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Kenmore 153.332.410 Water Heater User Manual

1. MN E MN 13 5 14 MUN LES 14 15 PING uium T 15 15 16 Gas IRegulrerle lis 15 PIPING 15 525 56 5 16 Gas PRESS Testno aden read 16 EGI rere ee nc a M Lo EM MR IM Me ee ee 16 COMBUSTION AIR SUPPLY amp VENTILATION 17 20 EUR SII 17 COMME INS CIO T 17 All Air tron Inside the a tt ee Ma 17 18 oo dne en E A 18 Louvers and GMES edicere 18 19 c r 19 OE DLL 19 c c 19 COMME GIONS 222 Tm 19 20 Chimney COMME CUO En 20 Vertical Exhaust
2. AI Ji TOR METAL DRAIN PANS EXPANSION TANKS FOR THERMAL EXPANSION CONDITIONS AVAILABLE IN 2 GALLONS 7 6 LITERS AND 5 GALLONS 18 9 LITERS AVAILABLE IN 20 508 mm DIAMETER FOR WATER HEATERS HAVING A DIAMETER 18 457 mm OR LESS 24 610mm DIAMETER FOR WATER HEATERS HAVING CAPACITY THROUGH LOCAL SEARS STORE OR SERVICE CENTER 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 WATER HEATER INSTALLATION KIT WITH FLEXIBLE CONNECTORS FOR 3 4 19 05 mm COPPER PLUMBING AND FLEXIBLE GAS CONNECTOR WITH FITTINGS ADDITIONAL TOOLS NEEDED WHEN SWEAT SOLDERING Tubing Cutters or Hacksaw BASIC TOOLS You may or may not need all these tools depending on your type of installation These tools can be purchased at your local Sears Store Propane Torch Soft Solder Pipe Wrenches 2 14 356 mm Solder Flux e Screwdriver Emery Cloth Tin Snips 6 1 82 m Tape or Folding Ruler Garden Hose Drill Pipe Dope or Teflon Tape Wire Brushes PROPANE oF CD TUBING CUTTER TORCH SLOT HEAD SCREWDRIVER hj TIN SNIPS PHILLIPS SCREWDRIVER ae O HACKSAW EMERY CLOTH PIPE DOPE ROLL OF TEFLON SQUEEZE TUBE TAPE USE ONLY ON USE FOR WATER AND GAS WATER CONNECTIONS CONNECTIONS 3 4 19 mm WIRE BRUSH y 2
3. e ROLL OF LEAD FREE SOLDER GARDEN HOSE 6 FOOT TAPE PIPE WRENCH 1 2 13 mm WIRE BRUSH SOFT SOLDER FLUX TYPICAL INSTALLATION Vent Pipe Draft Hood TO KNOW YOUR WATER HEATER GAS MODELS Anode Not Shown Hot Water Outlet Insulation Gas Supply Piping Manual Gas Shut off Valve Ground Joint Union Drip Leg Sediment Trap INSTALLINACCORDANCE WITH LOCAL CODES DRIP LEG AS REQUIRED BY LOCAL CODES ALL PIPING MATERIALS TO BE TO VENT TERMINATION ON ROOF DOvoZzserxzca Inner Door Outer Door Union Inlet Water Shut off Valve Cold Water Inlet Inlet Dip Tube Temperature Pressure Relief Valve Rating Plate Flue Baffle INSTALL THERMAL EXPANSION TANK IF WATER HEATER IS INSTALLED IN A CLOSED WATER SYSTEM SUPPLIED BY CUSTOMERS VALVE INSTALL PER LOCAL CODES MI POSITION Gas Control Valve Thermostat Drain Valve Pilot and Main Burner Flue Metal Drain Pan Piezo Igniter Base Ring Filter lt gt lt 5 GAS CONTROL VALVE THERMOSTAT WHITE RODGERS GAS CONTROL KNOB WATER TEMPERATURE DIAL ADJUSTING DIAL POSITION POSITION TOP VIEW U MANIFOLD BURNER ASSEMBLY MAIN BURNER Y THERMOCOUPLE
4. Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Avoid all ignition sources if you smell Natural or LP gas Do not expose water heater control to excessive gas A WARNING Fire Hazard For continued protection against riskof fire Do not install water heater on carpeted floor not operate water heater if flood damaged WARNING Overheated water can cause watertank explosion Properly sized temperature and pressure relief valve must be installed in opening provided A WARNING AWARNING Install vent system in accordance with codes Do not operate water heater if flood damaged High altitude orifice must be installed for operation above 7 700 feet 2 34 7m pressure EODD wu Do not operate if soot is present Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources away from faucets after extended 4 period of non use J Read instruction manual before installing using or servicing Do not obstruct water heater air intake with insulating jacket Do not place chemical vapor emitting products near water heater Gas and carbon monoxide detectors
5. Marca Registrada Marca de F brica de KCD IP LLC en Estados Unidos o Sears Brands LLC in otros pa ses MC Marque de commerce V Marque d pos e de Sears Brands LLC Au Canada pour service en francais 1 800 1 800 533 6937 WWW Sears ca
6. SMOKING AND CARBON 1 Insufficient secondary air Provide ventilation to water heater Check flue FORMATION SOOTING way flue baffle burner 2 Low gas pressure Check with gas utility company 3 Water heater flue or vent system 3 Clean locate source and correct blocked 4 Thermostat not functioning properly Replace thermostat 5 Heater installed in a confined area Provide fresh air ventilation 6 Burner flame yellow lazy See Burner Flame Yellow Lazy CONDENSATION 1 Temperature setting too low 1 Increase the temperature setting Refer to the Condensation sub section of this manual s Troubleshooting Guide BURNER FLAME FLOATS 1 Orifice too large Replace with correct orifice AND LIFTS OFF PORTS 2 High gas pressure Check with gas utility company 3 Water heater flue or vent system Clean flue and burner locate source and correct blocked 4 Cold drafts Locate source and correct BURNER FLAME TOO HIGH 1 too large 1 Replace with correct orifice FLAME BURNS AT ORIFICE 1 Thermostat not functioning properly Replace thermostat 2 Low gas pressure 2 Check with gas utility company PILOT FLAME 1 Pilot line or orifice clogged 1 Clean locate source and correct TOO SMALL 2 Low gas pressure 2 Check with gas utility company 37 PILOT LIGHT TROUBLESHOOTING FLOWCHART Does pilot light go out when Check Draft See Checking the button is released NO Draft section of this manual YES Has the ther
7. A properly operating burner should produce a soft blue flame Blue tips with yellow inner cones are satisfactory The tips of the flame may have a slight yellow tint The flame should not be all yellow or have a sharp blue orange color Contaminated air may cause an orange colored flame Contact a qualified technician if the flame is not satisfactory FIGURE 27 Emergency Shut Down IMPORTANT Should overheating occur or the gas supply fails to shut off turn off the water heater s manual gas control valve and call a qualified technician 24 Water Temperature Regulation Water temperature over 125 F 52 C can cause servere burns instantly resulting in severe injury or death A DANGER Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting Due to the nature of the typical gas water heater the water temperature in certain situations may vary up to 30 F 16 7 C higher or lower at the point of use such as bathtubs showers sink etc HOTTER WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes washing dish washing and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injur
8. If installing over carpeting the carpeting must be protected by a metal or wood panel beneath the water heater The protective panel must extend beyond the full width and depth of the water heater by at least three inches 76 2mm in any direction or if in an alcove or closet installation the entire floor must be covered by the panel e Figure 10 be used a reference guide to locate the specific clearance locations A minimum of 24 inches of front clearance should be provided for inspection and service BACK SIDES gt FRONT 24 MINIMUM FOR SERVICE TOP VIEW FIGURE 10 Filling the Water Heater Never use this water heater unless it is completely full of water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater To fill the water heater with water e Close the water heater drain valve by turning the handle to the right clockwise The drain valve is on the lower front of the water heater e Open the cold water supply valve to the water heater NOTE The cold water supply valve must be left open when the water heater is in use 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 connecti
9. FIGURE 21 Maintain vent pipe clearance requirements to local state and or the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition xx 211 Standard for Chimneys Fireplaces Vents and Solid Fuel Buming Appliances states that these chimneys are intended to be installed in accordance with the installation instructions provided with each chimney support assembly Minimum air space clearance to combustible materials should be maintained as marked on the chimney sections WATER SYSTEM PIPING Piping Installation Piping fittings and valves should be installed according to the installation drawing Figure 22 If the indoor installation area is subject to freezing temperatures the water piping must be protected by insulation The water supply pressure should not exceed 80 psi If this occurs a pressure reducing valve with a bypass may need to be installed in the cold water inlet line This should be placed on the supply to the entire house in order to maintain equal hot and cold water pressures IMPORTANT Heat cannot be applied to the water fittings on the heater as they may contain nonmetallic parts If solder connections are used solder the pipe to the adapter before attaching the adapter to the hot and cold water fittings IMPORTANT Always use a good grade of joint compound and be certain that all fittings are drawn up tight 1 Install the water piping and fittings as shown in Figure 22 Connect t
10. FORCE The burner needs to be removed for cleaning Call the Sears Service Center to remove and clean the burner and correct the problem that required the burner to be cleaned Housekeeping Vacuum around base of water heater for dust dirt and lint on a regular basis A DANGER Do not obstruct combustion air Openings at the bottom of the water heater Do not use or store flammable vapor products such as gasoline solvents or adhesives in the same room or area near water heater or other appliance At least annually check the base ring filter and flame arrester for any dust lint or debris that may have accumulated Clean as necessary Can cause serious injury or death AT LEAST ANNUALLY A VISUAL INSPECTION SHOULD BE MADE OF THE BASE RING FILTERAND FLAME ARRESTER CLEAN IF LINT ACCUMULATIONS ARE NOTICED INSTALLED IN SUITABLE AREA To ensure sufficient ventilation and combustion air supply proper clearances from the water heater must be maintained See Installation Instructions Combustible materials such as clothing cleaning materials or flammable liquids etc must not be placed against or adjacent to the water heater because they could catch on fire Anode Rod Inspection CAUTION Avoid water heater damage Inspection and replacement of anode rod required The anode rod is used to protect the tank from corrosion Most hot water tanks are equipped with an anode rod The submerged rod deter
11. Gas Vehl a 20 WATER SYSTEM PIPING a a doe oct dare 21 22 PIPING IMSTANQUON PT 21 Closed System Thermal 22 Temperature and Pressure Relief 22 T amp P Relief Valve and Pipe INSUIation ccccccecccceceeceeeeceneeceneeceneeceaeeeeaeeesaeeeseeeeseaeeseaeeseaceseeessusessaeessaeesseeesseeees 22 OPERATING YOUR WATER HEATER 23 25 Eignung 23 CRECKINO the Dram 24 Burner Flamme Sresi Autos 24 EIMerGeNGy SNUF DOWD eere 24 Water Temperature Regulation penabus eit 24 25 SERVICE ANDADJUSTMEN si tar pe 26 28 Vent System MIS OS CTO I 26 gt NONE 26 ae 26 FOULS RR E 27 An
12. PILOT TUBE MANIFOLD DOOR DISCHARGE PIPE DO NOT CAP OR PLUG 6 MAXIMUM AIR GAP FLOOR DRAIN FIGURE 1 10 IMPORTANT INFORMATION ABOUT THIS WATER HEATER This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident The new technology used in meeting these standards makes this product more sensitive to installation errors Please review the following checklist and make any required installation upgrades or changes Questions Contact Sears at 1 800 4 MY HOME 1 800 469 4663 Installation Checklist Water Heater Location Water heater location is important and can affect system performance Please check the following O Installation area free of corrosive elements and flammable materials Centrally located with the water piping system For new installations Located as close to the gas piping and vent pipe system as possible Located indoors and in a vertical position Protected from freezing temperatures O Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor Provisions made to protect the area from water damage Metal drain pan installed and piped to an adequate drain O Sufficient room to service the water heater See Clearances and Accessibility section of this manual O Water heater not located near an air moving device O Is the installed environment dirty exce
13. are available water heater Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual CAUTION Improper installation and use may result in property damage Do not operate water heater if flood damaged 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 SER VIG Eust latte er rif 2 SAFET FRECAUTONS 2 3 Fy aa eee 6 CUSTOMEIJTSESPONSIBIELEIES eee RO Oe Nos how En nr et ET med tt Ne 7 720 So nn e Mida 8 MATERIALS AND BASIC TOOLS IN EE DED decla bcd a debi 9 NON Tre 10 IMPORTANT INFORMATION ABOUT THIS WATER 11 Iistallauon GHeckllsE ute sara cs es E OE E mu en 11 INS TABLEATION INSTERUGT IONS unis totis pulcra eue th ia nga Ene nee m P ra ci tn 12 15 Removing the Old Water 12 UU t m 13 ILS MOG 5
14. extinguished Open the doors and windows for ventilation while flammable substances are in use If flammable liquids or vapors have spilled or leaked in area of the water heater leave the area immediately and call the fire department from a neighbor s home Do not attempt to clean the spill until all ignition sources have been extinguished WARNING Read instruction manual before installing using or servicing water heater Improper use may result in fire or explosion Maintain required clearances to combustibles Keep combustibles such as boxes magazines clothes etc away from the water heater area Site Location e Selecta location near the center of the water piping system The water heater must be installed indoors and in a vertical position on a level surface DO NOT install in bathrooms bedrooms or any occupied room normally kept closed e Locate the water heater as close to the chimney or gas vent as practical Consider the vent system piping and combustion air supply requirements when selecting the water heater location The venting system must be able to run from the water heater to termination with minimal length and elbows Locate the water heater near the existing gas piping If installing a new gas line locate the water heater to minimize the pipe length and elbows water heater should be located in an area not subject to freezing temperatures Water heaters located in un
15. frequently 2 Follow the Lighting Instructions to turn off the water heater and allow it to cool for 10 minutes before attempting to clean the base ring filter 3 Use a vacuum cleaner with a hose attachment to remove any dust or debris that may have accumulated on the filter NOTE If unable to inspect or clean the base ring filter follow the Cleaning the Combustion Chamber and Flame arrestor instructions 4 After the base ring filter has been cleaned follow the Lighting Instructions to return the water heater to service Removing the Manifold Burner Assembly 1 Turn off the gas supply to the water heater at the manual gas shut off valve This valve is typically located beside the water heater Figure 11 Note the position of the shut off valve in the open on position then proceed to turn it off 2 Onthelower front of the water heater locate the gas control valve thermostat see Figure 32 Before performing any maintenance it is important to turn the temperature dial on the gas control valve thermostat to its lowest setting 3 On top of the gas control valve thermostat turn the gas control knob to the OFF position WHITE RODGERS GAS VALVE 3 1 yr ef PILOT TUBE THERMOCOUPLE MANIFOLD TUBE FIGURE 31 4 Remove the outer door 5 Remove the two screws securing the manifold door assembly to the combustion chamber Figure 32 GAS CONT
16. furnish a new water heater of comparable output as permitted by such governmental regulations however the Owner will be charged Q the additional cost associated with the changes made to the replacement water heater design to comply with such governmental regulations Q Replacements and or repairs furnished under this warranty do not carry a new warranty and are only covered by the unexpired portion lt eS of the original warranty VS A 55 1 YEAR EXCLUSIVE KENMORE LABOR WARRANTY Sy For the first year from the date of purchase Sears will free of charge supply and install new water heater parts for defective ones ora Q 9 new water heater for one that develops leak lt Oe WARRANTY SERVICE O ee PX To obtain warranty service 1 800 4 MY HOME 1 800 469 4663 9 5 This warranty applies only while this product is in use the United States 5 K This warranty gives you specific legal rights and you may also have other rights which vary from state to state 5 lt yg y p gal rights y y 9 y 9 5 SR 5 Ne SEARS BRANDS MANAGEMENT CORPORATION Hoffman Estates IL 60179 A 5 ESE YEE MEL EME SN DANA ANA SA SAN AN NXENES XENXA NEXIS NA NA NX 2 The price of your water heater does not include free checkup service call On water heater installations arranged by Sears Sears warrants the installation A charge will be
17. made on service calls due to poor or incomplete installation These include a Adjusting thermostat b Condensation c Leaks in pipes or fittings Master Protection Agreements Congratulations on making a smart purchase Your new e 250 Food Loss Protection annually for any food spoilage Kenmore product is designed and manufactured for years that is the result of mechanical failure of any covered of dependable operation But like all products it may require refrigerator or freezer preventive maintenance or repair from time to time That s when having a Master Protection Agreement can save you money and aggravation e Rental reimbursement if repair of your covered product takes longer than promised e 10 discount off the regular price of any non covered repair The Master Protection Agreement also helps extend the life of your service and related installed parts new product Here s what the Agreement includes 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 e 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 The Master Protection Agreement is a risk free purchase If you cancel for any reason during the product warranty per
18. of the temperature and pressure relief valve is to discharge water in large quantities in the event of excessive temperature or pressure developing in the water heater The valve s relief pressure must not exceed the working pressure of the water heater as stated on the rating plate IMPORTANT Only a new temperature and pressure relief valve should be used with your water heater Do not use an old or existing valve as it may be damaged or not adequate for the working pressure of the new water heater Do not place any valve between the relief valve and the tank The Temperature amp Pressure Relief Valve e Must not be in contact with any electrical part e Must be connected to an adequate discharge line e Must not be rated higher than the working pressure shown on the rating plate of the water heater Discharge Line Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line e Must not be capped blocked plugged or contain any valve between the relief valve and the end of the discharge line e Must terminate a maximum of six inches above a floor drain or external to the building In cold climates it is recommended that the discharge line be terminated at an adequate drain inside the building e Mustbe capable of withstanding 250 F 121 C without distortion e Must be installed to allow complete drainage of both the valve and discharge line T amp P Relief
19. outlet connections Damage to the gas control valve thermostat may result Replacing the Gas Valve 1 To replace the gas control valve thermostat reassemble in reverse order When replacing the gas control valve thermostat thread a correctly sized pipe into the inlet and use it to turn the gas valve clockwise DO NOT OVER TIGHTEN or damage may result NOTE Use an approved TEFLON tape or pipe compound only on the threaded section of the gas control valve thermostat that screws into the tank 32 Reconnect the gas piping to the gas control valve thermostat NOTE Use an approved Teflon tape or pipe compound on the gas piping connections Attach the igniter and bracket to the new gas control valve thermostat clipping it at the back edge of thermostat and snapping it into place NOTE Do not use the pilot ferrule nut supplied with the new gas control valve thermostat unless the existing nut is not usable Reconnect the pilot tube manifold tube thermocouple igniter wire and thermal switch wires NOTE L P gas systems use reverse left hand threads on the manifold tube Fill the tank completely with water NOTE To purge the lines of any excess air keep the hot water faucet open for 3 minutes after a constant flow of water is obtained Turn on the gas supply and test the gas supply connections by brushing on an approved noncorrosive leak detection solution Bubbles forming indicate a leak Correct any leak found Check t
20. properly connected to the water heater remove the aerator at the nearest hot water faucet Open the hot water faucet and allow the tank to completely fill with water To purge the lines of any excess air keep the hot water faucet open for 3 minutes after a constant flow of water is obtained Close the faucet and check all connections for leaks 21 IN A CLOSED SYSTEM USEA m p THERMAL EXPANSION TANK COLD WATER SUPPLY TO FIXTURES PRESSURE REDUCING VALVE a WITH BYPASS I 2 1 HOT WATER COLD WATER INLET COLD WATER INLET VALVE SHUT OFF VALVE OUTLET TEMPERATURE AND PRESSURE T amp P RELIEF VALVE OPTIONAL TOP T amp P RELIEF VALVE NOT SHOWN DISCHARGE PIPE _DiscHar DO NOT CAP OR PLUG MASSACHUSETTS INSTALL A VACUUM RELIEF IN COLD WATER LINE PER SECTION 19 MGL 142 6 MAXIMUM AIR GAP DRAIN LINE 3 4 ID 0 MINIMUM 1 MINIMUM METAL DRAIN PAN TEMPERED WATER UNTEMPERED TO FIXTURES HOT WATER COLD WATER AERA OUTLET MIXING VALVE SET TO 120 F 3 FOLLOW THE MIXING VALVE MANUFACTURER S INSTRUCTIONS FIGURE 23 Please note the following system should be installed only with piping that is suitable for potable drinkable water such as copper CPVC or polybutylene This water heater must not be installed using iron piping or PV
21. volume of the room s must be of sufficient size to properly provide the necessary amount of fresh air to the water heater and other gas utilization equipment in the area If you are unsure that the structure meets this requirement contact your local gas utility company or other qualified agency for a safety inspection Each of the two openings shall have a minimum free area of 1 square inch per 1 000 BTUH of the total input rating of all gas utilization equipment in the confined area but not less than 100 square inches Figure 13 CONFINED SPACE PERMANENT OPENINGS 1 SQUARE INCH 1000 BTUH MINIMUM 100 SQ IN FIGURE 13 All Air from Outdoors Outdoor fresh air can be provided to a confined area either directly or by the use of vertical and horizontal ducts The fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors Attic or crawl spaces cannot be closed and must be properly ventilated to the outside Ductwork must be of the same cross sectional area as the free area of the opening to which they connect The minimum dimension of rectangular air ducts cannot be less than three inches The size of each of the two openings is determined by the method in which the air is to be provided Refer to Table 4 to calculate the minimum free area for each opening Figures 14 15 16 and 17 are typical examples of each method Louvers and Grilles In calculating fr
22. 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 drain valve may be leaking at the tank fitting Combustion products contain water vapor which can condense on the cooler surfaces of the tank Droplets form and drip onto the burner or run on the floor This is common at the time of start up after installation and when incoming water is cold Water in the water heater bottom or on the floor may be from condensation loose connections or the relief valve DO NOT replace the water heater until a full inspection of all possible water sources is made and necessary corrective steps taken Leakage from other appliances water lines or ground seepage should also be checked To check where threaded portion enters tank insert cotton swab between jacket opening and fitting If cotton is wet follow draining instructions in the Draining and Flushing section and then remove fitting Put pipe dope or teflon tape on the threads and replace When you are finished follow the steps in Filling the Water Heater in the Installation Instructions earlier in this manual TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION BURNER WILL NOT IGNITE 1 Pilot not lit 2 Thermostat set too low 3 4 the gas lines 5 Pilot line clogged 6 Main burner line clogged 7 Non
23. 30 e Water heaters installed in open spaces in buildings with unusually tight construction may still require outdoor air to function properly In this situation outside air openings should be sized the same as for a confined space e Modern home construction usually requires supplying outside air into the water heater area Confined Space For the correct and proper operation of this water heater ample air must be supplied for the combustion ventilation and dilution of flue gases Small enclosures and confined areas must have two permanent openings so that sufficient fresh air can be drawn from outside of the enclosure One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure as shown in Figure 12 The size of each opening free area is determined by the total BTUH input of all gas utilization equipment i e water heaters furnaces clothes dryers etc and the method by which the air is provided The BTUH input can be found on the water heater rating plate Additional air can be provided by two methods 1 All air from inside the building 2 All air from outdoors 12 MAXIMUM CLOSET OR PERMANENT OTHER OPENINGS TO CONFINED THE OUTSIDE OR SPACE ADDITIONAL ROOMS WITHIN THE BUILDING 12 MAXIMUM FIGURE 12 All Air from Inside the Building When additional air is to be provided to the confined area from additional room s within the building the total
24. 48 9006143 9006666 9000071 145 1280 9000056 9006449 e MODEL NUMBER e SERIAL NUMBER e GAS NATURAL OR PROPANE L P e PART DESCRIPTION THIS IS A REPAIR PARTS LIST NOT A PACKING LIST 40 NOTES 41 Get it fixed at your 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 05 1 800 469 4663 Canada WWW Sears com WWW Sears ca To purchase a protection agreement on a product serviced by Sears 1 800 827 6655 U S A 1 800 361 6665 Canada Para pedir servicio de reparaci n a domicilio y para ordenar piezas 1 888 SU HOGAR Sears WWW Sears com Registered Trademark Trademark of KCD IP LLC in the United States or Sears Brands LLC in other countries
25. ATER COLD WATER INLET FITTING FLOOR CEILING JOIST ETC STRAPPING 3 PRESSURE REDUCING VALVE WITH BY PASS i INLET COLD WATER SHUT OFF EXPANSION TANK 2 PRESSURE GAUGE ALTERNATE RECOMMENDED INSTALLATION HORIZONTAL MOUNTING FIGURE 42 Strange Sounds Possible noises due to expansion and contraction of some metal parts during periods of heat up and cool down do not represent harmful or dangerous conditions Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal See Condensation section Draft Hood Operation Check draft hood operation by performing a worst case depressurization of the building With all doors and windows closed and with all air handling equipment and exhaust fans operating such as furnaces clothes dryers range hoods and bathroom fans a match flame should still be drawn into the draft hood of the water heater with its burner firing If the flame is not drawn toward the draft hood shut off water heater and make necessary air supply changes to correct Condensation Whenever the water heater is filled with cold water some condensate will form while the burner is on A water heater may appear to be leaking when in fact the water is condensation This usually happens when e new water heater is filled with cold water for the first time e Burning gas produces water vapor In
26. C water piping e 5 only pumps valves or fittings that are compatible with potable water e tisrecommend that only full flow ball or gate valves are used in water piping installations The use of valves that may cause excessive restriction to water flow is not recommended e Use only 95 5 tin antimony or other equivalent solder Any lead based solder must not be used e Piping that has been treated with chromates boiler seal or other chemicals must not be used e Chemicals that may contaminate the potable water supply must not be added to the piping system Closed System Thermal Expansion CAUTION All water heaters eventually leak Do notinstall without adequate drainage As water is heated it expands thermal expansion In a closed system the volume of water will grow As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the limited 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 th
27. CIENT HOT WATER Thermostat set too low Sediment or lime in tank Water heater too small Wrong piping connections Leaking faucets Wasted hot water Long runs of exposed piping Hot water piping in outside wall Low gas pressure SLOW HOT WATER RECOVERY Insufficient secondary air Water heater flue or vent system blocked Low gas pressure Improper calibration Thermostat set too low Water heater too small Wrong piping connections Wasted hot water DRIP FROM RELIEF VALVE Excessive water pressure Heater stacking Closed water system 36 FVIR 14 Provide ventilation to water heater Check with gas utility company Clean locate source and correct Clean locate source and correct Proper fresh air ventilation Clean or replace orifice Replace igniter pilot assembly See Pilot Light Troubleshooting Flowchart section Remove and reconnect the wire leads at thermal switch confirm connections are tight and not loose Finger tighten then 1 4 turn with wrench Bleed the air from the gas line Check with gas utility company Check with gas utility company Notify utility install dirt trap in gas line Locate source and correct Replace thermostat Clean locate source and correct Replace thermocouple See maintenance section for inspection and cleaning of flame arrester Replace water heater eliminate flammable vapors source Contact Sears Service Inspect and clean base ring filter See External Cleaning amp
28. E 37 Reposition the manifold component block in the manifold door opening and secure it with the retainer clip Carefully bend the new pilot tube and thermocouple to match the bend of the manifold tube NOTE When bending DO NOT crimp or crease the pilot tube or thermocouple Figure 34 Before you proceed to the next step install the new brass ferrule nut in the gas control valve thermostat s pilot tube opening HAND TIGHTEN ONLY See Replacing the Manifold Burner Assembly Cleaning the Combustion Chamber and Flame arrestor 1 2 3 Follow procedure outlined in Removing the Manifold Burner Assembly Use a vacuum cleaner shop vac to remove all loose debris in the combustion chamber Figure 38 Use compressed air to clear any dust or debris that may have accumulated in the flame arrestor COMBUSTION CHAMBER FLAME ARRESTOR FIGURE 38 Reassemble by following the procedure under Replacing the Manifold Burner Assembly Replacing the Manifold Burner Assembly A WARNING Explosion Hazard Tighten both manifold door screws securely Remove any fiberglass between gasket and combustion chamber Replace viewport if glass is missing or damaged Replace manifold component block if missing or removed Replace door gasket if damaged Failure to follow these instructions can result in death explosion or fire 1 Check the door gasket for damage or imbedded debris prior to instal
29. HE DRAFT HOOD WITH THE FOUR SCREWS PROVIDED FIGURE 18 Align the legs of the draft hood with the slots provided Insert the legs and secure the draft hood to the water heater s top with the four screws provided as shown in Figure 18 Do not alter the draft hood in any way If you are replacing an existing water heater be sure to use the draft hood supplied with this water heater Vent Pipe Size It is important that you follow the guidelines in these instructions for sizing a vent pipe system If a transition to a larger vent size is required the vent transition connection must be made at the draft hood outlet Vent Connectors 1 Type B Double wall U L Listed Vent Pipe 2 Single wall Vent Pipe Maintain the manufacturer s specified minimum clearance from combustible materials when using type B double wall vent pipe Vent connectors made of type B double wall vent pipe material may pass through walls or partitions constructed of combustible material if the minimum listed clearance is maintained Maintain a six inch minimum clearance from all combustible materials when using single wall vent pipe IMPORTANT Single wall vent pipe cannot be used for water heaters located in attics and may not pass through attic spaces crawl spaces or any confined or inaccessible location A single wall metal vent connector cannot pass through any interior wall When installing a vent connector please note the following See Fi
30. Inspection Flood damage to a water heater may not be readily visible or immediately detectable However over a period of time a flooded water heater will create dangerous conditions which can cause DEATH SERIOUS BODILY INJURY OR PROPERTY DAMAGE Contact a Sears Service Center to replace a flooded water heater Do not attempt to repair the unit It must be replaced At least once a year a visual inspection should be made of the main burner and pilot burner See Figure 29 You should check for sooting Soot is not normal and will impair proper combustion Soot build up indicates a problem that requires correction before further use Turn OFF gas to water heater and leave off until repairs are made because failure to correct the cause of the sooting can result in a fire causing death serious injury or property damage FIGURE 29 Burner Cleaning A DANGER Failure to properly reseal the combustion chamber will disable the flammable vapor ignition resistance feature of this water heater which could result in death or serious injury Contact your local Sears Service Center for assistance Read instruction manual before installing using or servicing water heater If inspection of the burner shows that cleaning is required turn the gas control knob clockwise CN to the OFF position depressing slightly NOTE The knob cannot be turned from PILOT to OFF unless knob is depressed slightly DO NOT
31. Inspection of the Base Ring Filter Set temperature dial to lower setting Drain flush provide water treatment if needed Install adequate heater Correct piping dip tube must be in cold inlet Repair faucets Check with utility repair at once Advise customer Insulate piping Insulate piping Turn temperature dial to desired setting Drain flush provide water treatment if needed Install adequate heater Correct piping dip tube must be in cold inlet Repair faucets Advise customer Insulate piping Insulate piping Check with gas utility company Provide ventilation to water heater Check flue way flue baffle and burner Clean flue locate source and correct Check with gas utility company Replace thermostat Turn temperature dial to desired setting Install adequate heater Correct piping dip tube must be in cold inlet Advise customer Use a pressure reducing valve and relief valve Lower the thermostat setting See Closed System Thermal Expansion TROUBLESHOOTING CHART CONTINUED PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION THERMOSTAT FAILS TO Thermostat not functioning properly Replace thermostat SHUT OFF Improper calibration Replace thermostat COMBUSTION ODORS Insufficient secondary air Provide ventilation to water heater Check flue way flue baffle and burner Water heater flue or vent system 2 Clean locate source and correct blocked Heater installed in a confined area Provide fresh air ventilation
32. ROL VALVE THERMOSTAT MANIFOLD TUBE THERMOCOUPLE THERMAL VIEW PORT SWITCH MANIFOLD DOOR MANIFOLD MANIFOLD SCREWS 2 COMPONENT BLOCK FIGURE 32 6 Disconnect the thermocouple right hand thread pilot tube the igniter wire from the igniter button the two connectors attached to the thermal switch and manifold tube at the gas control valve thermostat Figures 31 amp 32 NOTE L P Gas systems use reverse left hand threads on the manifold tube 7 Grasp the manifold tube and push down slightly to free the manifold pilot tube and thermocouple 8 Carefully remove the manifold burner assembly from the burner compartment NOTE Be sure not to damage internal parts Removing the Burner from the Manifold Burner Assembly Natural Gas Low Nox amp L P Gas Burner 1 Take off the burner by removing the two 2 screws located underneath the burner 2 Check the burner to see if it is dirty or clogged The burner may be cleaned with soap and hot water Figure 33 a A 6 X 9 y b BURNER BOTTOM VIEW FIGURE 33 Replacing the Thermocouple 1 Remove the manifold burner assembly as directed previously 2 Liftthe retainer clip straight up from the back of the manifold component block using a flat blade screwdriver then remove the manifold component block from the manifold door Figure 34 3 Remove the burner See Removing the Burne
33. TER BUTTON eee THERMOCOUPLE WIRE TO ELECTRODE SNAP ON CONNECTOR NOTE SPARK GAP DISTANCE MEASURED FROM ELECTRODE TIP TO PILOT TIP ELECTRODE FIGURE 41 Testing the Igniter System Turn off the gas to the water heater at the manual gas shut off valve Watch the electrode tip while activating the igniter A visible spark should jump from the electrode To avoid shock do not touch the burner or any metal part on the pilot or pilot assembly If no spark is visible check the wire connections and make sure the electrode is not broken Replace the igniter if defective Dirt and rust on the pilot or electrode tip can prevent the igniter spark Wipe clean with a damp cloth and dry completely Rust can be removed from the electrode tip and metal surfaces by lightly sanding with an emery cloth or fine grit sandpaper Removing and Replacing the Gas Control Valve Thermostat IMPORTANT This water heater has a resettable thermal switch installed Do not attempt to disable or modify this feature in any way Use only factory authorized replacement parts Removing the Gas Valve 1 Turn off the gas supply to the water heater at the manual gas shut off valve This valve is typically located beside the water heater Note the position of the shut off valve in the open on position then proceed to turn it off Figure 11 On the lower front of the water heater locate the gas control valve thermostat See Figure 32 Before pe
34. TROUBEBSHOOEFINOGO XX3UIDE boe 33 35 Stan Blog Genre ERR Ls 33 34 Operational COMGINONS seo utin d bebsoseni esce etel cM edema 34 35 TROUBLESHOOTING CHAR adeb emt 36 37 PIEOT EIGHT TROUBLESHOOTING FEOWGHADBR Lucena kr VENE 38 PART O ORDERI Dt 40 41 PRODUCT WARRANTY f 3 YEAR LIMITED WARRANTY WATER HEATER F aN For three years from the date of purchase if this water heater is installed and operated in a single family home in accordance with the Se 9 owner s manual instructions all local applicable plumbing codes Sears will en 1 Supply free water heater parts for those that are defective in material workmanship 2 Supply a free water heater for one that develops a leak For the second through third year from the purchase date you must pay the labor cost for installation of parts or water heater 0 commercial institutional industrial or residential use two or more families the above limited warranty is only for two years During 5 second year you must pay the labor cost for parts or water heater installation SK 92 If governmental regulations prohibit Sears from furnishing a comparable model replacement water heater under this warranty Sears will lt
35. Use amp Care Guide Model No 153 332420 40 Gallon Tall 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 OWNER Retain these instructions for future reference FOR YOUR SAFETY An odorant is added to the gas used by this water heater ADVERTENCIA Si no puede leer o entender el ingl s y necesita el manual de instrucciones en espa ol puede solicitarlo al 1 800 821 2017 TRATE DE INSTALAR U OPERAR ESTE CALENTADOR DE AGUA SI NO ENTIENDE LAS INSTRUCCIONES No hacer caso de esta advertencia podr a originar lesiones graves o mortales P N 319357 000 0810 Sears Brands Management Corporation Hoffman Estates IL 60179 U S A www kenmore com www sears com WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DOIF YOU SMELL GAS e Donottry to light any appliance e Do not touch any electrical switch do not use any phone your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e f you cannot reach your gas supplier call the fire department Installation and s
36. VE T amp P RELIEF VALVE DRAIN LINE FIGURE 25 OPERATING YOUR WATER HEATER Lighting Instructions Explosion Hazard Read and understand these directions thoroughly before attempting to light or re light the pilot Make sure the view port is not missing or damaged See Figure 32 Make sure the tank is completely filled with water before lighting the pilot Check the rating plate near the gas control valve thermostat for the correct gas Do not use this water heater with any gas other than the one listed on the rating plate If you have any questions or doubts consult your gas supplier or gas utility company Replace view port if glass is missing or damaged Failure to do so can result in death explosion or fire WARNING if you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life FLAMMABLE BEFORE LIGHTING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A This appliance has a pilot which is lit by a piezo electric spark gas ignition system Do not open the inner door of the appliance and try to light the pilot by hand B BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS eDo not try to light any appliance eDo not touch any electric switch
37. Valve and Pipe Insulation The 1 Locate the temperature and pressure relief valve on the water heater also known as a T amp P relief valve See Figure 25 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 25 Apply gentle pressure to the insulation to ensure that it is fully seated on the T amp P Relief Valve Once seated secure the insulation with duct tape electrical tape or equivalent IMPORTANT The insulation and tape must not block the discharge opening or hinder access to the manual relief lever Figure 25 Ensure a discharge pipe is installed into the T amp P valve discharge opening per the instructions in this manual Locate the hot water outlet amp cold water inlet pipes to the water heater 5 Locate the slit running the length of a section of pipe insulation 6 Spread the slit open and slip the insulation over the cold water inlet pipe Apply gentle pressure along the length of the insulation to ensure that it is fully seated around the pipe Also ensure that the base of the insulation is flush with the water heater Once seated secure the insulation with duct tape electrical tape or equivalent 7 Repeat steps 5 and 6 for the hot water outlet pipe 8 Add additional sections of pipe insulation as needed T amp P RELIEF VALVE INSULATION MANUAL RELIEF 4 T amp P RELIEF VAL
38. a wrench until the crimp connection seals to the pilot tube Continue to tighten until the nut is tight in the gas 31 control valve thermostat Finally start the thermocouple nut and turn it all the way in by hand An additional quarter turn with a 3 8 open end wrench will then be sufficient to seat the lockwasher When you are finished connect the two wire leads that go to the thermal switch Reconnect the igniter wire Turn gas supply on and refer to the Lighting Instructions With the burner lit check the gas control valve thermostat supply line manifold component block manifold tube and pilot tube connections for leaks Check for leaks by brushing on an approved noncorrosive leak detection solution Bubbles forming indicate a leak Correct any leak found IMPORTANT All leaks must be fixed immediately 10 Replace the outer door FLAME ARRESTOR BRACKET d en 2 5 NS DOOR GASK lt SA 5 CLOSE UP INSIDE VIEW gt THE COMBUSTION CHAMBER TIP BRACKET MANIFOLD TUBE FIGURE 40 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 The spark gap of 0 125 inch is set when the electrode is installed at the factory Figure 41 Use only factory authorized piezoelectric igniter parts for replacement IGNI
39. acement of the entire gas control valve thermostat If the ECO should activate the water heater cannot be used until the gas control valve thermostat is replaced by a qualified technician Contact Sears at 1 800 4 MY HOME 1 800 469 4663 to request service Leakage Checkpoints 6 MAXIMUM AIR GAP FIGURE 43 35 AWARNING Read and understand instruction manual and safety messages before installing operating or servicing this water heater Failure to follow instructions and safety messages could result in death or serious injury Instruction Manual must remain with water heater Read this manual first Then before checking the water heater make sure the gas supply has been turned OFF and never turn the gas ON before the tank is completely full of water Never use this water heater unless it is completely filled with water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater A Water at the draft hood is water vapor which has condensed out of the combustion products This is caused by a problem in the vent Contact a qualified technician Condensation may be seen on pipes in humid weather 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
40. al 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 34 result of four factors which must all be present for the odor to develop e concentration of sulfate in the supply water e or no dissolved oxygen in the water e sulfate reducing bacteria within the water heater This harmless bacteria is non toxic to humans e excess of active hydrogen the tank This is caused by the corrosion protective action of the anode omelly 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 lines Contact Sears Service for further information concerning this chlorination treatment and an anode replacement kit 9001453 For short heaters use anode replacement kit 9006299 Anode replacement and chlorination of the tank are not covered by the water heater s limited warranty If the smelly water persists after the anode replacement and chlorination treatment it may be necessary to chlorinate
41. ater 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 these instructions can restrict the air flow required for proper combustion potentially resulting in fire asphyxiation serious personal injury or death e Do not apply insulation to the top of the water heater as this will interfere with safe operation of the draft hood e Do not cover the outer door thermostat or temperature amp pressure relief valve e Do not allow insulation to come within 2 50 8 mm of the floor to prevent blockage of combustion air flow to the burner e Do not cover the instruction manual Keep it on the side of the water heater or nearby for future reference e Do obtain new warning and instruction labels from Sears for placement on the blanket directly over the existing labels e inspect the insulation blanket frequently to make certain it does not sag thereby obstructing combustion air flow Clearances and Accessibility NOTE Minimum clearances from combustible surfaces are stated on the label adjacent to the gas control valve thermostat of the water heater The water heater is certified for installation on a combustible floor e IMPORTANT
42. conditioned spaces i e attics basements etc may require insulation of the water piping and drain piping to protect against freezing The drain and controls must be easily accessible for operation and service Maintain proper clearances as specified on the rating plate e Do not locate the water heater near an air moving device The operation of air moving devices such as exhaust fans ventilation systems clothes dryers fireplaces etc can affect the proper operation of the water heater Special attention must be given to conditions these devices may create Flow reversal of flue gases may cause an increase of carbon monoxide inside of the dwelling Figure 8 e water heater is located an area that is subjected to lint and dirt it may be necessary to periodically clean the base ring filter and flame arrestor see External Inspection amp Cleaning of the Flame arrestor e This water heater is not for use in manufactured mobile homes or outdoor installation NOTE This water heater must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition EXHAUST FAN i I L REVERSE FLOW OF GASES FIGURE 8 CAUTION All water heaters eventually leak Do notinstall without adequate drainage IMPORTANT The water heater should be located in an area where leakage of the tank or connections will n
43. conform with these instructions and the local code authority having jurisdiction In the absence of local codes installations shall comply with the following In the United States The National Fuel Gas Code ANSI Z223 1 NFPA 54 This publication is available from the Canadian Standards Association 8501 East Pleasant Valley Rd Cleveland Ohio 44131 or The National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 f after reading this manual you have any questions or do not understand any portion of the instructions call the Sears Service Center e Carefully plan the place where you are going to put the water heater Correct combustion vent action and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and fires See Figure 1 Examine the location to ensure the water heater complies with the nstallation Instructions section in this manual For California installation this water heater must be braced anchored or strapped to avoid falling or moving during an earthquake See instructions for correct installation procedures Instructions may be obtained from California s Office of the State Architect 1102 Q Street Suite 5100 Sacramento CA 95811 Instructions can also be downloaded to your computer at www dsa dgs ca gov Pubs Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248 CMR 2 00 State Plumbing Code an
44. d 248 CMR 5 00 Complies with 40 Ng J NOx requirements of Texas and most California AQM Districts WARNING Use two or more people to move and install the water heater Failure to do so can result in injury including back injury IMPORTANT Do not remove any permanent instructions labels or the data label from either the outside of the water heater or on the inside of water heater panels e Remove exterior packaging and place installation components aside Inspect all parts for damage prior to installation and start up Completely read all instructions before attempting to assemble and install this product e After installation dispose of recycle all packaging materials PRODUCT SPECIFICATIONS MODEL TANK CAPACITY INPUT RECOVERY MINIMUM DIAMETER DIMENSIONS NUMBER IN GACS ETRS RAIE RATE GALS VENT PIPE INCHES INCHES mm Btu hr PER HOUR DIA INCHES mm HEIGHT TO 90 F RISE mm JACKET TOP 153 332420 40 151 35500 3634 3 760 4 102 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 gu Water Heater Installation Kit 9000105 Kit contains all the parts you will need to connect 3 4 water lines to the water heater Complete Instructions Enclosed
45. ditioning amp Refrigeration HVAC R authorized service provider Use a fresh air supply that is free of corrosive elements and flammable vapors 11 Fresh air openings must be sized correctly with consideration given to the blocking effect of louvers and grilles O Ductwork must be the same cross sectional area as the openings Vent Pipe System Check for proper drafting at the water heater draft hood Refer to the Checking the Draft section of this manual for the test procedure If the procedure shows insufficient draft is present please check the following Draft hood properly installed Vent connectors securely fastened with screws and supported properly to maintain six inch clearance Vent connector made of approved material and sized correctly Vent pipe system installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI 2223 1 54 current edition Flue baffle properly positioned in the flue tube Check the vent system for restrictions obstructions and check the vent termination height Refertothe Combustion Air Supply and Ventilation section of this water heater manual for specific requirements Recheck for sufficient combustion air supply Water System Piping Temperature and pressure relief valve properly installed with a discharge line run to an open drain and protected from freezing All pipin
46. do not use any phone in your building eimmediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions elf you cannot reach your gas supplier call the fire department E FIGURE OFF POSITION GAS CONTROL 1 STOP Read the safety information above on this label 2 Set the thermostat to lowest setting PILOT LIGHTING Turn thermostat dial fully clockwise until it stops 3 Push the gas control knob down slightly and turn clockwise to OFF SEE FIGURE NOTE Knob cannot be turned from PILOT to OFF unless knob is pushed down slightly Do not force 4 Remove the outer burner door located below the gas control 5 Wait ten 10 minutes to clear out any gas If you then smell gas STOP Follow B in the above on this label If go to next step safety information you dont smell gas 6 This unit is equipped with a push button pilot ignitor which is used to light the pilot Locate the ignitor 11 the gas control 7 Turn gas control knob counterclockwise 2 to PILOT SEE FIGURE 8 The pilot is located on the left side of the burner It can be located by looking through the glass view port while pressing the piezo ignitor button several times Look for a spark at the pilot location Figure D 1 1 Set the thermostat to lowest setting PILOT LIGHTING 23 PILOT POSITION TOP KNOB Use only your hand to push in or turn the gas co
47. drain line When the water heater is drained disconnect the hose from the drain valve Close the drain valve The water heater is now completely disconnected and ready to be removed FIGURE 6 If you have galvanized pipes to the water heater loosen the two galvanized pipes with a pipe wrench at the union in each line Also disconnect the piping remaining to the water heater See Figure 7 These pieces should be saved since they may be needed when reconnecting the new water heater Disconnect the temperature pressure relief valve drain line When the water heater is drained disconnect the hose from the drain valve Close the drain valve The water heater is now completely disconnected and ready to be removed Mineral buildup or sediment may have accumulated in the old water heater This causes the water heater to be much heavier than normal and this residue if spilled out could cause staining FIGURE 7 Location Requirements WARNING Do not install in a mobile home Doing so can result in carbon monoxide poisoning and death The FVIR System is designed to reduce the risk of flammable vapor related fires The patented system protects your family by trapping the burning vapors within the water heater combustion chamber through the special flame arrestor The burning vapors literally burn themselves out without escaping back into the room In the event of a flammable vapor incident the FVIR System disables the wa
48. e each opening to have a minimum free area of 25 square inches Minimum free area 50 000 BTUH x 1 sq in 2000 BTUH 25 sq in These openings connect directly with the outdoors through a ventilated attic a ventilated crawl space or through an outside wall Consult the local codes of your area for specific ventilation and combustion air requirements GABLE VENT TO OUTDOORS INSTALL ABOVE INSULATION T5 OUTLET AIR TO ATTIC 1 SQ INCH PER 4000 BTUH CONFINED SPACE INLET AIR FROM THE CRAWL SPACE ALTERNATE AIR INLET 1 SQ INCH PER OPEN 4000 BTUH FOUNDATION VENT ALL AIR FROM OUTDOORS INLET AIR FROM VENTILATED CRAWL SPACE OUTLET AIR TO VENTILATED ATTIC FIGURE 14 GABLE VENT a TO OUTDOORS INSTALL ABOVE R INSULATION L dd Ek M OUTLET AIR P TO ATTIC 1 SQ INCH PER 4000 BTUH CONFINED SPACE INLET AIR DUCT 1 SQ INCH PER 4000 BTUH 12 MAXIMUM ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC FIGURE 15 1 SQ INCH PER 2000 BTUH CONFINED SPACE OUTDOOR AIR DUCTS 1 INCH PER 2000 BTUH ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS FIGURE 16 ALTERNATIVE OPENING LOCATION A 1 SQ INCH PER 3000 BTUH CONFINED SPACE ALL AIR FROM OUTDOORS USING A SINGLE PERMANENT OPENING FIGURE 17 Vent Pipe System This water heater uses a non direct single pipe vent system to remove exhaust gases created by the burning of fossil fuels Air for c
49. e harmful effects of thermal expansion Thermal expansion tanks are available from Sears stores and through the Sears Service Centers Contact the local plumbing inspector water supplier and or the Sears Service Center for assistance in controlling these situations For additional information see the Troubleshooting Guide later in this manual Temperature and Pressure Relief Valve 4A WARNING e Temperature pressure relief valve must comply with ANSI Z21 22 CSA 4 4 and ASME code Properly sized temperature pressure relief valve must be installed in opening provided Can result in overheating and excessive tank pressure Can cause serious injury or death TEMPERATURE AND PRESSURE T amp P RELIEF VALVE OPTIONAL TOP T amp P RELIEF VALVE NOT SHOWN DISCHARGE PIPE DO NOT CAP OR PLUG DRAIN LINE 3 4 ID MINIMUM _ DRAIN FIGURE 24 1 MINIMUM METAL DRAIN PAN gt 6 MAXIMUM AIR GAP 22 For protection against excessive pressures and temperatures a temperature and pressure relief valve must be installed in the opening marked T amp P RELIEF VALVE See Figure 24 This valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of listed equipment or materials as meeting the requirements for Relief Valves for Hot Water Supply Systems ANSI 221 22 The function
50. e next page Some states have a requirement for a lower setting Turn the water temperature dial clockwise CN to decrease the temperature or counterclockwise to increase the temperature Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance lt GAS CONTROL KNOB OFF PILOT ON 7 Sas vaio Nl 6 5919 10 25 NOYO TEMPERATURES SHOWN ARE APPROXIMATES AND MAY VARY Water Time for 1st Time for Permanent Burns Temperature Degree Burn 2nd amp 3rd Degree F Less Severe Burns Most Severe Burns U S Government Memorandum C P S C Peter L Armstrong Sept 15 1978 FIGURE 28 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 higher thermostat setting may be required to meet the increased 25 demand When leaving your home for extended periods vacations etc turn the temperature dial to its lowest setting This will maintain the water at low temperatures with minimum energy losses and prevent the tank from freezing during cold weather SERVICE AND ADJUSTMENT Vent System Inspection WARNING Flue gases may escape if vent pipe is not connected Be alert for obstructed sooted or deteriorated vent system to a
51. e terminated in a vertical position to facilitate the removal of the burnt gases An unused chimney flue or masonry enclosure may be used as a passageway for the installation of a gas vent Figure 21 Common combined venting is allowable with vertical type B vent systems and lined masonry chimneys as long as proper draft for the water heater is established under all conditions of operation CAUTION DO NOT common vent this water heater with any power vented appliance Figures 19 21 are examples of vent pipe system installations and may or may not be typical for your specific application Consult the National Fuel Gas Code NFPA 54 ANSI 2223 1 current edition and the guidelines set forth by prevailing local codes LISTED VENT CAP 2 FT MINIMUM ABOVE ANY OBJECT WITHIN 10 FT HORIZONTALLY 22 3 FT MINIMUM LEM SUPPORT STRAP MAINTAIN CLEARANCE T TYPE B DOUBLE WALL VENT PIPE MAINTAIN SPECIFIED CLEARANCE CONNECTOR SLOPE UP 1 4 IN PER FT MINIMUM VERTICAL GAS VENT SYSTEM WITH TYPE B DOUBLE WALL VENT PIPE FIGURE 20 TIT lt LISTED VENT MAINTAIN MANUFACTURER S SPECIFIED MINIMUM CLEARANCE 1 MAINTAIN SPECIFIED CLEARANCE SUPPORT STRAP MAINTAIN CLEARANCE VENT VENT CONNECTOR CONNECTOR SLOPE UP 1 4 IN PER FT MINIMUM UNUSED CHIMNEY VENTING THROUGH A CHIMNEY WITH TYPE B DOUBLE WALL VENT PIPE
52. eas Combustion air must be free of acid forming chemicals such as sulfur fluorine and chlorine These elements are found in aerosol sprays detergents bleaches cleaning solvents air fresheners paint and varnish removers refrigerants and many other commercial and household products When burned vapors from these products form highly corrosive acid compounds These products should not be stored or used near the water heater or air inlet Combustion and ventilation air requirements are determined by the location of the water heater The water heater may be located in either an open unconfined area or in a confined area or small enclosure such as a closet or small room Confined spaces are areas with less than 50 cubic feet for each 1 000 BTUH of the total input for all gas using appliances Unconfined Space A water heater in an unconfined space uses indoor air for combustion and requires at least 50 cubic feet for each 1 000 BTUH of the total input for all gas appliances The table below shows a few examples of the minimum square footage area required for various BTUH inputs TABLE 3 Minimum Square BTUH Input Feet with 8 Ceiling Typical Room with 8 Ceiling 17 TABLE 3 IMPORTANT e area must be open and be able to provide the proper air requirements to the water heater Areas that are being used for storage or contain large objects may not be suitable for water heater installation 25 x 30 28 x
53. ed 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 23 Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat see Figure 28 Using the lowest hot water temperature that meets your needs will also provide the most energy efficient operation of the water heater Never allow small children to use a hot water tap or to draw their own bath water Never leave a child or handicapped person unattended in a bathtub or shower NOTE A water temperature range of 120 F 140 F 49 C 60 C is recommended by most dishwasher manufacturers The thermostat of this water heater has been factory set at its lowest position It is adjustable and must be reset to the desired temperature setting to reduce the risk of scald injury The amp mark is indicative of approximately 120 F 49 C and is the preferred starting point See Figure 28 on th
54. ee area for ventilation and combustion air supply Openings consideration must be given to the blocking effect of protection louvers grilles and screens These devices can reduce airflow which in turn may require larger openings to achieve the required minimum free area Screens must not be smaller than 1 4 mesh If the free area through a particular design of louver or grille is known it should be used in calculating the specified free area of the opening If the design and free area are not known it can be assumed that most wood louvers will allow 20 25 of free area while metal louvers and grilles will allow 60 75 of free area Louvers and grilles must be locked open or interconnected with the equipment so that they are opened automatically during equipment operation Keep louvers and grilles clean and free of debris or other obstructions TABLE 4 Minimum Free Area of Permanent Openings for Ventilation and Combustion Air Supply All Air from Outdoors Only Based on total BTUH input rating for all utilizing equipment within the confined space Minimum Free Area Reference Opening Source Per Opening sq in Drawing Direct to outdoors 1 sq in per 4000 BTUH Figure 14 Vertical Ducts 1 sq in per 4000 BTUH Figure 15 Horizontal Ducts 1 sq in per 2000 BTUH Figure 16 Single Opening 1 sq in per 3000 BTUH Figure 17 Example A water heater with an input rating of 50 000 BTUH using horizontal ducts would requir
55. ervice 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 DANGER indicates an imminently hazardous situation which if not avoided will result DANGER 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 All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of in
56. etermine if a pilot flame is present and will shut off the gas supply to the main burner and the pilot if the flame is absent This unit is also equipped with a thermal switch designed to shut off the gas supply in the event the water heater has been exposed to flammable vapors e g spilled gasoline poor combustion caused by a blocked vent or insufficient combustion air If the thermal switch opens 1 Check the flame arrestor for signs of high temperature blue or black discoloration See Figure 38 2 If there are signs of high temperature or that the thermal switch has opened inspect your installation for problems with venting combustion air supply or a possible flammable vapor event See Pilot Light Troubleshooting Flowchart section Correct any issues prior to resetting the thermal switch If you suspect a flammable vapor incident has occurred do not use this appliance Immediately call a qualified technician to inspect the appliance Water heaters subjected to a flammable vapors ignition will require replacement of the entire water heater 3 Reset the thermal switch by depressing the small button in the center of the thermal switch Follow the Lighting Instructions found on the front of your water heater A high temperature limit switch or ECO Energy Cut Off in the tank is used to shut off the unit if the water temperature exceeds 195 F 91 C The ECO is a single use switch which if activated requires complete repl
57. flon tape marked as being resistant to the action of petroleum Propane L P gases See Figure 11 1 Install a readily accessible manual shut off valve in the gas supply line as recommended by the local utility Know the location of this valve and how to turn off the gas to this unit 2 Install a drip leg if not already incorporated as part of the water heater as shown The drip leg must be no less than three inches long for the accumulation of dirt foreign material and water droplets 3 Install a ground joint union between the gas control valve thermostat and the manual shut off valve This is to allow easy removal of the gas control valve thermostat 4 Turn the gas supply on and check for leaks Test all connections by brushing on an approved noncorrosive leak detection solution Bubbles will show a leak Correct any leak found MANUAL GAS SHUT OFF 64 ub GROUND JOINT UNION CHECK WITH LOCAL UTILITY FOR MINIMUM HEIGHT 3 E m DRIP d EE SUITABLE DRAIN gt FIGURE 11 6 MAXIMUM AIR GAP Gas Pressure the fuel is not spilled in the area of the water heater installation any source of ignition If the fuel is spilled while purging the piping system of air follow the WHAT TO DO IF YOU SMELL A WARN G GAS instructions on the cover of this manual LP Gas Only AWARNING Explosion Hazard Gas leaks can not al
58. functioning thermocouple 8 Non functioning thermostat 9 Heater installed in a confined area 1 1 2 3 4 5 6 7 8 9 1 Light pilot Turn temp dial to desired temperature Check with gas utility company Notify utility install trap in gas line Clean locate source and correct Clean locate source and correct Replace thermocouple Replace thermostat Provide fresh air ventilation SMELLY WATER Sulfides in the water Replace the anode with a special anode BURNER FLAME YELLOW LAZY Insufficient secondary air Low gas pressure Water heater flue or vent system blocked Main burner line clogged Heater installed in a confined area Obstruction in main burner orifice PILOT WILL NOT LIGHT OR REMAIN LIT Non functioning igniter The thermal switch tripped Wire lead connection at thermal switch loose 4 Thermocouple connection loose 4 5 Airin gas line 5 6 Low gas pressure 6 7 7 8 Dirt in gas lines 8 9 Cold drafts 9 10 Thermostat ECO switch open 10 11 Pilot line or orifice clogged 11 12 Non functioning thermocouple 12 Air for combustion obstructed 13 Flammable vapors incident function actuated Base ring filter obstructed HIGH OPERATION COSTS Thermostat set too high Sediment or lime in tank Water heater too small for job Wrong piping connections Leaking faucets Gas leaks Wasted hot water Long runs of exposed piping Hot water piping in exposed wall INSUFFI
59. g properly installed and free of leaks Heater completely filled with water Closed system pressure build up devices installed Mixing valve when applicable installed manufacturer s instructions See Water Temperature Regulation section Gas Supply and Piping O Gas type is the same as that listed on the water heater rating plate O Gas line equipped with shut off valve union and drip leg O Use pipe joint compound or teflon tape marked as being resistant to the action of petroleum Propane L P gases Adequate pipe size and approved pipe material An approved noncorrosive leak detection solution used to check all connections and fittings for possible gas leaks Correct any leak found Removing the Old Water Heater MANUAL GAS SHUT OFF et GROUND gt amp JOINT UNION CHECK WITH T DISCHARGE PIPE LOCAL UTILITY DO NOT CAP FOR MINIMUM HEIGHT OR PLUG 3 6 MAXIMUM DRIP LEG AIR GAP SUITABLE DRAIN FIGURE 2 Turn OFF the gas supply to the water heater If the main gas line shutoff valve serving all gas appliances is used also shut OFF the gas at each appliance Leave all gas appliances shut OFF until the water heater installation is completed See Figures 2 and 3 Open a nearby hot water faucet until the water is no longer hot When the water has cooled turn OFF the water su
60. gures 19 21 e Install the vent connector avoiding unnecessary bends which create resistance to the flow of vent gases e Install without dips or sags with an upward slope of at least 1 4 inch per foot e Joints must be fastened by sheet metal screws or other approved means It must be supported to maintain clearances and prevent separation of joints and damage e length of the vent connector cannot exceed 75 of the vertical vent height e vent connector must be accessible for cleaning inspection and replacement e Vent connectors cannot pass through any ceiling floor firewall or fire partition e is recommended but not mandatory that a minimum 12 inches of vertical vent pipe be installed on the draft hood prior to any elbow in the vent system IMPORTANT Existing vent systems must be inspected for obstructions corrosion and proper installation Chimney Connection IMPORTANT Before connecting a vent to a chimney make sure the chimney passageway is clear and free of obstructions The chimney must be cleaned if previously used for venting solid fuel appliances or fireplaces Also consult local and state codes for proper chimney sizing and application or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition e connector must be installed above the extreme bottom of the chimney to prevent potentially blocking the flue gases connec
61. he cold water supply 3 4 NPT to the cold water inlet fitting Connect the hot water supply 3 4 NPT to the hot water outlet fitting IMPORTANT Some models may contain energy saving heat traps to prevent the circulation of hot water within the pipes Do not remove the inserts within the heat traps 2 installation of unions in both the hot and cold water supply lines is recommended for ease of removing the water heater for service or replacement 3 The manufacturer of this water heater recommends installing a mixing valve or an anti scald device in the domestic hot water line as shown in Figure 23 These valves reduce the point of use temperature of the water by mixing cold and hot water and are readily available for use 4 If installing the water heater in a closed water system install an expansion tank in the cold water line as specified under Closed System Thermal Expansion 5 Install a shut off valve in the cold water inlet line It should be located close to the water heater and be easily accessible Know the location of this valve and how to shut off the water to the heater 6 A temperature and pressure relief valve must be installed in the opening marked Temperature and Pressure T amp P Relief Valve on the water heater A discharge line must be added to the opening of the T amp P Relief Valve Follow the instructions under Temperature and Pressure Relief Valve T After piping has been
62. he operation of the burner by following the lighting instructions on the front of the water heater With the burner lit check the gas control valve thermostat supply line manifold tube and pilot tube connections for leaks T Verify proper operation and then replace the outer door If additional information is required contact Residential Technical Assistance by referencing the number on the water heater TEFLON is a registered trademark of E l Du Pont De Nemours and Company FVIR System Operational Checklist Manifold gasket properly sealed Viewport not damaged or cracked Flame arrestor free of debris and undamaged Manifold component block properly installed No leaks at pilot and manifold connection Manifold door screws securely tightened P o Oo m c Depress the button on the thermal switch TROUBLESHOOTING GUIDE Start Up Conditions Thermal Expansion CAUTION Avoid water heater damage Install thermal expansion tank or device if necessary Contact qualified installer or service agency As water is heated it expands thermal expansion In a closed system the volume of water will grow As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent temperature pressure
63. ice at Is the igniter wire insulation burnt or NO 5 Is the pilot tube NO Does the flame show signs of discoloration damaged arrestor show signs YES 1 800 4 MY HOME 1 800 469 4663 FIGURE 44 38 NOTES 39 PARTS ORDER LIST Kenmore 36 GAS WATER HEATER MODEL NUMBER 153 332420 40 Gallon Tall Natural Part Description Anode Rod Base Ring Filter Burner Head Burner Orifice Draft Hood Drain Valve Gas Control Valve Thermostat nlet Tube w Gasket nner Door Gasket nstruction Manual Manifold Door Assembly Contains Manifold Tube Gasket Door Pilot Tube Thermocouple Manifold Component Block w Clip Thermal Switch Burner Head Burner Orifice and Pilot Assembly Nipple w Heat Trap Outer Door Piezo Igniter w Clip Pilot Assembly w Tubing and Fittings T amp P Relief Valve Temperature Adjustment Knob Thermocouple Manifold Component Block w Clip Not Shown 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 Numbers 9003944 9006616 9006136 9006699 9006647 9002402 F145 1555 9006690 9006141 319357 000 9006617 9003719 90066
64. iod we will provide a full refund Or a prorated refund anytime after the product warranty period expires Purchase your Master Protection Agreement today 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 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 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 e Annual Preventive Maintenance Check at your request no Sears Installation Service ones For Sears professional installation of home appliances garage door Fast help by phone we call it Rapid Resolution phone openers water heaters and other major home items in the U S A support from a Sears representative on all products Think of or Canada call 1 800 4 MY HOME us as a talking owner s manual e Power surge protection against electrical damage due to power fluctuations 6 CUSTOMER RESPONSIBILITIES Thank You for purchasing a Kenmore water heater Properly installed and maintained it should give you
65. iorates to protect the tank Instead of corroding the tank water ions attack and eat away the anode rod This does not affect the water s taste or color The rod must be maintained to keep the tank in operating condition Exposed Pitted Exposed Support Anode Support Wire Rod Wire FIGURE 29B 2 Anode deterioration depends on water conductivity not necessarily water condition A corroded or pitted anode rod indicates high water conductivity and should be checked and or replaced more often than an anode rod that appears to be intact Replacement of a depleted anode rod can extend the life of your water heater Inspection should be conducted by calling the Sears Service Center for an authorized contractor At a minimum the anode s should be checked annually after the warranty period Temperature Pressure Relief Valve Operation The temperature pressure relief valve must be manually operated at least once a year A DANGER e Burn hazard e Hot water discharge e Keep clear of relief valve discharge outlet When checking the temperature pressure relief valve operation make sure that 1 no one is in front of or around the outlet of the temperature pressure relief valve discharge line and 2 that the water discharge will not cause any property damage as the water may be extremely hot See Figure 30 TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE FIGURE 30 If after manually operating the valve it fails t
66. ity Table 2 LP Gas Capacity Table Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases at 11 inches water column pressure Based on a pressure drop of 0 5 inch water column Nominal Iron Pipe Length of Pipe Feet Size in 10 20 30 40 50 60 70 80 90 100 125 150 Example Input BTU requirement of the water heater 100 000 BTUH Total pipe length 80 feet 3 4 IPS required Additional tables are available in the latest edition of the National Fuel Gas Code ANSI 7223 1 16 COMBUSTION AIR SUPPLY amp VENTILATION AWARNING Carbon Monoxide Warning Follow all the local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition to properly install vent system Failure to do so can result in death explosion or carbon monoxide poisoning IMPORTANT Air for combustion and ventilation must not come from a corrosive atmosphere Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage The following types of installation not limited to the following will require outdoor air for combustion due to chemical exposure and may reduce but not eliminate the presence of corrosive chemicals in the air e beauty shops e photo processing labs e buildings with indoor pools e water heaters installed in laundry hobby or craft rooms e water heaters installed near chemical storage ar
67. jury 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 thorough understanding of this instruction manual and be able to perform repairs
68. lation Inspect the view port for damage and replace as required Insert the manifold burner assembly into the burner compartment making sure that the tip of the manifold tube engages in the slot of the bracket inside the combustion chamber Figures 39 amp 40 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 manifold burner assembly door to the combustion chamber and tighten securely Once the manifold burner assembly door is tightened visually inspect the door gasket between the manifold burner assembly door and the combustion chamber for spaces or gaps that would prevent a seal IMPORTANT Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber 6 During the following procedure do not cross thread or apply any thread sealant to any of the fittings listed below First reconnect the manifold tubing to the gas control valve thermostat NOTE L P gas systems use reverse left hand threads on the manifold tube NOTE If a ferrule nut needs to be installed for the pilot tube locate the one provided with your parts kit Install it in the gas control valve thermostat at the pilot location hand tight only Next insert the pilot tube into the ferrule nut until it bottoms out NOTE Hold the tube in this position Tighten the ferrule nut with
69. mal switch tripped Test the thermocouple using the following Are the wires from the gas procedure Disconnect the thermocouple from the Secure connections gas control valve thermostat Using a multimeter control valve thermostat firmly and attempt a relight 9 aie the body copper part of the thermocouple YES Attach the black lead to the end silver part of the thermocouple that connects to the gas control Are the wires damaged Is the thermocouple valve thermostat Follow the instruction to light and or frayed NO FAN the pilot and watch the voltage readings on the multimeter After 45 seconds the meter should YES YES Check for insufficient Tighten the connection combustion air Replace the gas control 5 YES 1 Does the thermocouple pass the test Replace the thermocouple YES read 12 millivolts DC or more 4 Is the base ring filter clean i e free Inspect and clean the base ring filter Refer to the External of lint dust or debris Inspection amp Cleaning of the Base Ring Filter section of this manual YES Are there openings for make up air to Install correct size make up air openings per NO the Combustion Air Supply and Ventilation enter the room section in this manual YES Are the openings of sufficient size See Combustion Air Supply and Ventilation Correct size of openings to section in this manual for req
70. nk and restart the heater as directed in this manual 28 If the water heater is going to be shut down for an extended period the drain valve should be left open IMPORTANT Condensation may occur when refilling the tank and should not be confused with a tank leak Service Before calling for repair service please read the Troubleshooting Guide in this manual If a condition persists or you are uncertain about the operation of the water heater let the Sears Service Center check it out Contact Sears Service Center at 1 800 4 MY HOME 1 800 469 4663 MAINTENANCE OF YOUR WATER HEATER Replacement Parts IMPORTANT The following maintenance procedures are for the FVIR System components and should be performed by a qualified technician Replacement parts may be ordered from Sears Parts and Service Centers or by calling 1 800 4 MY HOME 1 800 469 4663 When ordering replacement parts always have the following information ready 1 model serial and product number 2 type of gas 3 item number 4 parts description See the Parts Order List section for a list of available repair parts External Inspection amp Cleaning of the Base Ring Filter 1 At least annually check the base ring filter Figure 38 for any dust or debris that may have accumulated on the filter screen NOTE If the water heater is located in an area that is subjected to lint and dirt it may be necessary to check the base ring filter more
71. ntrol knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately contact a qualified installer or service agency to replace a flooded water heater Do not attempt to repair the unit must be replaced DO NOT USE THIS APPLIANCE IF THERE HAS BEEN AN IGNITION OF VAPORS Immediately call a qualified service technician to inspect the appliance Water heaters subjected to a flammable vapors ignition will show a discoloration on the air intake grid and require replacement of the entire water heater UNTER MAIN BURNER ON POSITION THERMOCOUPLE FIGURE D 9 Once the pilot has been found push the gas knob all the way down Immediately press the pilot ignitor button rapidly 4 to 5 times If the pilot will not light repeat step 3 through 9 10 Continue to hold the gas control knob down for about one 1 minute after the pilot is lit Release the gas control knob and it will pop back m Pilot should remain lit If it goes out repeat step 3 through 9 It may take several minutes for air to clear the lines before the pilot will light f knob does not pop up when released stop and immediately call your service technician or gas supplier f the pilot will not stay lit after several tries turn the gas cont
72. o completely reset and continues to release water immediately close the manual gas shut off valve and the cold water inlet valve and call the Sears Service Center If the temperature pressure relief valve on the appliance weeps or discharges periodically this may be due to thermal expansion You may have a check valve installed in the water line or a water meter with a check valve Consult the Sears Service Center for further information Do not plug the temperature pressure relief valve Draining and Flushing A DANGER Hotwater discharge burn hazard Keep clear of relief valve discharge unit Temperature limiting valves available Read instruction manual for safe temperature setting 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 Opena nearby 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 Openthe 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 ta
73. ode 50996 E Em 27 Temperature Pressure Relief Valve Operation 27 ES RUN 27 28 lu 28 MAINTENANCE OF YOUR WATER sel EIR 29 32 ata 29 External Inspection amp Cleaning of the Base Ring nnns 29 Removing the Manifold B rner ASsermbly a i ie 1e de uus Ve NEN Deni ud PR dis Ux 29 Removing the Burner from the Manifold Burner 29 Replacing unme rnermmnocouple i5 dedo es ated a 29 30 Replacing the Pilot Pilot Tube ASSSmbly ier E onto 30 Cleaning the Combustion Chamber and 30 Replacing the Manifold Burner Assembly 31 Piezoelectric qub idee suia Doch icri bel ont axis Bede 31 SV SUSI TEN 32 Removing and Replacing the Gas Control 32 FVIR System Operational Checklist 32
74. ombustion is taken from the immediate water heater location or is ducted in from the outside see Combustion Air Supply and Ventilation This water heater must be properly vented for the removal of exhaust gases to the outside atmosphere Correct installation of the vent pipe system is mandatory for the proper and efficient operation of this water heater and is an important factor in the life of the unit The vent pipe must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition The vent pipe installation must not be obstructed so as to prevent the removal of exhaust gases to the outside atmosphere IMPORTANT The use of vent dampers is not recommended by the manufacturer of this water heater Although some vent dampers are certified by CSA International this certification applies to the vent damper device only and does not mean they are certified for use on this water heater U L recognized fuel gas and carbon monoxide CO detectors are recommended in all applications and should be installed 19 using the manufacturer s instructions and local codes rules or regulations IMPORTANT If you lack the necessary skills required to properly install this venting system you should not proceed but get help from a qualified technician Draft Hood Installation SHEET METAL SCREWS FOUR PROVIDED JACKET TOP INSTALL T
75. ons for leaks Repair as needed CAUTION Avoid water heater damage Fill tank with water before operating GAS SUPPLY AWARNING Explosion Hazard Use a new CSA approved gas supply line Install a shut off valve Do not connect a natural gas water heater to an L P gas supply Do not connect an L P gas water heater to a natural gas supply Failure to follow these instructions can result in death explosion or carbon monoxide poisoning Gas Requirements IMPORTANT Read the rating plate to be sure the water heater is made for the type of gas you will be using in your home This information will be found on the rating plate located near the gas control valve thermostat If the information does not agree with the type of gas available do not install or light Call your dealer NOTE An odorant is added by the gas supplier to the gas used by this water heater This odorant may fade over an extended period of time Do not depend upon this odorant as an indication of leaking gas Gas Piping The gas piping must be installed according to all local and state 15 codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition Tables 1 and 2 on the following page provide a sizing reference for commonly used gas pipe materials Consult the National Fuel Gas Code for the recommended gas pipe size of other materials NOTE Use pipe joint compound or te
76. or aerate your water supply to eliminate the problem Do not remove the anode leaving the tank unprotected By doing so all warranty on the water heater tank is voided AIR In Hot Water Faucets A WARNING Flammable hydrogen gases may be present Keep all ignition sources away from faucet when turning on hot water HYDROGEN GAS Hydrogen gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable and explosive To prevent the possibility of injury under these conditions we recommend the hot water faucet located farthest away be opened for several minutes before any electrical appliances which are connected to the hot water system are used such as a dishwasher or washing machine If hydrogen gas is present there will probably be an unusual sound similar to air escaping through the pipe as the hot water faucet is opened There must be no smoking or open flame near the faucet at the time it is open Safety Shut off and Thermal Switch This water heater is designed to automatically shut off in the event of the following 1 The pilot flame is extinguished for any reason 2 The water temperature exceeds 195 F 91 C 3 Excessive build up of dust on the base ring filter or flame arrestor See Maintenance of your Water Heater Section 4 The ignition of flammable vapors A thermocouple is used to d
77. ot result in damage to the area adjacent to the water heater or to lower floors of the structure Due to the normal corrosive action of water the tank will eventually leak after an extended period of time Also any external plumbing leak including those from improper installation may cause early failure of the tank due to corrosion if not repaired If the homeowner is uncomfortable with making the repair a qualified technician should be contacted A suitable metal drain pan should be installed under the water heater as shown below to help protect the property from damage which may occur from condensate formation or leaks in the piping connections or tank The pan must limit the water level to a maximum depth of 1 3 4 and be two inches wider than the heater and piped to an adequate drain NOTE The pan must not restrict combustion air flow Locate the water heater near a suitable indoor drain Outside drains are subject to freezing temperatures which can obstruct the drain line The piping should be at least 3 4 ID and pitched for proper drainage PIPED TO AN Eno y Le DRAIN E ir LEE AT LEAST 2 GREATER THAN THE DIAMETER OF THE WATER HEATER FIGURE 9 Water heater life depends upon water quality water usage water temperature and the environment in which the water heater is installed Water heaters are sometimes installed in locations where leakage may result in property damage even with the use of a metal drain pan piped to a d
78. pply to the water heater at the water shut off valve or water meter Some installations require that the water be turned off to the entire house See Figures 2 and 4 FIGURE 4 Check again to make sure the gas supply is OFF to the water heater Then disconnect the gas supply connection from the gas control valve ADANGER Burn hazard Hot water discharge Keep hands clear of drain valve discharge 5 12 INSTALLATION INSTRUCTIONS Attach a hose to the water heater drain valve and put the other end in a floor drain or outdoors See Figures 2 and 5 Open the water heater drain valve The water passing out of the drain valve may be extremely hot To avoid being scalded make sure all connections are tight and that the water flow is directed away from any person FIGURE 5 Disconnect the vent pipe from the draft hood where it connects to the water heater In most installations the vent pipe can be lifted off after any screw or other attached devices are removed Dispose of the draft hood The new water heater has a draft 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
79. r from the Manifold Burner Assembly 4 Pull the thermocouple from the pilot assembly Figure 35 IMPORTANT Be careful not to bend or alter the position of the pilot assembly components 5 Insert the thermocouple tip into the holes provided in the pilot bracket until it clicks into place NOTE The base of the thermocouple must be flush with the base of the pilot bracket Position the new thermocouple through the bottom opening of the manifold component block Figure 34 Be sure igniter wire is positioned through the small opening of the manifold component block Re attach the burner Note the orientation of the burner Figure 33 See Replacing the Manifold Burner Assembly FERRULE NUT P THERMOCOUPLE SHOWN FOR CLARITY MANIFOLD TUBE PILOT TUBE MANIFOLD BURNER MANIFOLD 9 DOOR OPENING COMPONENT BLOCK FIGURE 34 a J FIGURE 35 Replacing the Pilot Pilot Tube Assembly 1 Remove the manifold burner assembly See Removing the Manifold Burner Assembly Lift the retainer clip straight up from the back of the manifold component block using a flat blade screwdriver then remove the manifold component block from the manifold door Figure 34 IMPORTANT Be careful not to bend or alter the position of the pilot tube It will be used as a bending template for the new pilot assembly 3 f Take off the burner by removing the two 2 scre
80. rain However unanticipated damage can be reduced or prevented by a leak detector or water shut off device used in conjunction with a piped metal drain pan These devices are available from some plumbing supply wholesalers and retailers and detect and react to leakage in various ways e Sensors mounted in the metal drain pan that trigger alarm or turn off the incoming water to the water heater when water is detected e Sensors mounted in the metal drain pan that turn off the water supply to the entire home when water is detected in the drain pan e Water supply shut off devices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater e Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply Insulation Blankets Insulation blankets available to the general public for external use on gas water heaters are not necessary with Kenmore products The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters Your Kenmore water heater meets or exceeds the National Appliance Energy Conservation Act standards with respect to insulation and standby loss requirements making an insulation blanket unnecessary WARNING Do not obstruct water heater air intake with insulating blanket Gas and carbon monoxide detectors are available Install water he
81. relief valve operation water discharged from the valve due to excessive pressure build up The temperature pressure relief valve is not intended for the constant relief of thermal expansion This condition is not covered under the limited warranty A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion Thermal expansion tanks are available from Sears stores and through the Sears Service Centers Contact the local plumbing inspector water supplier and or the Sears Service Center for assistance in controlling these situations See Figure 42 Table 5 Thermal Expansion Tank Specifications Number Capacity in Inches Fitting In Gallons On Tank 153 331050 11 279 mm 14 3 4 375 3 4 Male Table 6 Expansion Tank Sizing Chart Inlet Water Pressure Water Heater Capacity Gallons Expansion Tank Capacity Needed Highest recorded inlet water pressure in a 24 hour period or regulated water pressure 33 NOTE Expansion tanks are pre charged with a 40 psi air charge If the inlet water pressure is higher than 40 psi the expansion tank s air pressure must be adjusted to match that pressure but must not be higher than 80 psi WATER HEATER 3 COLD WATER PRESSURE INLET FITTING REDUCING VALVE WITH BY PASS HOT SS COLD INLET COLD WATER SHUT OFF PRESSURE GAUGE RECOMMENDED INSTALLATION VERTICAL MOUNTING WATER HE
82. rforming any maintenance it is important to turn the temperature dial on the gas control valve thermostat to its lowest setting On top of the gas control valve thermostat turn the gas control knob to the OFF position See Lighting Instructions on the water heater Drain the water heater Refer to the section of Draining and Flushing section and follow the procedure Disconnect the igniter wire from the igniter NOTE There are two types of igniters If you have the square igniter slide the igniter bracket backwards away from the gas valve to remove it If you have the round igniter first remove the igniter from the bracket by depressing front and rear holding tabs and lift Next remove the igniter bracket from the gas valve Disconnect the thermocouple right hand threads pilot tube and manifold tube at the gas control valve thermostat Figure 31 NOTE L P gas systems use reverse left hand threads on the manifold tube Also disconnect the thermal switch wires Refer to Gas Piping section Figure 11 and disconnect the ground joint union in the gas piping Disconnect the remaining pipe from the gas control valve thermostat T To remove the gas control valve thermostat thread a correctly sized pipe into the inlet and use it to turn the gas control valve thermostat counterclockwise Do not use a pipe wrench or equivalent to grip body Damage may result causing leaks Do not insert any sharp objects into the inlet or
83. rol knob clockwise 7 to OFF and call your service technician or gas supplier SEE FIGURE A Once the pilot flame is established replace the outer burner door 12 At arm s length away turn gas control knob counterclockwise 2 to ON SEE FIGURE 3 Set thermostat to desired setting DANGER Hotter water increases the risk of scald injury Consult the instruction manual before changing temperature 2 Push gas control knob down slightly and turn clock wise C to OFF not force SEE FIGURE Checking the Draft AWARNING Burn Hazard Do not touch vent EKIA E Doing so can result in burns After successfully lighting the water heater allow the unit to operate for 15 minutes and check the draft hood relief opening for proper draft Figure 26 Make sure all other appliances in the area are operating and all doors are closed when performing the draft test Pass a match flame around the relief opening of the draft hood A steady flame drawn into the opening indicates proper draft DRAFT HOOD RELIEF d OPENING 2 FIGURE 26 MATCH If the flame flutters or is blown out combustion products are escaping from the relief opening If this occurs do not operate the water heater until proper adjustments or repairs are made to the vent pipe system and or air supply requirements Burner Flames Inspect the burner flames through the viewport and compare them to the drawing in Figure 27
84. ssive amounts of lint dirt dust etc If so the base ring filter located on the bottom of the water heater will need to be cleaned periodically Refer to the Maintenance of your Water Heater section of this manual for information on cleaning the base ring filter Combustion Air Supply and Ventilation Check for sufficient combustion air supply Insufficient air for the combustion of gas will result in the flame becoming lazy thereby allowing heat to build up in the combustion chamber This excessive heat will cause a thermal switch on the door assembly to trip 15 the water heater installed in a closet or other small enclosed space If so Are there openings for make up air to enter and exit the room area Are the openings of sufficient size Remember if there are other gas fired or air consuming appliances in the same room you need more make up air Refer to the Installation Instructions and Combustion Air Supply and Ventilation sections for specific requirements Make sure that fresh air is not taken from areas that contain negative pressure producing devices such as exhaust fans dryers fireplaces etc Is there a furnace air handler in the same room space as the water heater If so has a return air duct system been attached that exits the room If so check for leaks on the air duct system If no air duct system is present correct immediately by contacting a local Heating Ventilation Air Con
85. stem and the line capped e Ifthe gas lines are to be tested at a pressure less than 14 W C as given in the warning on the front page the water heater must be isolated from the gas supply piping system by closing its manual shut off valve When your L P tank runs out of fuel turn off the gas at all gas appliances including pilot lights After the tank is refilled all appliances must be re lit according to their manufacturer s instructions NOTE Air may be present in the gas lines and could prevent the pilot from lighting on initial start up The gas lines should be purged of air by a qualified technician after installation of the gas piping system While purging the gas piping system of air ensure that Table 1 Natural Gas Pipe Capacity Table Cu Ft Hr Capacity of gas pipe of different diameters and lengths in cu ft per hr with pressure drop of 0 3 in and specific gravity of 0 60 natural gas Nominal Iron Pipe Length of Pipe Feet Size in 10 20 30 40 50 60 70 80 90 100 125 150 175 200 After the length of pipe has been determined select the pipe size which will provide the minimum cubic feet per hour required for the gas input rating of the water heater By formula Gas Input of Water Heater BTU HR Heating Value of Gas BTU FT The gas input of the water heater is marked on the water heater data plate The heating value of the gas BTU FT may be determined by consulting the local natural gas util
86. 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 FIRE AND EXPLOSION HAZARD Can result in serious injury or death fi j 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 Roebuck and Co 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 ater temperature over 1257 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
87. ter heater by shutting off the gas supply to the water heater s burner and pilot preventing re ignition of any remaining flammable vapors in the area This will not prevent a possible fire explosion if the igniter is depressed and flammable vapors have accumulated in the combustion chamber with the pilot light off If you suspect a flammable vapor incident has occurred do not use this appliance Do not attempt to light this appliance or depress the igniter button if you suspect flammable vapors have accumulated inside or outside the appliance Immediately call a qualified technician to inspect the appliance Water heaters subjected to a flammable vapors incident will show a discoloration on the flame arrestor and require replacement of the entire water heater AWARNING o j J Flammable Vapors FIRE AND EXPLOSION HAZARD Can result in serious injury or death A Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Storage of or use of gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance can result in serious injury or death Read and follow water heater warnings and instructions Do not use or store flammable products such as gasoline solvents or adhesives in the same room or area near the water heater If such flammables must be used all gas burning appliances in the vicinity must be shut off and their pilot lights
88. tor must be firmly attached and sealed to prevent it from falling out e Toaid in removing the connector a thimble or slip joint may be used connector must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney Figure 19 LISTED LINED CHIMNEY TT 2 MINIMUM ABOVE ANY OBJECT 3 FT MINIMUM a FEN ume SUPPORT STRAP E MAINTAIN CLEARANCE DO NOT EXTEND VL C E 4 VENT BEYOND EDGE OF CHIMNEY HAR HHH HHE CONNECTOR CHIMNEY TERMINATION VENT SYSTEM FIGURE 19 Do not terminate the vent connector in a chimney that has not been certified for this purpose Some local codes may prohibit the termination of vent connectors in a masonry chimney Vertical Exhaust Gas Vent Vertical exhaust gas vents must be installed with U L listed type B vent pipe according to the vent manufacturer s instructions and the terms of its listing It must be connected to the water heater s draft hood by a listed vent connector or by directly originating at the draft hood opening Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer s instructions Gas vents must be supported to prevent damage joint 20 separation and maintain clearances to combustible materials Figures 20 and 21 IMPORTANT This gas vent must b
89. uirements allow sufficient air YES 2 Is 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 Contact a local Heating Ventilation Air See the Location Requirements and Combustion Air Conditioning amp Refrigeration authorized Supply and Ventilation sections in this manual service provider Is there proper drafting at the Check the vent system for restrictions obstructions and check the vent draft hood See Checking the termination height Refer to the Installation Instructions section of this Draft section in this manual manual for specific requirements YES Is the flame arrestor free from Refer to the Maintenance of Your Water Heater section of this debris due to excessive lint dirt manual for information on cleaning the flame arrestor dust or oil YES Check the water heater for a Flammable Vapor FV event Note it may be necessary to remove the manifold door assembly to visually inspect the water heater Reference the Maintenance of your Water Heater section of this manual for removal instructions THERMAL SWITCH of discoloration and YES or debris vis Shut off the gas supply to the water heater at the manual gas shut off valve then contact Sears Serv
90. void serious injury or death Do not store corrosive chemicals in vicinity of water heater Chemical corrosion of flue and vent system can cause serious injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual At least once a year a visual inspection should be made of the venting system You should look for e Obstructions which could cause improper venting The combustion and ventilation air flow must not be obstructed e 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 clean or replace the flue and venting before resuming operation of the water heater Burner
91. 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 winter and early spring months when incoming water temperatures are at their lowest Good venting is essential for a gas fired water heater to operate properly as well as to carry away products of combustion and water vapor Smoke Odor It is not uncommon to experience a small amount of smoke and odor during the initial start up This is due to burning off of oil from met
92. ways be detected by smell Gas suppliers recommend that you use a gas detector approved by UL or CSA Explosion Hazard For more information contact your gas supplier 2 dias dd Have a qualified person make sure L P gas pressure If a gas leak is detected follow the What to do if you does not exceed 13 water column smell gas instructions on the cover of this manual Examples of a qualified person include licensed plumbers authorized gas company personnel and IMPORTANT The gas supply pressure must not exceed the maximum authorized service personnel supply pressure as stated on the water heater s rating plate The minimum supply pressure is for the purpose of input adjustment Failure to do so can result in death explosion or fire Gas Pressure Testing IMPORTANT This water heater and its gas connection must be leak tested before placing the appliance in operation Liquefied petroleum gas is over 50 heavier than air and in the occurrence of a leak in the system the gas will settle at floor level Basements crawl spaces closets and areas below ground level will serve as pockets for the accumulation of gas Before lighting an L P gas water heater smell all around the appliance at floor level If you smell gas follow the instructions e Ifthe code requires the gas lines to be tested at a pressure exceeding 14 W C the water heater and its manual shut off valve must be disconnected from the gas supply piping sy
93. ws located underneath the burner See Figure 33 Remove and keep the screw securing the pilot assembly to the pilot bracket Figure 36 Remove and keep the old pilot tube and thermocouple Using the old pilot tube as a guide bend the new pilot tube to match the old one NOTE Make only the bends closest to the pilot before going to the next step Figure 36 OTHER FITTINGS NOT SHOWN FOR CLARITY E IGNITER WIRE rHERMOCOUPLE FIRST BEND S FIGURE 36 Route the new pilot tube thermocouple and igniter wire through the manifold burner door opening Figure 34 30 10 11 12 13 14 15 16 Connect the new pilot tube and tighten the nut securing it to the pilot assembly IMPORTANT Keep the pilot orifice in the pilot when making the connection Do not operate the water heater without the pilot orifice installed Install the thermocouple making sure that it is fully seated Attach the pilot assembly to the pilot bracket and secure using the screw removed earlier Re attach the burner Note the orientation of the burner Figure 33 Position the new pilot tube through the largest opening of the manifold component block NOTE The largest opening should be located at the top position The igniter wire should be located in the middle opening and thermocouple in the bottom opening Figure 37 PILOT TUBE THERMOCOUPLE MANIFOLD COMPONENT BLOCK FIGUR
94. years of trouble free service If you should decide that you want the new water heater professionally installed by Sears call 1 800 4 MY HOME They will arrange for prompt quality installation by Sears authorized contractors Abbreviations Found In This Instruction Manual e CSA Canadian Standards Association e ANSI American National Standards Institute e National Fire Protection Association e ASME American Society of Mechanical Engineers e GAMA Gas Appliance Manufacturers Association Important Information About This Water Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation environments Please review the Installation Checklist found at the end of the installation instructions section and make any required installation upgrades or changes This manual contains instructions for the installation operation and maintenance of the gas fired water heater It also contains warnings 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

Kenmore 153.332.410 Water Heater User Manual

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