does not blink after three lighting attempts check to make sure unit is getting gas Remove the outer door Press reset button Replace outer door Turn Gas Control Valve Thermostat knob to OFF Wait 10 minutes then attempt to light Pilot by following the lighting instructions on the water heater s label Look through the view port for the Pilot flame If Pilot is not visible the spark igniter or gas supply to the Pilot should be checked If the Pilot is visible and the Status Light does not blink after 90 seconds of continuous Pilot operation the Pilot flame may not be heating the Thermopile sufficiently weak Pilot the Thermopile may be defective or wiring connectors may be loose NOTE If the water heater has been operating but has stopped and will not re light check the flame arrestor for signs of high temperature blue or black discoloration indicating a flammable vapor incident 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 subjected to a flammable vapors ignition will require replacement of the entire water heater RED LIGHT ON SOLID Pilot light was recently extinguished Turn Gas Control Valve Thermostat knob to OFF and the Thermopile is cooling Wait 10 minutes for the Thermopile to cool then attempt to relight Pilot by following the lighting instructions on the
74. ided Figure 9 Simply pre drill each screw location in the metal drain pan and water heater jacket with a 1 8 drill bit Because of installation variances these brackets can be located at any points around the circumference of the jacket However they should be spaced apart at equal distances 14 CAUTION When making pilot holes in the water heater itself ensure that you drill only the outer jacket Also to prevent leaks in the metal drain pan seal each drill location with a heavy bead of silicone sealant 2 Secure the top of the water heater with the provided bracket and screws or install other acceptable means of support e g support strap BOTTOM OF WATER HEATER SCREW BRACKET FIGURE 9 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 detectors are available Install water heater in accordance with the instruction manual Breathing carbon monoxide can cause brain damage or death Always read
75. ility pet e eer Ce leer Ee rette CaN ede Poe eo ee 15 Filino the Water Heater cies rre t t e ip P e EH te tty eee hier E A ni Gu Heap ve E Cep heo ati 15 GAS CONVERSION Ri e eR ERR ora RM er ei d CER D a ARE 16 GAS SUPPLY cR 17 18 Gas Requirements ict e tad tated ashes ees eed mia ual ial oad iam cde 17 GAS bm I E 17 GaS inion nee aed leone eae ties necator ea ete lesen te 17 Gas Pressure repe e epe e eate ee nue jen elu deed ec sua duels bee eae ge ee aaepe ee reper 17 EE 18 COMBUSTION AIR SUPPLY amp 19 20 Vent PDE SyS E Mi 5 EET 19 Draft Hood Installation ierit Ere e d ee don at dr did dettes 19 Root Jack Installation un iet e re deer vt e We P a e de te tur fe d Rte 19 EE 20 WATER SYSTEM PIPING eite tit ete ner rg E eet e e ep tutors eta en REI ERE E SERERE 21 23 Piping Installation i o dan teo edet dett c deg ede eb debts 21 Water Piping Pressure Test tended e dede cuddle d danger ear ede amr deu ege ea 22 Closed System Thermal Expansion sse eene ennemi nennen nnne 22 Temperature and Pressure Relief Valve c cccceccececceeeeeceeeeceececeeeeeeeeeceaaaaaaeeaeceeeeeeeeeegdeaaeaeaeeaeeeeeeeeeeeeesena
76. king a smart purchase Your new Kenmore product is designed and manufactured for years of dependable operation But like all products it may require preventive maintenance or repair from time to time That s when having a Master Protection Agreement can save you money and aggravation The Master Protection Agreement also helps extend the life of your new product Here s what the Agreement includes Parts and labor needed to help keep products operating properly under normal use not just defects Our coverage goes well beyond the product warranty No deductibles no functional failure excluded from coverage real protection Expert service by a force of more than 10 000 authorized Sears service technicians which means someone you can trust will be working on your product Unlimited service calls and nationwide service as often as you want us whenever you want us No lemon guarantee replacement of your covered product if four or more product failures occur within twelve months Product replacement if your covered product can t be fixed e Annual Preventive Maintenance Check at your request extra charge Fast help by phone we call it Rapid Resolution phone support from a Sears representative on all products Think of us as a talking owner s manual Power surge protection against electrical damage due to power fluctuations C Leaks in pipes or fittings 250 Food
77. l a higher thermostat setting may be required to meet the increased demand When leaving your home for extended periods vacations etc turn the temperature dial to its lowest setting This will maintain the water at low temperatures with minimum energy losses and prevent the tank from freezing during cold weather 27 Operating the Temperature Control System OFF 7 D PILOT FIGURE 24B Water Temperature Adjustment The water temperature setting can be adjusted from 55 F to 155 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 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 55 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 Status Light Code Normal Flashes OFlashes Indicates Control Off Pilot Out e 1Flash Indicates Normal Operation e A solid red light indicates that valve thermostat is shutting down the gas control Diagn
78. l parts B Convert the Gas Control Valve Thermostat 1 Remove the cap shown in Figure 12 2 Remove the conversion fitting by turning it counter clockwise with a flathead screwdriver 3 Thread the opposite end of the conversion fitting into the opening by turning it clockwise then tighten it with a flathead screwdriver a LP GAS If you are converting the unit to use LP gas propane verify that LP is marked on the exposed end of the fitting LP must face outward toward you See GAS CONTROL VALVE THERMOSTAT CONNECTIONS IGNITER n WHITE BUTTON Poi a WIRE RIGHT IGNITER SIDE Wd RED WIRE WIRE 4 XS r t LEFT SIDE MANIFOLD TUBE PILOT TUBE IGNITER WIRE GAS CONTROL THERMOPILE TEMPERATURE KNOB WIRE CONNECTIONS PIEZO IGNITER BUTTON my PILOT TUBE EMI MANIFOLD TUBE VIEWPORT EM Ga THERMAL li eu pl SWITCH OUTER DOOR TL MANIFOLD 7 DOOR MANIFOLD COMPONENT BLOCK FIGURE 11 NOT SHOWN MANIFOLD SCREW 2 16 Figure 12 If NAT faces outward repeat step 2 b NATURAL GAS If you are converting the unit to use natural gas verify that NAT is marked on the exposed end of the fitting NAT must face outward toward you See Figure 12 If LP faces outward repeat step 2 Replace the cap Install the Conversion Manifold Burner Assem
79. me of water increases 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 For additional information see the Troubleshooting Guide later in this manual 22 Temperature and Pressure Relief Valve A WARNING 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 Do not plug block or cap the discharge line Failure to follow this warning can result in excessive tank pressure serious injury or death TEMPERATURE AND PRESSURE T amp P RELIEF VALVE OPTIONAL TOP T a
80. mp P RELIEF VALVE NOT SHOWN DISCHARGE PIPE DO NOT CAP OR PLUG Q PAN DRAIN LINE 3 4 ID 0 MINIMUM 1 MINIMUM H METAL DRAIN LINE TERMINATES DRAIN PAN eea EXTERNAL TO BUILDING FIGURE 20 For protection against excessive pressures and temperatures a temperature and pressure relief valve must be installed in the opening marked T amp P RELIEF VALVE See Figure 20 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
81. ners 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 Vent Pipe System This water heater uses a non direct single pipe vent system to remove exhaust gases created by the burning of fossil fuels Air for combustion is taken from the immediate water heater location or is ducted in from the outside see Enclosure Installation 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 Manufactured home manufacturers must conform with The Manufactured Home Construction and Safety Standard Title 24 CFR Part 3280 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 onl
82. ng Ventilation Air Conditioning amp Refrigeration HVAC R authorized service provider Use a fresh air supply that is free of corrosive elements and flammable vapors 11 Fresh air openings must be sized correctly with consideration given to the blocking effect of louvers and grilles Vent Pipe System Check for proper drafting at the water heater draft hood Refer to the Checking the Draft section of this manual for the test procedure If the procedure shows insufficient draft is present please check the following Draft hood properly installed Vent connectors securely fastened with screws and supported properly to maintain six inch clearance Vent connector made of approved material and sized correctly Vent pipe system installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI 2223 1 NFPA 54 current edition Manufactured home manufacturers must conform with the Manufactured Home Construction and Safety Standard Title 24 CFR Part 3280 Flue baffle properly positioned in the flue tube Check the vent system for restrictions obstructions and check the vent termination height Refer to the Combustion Air Supply and Ventilation section of this water heater manual for specific requirements Recheck for sufficient combustion air supply Water System
83. ns and the local code authority having jurisdiction In the absence of local and state codes installations shall comply with the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition Manufactured home manufacturers The installation must conform to The Manufactured Home Construction and Safety Standard Title 24 CFR Part 3280 These publications are available as follows The National Fuel Gas Code is available through The Canadian Standards Association 8501 East Pleasant Valley Rd Cleveland Ohio 44131 or The National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 The Manufactured Home Construction and Safety Standard Title 24 CFR Part 3280 is available through The U S Department of Housing and Urban Development HUD 451 7th Street S W Washington DC 20410 Offices are also located throughout the United States Check your phone listings for the local authorities having jurisdiction over your installation f after reading this manual you have any questions or do not understand any portion of the instructions call the Sears Service Center Carefully plan the place where you are going to 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 thi
84. nvert from one gas to another Failure to use the correct gas can cause problems which can result in death serious bodily injury or property damage If you have any questions or doubts consult your gas supplier or gas utility company Water heaters using bottled propane or liquefied petroleum gas LPG are different from natural gas models A natural gas water heater will not function safely on bottled propane or liquefied petroleum gas LPG and a propane gas water heater will not function safely on natural gas PRODUCT SPECIFICATIONS MODEL TANK CAPACITY TYPE INPUT RECOVERY MINIMUM DIAMETER DIMENSIONS NUMBER IN GALS LTRS OF RATE RATE GALS VENT PIPE INCHES INCHES mm GAS Btu hr PER HOUR DIA INCHES mm HEIGHT TO 90 F RISE mm JACKET TOP amo EET Emp xm monem eem seem 153 336940 40 151 prd EZ 3 76 OR 4 102 20 508 58 25 1480 MATERIALS AND BASIC TOOLS NEEDED MATERIALS NEEDED To simplify the installation Sears has available the installation parts shown below You may or may not need all of these materials depending on your type of installation pue Gas Water Heater Installation Kit 9000105 Kit yo EA Water Complete Enclosed 2 Ts T M EXPANSION TANKS FOR THERMAL EXPANSION CONDITIONS AVAILABLE IN 2 GALLONS 7 6 LITERS AND 5 GALLONS 18 9 LITERS
85. od 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 WARNING Do not install this water heater in any occupied space of the manufactured mobile home Doing so can result in carbon
86. off valve on the gas supply pipe Figure 2 3 Drain the water heater Refer to the section of Draining and Flushing and follow the procedure 4 Disconnect the igniter wire from the igniter lead wire Use needle nose pliers to disconnect the red and white thermopile wires Disconnect the pilot tube 7 16 wrench and manifold tube 3 4 wrench at the gas control valve thermostat Figure 28 5 Refer to Gas Piping Figure 2 and disconnect the ground joint union in the gas piping Disconnect the remaining pipe from the gas control valve thermostat 34 6 To remove the gas control valve thermostat thread a 4 section of gas pipe into the inlet and use it to turn the gas control valve thermostat counterclockwise Do not use a 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 Control Valve Thermostat To replace the gas control valve thermostat reassemble in reverse order When replacing the gas control valve thermostat thread a 4 section of gas pipe into the inlet and use it to turn the gas control valve thermostat clockwise DO NOT OVER TIGHTEN damage may result Be sure to use approved Teflon tape or pipe joint compound on the gas piping connections and fitting on the back of the gas control valve that screws into the tank
87. or s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the 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
88. ostic Flashes If the water heater is not working look for the following diagnostic flashes after lighting the pilot For more details see Status Light and Diagnostic Code Troubleshooting Chart 2 Flashes Indicates Thermopile Voltage Low 4Flashes Indicates Overheat Failure 5 Flashes Indicates Sensor Failure Flashes Indicates Electronic Control Failure 8Flashes See Status Light and Diagnostic Code Troubleshooting Chart SERVICE AND ADJUSTMENT Vent System Inspection A 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 system can cause serious injury or 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 Obstructions which could cause improper venting The combustion and ventilation air flow must not be obstructed Damage or deterioration which could cause improper venting or leakage of combustion products Rusted flakes around top of water heater Be sure the vent piping is properly connected to prevent escape of dangerous flue gasses which could cause deadly asphyxiation Obstructions and deteriorated vent systems may pre
89. other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally handicapped If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at the hot water taps used by these people or at the water heater Mixing valves are available at plumbing supply or hardware stores See Figure 18 Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat see Figure 24A Using the lowest hot water temperature that meets your needs will also provide the most energy efficient operation of the water heater Never allow small children to use a hot water tap or to draw their own bath water Never leave a child or handicapped person unattended in a bathtub or shower NOTE A water temperature range of 120 F 140 F 49 C 60 C is recommended by most dishwasher manufacturers The thermostat is adjusted to the pilot position when it is shipped from the factory Water temperature can be regulated by moving the temperature dial to the preferred setting T
90. r flue or vent system blocked 4 Cold drafts 5 Incorrect gas conversion if unit was converted to use a different type of gas BURNER FLAME TOO HIGH 1 Orifice too large 2 Incorrect gas conversion if unit was converted to use a different type of gas FLAME BURNS AT ORIFICE 1 Thermostat not functioning properly 2 Low gas pressure 3 Incorrect gas conversion if unit was converted to use a different type of gas PILOT FLAME 1 TOO SMALL 2 Pilot line or orifice clogged Low gas pressure 39 1 2 3 4 5 1 2 1 2 3 1 2 Provide ventilation to water heater Check flue way flue baffle and burner Clean locate source and correct Provide fresh air ventilation Clean filter See External Inspection amp Cleaning of the Base Ring Filter section Clean filter See Cleaning the Combustion Chamber and Flame Arrestor section Provide ventilation to water heater Check flue way flue baffle burner Check with gas utility company Clean locate source and correct Replace thermostat Provide fresh air ventilation See Burner Flame Yellow Lazy Clean filter See External Inspection amp Cleaning of the Base Ring Filter section Clean filter See Cleaning the Combustion Chamber and Flame Arrestor section Contact a qualified technician Increase the temperature setting Refer to the Condensation sub section of this manual s Troubleshooting Guide Replace with correct orifice
91. re setting Hot is approximately 120 Replace the outer door If the Pilot Does Not Light 1 Wait 10 minutes before another lighting attempt If the pilot does not light the Igniter may not be sparking or the unit may not be getting gas or for a new installation there may still be air in the gas line Each time you click the igniter button you should be able to see the spark by looking through the view port See 24 AWARNING Explosion Hazard Replace view port if glass is missing or damaged Failure to do so can result in death explosion or fire Figure 29 You may have to darken the room lights to see the spark You do not have to push the Control Knob in to check the Igniter button Simply look through the sight glass while clicking the Igniter button and look for a spark If you can t see a spark when the Igniter button is clicked check the wiring connections from the Igniter button and make sure that they are tight If you see the Igniter spark try relighting the pilot by following the instructions on the water heater s label Ensure that the gas supply is turned on There may be air in the gas line and several lighting attempts may be needed to completely fill the line with gas and successfully light the pilot If the Pilot Lights but the Status Light Does Not Blink 1 If the pilot lights continue to hold the Control Knob in until the Status Light blinks If the pilot is lit and remains li
92. res through the opening in the manifold door See Figure 31 Using the pilot screw removed earlier attach the new pilot thermopile assembly Reattach the burner to the manifold using the screws removed earlier NOTE Make sure the burner scoop is oriented to the pilot side of the manifold tube Figure 30 Reinstall the manifold component block in the manifold door Ensure that the pilot tube and wires are positioned as shown in Figure 33 Carefully bend the new pilot tube to match the bend of the manifold tube NOTE When bending DO NOT crimp or crease the pilot tube Before you proceed to the next step install the new brass ferrule nut in the gas control valve thermostat s pilot tube opening HAND TIGHT ONLY Install the manifold burner assembly Refer to the Replacing the Manifold Burner Assembly section for instructions MANIFOLD COMPONENT BLOCK ae IGNITER WIRE PASSES THROUGH CENTER OF MANIFOLD COMPONENT BLOCK SMALLEST HOLE RED THERMAL SWITCH WIRE CONNECTS TO THE GAS CONTROL VALVE THERMOSTAT CONNECTS TO THE GAS CONTROL T WHITE THERMOPILE WIRE connects To THE G RED THERMAL SWITCH WIRE Vd THERMOPILE WIRES PASS THROUGH TOP HOLE OF MANIFOLD COMPONENT BLOCK PILOT TUBE PASSES THROUGH BOTTOM HOLE OF MANIFOLD COMPONENT BLOCK LARGEST HOLE FIGURE 33 External Inspection amp Cleaning of the Base Ring Filter 1
93. s in the vicinity of this or any other appliance can result in serious injury or death Do not store or use gasoline or other flammable Read and follow water heater warnings and instructions Do not use or store flammable products such as gasoline solvents or adhesives in the same room or area near the water heater If such flammables must be used all gas burning appliances in the vicinity must be shut off and their pilot lights extinguished Open the doors and windows for ventilation while flammable substances are in use If flammable liquids or vapors have spilled or leaked in the area of the water heater leave the area immediately and call 13 the fire department from a neighbor s home Do not attempt to clean the spill until all ignition sources have been extinguished WARNING Read instruction manual before installing using or servicing water heater Improper use may result in fire or explosion Maintain required clearances to combustibles Keep combustibles such as boxes magazines clothes etc away from the water heater area Site Location DO NOT install this water heater in any occupied space of the manufactured mobile home There shall be no openings between the occupied space of the manufactured mobile home and the water heater enclosure The water heater must be installed indoors and in a vertical position on a level surface Do not install in bathrooms bedrooms or any occupi
94. s manual For California installation this water heater must be braced anchored or strapped to avoid falling or moving during an earthquake See instructions for correct installation procedures Instructions may be obtained from California s Office of the State Architect 1102 Q Street Suite 5100 Sacramento CA 95811 Instructions can also be downloaded to your computer at www dsa dgs ca gov Pubs Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248 CMR 2 00 State Plumbing Code and 248 CMR 5 00 Complies with 40 Ng J NOx requirements of Texas and most California AQM Districts 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 A DANGER Do not use this water heater with any gas other than the one listed on the data plate unless the water heater has been properly converted Refer to the Gas Conversion section of this manual to co
95. sent 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 At least once a year a visual inspection should be made of the main burner and pilot burner See Figure 25 To access the burner and 28 pilot follow the instructions in Maintenance of Your Water Heater 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 becaus
96. system DRIP FROM RELIEF VALVE 1 2 3 1 1 2 3 2 3 4 5 6 T Provide ventilation to water heater Check flue way flue baffle and burner Clean flue locate source and correct Check with gas utility company Replace thermostat Clean filter See External Inspection amp Cleaning of the Base Ring Filter section Clean filter See Cleaning the Combustion Chamber and Flame Arrestor section Contact a qualified technician Use a pressure reducing valve and relief valve Lower the thermostat setting See Closed System Thermal Expansion THERMOSTAT FAILS TO Thermostat not functioning properly Replace thermostat SHUT OFF Improper calibration Replace thermostat COMBUSTION ODORS Insufficient combustion air Water heater flue or vent system blocked Heater installed in a confined area Base Ring Filter blocked with lint dust FVIR Flame Arrestor blocked with lint SMOKING AND CARBON FORMATION SOOTING Insufficient combustion air Low gas pressure Water heater flue or vent system blocked Thermostat not functioning properly Heater installed in a confined area Burner flame yellow lazy Base Ring Filter blocked with lint dust FVIR Flame Arrestor blocked with lint dust Incorrect gas conversion if unit was converted to use a different type of gas CONDENSATION 1 Temperature setting too low BURNER FLAME FLOATS AND LIFTS OFF PORTS 1 Orifice too large 2 High gas pressure 3 Water heate
97. t 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 e Burning gas produces water vapor in water heaters particularly high efficiency models where flue temperatures are lower Large amounts of hot water are used in a short time and the refill water in the tank is very cold Moisture from the products of combustion condense on the cooler tank surfaces and form drops of water which may fall onto the burner or other hot surfaces to produce a sizzling or frying noise 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 washing machines and shower
98. t blinking after three lighting attempts turn the gas control temperature knob to OFF and call a qualified service technician or your gas supplier DANGER Hotter water increases the risk of scald injury Consult the instruction manual before changing temperature Refer to the Lighting Instructions in the Installation Manual for more detailed troubleshooting information ON POSITION Turn the gas control temperature knob counterclockwise to the OFF setting The status light will stop blinking and stay on for a short time after the water heater is turned off See Figure A 25 Checking the Draft AWARNING Burn Hazard Do not touch vent ELIT 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 22 Make sure all other appliances in the area are operating and all doors are closed when performing the draft test Pass a match flame around the relief opening of the draft hood A steady flame drawn into the opening indicates proper draft DRAFT HOOD RELIEF OPENING MATCH sl FIGURE 22 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
99. t for 90 seconds and the Status Light still does not blink the thermopile connections may be loose the thermal switch may need to be reset or the thermopile may be defective Remove the outer door Press the reset button on the thermal switch Figure 29 If switch clicks it may have tripped Do not light the Pilot if flammable vapors are present Check flame arrestor for signs of discoloration which could be caused by flammable vapors If the flame arrestor is discolored do not attempt to relight the Pilot Have the water heater inspected by a qualified service technician Check the wiring connections from the thermopile and the thermal switch to the gas control valve thermostat Ensure that all wiring connections are tight See Figure 29 Replace the outer door Wait 10 minutes and try to light the Pilot according to the instructions on the water heater s label While clicking the Igniter button continuously the Control Knob must be set to Pilot and held in until the Status Light blinks Once the Status Light blinks release the Control Knob and set the Knob to the desired temperature setting is approximately 120 F WARNING you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life BEFORE LIGHTING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES C Use only your hand to push in or turn the gas control A
100. ted from the gas supply piping system and the line capped gas lines are to be tested at a pressure less than 14 W C the water heater must be isolated from the gas supply piping system by closing its manual shut off valve 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 and regulations 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 the fuel is not spilled in the area of the water heater installation or any source of ignition If the fuel is spilled while purging the piping system of air follow the WHAT TO DO IF YOU SMELL GAS instructions on the cover of this manual LP Gas Only Liquefied petroleum gas is over 50 heavier than air and in the AWARN G occurrence of a leak in the system the gas will settle at floor level Basements crawl spaces skirted areas under mobile homes even when ventilated 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 as given in the warning on the front page x Explosion
101. tion Exposed Support Wire FIGURE 26 Temperature Pressure Relief Valve Operation The temperature pressure relief valve must be manually operated at least once a year ADANGER 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 27 TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE FIGURE 27 If after manually operating the valve it fails to completely reset and continues to release water immediately turn off the gas supply and drain the water heater see Draining and Flushing Once the water heater is completely drained replace the temperature pressure relief valve with a new one If the temperature pressure relief valve on the appliance weeps or discharges periodically this may be due to thermal expansion You may have a check valve installed in the water line or a water meter with a check valve Consult the Sears Service Center for further information Draining and Flushing ADANGER Hot water discharge burn hazard Keep clear of relief valve discharge unit Temperature limiting valves are available Read instruction manual for safe temperature setting
102. ty 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 Is the water heater installed in a closet or other small enclosed space If so Are there openings for make up air to enter and exit the room area Are the openings of sufficient size Remember if there are other gas fired or air consuming appliances in the same room you need more make up air Refer to the Installation Instructions and Combustion Air Supply and Ventilation sections for specific requirements Make sure that fresh air is not taken from areas that contain negative pressure producing devices such as exhaust fans dryers fireplaces etc Is there a furnace air handler in the same room space as the water heater If so has a return air duct system been attached that exits the room If so check for leaks on the air duct system If no air duct system is present correct immediately by contacting a local Heati
103. y and does not mean they are certified for use on this water heater 19 U L recognized fuel gas and carbon monoxide CO detectors are recommended in all applications and should be installed using the manufacturer s instructions and local codes rules or regulations IMPORTANT e f you lack the necessary skills required to properly install this venting system you should not proceed but get help from a qualified technician DO NOT common vent this water heater with any other appliance Draft Hood Installation SHEET METAL SCREWS FOUR PROVIDED INSTALL THE DRAFT HOOD WITH THE FOUR SCREWS PROVIDED FIGURE 14 Align the legs of the draft hood with the slots provided Insert the legs and secure the draft hood to the water heater s top with the four screws provided as shown in Figure 14 Do not alter the draft hood in any way If you are replacing an existing water heater be sure to use the draft hood supplied with this water heater Roof Jack Installation This water heater must have a properly installed draft hood and be connected to a listed roof jack that terminates to the outdoors The roof jack vent pipe must be secured to the draft hood with sheet metal screws Roof jack not furnished The following roof jack models are certified for use with this water heater 1 Field Controls No 987 2 Ventline 2073 3 White Metal Products 3RJ Install the roof jack according to its manufacturer s instructions

Kenmore 30 gal. Mobile Home Natural Gas Water Heater Installation Guide

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