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Kenmore 6-Year Manufacturer's Warranty

1. Do not operate water heater if flood damaged ADANGER Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk forscald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting A WARNING Overheated water can cause watertank explosion Properly sized temperature and pressure relief valve must be installed in opening provided A WARNING 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 LP gas Do not expose water heater control to excessive gas pressure Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources away from faucets after extended period of non use e Read instruction manual before installing using or servicing water heater 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 2 000 feet 610 m Do not operate if soot buildup Do not obstruct water heater air intake with insulating jacket D
2. DIMENSIONS IN INCHES mm HEIGHT TO JACKET TOP 56 3 8 1432 58 5 8 1489 57 3 8 1457 MINIMUM VENT PIPE INCHES mm 3 76 OR 4 102 3 76 OR 4 102 3 76 OR 4 102 DIAMETER INCHES mm 16 406 18 457 20 508 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 ES Gas Water Heater Installation Kit 9000105 a5 2 gt 2 2 2 gt gt gt gt Cc T NOTA EXPANSION TANKS FOR THERMAL EXPANSION CONDITIONS AVAILABLE Lp 0008 VU CUL OOOO M METAL DRAIN PANS AVAILABLE IN 20 508 mm DIAMETER FOR WATER HEATERS HAVING A IN 2 GALLONS 7 6 LITERS AND 5 GALLONS 18 9 LITERS CAPACITY THROUGH LOCAL SEARS STORE OR SERVICE CENTER WATER HEATER INSTALLATION KIT WITH FLEXIBLE CONNECTORS FOR 3 4 19 05 mm COPPER PLUMBING AND FLEXIBLE GAS CONNECTOR WITH FITTINGS DIAMETER 18 457 mm OR LESS 24 610mm DIAMETER FOR WATER HEATERS HAVING A DIAMETER 22 559 mm OR LESS AND AVAILABLE IN 28 711 mm DIAMETER FOR WATER HEATERS HAVING A DIAMETER 26 660 mm OR LESS BASIC TOOLS You may or may not need all these tools depending on your type of installation These tools can be purchased at your local Sear
3. A WARNING Vent dampers must be certified in accordance with ANSI 221 68 Vent damper must permit proper drafting of water heater Install properly sized venting Do net install without venting outdoors Do notinstall without drafthood If common vented install in accordance with NFPA 54 Be alert for obstructed or deterio rated vent system to avoid serious injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual To ensure proper venting of this gas fired water heater the correct vent pipe diameter must be utilized Any additions or deletions of other gas appliances on a common vent with this water heater may adversely affect the operation of the water heater Consult your gas supplier if any such changes are planned For replacement heater installations where pre existing venting is used the venting must be inspected for obstructions and if deterioration is present it must be replaced IMPORTANT Do not common vent this water heater with any power vented appliance For proper venting in certain installations a larger diameter vent pipe may be necessary Consult your local Sears Service Center or gas supplier to aid you in determining the proper venting for your water heater from the vent tables in the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 Periodically check the venting system for signs of obstruction or deterioratio
4. INSTALL THERMAL EXPANSION TANK IF WATER HEATER IS INSTALLED IN A CLOSED WATER SYSTEM V PILOT AND BUNER DOOR ASSEMBLIES VACUUM RELIEF ai VALVE E SE gt T INSTALL PER LA TA LOCAL CODES IGNITER WIRE PILOT TUBE SN MAIN BURNER CONNECTORS RETAINER A lt CLIP x A MANIFOLD R PILOT KIL COMPONENT ASSEMBLY BLOCK SEE BELOW gt gt DISCHARGE PIPE BURNER DOOR Do not cap or plug y w H g v 8 U 6 MAXIMUM NG lt a AIR GAP j PILOT ASSEMBLY ee g UTE RO 4 J X L K ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS FIGURE 1 TOPVIEW 8 INSTALLATION INSTRUCTIONS Removing the Old Water Heater e O i i ere ch i MANUAL GAS SHUT OFF VALVE a gt t GROUND _ JOINT UNION CHECK WITH T DISCHARGE PIPE LOCAL UTILITY DO NOT CAP FOR MINIMUM HEIGHT OR PLUG 37 MINIMUM 6 MAXIMUM AIR GAP DRIP LEG SUITABLE Y DRAIN FIGURE 2 O 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
5. TYPICALINSTALCATION 0 ieee else eile sd dodo Bie ed a ee iB A a eN aia 8 INSTALLATION INS TRUC ONS rraiki h kdi leai deea ia aeaa aa daadaa d eatae kandidi niaire daie aiik 9 18 Removing the Old Water Heat 25 45 fives cade nese A AE ARNA AEE AAAA A 9 Facts to Consider About the LocatiON sssini as iiine iadi aia ai eai a a ia aaia 10 11 Insulation Blankets siie eaea aeaa aa aa ai aa aiad ae aaaea a a a a ieran 11 12 Combustion Air and Ventilation Appliances in Unconfined Spaces cccccecceeeeeeeeeeeeneeceeeeeeeeeeeseesencsecnesaeeeeeees 12 Combustion Air and Ventilation Appliances in Confined Spaces eccccccceceeeeeeeeeceeecneeeeeeeeeeeeeseeeeeseenaees 12 13 Water Piping cisrenan ii A A ai 13 14 T amp P Valve and Pipe Insulation siinne cc iii aida a dae 14 Temperature Pressure Relief Valve cocooocnocococcoooooononononononcnonononnnnnnnnnnnnnnnnnnnnonononenennanannnnnnnnananananenennnanas 15 16 Filling the Water Heater civioincoici a a a a a caida 16 A E EEE TE E E TENE ds hecho ianed ieiinda ceeind a een Mehdi dee ibde teeta ichedans 16 17 Gas PIPING siii diia 17 18 Sediment TAP iii it cai 18 OPERATING INSTRUCTIONS oocociccccncocnnocncncncononononononononononenenonononononenenonononenenennnonenennnnnnnononnnnnnnnnnnnnnnnnrnnnnnnnrnrnrnrnrnrnennass 19 21 Lighting Operating Label A A eae ete aed 19 Temperature Regulation tai td oat naa aia 20 Operating the Temperature Control System onnoccnonnnccccc
6. lift white lever outward then gently pull the plug downward Also use needle nose pliers to disconnect the red and white thermopile wires from the gas control valve thermostat See Figures 24 amp 25 GAS CONTROL VALVE THERMOSTAT TEMPERATURE SENSOR WIRE CONNECTION THERMOPILE WIRE CONNECTIONS PIEZO IGNITER BUTTON MANIFOLD TUBE PILOT TUBE TEMPERATURE SENSOR VIEWPORT OUTER DOOR NOT SHOWN BURNER DOOR BURNER DOOR SCREWS 2 MANIFOLD COMPONENT BLOCK FIGURE 24 Grasp the manifold tube and push down slightly to free the manifold pilot tube and thermopile Carefully remove the burner door assembly from the burner compartment NOTE Be sure not to damage internal parts IGNITER A Li WHITE BUTTON iT WIRE a RIGHT IGNITER SIDE LEAD 1 7 WIRE PILOT A TUBE RED WIRE IGNITER MANIFOLD LEFT WIRE TUBE SIDE FIGURE 25 23 Ultra Low NOx Natural Gas Burner Check the burner to see if it is dirty or clogged The burner may be cleaned with soft paint brush Figure 26 Do not use a wire brush or any tool that may damage the burner screen Important Do not use the burner if the burner screen is damaged NOTE Damage may be rips or holes in the burner screen Discoloration is normal JD PILOT ASSEMBLY USE BRUSH ON THIS SURFACE CQUVUVOT A ayy NX FIGURE 26 Replacing the Pilot Thermopile A
7. 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 6 Check again to make sure the gas supply is OFF to the water heater Then disconnect the gas supply connection from the gas control valve ADANGER Burn hazard Hotwater discharge Keep hands clear of drain valve discharge 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 Disconnect the vent pipe from the draft hood where it connects to the water heater In most installations the vent pipe can be FIGURE 5 lifted off after any screw or other attached devices are removed Dispose of the draft hood The new water heater has a draft hood which must be used for proper operation If you have copper piping to the water heater the two copper water pipes can be cut with a hacksaw approximately four inches away from where they connect to the water heater See Figure 6 This will avoid cutting off pipes too short Additional cuts can be made later if necessary Disconnect the temperature pressure relief valve drain line When the water heater is drained disconnect the hose from the drain valve Close the drain valve The water heater is
8. with water heater Read this manual first Then before checking the water heater make sure the gas supply has been turned OFF and never turn the gas ON before the tank is completely full of water Never use this water heater unless it is completely filled with water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater A Water at the draft hood is water vapor which has condensed out of the combustion products This is caused by a problem in the vent Contact a qualified technician B Condensation may be seen on pipes in humid weather or pipe connections may be leaking C The anode rod fitting may be leaking D Small amounts of water from temperature pressure relief valve may be due to thermal expansion or high water pressure in your area E The temperature pressure relief valve may be leaking at the tank fitting F Water from a drain valve may be due to the valve being slightly opened G The drain valve may be leaking at the tank fitting H Combustion products contain water vapor which can condense on the cooler surfaces of the tank Droplets form and drip onto the burner or run on the floor This is common at the time of start up after installation and when incoming water is cold Water in the water heater bottom or on the floor may be from condensation loose connections or the reli
9. Burner Door Assembly section Replacing the Burner Door Assembly A WARNING Fire or Explosion Hazard Tighten both manifold door screws securely Remove any fiberglass between gasket and combustion chamber Replace viewport if glass is missing or damaged e Replace manifold component block if missing or removed e Replace door gasket if damaged Failure to follow these instructions can result in death explosion or fire a Read instruction manual before installing using or servicing water heater 1 Check the door gasket for damage or imbedded debris prior to installation AMWARNING Replace viewport if glass is missing or damaged Failure to do so can result in death explosion or fire Inspect the viewport for damage and replace as required Insert the burner assembly into the burner compartment making sure that the burner assembly sits firmly against the burner bracket inside the combustion chamber Figure 30 4 Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion chamber 5 Replace the two screws which secure the burner assembly to the combustion chamber and tighten securely There should be no space between the gasket part of the burner door and combustion chamber IMPORTANT Do not operate the water heater if the door gasket does not create a seal between the burner door and the combustion chamber 6 Reconnect
10. Do not connect tubing directly to discharge drain unless a 6 inch air gap is provided To prevent bodily injury hazard to life or property damage the relief valve must be allowed to discharge water in quantities should circumstances 15 HOT WATER COLD WATER OUTLET INLET lt a SHUTOFF VALVE y HOT a COLD DRAFT HOOD TEMPERATURE PRESSURE RELIEF VALVE OPTIONAL TOP T amp P RELIEF VALVE NOT SHOWN 74 DISCHARGE PIPE Do not cap or plug DRAIN VALVE 6 MAXIMUM AIR GAP FLOOR DRAIN FIGURE 16 CAUTION Temperature pressure relief valve discharge pipe must terminate at adequate drain demand Ifthe discharge pipe is not connected to a drain or other suitable means the water flow may cause property damage The Discharge Pipe Shall not be smaller in size than the outlet pipe size of the valve or have any reducing couplings or other restrictions Shall not be plugged or blocked Shall be of material listed for hot water distribution Shall be installed so as to allow complete drainage of both the temperature pressure relief valve and the discharge pipe Shall terminate a maximum of six inches above a floor drain or external to the building In cold climates it is recommended that the discharge pipe be terminated at an adequate drain inside the building e Shall terminate at an adequate drain Shall not
11. Models 9003915 9003915 9003915 3 Heat Trap Hot Some Models 9003915 9003915 9003915 4 Cold Water Dip Tube 9003637 9002432 9002432 5 Anode Rod 9003892 9003892 9003892 6 T amp P Relief Valve Located Top Or Side 9000071 9000071 9000071 7 Drain Valve 9000254 9000254 9000254 8 Gas Control Valve Thermostat 9007631 9007631 9007631 9 Outer Door 700795 018 700795 018 700795 018 10 Pilot Thermopile Assembly Natural Gas 9007633 9007633 9007633 11 Burner Door Assembly Natural Gas Low Nox 9007655 9007656 9007657 12 Manifold Component Block With Retainer Clip 9006449 9006449 9006449 13 Burner Door Gasket 9006141 9006141 9006141 14 Viewport Assembly 9006142 9006142 9006142 15 Thermopile 9007630 9007630 9007630 16 Temperature Sensor 9007634 9007634 9007634 17 Flexible Manifold Tube 9006445 9006445 9006445 18 Instruction Manual 319588 002 319588 002 319588 002 Not Shown Includes Inner Door Gasket Flexible manifold tube sold as a separate part burner not included 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 WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE FOLLOWING INFORMATION MODEL NUMBER SERIAL NUMBER TYPE GAS NATURAL PART DESCRIPTION THIS IS A REPAIR PARTS LIST NOT A PACKING LIST 35 Get it fixed at your
12. TOO SMALL 2 Low gas pressure 2 Check with gas utility company 2 3 4 5 6 2 3 CONDENSATION 1 Temperature setting too low 1 Increase the temperature setting 1 1 32 STATUS LIGHT TROUBLESHOOTING CHART LED STATUS PROBLEM CORRECTIVE ACTION 0 FLASHES LED NOT LIT Pilot light is not lit Not enough Follow the lighting instructions on the front of power millivolts to keep it lit the water heater and record any diagnostic codes See Status Light Codes section 1 FLASH EVERY 3 SECONDS Normal Normal operation No corrective action necessary 2 FLASHES Insufficient power millivolts to the 1 Check all wiring connections If problem gas control valve thermostat persists proceed to step 2 Replace the thermopile If you feel uncomfortable with this procedure contact a qualified technician 4 FLASHES High water temperature has Replace the gas control valve thermostat If activated the over heat sensor you feel uncomfortable with this procedure contact a qualified technician 5 FLASHES Water temperature sensor failure Replace the gas control valve thermostat If you feel uncomfortable with this procedure contact a qualified technician 7 FLASHES Gas Control Valve Thermostat Replace the gas control valve thermostat If failure you feel uncomfortable with this procedure contact a qualified technician 8 FLASHES This condition only appears if the Make sure that the gas control valve gas control tempe
13. Temperature limiting valves are available Read instruction manual for safe temperature setting HOTTER WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes washing dish washing and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally handicapped If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve 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 Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat see Figures 21 and 22 20 Never allow small children to use a hot water tap or to draw their own bath water Never leave a child or handicapped person unattended in a bathtub or shower NOTE Awater temperature range of 120 F 140 F 49 C 60 C is recommended by most dishwasher manufacturers IMPORTANT Adjusting the thermo
14. 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 HOME They will arrange fo
15. cadet tdi 27 TROUBLESHOOTING GUIDE wis aii A aos 28 34 Start Up Gonditions 0 A AAA eed td 28 Thermal EXPUSO ura A iii 28 SIFANGES SOUNAS ica dr ad dad coat ites 28 Draft H00d Operation a 28 A A O ee tes at eae ten 29 SMOC OG OR asia e e et eat cee chat 29 Operational Conditions sc sei a a a co Save wa anat caueca san a aa aeset a A aa aaa a 29 30 omel odo 2255 oea E a E E EE E aia 29 Water Tomperature Sta Ching ain ina EEEE NEE E S E E OES E E A OEE 29 Air in Hot Water Faucets E E E EE EE E E E A E A E A ETE 29 O EA A NE E E ee A E E EA T 29 30 TROUDIESHOOUING NOMS a area ee E E eases OE EEE E eee E R 30 34 PARTS ORDER EIS E A E E E NE da tii OTE TA 35 PRODUCT WARRANTY 6 YEAR LIMITED WARRANTY ON WATER HEATER For six years from the date of purchase if this water heater is installed and Operate 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 wate
16. have an expansion tank to relieve the pressure built by thermal expansion in the water system Refer to the Thermal Expansion section under Troubleshooting Guide or contact local plumbing authority or local Sears Service Center on how to control this situation NOTE To protect against untimely corrosion of hot and cold water fittings it is strongly recommended that di electric unions or couplings be installed on this water heater when connected to copper pipe CAUTION Avoid water heater damage Install thermal expansion tank if necessary Do not apply heat to cold water inlet Contact qualified installer or Sears Service Center Figure 15 shows the typical attachment of the water piping to the water heater The water heater is equipped with 3 4 NPT water connections NOTE If using copper tubing solder tubing to an adapter before attaching the adapter to the cold water inlet connection Do not solder the cold water supply line directly to the cold water inlet It will harm the dip tube and damage the tank Look at the top cover of the water heater The water outlet is marked HOT Put two or three turns of Teflon tape around the threaded end of the threaded to sweat coupling and around both ends of the 3 4 NPT threaded nipple Using flexible connectors connect the hot water pipe to the hot water outlet on the water heater Look at the top of the water heater The cold water inlet is ma
17. information concerning an Anode Replacement Kit 9001453 and this Chlorination Treatment Anode replacement and chlorination of the tank are not covered by the water heater s limited warranty If the smelly water persists after the anode replacement and chlorination treatment it may be necessary to chlorinate or aerate your water supply to eliminate the problem Do not remove the anode leaving the tank unprotected By doing so all warranty on the water heater tank is voided Water Temperature Stacking Stacking occurs when a series of short draws of hot water 3 gallons or less are taken from the water heater tank This causes increased cycling of the burner and can result in increased water temperatures at the hot water outlet This water heater s temperature control has been designed to accurately regulate the water temperature However under certain operating conditions the water temperature may temporarily exceed the dial setting Consequently in addition to setting the temperature no higher than 120 F we recommend the installation of a mixing valve or an anti scald device in the hot water supply line or at the point of use to further reduce the risk of scald injury These devices can be obtained from a plumbing service agency or your retail supplier AIR In Hot Water Faucets A WARNING Explosion Hazard Flammable hydrogen gases may be present Keep all ignition sources away from faucet when turning o
18. 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 Facts to Consider About the Location Carefully choose an indoor location for the new water heater The placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance This water heater is not for use in manufactured mobile homes or outdoor installation Whether replacing an old water heater or putting the water heater in a new location the following critical points must be observed e Select a location indoors as close as practical to the gas vent or chimney to which the water heater vent is going to be connected and as centralized with the water piping system as possibl
19. the manifold tubing 3 4 wrench pilot tubing 7 16 wrench temperature sensor wires and thermopile wires to the gas control valve thermostat See Figure 25 for the correct position of the thermopile wires Do not cross thread or apply any thread sealant to the fittings Reconnect the igniter wire 8 Turn the gas supply on and refer to Lighting Instructions in the Operating Instructions section 9 Check for leaks by brushing on an approved noncorrosive leak detection solution Bubbles forming indicate a leak Correct any leak found IMPORTANT All leaks must be fixed immediately 10 Replace the outer door wn A 25 FLAME TRAP BRACKET DOOR GASKET FIGURE 30 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 31 Use only factory authorized piezoelectric igniter parts for replacement THERMOPILE PILOT fede OPPOSITE SIDE WIRE TO ELECTRODE IGNITER BUTTON FIGURE 31 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 co
20. thorough understanding of this instruction manual and be able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer e Gas Supplier The natural gas or propane utility or service who supplies gas for utilization by the gas burning appliances within this application The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the natural gas meter or propane storage tank of a building Many gas suppliers also offer service and inspection of appliances within the building AWARNING FIRE AND EXPLOSION HAZARD Can result in serious injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Storage of or use of gasoline or other flammable vapors or liquids in the Flammable Vapors vicinity of this or any other appliance can result in serious injury or death Read and follow water heater warnings and instructions Sears Brands Management Corporation AWARNING Read and understand instruction manual and safety messages before installing operating or servicing this water heater Failure to follow instructions and safety messages could result in death or serious injury Instruction manual must remain with water heater AWARNING Fire Hazard For continued protection against risk of fire Do not install water heater on carpeted floor
21. to which they connect The minimum short side dimension of rectangular air ducts shall not be less than 3 inches 7 6 cm See Figure 13 FIGURE 13 Alternatively a single permanent opening may be used when communicating directly with the outdoors or with spaces that freely communicate with the outdoors The opening shall have a minimum free area of 1 square inch per 3 000 BTU per hour 7 3 cm kW of total input rating of all equipment in the enclosure See Figure 13A ALTERNATE OPENING LOCATION FIGURE 13A Louvers and Grilles In calculating free area consideration shall be given to the blocking effect of louvers grilles or screens protecting openings Screens used shall not be smaller than 1 4 inch 6 4 mm mesh Ifthe free area through a design of louver or grille is known it should be used in calculating the size opening required to provide the free area specified If the design and free area is not known it may be assumed that wood louvers will be 20 25 percent free area and metal louvers and grilles will have 60 75 percent free area Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation Special Conditions Created by Mechanical Exhausting or Fireplaces operation of exhaust fans ventilation systems clothes dryers or fireplaces may create conditions requiring special attention to avoid unsatisfactory operation of i
22. 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 Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank Table 1 Thermal Expansion Tank Specifications Model Capacity in Inches Fitting Number In Gallons On Tank 153 331020 8 203 mm 12 3 4 323 mm 3 4 Male 153 331050 11 279 mm 14 3 4 375 mm 3 4 Male Table 2 Expansion Tank Sizing Chart Inlet Water Heater Capacity Gallons Water Pressure NS SE Expansion 40 psi 70psi Highest recorded inlet water pressure in a 24 hour period or regulated water pressure NOTE Expansion tanks are pre charged with a 40 psi air charge If the inlet water pressure is higher than 40 psi the expansion tank s air pressure must be adjusted to match that pressure b
23. weather stripping heavily insulated caulked vapor barrier etc additional air may need to be provided using the methods described in Combustion Air and Ventilation for Appliances Located in Confined Spaces Combustion Air and Ventilation for Appliances Located in Confined Spaces CONFINED SPACE is a space whose volume is less than 50 cubic feet per 1 000 Btu per hour 4 8 m per kW of the aggregate input rating of all appliances installed in that space A ALL AIR FROM INSIDE BUILDINGS See Figure 9 on page 11 and Figure 10 below The confined space shall be provided with two permanent openings communicating directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination Each opening shall have a minimum free area of one square inch per 1 000 Btu per hour 22 cm kW of the total input rating of all gas utilization equipment in the confined space but not less than 100 square inches 645 cm One opening shall commence within 12 inches 30 cm of the top and one commencing within 12 inches 30 cm of the bottom of the enclosures CHIMNEY OR GAS VENT OPENINGS FURNACE WATER HEATER FIGURE 10 B ALL AIR FROM OUTDOORS See Figures 9 11 12 13 and 13A 12 The confined space shall be provided with two per
24. will shut off the gas supply to the main bumer and pilot if the flame is absent This unit is also equipped with a combustion chamber temperature sensor This sensor will shut off the gas supply to the bumer if lint dust or other contaminants pollute the burner If the gas control valve thermostat shuts off the gas supply check the diagnostic flash code and refer to the Status Light Troubleshooting Chart If necessary also refer to the Troubleshooting Guide Also a temperature limit switch or ECO Energy Cut Off sensor located in the gas control valve thermostat is used to shut off the water heater if the water temperature exceeds 189 F 87 C The Diagnostic Status Light will flash a code indicating an Overheat Failure 4 Flashes See Operating the Temperature Control System If the ECO has functioned the gas control valve thermostat should be replaced by a qualified technician Contact Sears Service for service information If the Diagnostic Status Light indicates an LDO Occurrence 10 Flashes refer to the Status Light Troubleshooting Chart Leakage Checkpoints 6 MAXIMUM AIR GAP FIGURE 36 30 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
25. 23 1 NFPA 54 This publication is available from the Canadian Standards Association 8501 East Pleasant Valley Rd Cleveland Ohio 44131 or The National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 If after reading this manual you have any questions or do not understand any portion of the instructions call the Sears Service Center Carefully plan the place where you are going to put the water heater Correct combustion vent action and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and fires See figure 1 Examine the location to ensure the water heater complies with the Facts to Consider About the Location section in this manual For California installation this water heater must be braced anchored or strapped to avoid falling or moving during an earthquake See instructions for correct installation procedures Instructions may be obtained from the California 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 Complies with 10 ng J SCAQMD rule 1121 and districts having equivalent NOx requirements PRODUCT SPECIFICATIONS RECOVERY RATE GALS PER HOUR 90 F RISE TANK CAPACITY IN MODEL NUMBER GALS LTRS INPUT RATE Btu hr TYPE OF GAS NATURAL NATURAL NATURAL 153 330200 153 330220 153 330230 30 114 40 151 50 189
26. Even though this water heater is a flammable vapor ignition resistant water heater and is designed to reduce the chances of flammable vapors being ignited gasoline and other flammable substances should never be stored or used in the same vicinity or area containing a gas water heater or other open flame or spark producing appliance Also the water heater must be located and or protected so it is not subject to physical damage by a moving vehicle AWARNING For continued protection against risk of fire Do not install water heater on carpeted floor Do not operate water heater if flood damaged This water heater must not be installed directly on carpeting Carpeting must be protected by metal or wood panel beneath the appliance extending beyond the full width and depth of the appliance by at least 3 inches 76 2mm in any direction or if the appliance is installed in an alcove or closet the entire floor must be covered by the panel Failure to heed this warning may result in a fire hazard A WARNING Read instruction manual before installing using or servicing water heater Improper use may result in fire or explosion Maintain required clearances to combustibles Minimum clearances between the water heater and combustible surfaces are 0 inch at the sides and rear 4 inches 102 mm at the front and 6 inches 153 mm from the vent pipe See Figure 8 Clearance from the top of the jacket is 8 i
27. M RELIEF VALVE 1 Excessive water pressure 1 Use a pressure reducing valve and relief valve Heater stacking 2 Lower the thermostat setting Closed water system 3 See Closed System Thermal Expansion THERMOSTAT FAILS TO 1 Thermostat not functioning properly 1 Replace thermostat SHUT OFF 2 Improper calibration 2 Replace thermostat 1 1 COMBUSTION ODORS Insufficient secondary air Provide ventilation to water heater Check flue way flue baffle and burner 2 Flue clogged 2 Clean locate source and correct 3 Heater installed in a confined area 3 Provide fresh air ventilation 1 1 2 3 SMOKING AND CARBON Insufficient secondary air Provide ventilation to water heater Check FORMATION SOOTING flue way flue baffle burner Low gas pressure 2 Check with gas utility company Flue clogged 3 Clean locate source and correct Thermostat not functioning properly 4 Replace thermostat Heater installed in a confined area 5 Provide fresh air ventilation Burner flame yellow lazy 6 See Burner Flame Yellow Lazy 2 3 BURNER FLAME FLOATS AND LIFTS OFF PORTS Orifice too large High gas pressure Flue clogged Replace with correct orifice Check with gas utility company Clean flue and burner locate source and correct 4 Cold drafts 4 Locate source and correct BURNER FLAME TOO HIGH 1 Orifice too large 1 Replace with correct orifice PILOT FLAME 1 Pilot line or orifice clogged 1 Clean locate source and correct
28. NECTORS PILOT THERMOPILE ASSEMBLY PILOT TUBE FERRULE NUT NOT SHOWN FIGURE 28 Push the new pilot assembly connectors through the opening in the burner door See Figure 27 Attach the pilot assembly to the Burner Door Assembly Position the new thermopile wires through the top opening of the manifold component block Figure 27 Be sure that the igniter wire is positioned through the middle opening of the manifold component block Position the pilot tube through the bottom opening of the manifold component block See Replacing the Burner Door Assembly 24 External Inspection amp Cleaning of the Flame Trap Although not likely to occur if debris collects on the flame trap flame arrestor use a vacuum compressed air or a soft bristle brush to remove it NOTE If unable to inspect or clean the flame trap from underneath follow the Cleaning the Combustion Chamber and Flame Trap section instructions FLASHLIGHT MIRROR Sa FIGURE 29 Cleaning the Combustion Chamber and Flame Trap 1 Follow the procedure outlined in Removing the Burner Door Assembly section 2 Use a vacuum cleaner shop vac to remove all loose debris in the combustion chamber Figure 30 Use compressed air to clear any dust or debris that may have accumulated in the flame trap flame arrestor 3 Reassemble following the procedure under the Replacing the
29. Use amp Care Guide Model No 153 330200 30 Gallon Tall 153 330220 40 Gallon Tall 153 330230 50 Gallon Tall LOW LEAD COMPLIANT Kenmore Gas Water Heater For potable water heating only Not suitable for space heating Not for use in mobile homes INSTALLER Affix these instructions to or near the water heater WARNING If the information in these instructions is not followed exactly a fire OWNER Retain these instructions for future or explosion may result causing property reference damage personal injury or death FOR YOUR SAFETY An odorant is added to Do not store or use gasoline or other the gas used by this water heater flammable vapors and liquids in the vicinity of this or any other appliance ADVERTENCIA WHAT TO DO IF YOU SMELL GAS Si no puede leer o entender el ingl s y necesita el manual de instrucciones en espa ol puede solicitarlo al 1 800 821 2017 NO e Donottry to light any appliance 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 e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier P N 319588 002 1010 from a neighbor s phone Follow the E E Sears Brands Management Corporation gas supplier S instructions Hoffman Estates IL 60179 U S A e If you cannot reach your gas supplier www kenmore com c
30. a pilot which is lighted by a piezoelectric igniter When lighting the pilot follow these instructions exactly 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 C Use only your hand to push in or turn the gas control temperature knob Never use tools If the knob will not push in or move 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 call a qualified service technician to inspect the appliance Water heaters subjected to flood conditions or anytime the gas controls main burner or pilot have been submerged in water require replacement of the entire water heater 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 bottom of combustion chamber and require replacement of the entire water heater LIGHTING INSTRUCTIONS 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 itis set to PILOT correctly While holding the gas control temperature knob in click the igniter bu
31. a smart purchase Your new Kenmore product is designed and manufactured for years of dependable op eration 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 e Product replacement if your covered product can t be fixed Annual Preventive Maintenance Check at your request no extra charge Fast help by phone we call it Rapid Resolution phone support from a Sears representative on all products Think of us as a talking owner s manual Power surge protection against electrical damage due to power fluctuations c Leaks in pipes or fittings 250 Food Loss Protection
32. all the fire department www sears com Installation and service must be performed by a qualified installer service agency or the gas supplier SAFE INSTALLATION USE AND SERVICE Your safety and the safety of others is extremely important in the installation use and servicing of this water heater Many safety related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard Read and obey all safety messages and instructions throughout this manual It is very important that the meaning of each safety message is understood by you and others who install use or service this water heater This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death gt DANGER indicates an imminently hazardous situation which if not avoided will result in death or injury WARNING indicates a potentially hazardous situation which if not avoided could result WARNING in death or injury CAUTION indicates a potentially hazardous situation which if not avoided could result CAUTION in minor or moderate injury CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided could result in property damage DANGER All safety messages will generally tell you about the type of hazard w
33. e e Selected location must provide adequate clearances for servicing and proper operation of the water heater CAUTION All water heaters eventually leak Do notinstall without adequate drainage Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak the flow will not cause damage to the structure For this reason it is not advisable to install the water heater in an attic or upper floor When such locations cannot be avoided a suitable metal drain pan should be installed under the water heater Metal drain pans are available at your local Sears or hardware store Such adrain pan must have a minimum length and width of at least 2 inches 51 mm greater than the water heater dimensions and must be piped to an adequate drain The pan must not restrict combustion air flow Water heater life depends upon water quality water pressure 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 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 ala
34. ed Clean locate source and correct Main burner line clogged Clean locate source and correct Heater installed in a confined area Proper fresh air ventilation Obstruction in main burner orifice Clean or replace orifice PILOT WILL NOT LIGHT OR Non functioning igniter Replace igniter pilot assembly REMAIN LIT Thermopile connection loose Seat connector firmly in socket Air in gas line Bleed the air from the gas line Proper Lighting Sequence not followed Do not attempt to relight if the red light is Gas Control Temperature Knob was not lit and the pilot flame is not visible through held in for sufficient time the view port Wait until the red light is no longer lit then follow lighting instructions on the water heater Low gas pressure 5 Check with gas utility company No gas 6 Check with gas utility company Dirt in gas lines 7 Notify utility install dirt trap in gas line Cold drafts 8 Locate source and correct ECO switch open Replace gas control valve thermostat Pilot line or orifice clogged 10 Clean locate source and correct Non functioning thermopile Replace thermopile Air for combustion obstructed See maintenance section for inspection and cleaning of flame trap Flammable vapors incident FVIR function Eliminate flammable vapor source s utilized Call 1 800 4 MY HOME 1 800 469 4663 HIGH OPERATION COSTS Thermostat set too high Set temperature dial to lower setting Sediment or lime in tank D
35. ef 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 section and then remove fitting Put pipe dope or teflon tape on the threads and replace When you are finished follow the steps in Filling the Water Heater in the Installation Instructions earlier in this manual TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION BURNER WILL NOT IGNITE 1 Pilot not lit 1 Light pilot 2 Thermostat set too low 2 Turn temp dial to desired temperature 3 Nogas 3 Check with gas utility company 4 Dirt in the gas lines 4 Notify utility install trap in gas line 5 Pilot line clogged 5 Clean locate source and correct 6 Main burner line clogged 6 Clean locate source and correct 7 Non functioning thermopile 7 Replace thermopile 8 Non functioning thermostat 8 Replace thermostat 9 Heater installed in a confined area 9 Provide fresh air ventilation 1 1 SMELLY WATER Sulfides in the water Replace the anode with a special anode BURNER FLAME YELLOW Insufficient secondary air Provide ventilation to water heater LAZY Low gas pressure Check with gas utility company Flue clogg
36. efficient operation of the appliance producing carbon monoxide gas in excess of the safe limits This could result in serious injury or death Contact your local gas supplier for any specific changes that may be required in your area AWARNING Use joint compound or tape compatible with propane Leak test before operating heater Disconnect gas piping and shut off valve before pressure testing system Use pipe joint compound or Teflon tape marked as being resistant to the action of petroleum Propane L P gases The appliance and its gas connection must be leak tested before placing the appliance in operation The appliance and its individual shutoff valve shall be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 pound per square inch 3 5 kPa It shall be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 pound per square inch 3 5 kPa Connecting the gas piping to the gas control valve of the water heater can be accomplished by either of the two methods shown in Figures 19 and 20 TEFLON is a registered trademark of E I Du Pont De Nemours and Company 18 Sediment Traps AWARNING Contaminants in gas lines can cause Tire or explosion Clean all installati
37. hat can happen if you do not follow the safety message and how to avoid the risk of injury The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances WARNING This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances included in the act IMPORTANT DEFINITIONS e 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 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
38. have any valve between the relief valve and tank ADANGER Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury ar death Children the elderly and the physically or mentally disabled are at highest risk forscald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting The temperature pressure relief valve must be manually operated at least once a year Caution should be taken to ensure that 1 no one is in front of or around the outlet of the temperature pressure relief valve discharge line and 2 the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions and replace the temperature pressure relief valve with a new one CAUTION Avoid water heater damage gt Fill tank with water before operating Filling the Water Heater Never use this water heater unless it is completely full of water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater To fill the water heater with water e Close the wa
39. home or ours Your Home For troubleshooting product manuals and expert advice managemylife www managemylife com For repair in your home of all major brand appliances lawn and garden equipment or heating and cooling systems no matter who made it no matter who sold it For the replacement parts accessories and owner s manuals that you need to do it yourself For Sears professional installation of home appliances and items like garage door openers and water heaters 1 800 4 MY HOME 1 800 469 4663 Call anytime day or night U S A and Canada www sears com www sears ca Our Home For repair of carry in items like vacuums lawn equipment and electronics call anytime for the location of your nearest Sears Parts amp Repair Service Center 1 800 488 1222 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 www sears com Au Canada pour service en francais 1 800 LE FOYER 1 800 533 6937 WWW Sealrs Ca Sears Registered Trademark Trademark of KCD IP LLC in the United States or Sears Brands LLC in other countries Marca Registrada Marca de Fabrica de KCD IP LLC en Estados Unidos o Sears Brands LLC in otros paises MC Marque de commerce Marque d po
40. ht 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 start blinking after three lighting attempts turn the gas control temperature knob to OFF and call a qualified service technician or your gas supplier Thermopile Pilot TO TURN OFF GAS TO APPLIANCE short time after the water heater is turned off Temperature Regulation 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 The preferred starting point is 120 F at the HOT setting Align the knob with the desired water temperature as shown in Figure 22 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 Due to the nature of the typical gas water heater the water temperature in certain situations may vary up to 30F 16 7 C higher or lower at the point of use such as bathtubs showers sink etc ADANGER Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury ar death Children the elderly and the physically or mentally disabled are at highest risk forscald injury Feel water before bathing or showering
41. ings 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 Visibly inspect flame arrestor at least once every six months and clean if accumulated lint Can cause serious death injury or AT LEAST ONCE EVERY SIX MONTHS AVISUAL INSPECTION SHOULD BE MADE OF THE FLAME ARRESTOR CLEAN IF LINT ACCUMULATIONS ARE NOTICED INSTALLED IN SUITABLE AREA To ensure sufficient ventilation and combustion air supply proper clearances from the water heater must be maintained See Facts to Consider About the Location section Combustible materials such as clothing cleaning materials or flammable liquids etc must not be placed against or adjacent to the water heater because they could catch on fire Anode Rod Inspection CAUTION Avoid water heater damage Inspection and replacement of anode rod required The anode rod is used to protect the tank from corrosion Most hot water tanks are equipped with an anode rod The submerged rod deteriorates to protect the tank Instead of corroding the tank water ions attack and eat away the anode rod This does not affect the water s taste or color The rod must be maintained to keep the tank in operating condition EXPOSED we a 5 z a oe PITTED ANODE Rop___ FIGURE 32 EXPOSED SUPPORT WIRE Anode deterioration depends o
42. ith a tank leak Follow the lighting instructions in the Lighting section to restart the water heater Drain Valve Washer Replacement See Figure 34 1 Turn OFF gas supply to water heater 2 Follow Draining instructions 3 Turning counter clockwise f remove the cap 4 Unscrew the stem by turning it counter clockwise f and remove it from the drain valve body al Remove the bottom washer and put the new one in place 6 Re insert the stem into the drain valve body and retighten the cap to the body using a wrench DO NOT OVER TIGHTEN 7 Follow instructions in the Filling The Water Heater section 8 Check for leaks 9 Follow the lighting instructions in the Lighting section to restart the water heater CAP WASHER FIGURE 34 Service Before calling for repair service read the Start Up Conditions and Operational Conditions found in the Troubleshooting Guide of 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 TROUBLESHOOTING GUIDE Start Up Conditions Thermal Expansion CAUTION Avoid water heater damage Install thermal expansion tank or device if necessary Contact qualified installer or service agency As water is heated it expands thermal expansion In a closed system the volume of
43. manent openings one commencing within 12 inches 30 cm of the top and one commencing within 12 inches 30 cm from the bottom of the enclosure The openings shall communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors CHIMNEY OR GAS VENT VENTILATION LOUVERS Ska EACH END OF ATTIC SJ OUTLET AIR Tr WATER HEATER gi A FURNACE INLET AIR DUCT ALT INLET AIR VENTILATION LOUVERS FIGURE 11 e When directly communicating with the outdoors each opening shall have a minimum free area of 1 square inch per 4 000 Btu per hour 5 5 cm kW of total input rating of all equipment in the enclosure See Figure 11 e When communicating with the outdoors through vertical ducts each opening shall have a minimum free area of 1 square inch per 4 000 BTU per hour 5 5 cm kW of total input rating of all equipment in the enclosure See Figure 12 e CHIMNEY OR GAS VENT VENTILATION LOUVERS y EACH END OF ATTIC WATER HEATER FURNACE INLET AIR DUCT ENDS 1 OR 30 cm ABOVE FLOOR FIGURE 12 e When communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 square inch per 2 000 BTU per hour 11 cm kW of total input rating of all equipment in the enclosure See Figure 13 e When ducts are used they shall be of the same cross sectional area as the free area of the openings
44. n and replace if needed The combustion and ventilation air flow must not be obstructed The water heater with draft hood installed must be connected to a chimney or listed vent pipe system which terminates to the outdoors Never operate the water heater unless it is vented to the outdoors and has adequate air supply to avoid risks of improper operation explosion or asphyxiation For proper draft hood attachment the draft hood legs may be angled slightly inward e Place the draft hood legs in the receiving holes on the top of the water heater The legs will snap in the holes to give a tight fit Secure the legs to top with sheet metal screws See Figure 17 e Place the vent pipe over the draft hood With the vent pipe in position drill a small hole through both the vent pipe and draft hood Secure them together with a sheet metal screw Obstructed or deteriorated vent systems may present serious health risk or asphyxiation SHEET METAL SCREWS Four provided Cc L_ DRAFT HOOD LEGS s A te LEGS SN Y 2 Bisz SLOT A eT TOP SLOT INSTALL THE DRAFT HOOD WITH THE FOUR SCREWS PROVIDED FIGURE 17 The vent pipe from the water heater must be no less than the diameter of the draft hood outlet on the water heater and must slope upward at least 1 4 inch per linear foot 21 mm per meter See Figure 18 TO CHIMNEY MIN 1 4 INCH RISE PER LINEAR FOOT 21 mm PER METER FIGURE 18 All ven
45. n hot water HYDROGEN GAS Hydrogen gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable and explosive To prevent the possibility of injury under these conditions we recommend the hot water faucet located farthest away be opened for several minutes before any electrical appliances which are connected to the hot water system are used such as a dishwasher or washing machine If hydrogen gas is present there will probably be an unusual sound similar to air escaping through the pipe as the hot water faucet is opened There must be no smoking or open flame near the faucet at the time it is open Safety Shut Off This water heater is equipped with an automatic gas shutoff system This system works when high water temperatures are present The high temperature shutoff is built into the gas control valve It is non resettable If the high temperature shutoff activates the gas control valve must be replaced Turn OFF the entire gas supply to the water heater and contact your gas supplier 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 3 Excessive contaminants in the combustion chamber 4 The ignition of flammable vapors A thermopile is used to determine if a pilot flame is present and
46. n or replace the flue and venting before resuming operation of the water heater 22 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 See Figure 23 CORRECT FLAME SOFT BLUE ANE ADN at FIGURE 23 Inspect burner flames through viewport Flames should be very small with a blue haze and small amounts of yellow or orange at the edges After several minutes of operation the burner screen may glow red If large flames are observed at any time shut off the unit and contact the Sears Service Center Removing the Burner Door Assembly 1 Turn off the gas to the water heater at the manual shut off valve Figure 2 Turn the gas control temperature knob to the OFF position Figure 22 Remove the outer door Remove the two screws 1 4 nut driver securing the burner door assembly to the combustion chamber Figure 24 Disconnect the pilot tube 7 16 wrench the igniter wire from the igniter lead wire and manifold tube 3 4 wrench at the gas control valve thermostat Disconnect the sensor wires
47. n release the gas control l temperature knob Is the igniter producing a YES spark NO Follow the Testing the Igniter Set thermostat to desired temperature System section in this manual Section B Pilot light repeatedly goes out Remove the burner door assembly Are the flame trap and burner free from debris due to excessive lint dirt dust or oil Refer to the Maintenance of your Water Heater section of this manual for information on cleaning the flame trap and burner Does the flame trap show signs of discoloration YES Reassemble the heater and attempt to return the heater to service Does the pilot remain lit YES N Set to desired temperature o Shut off the gas supply to the water heater at the manual gas shut off valve then 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 Thermopile Assembly instructions in the manual Reassemble and restore to service 34 Section C Pilot light will not remain lit Check for insufficient combustion air Are the combustion air supply and ventilation openings Correct size of of sufficient size See Combustion Air Supply and NO openings to allow Ventilation section in this manual for requirements sufficient air YES NOM ls
48. n 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 The anode rod should be checked after a maximum of three years of use then annually until the condition of the anode rod dictates the replacement of it NOTE Artificially softened water requires the anode rod to be inspected annually Temperature Pressure Relief Valve Operation The temperature pressure relief valve must be manually operated at least once a year ADANGER Burnhazard Hot water discharge Keep clear of relief valve discharge outlet When checking the temperature pressure relief valve operation make sure that 1 no one is in front of or around the outlet of the temperature pressure relief valve discharge line and 2 that the water discharge will not cause any property damage as the water may be extremely hot see Figure 33 TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE FIGURE 33 If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions and replace the temperature pressu
49. nches 203 mm on most models Note that a lesser dimension may be allowed on some models Refer to the label attached adjacent to the gas control valve on the water heater TOP VIEW TOP VIEW OF CLOSET OF CLOSET WITHOUT DOOR WITH DOOR 0 MIN ARS 0 MIN FIGURE 8 Install water heater in accordance with the instruction manual and NFPA 54 To avoid injury combustion and ventilation air must be taken from outdoors Do not place chemical emitting products near heater vapor water Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual A gas water heater cannot operate properly without the correct amount of air for combustion See Figure 9 Do not install in a confined area such as a closet unless you provide air as shown in the Locating The New Water Heater section Never obstruct the flow of ventilation air If you have any doubts or questions at all call your gas supplier Failure to provide the proper amount of combustion air can result in a fire or explosion and cause death serious bodily injury or property damage 11 12 MAX 30 cm RECTANGULAR 3 MIN AIR DUCT 76 2 mm AIR DUCT 12 MAX 30 cm FRONT VIEW OF DOOR FIGURE 9 If this water heater will be used in beauty shops barber shops cleaning establishments or self service laundries with dry cleaning equipment it is impe
50. nnections and make sure the electrode is not broken Replace the electrode if defective NOTE The electrode is part of the pilot assembly and cannot be replaced separately 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 Removing the Gas Control Valve Thermostat 1 Turn the gas control temperature knob to the OFF position Figure 22 2 Turn off the gas at the manual shut off valve on the gas supply pipe Figure 2 3 Drain the water heater Refer to the section on Draining and Flushing and follow the procedure 4 Disconnect the igniter wire from the igniter lead wire Disconnect the temperature sensor wire then 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 25 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 6 To remove the gas control valve thermostat thread a 4 inch section of gas pipe into the inlet and use it to turn the gas control valve thermostat counterclockwise Do not use a pipe
51. nnnnocccncnnonononannnonn nn nnnn nono nn aran nn rara 21 SERVICE AND ADJUSTMENT Tirra eaa a dla pl meetin te 22 27 Venting System Inspection A A A ae eee eae 22 Burner JMSPECHOM i a da aul a td e cds 22 Removing the Burner Door Assembly 220 8 Acie sects eclaeie tdi 23 Ultra Low NOx Natural Gas Burmehs cccn cherie aries aeaa e dias 23 Replacing the Pilot Thermopile Assembly oooooooconnnnncccccnnnooccccnnnonrnccnnnnnnnccnnn nano cnn rra 23 External Inspection amp Cleaning of the Flame Trap ccccccceeeeeeeeeeeceeceeeeeeeeeeesececeaecaeeeeeeeeeeeeeseecaueeeeeeeeeeeeeeneees 24 Cleaning the Combustion Chamber and Flame Trap ooooonnncccccnnnnccccccnononcnncno nono nan nn nn n o nn a ron rra rra 24 Replacing the Burner Door Assembly arite ma eaei Ea TEE dc 25 Piezoelectric igniter System ohio a A A 25 Testing the Igniter Systemi orii a E A EE dante date SAE A A E ATE A teeaceds 25 Removing and Replacing the Gas Control Valve Thermostat oocccinnnnncccnnnnnacccccnnnnonccnnn nan nc cnn narran rn rca 26 Housekeeping ici A A 26 Anode Rod Inspections a A A det 26 27 Temperature Pressure Relief Valve Operation oooooooncnnnnnncnoncononnccnnnoncnonnnnnnnnnoncnnnnnnnnnnnnnnnnnnnn nn nn nn nnnr ran nnnnnnnnnnnnnnn 27 Draining eiei a A A o 27 Drain Valve Washer Replacement cccccccecceeeeeeeeececeeceeeeeeeeeceeeaaaaeaeceeceeeeeeegesegeaeaanaeeeeeeeeeeesencineeeeeseeeeeeeeeeeees 27 SENICE A A A A A eect cathe
52. nstalled gas utilization equipment 13 Water Piping ADANGER Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children 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 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 cleaning and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally handicapped If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at the hot water taps used by these people or at the water heater Mixing valves are available at plumbing supply or hardware stores See Figure 14 Valves for reducing point of use temperature by mixing cold and hot water are also available Follow manufac
53. nts refrigerator and air conditioner refrigerants swimming pool chemicals calcium and sodium chloride waxes bleach and process chemicals are typical compounds which are potentially corrosive Gas Piping A WARNING Do not use water heater with any gas other than the gas shown onthe rating plate Excessive pressure to gas control valve can cause serious injury or death Turn off gas installation lines during Contact qualified installer or service agency Make sure the gas supplied is the same type listed on the model rating plate The inlet gas pressure must not exceed 14 inch water column 3 5kPa for natural and propane gas L P gas The minimum inlet gas pressure listed on the rating plate is for the purpose of input adjustment If the gas control valve is subjected to pressures exceeding 1 2 pound per square inch 3 5kPa the damage to the gas control valve could result in a fire or explosion from leaking gas If the main gas line shutoff serving all gas appliances is used also turn OFF the gas at each appliance Leave all gas appliances shut OFF until the water heater installation is complete A gas line of sufficient size must be run to the water heater Consult the current edition of National Fuel Gas Code ANSI Z223 1 NFPA 54 and your gas supplier concerning pipe size There must be e Areadily accessible manual shut off valve in the gas supply line serving the water hea
54. o 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 CAUTION Improper installation and use may result in property damage Do not operate water heater if flood damaged Inspect and replace anode Install in location with drainage Fill tank with water before operation Be alert for thermal expansion Refer to instruction manual for installation and service TABLE OF CONTENTS SAFE INSTALLATION USE AND SERVICE uu cccccccscscsescesscscscscececscavavssscacecasaasssscacacacscsssnasacacscaciessacacscieaeseatecs 2 SAFETY PRECAUMIONS a i A daah doves saved a AA a 2 3 TABEE OF CONTENTS aeee i aE E a a ia eres dese 4 WAR RAN Yes 2225 ee fit ns ote es del cele ae ole eu do dd ea D ld da 5 CUSTOMER RESPONSIBILITIES 2 0 0 ceccccececcceecsescssenesesesesesnesesesnecesescececensncacensvansnsasacsneesssseececeaeacesenenaneasasenseseeeneneneasees 6 PRODUCT SPECIFICATIONS vci den a ei ii ia l aa d a l ae ain d andela a iui elnie 6 MATERIALS AND BASIC TOOLS NEEDED Wu csssssesesesesesesesesesesescsenssesesesesesanssssesesesenesesesesesenaneeesesesenananees 7 Material Nec a Ane tad ead taeda A AG Lala Dead boas nls ae ali od de E he tala cee 7 BaSIG OOS sate crates ieet tae er ae aha te Anat aaa canes ace teh Mech E aloe fan eae Cad ean O 7
55. on gas piping before Install drip leg in accordance with NFPA 54 Contaminants in the gas lines may cause improper operation of the gas control valve that may result in fire or explosion Before attaching the gas line be sure that all gas pipe is clean on the inside To trap any dirt or foreign material in the gas supply line a drip leg sometimes called a sediment trap must be incorporated in the piping The drip leg must be readily accessible Install in accordance with the Gas Piping section Refer to the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 Asediment trap shall be installed as close to the inlet of the water heater as practical at the time of water heater installation The sediment trap shall be either a tee fitting with a capped nipple in the bottom outlet or other device recognized as an effective sediment trap If a tee fitting is used it shall be installed in conformance with one of the methods of installation shown in Figures 19 and 20 na GROUND JOINT UNION OPTIONAL E GAS CONTROL VALVE THERMOSTAT DRIP LEG SEDIMENT TRAP FIGURE 19 GAS PIPING WITH FLEXIBLE CONNECTOR GROUND JOINT UNION OPTIONAL ES GAS CONTROL BLACK PIPE VALVE THERMOSTAT u SEDIMENT TRAP DRIP LEG Ra FIGURE 20 GAS PIPING WITH ALL BLACK IRON PIPE TO GAS CONTROL OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE LIGHTING A This appliance has
56. ot connected Be alert for obstructed sooted or deteriorated vent system to avoid serious injury or death Do not store corrosive chemicals in the vicinity of water heater Chemical corrosion of flue and vent system can cause serious injury of death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual At least once a year a visual inspection should be made of the venting system You should look for e Obstructions which could cause improper venting The combustion and ventilation air flow must not be obstructed Damage or deterioration which could cause improper venting or leakage of combustion products e Rusted flakes around top of water heater Be sure the vent piping is properly connected to prevent escape of dangerous flue gasses which could cause deadly asphyxiation Obstructions and deteriorated vent systems may present serious health risk or asphyxiation Chemical vapor corrosion of the flue and vent system may occur if air for combustion contains certain chemical vapors Spray can propellants cleaning solvents refrigerator and air conditioner refrigerants swimming pool chemicals calcium and sodium chloride waxes bleach and process chemicals are typical compounds which are potentially corrosive If when inspecting the vent system you find sooting or deterioration something is wrong Call the local gas supplier to correct the problem and clea
57. r 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 e a sulfate reducing bacteria within the water heater This harmless bacteria is non toxic to humans e an excess of active hydrogen in the tank This is caused by the corrosion protective action of the anode Smelly water may be eliminated or reduced in some water heater models by replacing the anode s with one of less active material and then chlorinating the water heater tank and all hot water 29 lines Contact Sears Service for further
58. r heater installation If governmental regulations prohibit Sears from furnishing a comparable model replacement water heater under this warranty Sears will furnish a new water heater of comparable output as permitted by such governmental regulations however the Owner will be charged for the additional cost associated with the changes made to comply with such governmental regulations Replacements furnished under this warranty do not carry a new warranty and are only covered by the unexpired portion of the original warranty 1 YEAR EXCLUSIVE KENMORE LABOR WARRANTY For the first year from the date of purchase Sears will free of charge supply and install new water heater parts for defective ones or a new water heater for one that develops a leak WARRANTY SERVICE To obtain warranty service call 1 800 4 MY HOME 1 800 469 4663 This warranty applies only while this product is in use in the United States This warranty gives you specific legal rights and you may also have other rights which vary from state to state SEARS BRANDS MANAGEMENT CORPORATION Hoffman Estates IL 60179 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 making
59. r prompt quality installation by Sears authorized contractors Abbreviations Found In This Instruction Manual CSA Canadian Standards Association ANSI American National Standards Institute NFPA National Fire Protection Association ASME American Society of Mechanical Engineers GAMA Gas Appliance Manufacturers Association This gas fired water heater is design certified by CSA INTERNATIONAL under American National Standard CSA Standard for Gas Water Heaters ANSI Z21 10 1 CSA 4 1 current edition Read the Safety Precautions section first pages 2 and 3 of this manual and then read the entire manual carefully If you don t follow the safety rules the water heater will not operate properly It could cause DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE 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 The installation must conform with these instructions and the local code authority having jurisdiction In the absence of local codes installations shall comply with the current edition of The National Fuel Gas Code ANSI Z2
60. rain flush provide water treatment if needed Water heater too small for job Install adequate heater Wrong piping connections Correct piping dip tube must be in cold inlet Leaking faucets Repair faucets Gas leaks Check with utility repair at once Wasted hot water Advise customer Long runs of exposed piping Insulate piping Hot water piping in exposed wall Insulate piping INSUFFICIENT HOT WATER 1 Thermostat set too low Turn temperature dial to desired setting Sediment or lime in tank Drain flush provide water treatment if needed Water heater too small Install adequate heater Wrong piping connections Correct piping dip tube must be in cold inlet Leaking faucets Repair faucets Wasted hot water Advise customer Long runs of exposed piping Insulate piping Hot water piping in outside wall Insulate piping Low gas pressure Check with gas utility company SLOW HOT WATER Insufficient secondary air Provide ventilation to water heater Check RECOVERY flue way flue baffle and burner Flue clogged Clean flue locate source and correct Low gas pressure Check with gas utility company Improper calibration Replace thermostat Thermostat set too low Turn temperature dial to desired setting Water heater too small Install adequate heater Wrong piping connections Correct piping dip tube must be in cold inlet Wasted hot water Advise customer 31 TROUBLESHOOTING GUIDE Continued DRIP FRO
61. rative that the water heater or water heaters be installed so that combustion and ventilation air be taken directly from outdoors direct vent Propellants of aerosol sprays and volatile compounds cleaners chlorine based chemicals refrigerants etc in addition to being highly flammable in many cases will also change to corrosive hydrochloric acid when exposed to the combustion products of the water heater The results can be hazardous and also cause product failure 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 De 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 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 the
62. rature knob has thermostat knob is set to OFF Wait one been turned off and the thermopile minute Remove the outer door Look through continued to produce electric the sight glass for a pilot flame If a pilot power This condition can occur flame is observed with the gas control valve if the thermopile does not cool thermostat knob set to the OFF position the down as quickly as expected when pilot valve is stuck open Turn the main gas the unit is shut off This condition supply OFF Replace the gas control valve can also occur if the gas control thermostat If you feel uncomfortable with this temperature knob has been turned procedure contact a qualified technician o tley es ds ie If the pilot flame is not observed when the gas eee in the o p control valve thermostat knob is set to the OFF pen position ah E position wait 10 minutes for the thermopile 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 Contact a qualified technician if you are uncomfortable with this procedure 9 FLASHES Combustion chamber temperature 1 Check all connections If the problem sensor circuit is open or shorted persists proceed to step 2 Replace the temperature sensor If you feel uncomfortable with this procedure contact a qualified technician If the problem persists proceed to step 3 Replace the gas cont
63. re relief valve with a new one If the temperature pressure relief valve on the appliance weeps or discharges periodically this may be due to thermal expansion You may have a check valve installed in the water line or a water meter with a check valve Consult the Sears Service Center for further information Do not plug the temperature pressure relief valve Draining ADANGER Burn hazard Hot water discharge Keep hands clear of drain valve discharge 27 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 1 Turn off the gas to the water heater at the manual gas shut off valve 2 Openanearby hot water faucet until the water is no longer hot 3 Close the cold water inlet valve 4 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 w
64. recognized testing laboratory that maintains periodic inspection of production of listed equipment as meeting the requirements for Relief Valves for Hot Water Supply Systems ANSI 721 22 and the code requirements of ASME If replaced the valve must meet the requirements of local codes but not less than a combination temperature and pressure relief valve certified as indicated in the above paragraph The valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater 150 psi 1 035kPa and a discharge capacity not less than the water heater input rate as shown on the model rating plate For safe operation of the water heater the relief valve must not be removed from its designated opening nor plugged The temperature pressure relief valve must be installed directly into the fitting of the water heater designed for the relief valve Position the valve downward and provide tubing so that any discharge will exit only within 6 inches 15 3 cm above or at any distance below the structural floor see Figure 16 Be certain that no contact is made with any live electrical part The discharge opening must not be blocked or reduced in size under any circumstances Excessive length over 30 feet 9 14 m or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve No valve or other obstruction is to be placed between the relief valve and the tank
65. rked COLD Put two or three turns of Teflon tape around the threaded end of the threaded to sweat coupling and around both ends of the 3 4 NPT threaded nipple Using flexible connectors connect the cold water pipe to the cold water inlet of the water heater NOTE This water heater is super insulated to minimize heat loss from the tank Further reduction in heat loss can be accomplished by insulating the hot water lines from the water heater TEFLON is a registered trademark of E I Du Pont De Nemours and Company 14 INSTALLATION COMPLETED USING INSTALLATION KIT FLEXIBLE WATER SHUTOFF CONNECTORS VALVE HOT WATER COLD WATER OUTLET _ AN INLET lt Ey E O Of E C e THREADED TO THREADED TO SWEAT COUPLING SWEAT COUPLING 3 4 THREADED LS 3 4 THREADED COUPLING a ES COUPLING DRAFT HOOD CN TEMPERATURE PRESSURE RELIEF VALVE N DISCHARGE PIPE Do not cap or plug 6 MAXIMUM AIR GAP T FLOOR DRAIN FIGURE 15 T amp P Valve and Pipe Insulation 1 Locate the temperature and pressure relief valve on the water heater also known as a T amp P relief valve See Figure 15A 2 Locate the slit running the length of the T amp P relief valve insulation 3 Spread the slit open and fit the insulation over the T amp P relief valve See Figure 15A 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 wi
66. rm or turn off the incoming water to the water heater when leakage is detected Sensors mounted in the metal drain pan that turn off the water supply to the entire home when water is detected in the metal drain pan 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 10 e Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply A WARNING Fire or Explosion Hazard Da 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 LP gas Do not expose water heater control to excessive gas pressure Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources away from faucets after extended period of non use e Read instruction manual before installing using or servicing water heater INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS VAPORS ARE LIKELY TO BE PRESENT OR STORED GARAGES STORAGE AND UTILITY AREAS ETC Flammable liquids Such as gasoline solvents propane LP or butane etc and other substances such as adhesives etc emit flammable vapors which can be ignited by a gas water heater s pilot light or main burner The resulting flashback and fire can cause death or serious burns to anyone in the area
67. rol valve thermostat If you feel uncomfortable with this procedure contact a qualified technician 10 FLASHES LDO occurrence was detected Reset the system by following these steps in the combustion chamber 1 Turn the temperature adjustment knob contaminants to OFF 2 Unplug the thermopile plug from the gas control valve thermostat 3 Wait for about three minutes 4 Plug the thermopile plug back into the gas control valve thermostat 5 Turn the temperature adjustment knob to PILOT and restart the water heater as directed in this manual If the problem persists proceed to step 2 Follow the procedure outlined in Cleaning the Combustion Chamber and Flame Trap If the problem persists proceed to step 3 Shut off the gas supply to the water heater and contact Sears Service 1 800 4 MY HOME 1 800 469 4663 33 PILOT LIGHT TROUBLESHOOTING CHART 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 instructions on the front of the water heater While repeatedly depressing the igniter button push in and hold the gas control temperature knob until the pilot is lit and maintains a stable flame status light Have you bled all the air from the pilot tube and gas supply line YES will blink the
68. ry air supply changes to correct Condensation Whenever the water heater is filled with cold water some condensate will form while the burner is on A water heater may appear to be leaking when in fact the water is condensation This usually happens when Anew water heater is filled with cold water for the first time e Burning gas produces water vapor In water heaters particularly high efficiency models where flue temperatures are lower e 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 heads Excessive condensation may be noticed during the winte
69. s e de Sears Brands LLC
70. s Store e Pipe Wrenches 2 14 356 mm e Screwdriver e Tin Snips 1 82 m Tape or Folding Ruler e Garden Hose e Drill e Pipe Dope or Teflon Tape CD SLOT HEAD SCREWDRIVER SS TIN SNIPS PHILLIPS SCREWDRIVER eo PIPE DOPE ROLL OF TEFLON SQUEEZE TUBE TAPE USE ONLY ON USE FOR WATER AND GAS WATER CONNECTIONS CONNECTIONS CWE rh IN PIPE WRENCH 6 FOOT TAPE GARDEN HOSE ADDITIONAL TOOLS NEEDED WHEN SWEAT SOLDERING e Tubing Cutters or Hacksaw e Propane Torch e Soft Solder e Solder Flux e Emery Cloth e Wire Brushes PROPANE TORCH TUBING CUTTER e CO gt 3 ROLL OF HACKSAW EMERY CLOTH Ce 3 4 19 mm WIRE BRUSH Cea 1 2 13 mm WIRE BRUSH ROLL OF LEAD FREE SOLDER SOFT SOLDER FLUX TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER GAS MODELS A Vent Pipe J Drip Leg Sediment Trap S Flue Baffle B Draft Hood K Inner Door T Gas Control Valve Thermostat C Anode L Outer Door U Drain Valve D Hot Water Outlet M Union V_ Pilot and Burner Door Assemblies E Outlet N Inlet Water Shut off Valve W Flue F Flexible Water Connections O Cold Water Inlet X Metal Drain Pan G Gas Supply P Inlet Dip Tube H Manual Gas Shut off Valve Q Temperature Pressure Relief Valve Ground Joint Union R Rating Plate INSTALL INACCORDANCE WITH LOCAL CODES T GAS CONTROL VALVE THERMOSTAT DRIP LEG AS REQUIRED BY LOCAL CODES TO VENT TERMINATION ON
71. s 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 LIST OF STATUS CODES ARE SHOWN AT TOP OF GAS CONTROL VALVE THERMOSTAT STATUS LIGHT Status Light Codes Normal Flashes OFlashes Indicates Control Off Pilot Out 1Flash Indicates Normal Operation e Continuous Light indicates the gas control valve thermostat is shutting down Diagnostic Flashes If the water heater is not working look for the following diagnostic flashes after lighting the pilot 2 Flashes Indicates thermopile voltage is low 4 Flashes Indicates overheat failure 5 Flashes Indicates water temperature sensor failure 7 Flashes Indicates electronic control failure 8 Flashes See Status Light Code Troubleshooting Chart 9 Flashes Indicates chamber temperature sensor circuit is open or shorted 10 Flashes Indicates an LDO occurrence was detected in the combustion chamber contaminants FIGURE 22B 21 SERVICE AND ADJUSTMENT Vent System Inspection A WARNING Flue gases may escape if vent pipe is n
72. se instructions can restrict the air flow required for proper combustion potentially resulting in fire asphyxiation serious personal injury or death Do not apply insulation to the top of the water heater as this will interfere with safe operation of the draft hood Do not cover the outer door thermostat or temperature pressure relief valve Donot allow insulation to come within 2 50 8 mm of the floor to prevent blockage of combustion air flow to the burner Do not cover the instruction manual Keep it on the side of the water heater or nearby for future reference Do obtain new warning and instruction labels from Sears for placement on the blanket directly over the existing labels Do inspect the insulation blanket frequently to make certain it does not sag thereby obstructing combustion air flow Combustion Air and Ventilation for Appliances Located in Unconfined Spaces UNCONFINED SPACE is space whose volume is not less than 50 cubic feet per 1 000 Btu per hour 4 8 m per kW of the aggregate input rating of all appliances installed in that space Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors are considered a part of the unconfined space In unconfined spaces in buildings infiltration may be adequate to provide air for combustion ventilation and dilution of flue gases However in buildings of tight construction for example
73. ssembly al 2 Remove the burner assembly as directed previously 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 burner door assembly Figure 27 IGNITER WIRE THERMOPILE CONNECTORS RETAINER CLIP MANIFOLD COMPONENT BLOCK BURNER DOOR OPENING FIGURE 27 Locate and remove the phillips screw attaching the pilot to the pilot bracket then pull the pilot thermopile assembly including the igniter wire out of the bumer door assembly Using a 7 16 wrench loosen the nut securing the pilot tube to the pilot assembly right hand threads Pull the pilot tube from the pilot assembly Figure 28 IMPORTANT Be careful not to bend or alter the position of the pilot assembly components 11 Using the old pilot tube 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 NOTE Skip this step if you are reusing the existing pilot tube Reconnect the pilot tube and tighten the nut securing it to the new pilot assembly To prevent any bending of the pilot bracket use pliers to hold the pilot assembly bracket while tightening the pilot nut IMPORTANT Keep the pilot orifice in the pilot when making the connection DO NOT operate the water heater without the pilot orifice installed a PILOT THERMOPILE THERMOPILE CON
74. stat past the 120 F bar on the temperature dial will increase the risk of scald injury Hot water can produce first degree burns within Water Temperature F Time for Permanent Burns 2nd amp 3rd Degree Most Severe Burns Time for 1st Degree Burn Less Severe Burns U S Government Memorandum C P S C Peter L Armstrong Sept 15 1978 FIGURE 21 GAS CONTROL TEMPERATURE KNOB 120 F APPROX MARK 155 F STATUS ae LIGHT a Q e APPROX VAC pior OFF IGNITER 55 F FIGURE 22 NOTE During low demand periods when hot water is not being used a lower thermostat setting will reduce energy losses and may satisfy your normal hot water needs If hot water use is expected to be more than normal a higher thermostat setting may be required to meet the increased demand When leaving your home for extended periods vacations etc turn the temperature dial to the vacation VAC setting This will maintain the water at low temperatures with minimum energy losses and prevent the tank from freezing during cold weather Operating the Temperature Control System 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 See Figure 22 on page 20 NOTE The temperatures indicated are approximates The actual temperature of the heated water may vary Operating Mode
75. t gases must be completely vented to the outdoors of the structure dwelling Install only the draft hood provided with the new water heater and no other draft hood Vent pipes must be secured at each joint with sheet metal screws There must be a minimum of 6 inches 153 mm clearance between single wall vent pipe and any combustible surface Fill and seal any clearance between single wall vent pipe and combustible surfaces with mortar mix cement or other noncombustible substance For other than single wall follow vent pipe manufacturer s clearance specifications To ensure a tight fit of the vent pipe in a brick chimney seal around the vent pipe with mortar mix cement A WARNING Flue gases may escape if vent pipe is not connected Do not store corrosive chemicals in vicinity of water heater Chemical corrosion of flue and vent system can cause serious injury or death Contact a qualified installer or service agency Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Failure to have required clearances between vent piping and combustible surfaces will result in a fire hazard Be sure vent pipe is properly connected to prevent escape of dangerous flue gases which could cause deadly asphyxiation 17 Chemical vapor corrosion of the flue and vent system may occur if air for combustion contains certain chemical vapors Spray can propellants cleaning solve
76. ter A drip leg sediment trap ahead of the gas control valve to help prevent dirt and foreign materials from entering the gas control valve e A flexible gas connector or a ground joint union between the shut off valve and control valve to permit servicing of the unit Be sure to check all the gas piping for leaks before lighting the water heater Use a soapy water solution not a match or open flame Rinse off soapy solution and wipe dry The minimum inlet gas pressure shown on the rating plate is that which will permit firing at the rated input A WARNING High altitude orifice must be installed for operation above 2 000 feet 610 m Contact a qualified installer or service agency Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Water heaters covered in this manual have been tested and approved for installation at elevations up to 2 000 feet 610 m above sea level For installation above 2 000 feet 610 m the water heater s Btu input should be reduced at the rate of 4 percent for each 1 000 feet 305 m above sea level which requires replacement of the burner orifice in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 Contact your local gas supplier for further information Failure to replace the standard orifice with the proper high altitude orifice when installed at elevations above 2 000 feet 610 m could result in improper and in
77. ter heater drain valve by inserting a flat head screwdriver in the slot on the stem and turn 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 e To ensure complete filling of the tank allow air to exit by opening the nearest hot water faucet Allow water to run until a constant flow is obtained This will let air out of the water heater and the piping e Check all water piping and connections for leaks Repair as needed Venting VENT DAMPERS Any vent damper whether it is operated thermally or otherwise must be removed if its use inhibits proper drafting of the water heater Thermally Operated Vent Dampers Gas fired water heaters having thermal efficiency in excess of 80 may produce a relatively low flue gas temperature Such temperatures may not be high enough to properly open thermally operated vent dampers This would cause spillage of the flue gases and may cause carbon monoxide poisoning Vent dampers must bear evidence of certification as complying with the current edition of the American National Standard ANSI 221 68 ANSI 221 66 amp 67 respectively cover electrically and mechanically actuated vent dampers Before installation 16 of any vent damper consult your local Sears Service Center or the local gas supplier for further information
78. th duct tape IMPORTANT The insulation or tape should not block or cover the T amp P relief valve drain opening Also the insulation or tape should not block or hinder access to the manual relief lever Figure 15A 4 Locate the hot water outlet amp cold water inlet pipes to the water heater 5 Locate the slit running the length of a section of pipe insulation 6 Spread the slit open and slip the insulation over the cold water inlet pipe Apply gentle pressure along the length of the insulation to ensure that it is fully seated around the pipe Also ensure that the base of the insulation is flush with the water heater Once seated secure the insulation with duct tape 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 15A Temperature Pressure Relief Valve A WARNING Explosion Hazard Temperature pressure relief valve must comply with ANSI 221 22 and ASME code Properly sized temperature pressure relief valve must be installed in opening provided e Can result in overheating and excessive tank pressure Can cause serious injury or death This heater is provided with a properly certified combination temperature pressure relief valve by the manufacturer The valve is certified by a nationally
79. there a furnace air handler in the same room as the water heater YES Does the return air duct for the furnace air handler draw its air from a separate location than the water heater Refer to the Installation Instructions section of this manual Contact a local Heating Ventilation Air Conditioning 8 Refrigeration authorized service provider to correct the combustion air supply ventilation issue Check the vent system for restrictions obstructions and check the vent termination height Refer to the Is there proper drafting at the drafthood See Draft Hood Operation section of manual YES Installation Instructions section of this manual for specific requirements 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 contact Sears Service at 1 800 4 MY HOME 1 800 469 4663 PARTS ORDERLIST ORDER LIST KENMORE ULTRA LOW NOx GAS WATER HEATER MODEL NO S 153 330200 30 Gallon 153 330220 40 Gallon 153 330230 50 Gallon Alternate anode Anode location for side T amp P location for top T amp P Model Numbers Key No Part Description 153 330200 153 330220 153 330230 1 Draft Hood 185917 001 185917 001 185917 001 2 Heat Trap Cold Some
80. tton continuously about once a second for up to 90 seconds or until Status Light begins to blink Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department 1 STOP It is imperative that you read all safety warnings 5 before lighting the pilot Turn the gas control temperature knob counterclockwise 1 to the OFF setting Gas control temperature kno Status light Index mark Wait ten 10 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you do not smell gas go to the next step 4 Turn the gas control temperature knob clockwise 1 Turn the gas control temperature knob counterclockwise to the OFF setting The status light will stop blinking and stay on for a A to PILOT V VAC pip OF When the status light starts blinking release the gas control temperature knob Set the gas control tempera ture knob to the desired setting 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 lig
81. turer s instructions for installation of the valves Before changing the factory setting on the thermostat read the Temperature Regulation section in this manual HOT WATER OUTLET COLD WATER TEMPERED y WATER OUTLET el _ DS 4 TO COLD WATER Du INLET ON WATER HEATER MIXING HOT WATER VALVE OUTLET ON WATER HEATER FIGURE 14 A WARNING Do not connect to non potable water system This water heater shall not be connected to any heating systems or component s used with a non potable water heating appliance Toxic chemicals such as those used for boiler treatment shall not be introduced into this system The water supply pressure should not exceed 80 psi If this occurs a pressure reducing valve with a bypass should be installed in the cold water inlet line This should be placed on the supply to the entire house in order to maintain equal hot and cold water pressures In addition the water within the water heater tank expands as itis heated increasing the pressure of the water system Ifthe relieving point of the water heater s temperature pressure relief valve is reached the valve will relieve the excess pressure The temperature pressure relief valve is not intended for the constant relief of thermal expansion This is an unacceptable condition and must be corrected It is recommended that any devices installed which could create a closed system have a by pass and or the system
82. ut must not be higher than 80 psi 28 WATER HEATER 3 COLD WATER PRESSURE INLET FITTING REDUCING VALVE WITH BY PASS HOT Paha as A INLET COLD WATER SHUT OFF 2 PRESSURE GAUGE RECOMMENDED INSTALLATION VERTICAL MOUNTING WATER HEATER COLD WATER INLET FITTING FLOOR CEILING JOIST ETC STRAPPING 3 PRESSURE REDUCING x VALVE WITH 1 BY PASS EXPANSION TANK 2 Pa t PRESSURE GAUGE INLET GOLD WATER SHUT OFF ALTERNATE RECOMMENDED INSTALLATION HORIZONTAL MOUNTING FIGURE 35 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 AWARNING Burn Hazard Do not touch vent Doing so can result in burns O ICE Check draft hood operation by performing a worst case depressurization of the building With all doors and windows closed and with all air handling equipment and exhaust fans operating such as furnaces clothes dryers range hoods and bathroom fans a match flame should still be drawn into the draft hood of the water heater with its burner firing If the flame is not drawn toward the draft hood after 15 minutes of burner operation shut off water heater and make necessa
83. wrench or equivalent to grip body Damage may result 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 inch 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 e 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 tank Be sure to remove the pilot ferrule nut from the new gas control valve thermostat e Turn the gas supply on and check for leaks Test the water heater by brushing on an approved noncorrosive leak detection solution Bubbles forming indicate a leak Correct any leak found e Be sure tank is completely filled with water before lighting and activating the water heater Follow the Lighting Instructions in the Operating Instructions section 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 26 Housekeeping Vacuum around base of water heater for dust dirt and lint on a regular basis A DANGER Do not obstruct combustion air open

Kenmore 6-Year Manufacturer's Warranty

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