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Kenmore 153.331492 Water Heater User Manual

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1. Reassemble and restore to service VS THERMAL SWITCH FIGURE 43 39 PARTS ORDER LIST HYDROSENSE GAS WATER HEATER MODEL NUMBERS 153 331492 40 Gallon Tall Natural 153 331592 50 Gallon Tall Natural BURNER ASSEMBLY GAS CONTROL VALVE THERMOSTAT Part Description 5555 gt w gt B 5 m 2 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 153 331592 153 331492 Anode Rod Secondary 9003934 9003934 9001829 Base Ring Filter 9006660 Burner Head 9006793 Burner Orifice 186016 034 Draft Hood 9006647 Drain Valve 9002402 Gas Control Valve Thermostat 9006149 Gas Valve Assembly 9006147 Electronic Control Module 9006148 nlet Tube w Gasket 9002059 nner Door Gasket 9006795 nstruction Manual 186422 001 23600 Manifold Door Assembly Contains Manifold Tube Gasket Door Pilot Tube Thermopile Two Piece Wire Connector w 300679 3096 96 Clip Thermal Switch and Pilot Assembly Nipple w Heat Trap 9003719 9003719 Outer Door 9006648 9006648 Pilot Assembly w Tubing and 9006792 9006792 Fitt
2. 4 2 2 2 2 16 60000 10 Installation eini le dil 10 INSTALLATION INSTRUCTIONS 11 14 Removing the Old Water eene eene eene nenne esses nasse nenas anas A si seres asas asa 11 Location Requirements oor Cari erat vehi ect A PE ts dad 12 Site Nere ulej E 12 Insulation Blankets te E epe uteri sp ve res EE EE EE seed 13 Cl arances arid e eat ret rib epi ee ER SR PEU GUY 13 14 Filling the Water Heater a i o f nere rer e Pr ce Eg rae ame reb Ta D Dvd 14 GAS SUPPLY LIT eeepc eio nmi d eate A 14 15 Gas Req irements 5 aiu e ettet hee eves bee a esee dvs tant tico Jaden ke do a 14 aee A AN San ee 14 a ia b ETE 15 Gas Pressure Testing AME 15 COMBUSTION AIR e Rh t nata ox eio eu 16 19 Unconfined Space re rette e ere ee etd nero bote euet vend crie etu feta secl 16 COnMfMG dS Paes EE 16 All Air from Inside the Buildin a a wale Ns 16 17 LE a Ba a 17 Lovvers and e B a u a a 17 Vent Pipe SvSteMi sa DILE 18 Hood Installatiot iii ise tani ie i Be ra 18 Vent Piper
3. AWARNING A WARNING Read and understand instruction Fire Hazard manual and safety messages For continued protection against before installing operating or riskof fire servicing this water heater Do not install water heater on Failure to follow instructions and carpeted floor safety messages could result in death or serious injury Do not operate water heater if Instruction manual must remain flood damaged with water heater Water temperature over 125 F TM 5 AWARNING 52 can cause severe burns instantly resulting in severe injury Explosion Hazard or death Children the elderly and the 22 physically or mentally disabled l are at highest risk for scald injury sized temperature COM Feel water before bathing or RM ewe and pressure relief valve must showering be installed in opening Temperature limiting valves are provided available Read instruction manual for safe temperature setting A WARNING AWARNING Fire or Explosion Harzard la system in accordance with Do not store or use gasoline or other flammable vapors and Do not operate water heater if flood liquids in the vicinity of this or any other appliance damaged Avoid all ignition sources if you smell Natural or LP gas High altitude orifice must be installed for Do not expose water heater control to excessive gas operation above 7 700 feet 2 347m pressure Do
4. nm Ina ar inspect and clean the base ring filter Refer to the External inspection and Cleaning of the Base Ring Filter section Correct size of openings to allow sufficient air Is there a furnace air handler in the same room as the water heater Contact a qualified technician to correct the combustion air supply ventilation issue Check the vent system for restrictions obstructions and check the vent termination height Refer to the Installation Instructions to excessive lint dirt dust or oil the flame arrestor and burner section of this manual for specific requirements Contact Sears Service at 1 800 4 MY HOME 1 800 469 4663 Does the flame arrestor show signs of discoloration YES Reassemble the heater press the thermal Switch and attempt to return the heater to service Does the pilot remain lit Set to desired temperature NOTE If you are still experiencing difficulties after following the steps in sections A B and C please contact Sears Service at 1 800 4 MY HOME 1 800 469 4663 Shut off the gas supply to the water heater at the manual gas shut off valve then contact Sears Service at 1 800 4 MY HOME 1 800 469 4663 THERMAL SWITCH LOCATION Does the diagnostic status light on the gas control valve thermostat give a two flash error code NO Refer to the Replacing the Pilot Pilot Tube Assembly instructions
5. Remove exterior packaging and place installation components aside Inspect all parts for damage prior to installation and start up Completely read all instructions before attempting to assemble and install this product After installation dispose of recycle all packaging materials PRODUCT SPECIFICATIONS MODEL TANK CAPACITY TYPE INPUT NUMBER IN GALS LTRS OF RATE GAS Btu hr RECOVERY MINIMUM DIAMETER RATE GALS VENT PIPE INCHES PER HOUR DIA INCHES mm HEIGHT TO 90 F RISE mm JACKET TOP 153 331492 40 151 40000 420 3 76 084 102 20 508 58 14 1477 153 331592 50 189 40 000 420 3 76 084 102 22 559 57 28 1455 DIMENSIONS INCHES mm 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 EL i 8 7 EXPANSION TANKS FOR THERMAL EXPANSION a CONDITIONS AVAILABLE ee IN 2 GALLONS 7 6 LITERS AND 5 GALLONS 18 9 LITERS CAPACITY THROUGH LOCAL SEARS STORE OR SERVICE CENTER WATER HEATER INSTALLATION KIT WITH FLEXIBLE CONNECTORS FOR 3 4 19 05 mm OR 1 2 12 7 mm THREADED OR COPPER PLUMBING AND FLEXIBLE WATER METAL DRAIN PANS AVAILABLE IN 20 508 mm DIAMETER FOR WATER HEATERS HAVING A DIAMETER 18
6. 4 lower front of the electronic control module with a T15 torx Reconnect the manifold tube pilot tube and inlet gas supply erm line to the gas valve Tighten securely NOTE Use an approved Teflon tape or pipe compound on the gas piping 5 Depress the two plastic locking tabs on the top surface connections of the electronic control module with a 3 16 slotted n 3 Connect the thermopile tank sensor and igniter wire screwdriver plugs 6 Grasp the sides of the electronic control module and pull Turn on the gas supply and test the gas supply connections outward to remove by brushing on an approved noncorrosive leak detection solution Bubbles forming indicate a leak Correct any leak C Removing the Gas Valve Assembly found 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 1 Follow steps 1 to 6 in B above to remove the electronic control module Check the operation of the burner by following the lighting instructions on the front of the water heater With the burner lit check the gas control valve thermostat supply line manifold tube and pilot tube connections for leaks Installing the Electronic Control Module dais tne GAS Piping SECHOR Figure Niyang disconnect 1 Align the two plastic locking tabs on the top surface of the the ground joint union in the gas piping Next
7. COMBUSTION AIR SUPPLY amp VENTILATION TABLE 2 Minimum Square BTUH Input Feet with 8 Ceiling A WARNING 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 beauty shops photo processing labs buildings with indoor pools water heaters installed in laundry hobby or craft rooms water heaters installed near chemical storage areas Combustion air must be free of acid forming chemicals such as sulfur fluorine and chlorine These elements are found in aerosol sprays detergents bleaches cleaning solvents air fresheners paint and varnish removers refrigerants and many other commercial and household products When burned vapors from these products form highly corrosive acid compounds These products should not be stored or used near the water heater or air inlet Combustion and ventilatio
8. The temperature pressure relief valve must be manually operated at least once a year ADANGER Burn harzard 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 to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions and replace the temperature pressure relief valve with a new one If the temperature pressure relief valve on the appliance weeps or discharges periodically this may be due to thermal expansion You may have a check valve installed in the water line or a water meter with a check valve Consult the Sears Service Center for further information Do not plug the temperature pressure relief valve Draining and Flushing ADANGER Hotwater discharge burn hazard Keep clear of relief valve discharge unit Temperature limiting valves are available Read instruction manual for safe temperature setting It is recommended that the tank be drained and flushed every 6 months to remove
9. s 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 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 determine if a pilot flame is present and will shut off the gas supply to the main burner and the pilot if the flame is absent This unit is also equipped with a thermal Switch designed to shut off the gas supply in the ev
10. 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 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 bi ATA MANUAL GAS SHUT OFF GROUND JOINT UNION CHECK WITH LOCAL UTILITY FOR MINIMUM HEIGHT 3 MINIMUM _ DRIP TA ES MM SUITABLE DRAIN 7 FIGURE 11 Gas Pressure WARNING Explosion Hazard Gas leaks can not alwavs be detected bv smell Gas suppliers recommend that vou use a gas detector approved bv UL or CSA For more information contact vour gas supplier If a gas leak is detected follow the What to do if you smell gas instructions on the cover of this manual IMPORTANT The gas supply pressure must not exceed the maximum supply pressure as stated on the water heater s rating plate The minimum supply pressure is for the purpose of input adjustment Table 1 Natural Gas Pipe Capacity Table Cu Ft Hr Gas Pressure Testing IMPORTANT This water heater and its gas connection must be leak tested before placing the appliance in operation fthe code requires the gas lines to be tested at a pressure exceeding 14 W C the water heater and its manual shut off valve must be disconnec
11. disconnect itre imlab pas tegas valve electronic control module with the openings of the gas valve 9 9 back plate Press on the front of the control module until it 3 Loosen the flare nut that connects the pilot tube to the locks into position bottom of the gas control valve assembly with a 7 16 open Reinstall the torx screw on the lower front of the electronic end wrench Pull down on the pilot tube to separate the tube control module beside pilot tube with a T15 torx screwdriver from the gas valve l Tighten securelv 4 Loosen the flange nut that connects the burner tube to rss Reconnect the wire connectors from the piezo igniter tank gas conta valve With a vd sensors and thermopile to the electronic control module Pull down on the burner tube to separate the tube from the P f gas valve Light the heater following the lighting and operating 5 Unscrew and remove the gas valve assembly and backplate MA Me frontsurtace o Ne neater by turning it to the left Continue until it separates from the gas valve nipple that is threaded into the tank The gas TEFLON is a registered trademark of E l Du Pont De Nemours valve nipple remains attached to the tank and Company 6 Check for water leaks around the threads of the gas valve nipple which is still attached the tank If leaks appear drain the tank and contact a qualified service tec
12. 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 A WARNING Flammable Vapors FIRE AND EXPLOSION HAZARD Can result in serious injury or death vapors and liquids the vicinity of this or 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 Do not store or use gasoline or other flammable Read and follow water heater warnings and instructions Do not use or store flammable products such as gasoline solvents or adhesives in the same room or area near the water heater If such flammables must be used all gas burning appliances in the vicinity must be shut off and their pilot lights extinguished Open the doors and windows for ventilation while flammable substances are in use If flammable liquids or vapors have spilled or leaked in the area of the water heater leave the area immediately and call the fire department from a neighbor s home Do not attempt to clean the spill until all ignition sources have been extinguished WARNING e Read instruction manual before installing using or servicing water heater e Improper use may result in fi
13. module 6 second solid light Pilot stays lit only when control knob Gas control valve failure Replace gas control followed by 8 flashes is depressed in PILOT position valve thermostat and burner off Run tank sensor calibration check 7 flashes Electronic control module failure Replace electronic control module pilot on or off and burner off 6 second solid light with Overheat failure and electronic control module combinations of 4 7 de adn PLOT position knob failure Replace gas control valve thermostat flashes 6 second solid light with Electronic control module failure and gas combinations of 7 8 ea ke knob control valve failure Replace gas control valve flashes p thermostat 6 second solid light with Overheat failure electronic control module combinations edn PLOT position knob failure and gas control valve failure Replace of 4 7 8 flashes gas control valve thermostat Wait until light goes outto restart the gas control valve thermostat 6 second solid light with Overheat failure and gas control valve failure ee of 4 8 adn PILOT position kno Replace gas control valve thermostat ashes i Continuous solid light System shutdown safety interlock Flashes are approximately 1 10 second in duration with approximately three seconds between groups of flashes 36 TROUBLESHOOTING CHART CONTINUED PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION BURNER WILL
14. 457 mm OR LESS 24 610mm DIAMETER FOR WATER HEATERS HAVING A DIAMETER 22 559 mm OR LESS AND AVAILABLE IN 28 711 mm DIAMETER FOR WATER HEATERS HAVING A DIAMETER 26 660 mm OR LESS HEATER GAS CONNECTOR WITH FITTINGS BASIC TOOLS You may or may not need all these tools depending on your type of installation These tools can be purchased at your local Sears Store Pipe Wrenches 2 14 356 mm Screwdriver Tin Snips e 6 1 82 m Tape or Folding Ruler Garden Hose Drill Pipe Dope or Teflon Tape SLOT HEAD SCREWDRIVER SS PHILLIPS SCREWDRIVER TIN SNIPS PIPE DOPE ROLL OF TEFLON SQUEEZE TUBE TAPE USE ONLY ON USE FOR WATER AND GAS WATER CONNECTIONS CONNECTIONS E GARDEN HOSE 2 6 FOOT PIPE WRENCH ADDITIONAL TOOLS NEEDED WHEN SWEAT SOLDERING Tubing Cutters or Hacksaw Propane Tank Soft Solder Solder Flux Emery Cloth Wire Brushes PROPANE TUBING CUTTER TORCH ean 229 da D ROLL OF EMERY CLOTH HACKSAW CE 3 4 19 mm WIRE BRUSH O ROLL OF LEAD FREE SOLDER 1 2 13 mm WIRE BRUSH SOFT SOLDER FLUX TVPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER GAS MODELS A Vent Pipe J Inner Door S Gas Control Valve Thermostat B Draft Hood K Outer Door T Drain Valve C Anode Not Shown L Union U Pilot and Main Burner D Hot Water Outlet M Inlet Water Shut off Valve V Flue E Insula
15. Failure to follow these instructions can restrict the air flow required for proper combustion potentially resulting in fire asphyxiation serious personal injury or death Do not apply insulation to the top of the water heater as this will interfere with safe operation of the draft hood Do not cover the outer door thermostat or temperature 8 pressure relief valve Do not allow insulation to come within 2 50 8 mm of the floor to prevent blockage of combustion air flow to the burner Do not cover the instruction manual Keep it on the side of the water heater or nearby for future reference Doobtain new warning and instruction labels from Sears for placement on the blanket directly over the existing labels Doinspect the insulation blanket frequently to make certain it does not sag thereby obstructing combustion air flow Clearances and Accessibility NOTE Minimum clearances from combustible materials are stated on the label adjacent to the gas control valve thermostat of the water heater The water heater is certified for installation on a combustible floor IMPORTANT If installing over carpeting the carpeting must be protected by a metal or wood panel beneath the water 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
16. NOT IGNITE 1 Pilot not lit 1 Light pilot 2 Thermostat set too low 2 Turn temp dial to desired temperature 3 Nogas 3 Check with gas utility company 4 the gas lines 4 Notify utility install trap in gas line 5 Pilot line clogged 5 Clean locate source and correct 6 Main burner line clogged 6 Clean locate source and correct 7 Non functioning thermopile 7T Replace thermopile 8 Non functioning thermostat 8 Replace thermostat 9 Heater installed in a confined area 9 Provide fresh air ventilation 1 1 SMELLY WATER Sulfides in the water Replace the anode with a special anode BURNER FLAME YELLOW Insufficient secondary air Provide ventilation to water heater LAZY Low gas pressure Check with gas utility company Water heater flue or vent system blocked Clean locate source and correct Main burner line clogged Clean locate source and correct Heater installed in a confined area Proper fresh air ventilation Obstruction in main burner orifice Clean or replace orifice PILOT WILL NOT LIGHT OR Non functioning igniter Replace igniter pilot assembly REMAIN LIT The thermal switch tripped SeePilot Light Troubleshooting Flowchart section Wire lead connection at thermal switch 3 Remove and reconnect the wire leads loose thermal switch confirm connections are tight and not loose Thermopile connection loose Correct the connection s Air in gas line Bleed the air from the gas line Low gas pressure Check
17. 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 DO NOT crimp or crease the pilot tube Push the new pilot assembly connectors through the hole in the manifold door where the two piece wire connector will be seated See Figure 35 Reconnect the 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 Reattach the pilot shield and pilot assembly to the pilot bracket Reattach the burner and secure with the screws removed earlier NOTE See Figure 34 for correct burner orientation Position the new pilot tube through the largest opening of the two piece wire connector NOTE The largest opening should be located at the top position The igniter wire should be located in the middle opening and thermopile wires in the bottom opening Reposition the two piece wire connector in the manifold door opening and secure it with the retainer clip 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 Burner and other fittings A not shown for clarity N Thermopile Connector f Retainer Clip Two Piece Wire Connector FIGURE 35 Pilot Thermopile We PRY Pil
18. chimney support assembly Minimum air space clearance to combustible materials should be maintained as marked on the chimney sections WATER SVSTEM 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 the cold water supply 3 4 NPT to the cold water inlet fitting Connect the hot water supply 3 4 NPT to the hot water outlet fitting IMPORTANT Some models may contain energy saving heat traps to prevent the circulation of hot water within the pipes Do not remove the inserts within the heat traps 2 The installation of unions in both the hot and cold water
19. covered repair service and related installed parts Once you purchase the Agreement a simple phone call is all that it takes for you to schedule service You can call anytime day or night or schedule a service appointment online The Master Protection Agreement is a risk free purchase If you cancel for any reason during the product warranty period we will provide a full refund Or a prorated refund anytime after the product warranty period expires Purchase your Master Protection Agreement today Some limitations and exclusions apply For prices and additional information in the U S A call 1 800 827 6655 Coverage in Canada varies on some items For full details call Sears Canada at 1 800 361 6665 Sears Installation Service For Sears professional installation of home appliances garage door openers water heaters and other major home items in the U S A or Canada call 1 800 4 MY HOME CUSTOMER RESPONSIBILITIES Thank You for purchasing a Kenmore water heater Properly installed and maintained it should give you years of trouble free service If you should decide that you want the new water heater professionally installed by Sears call 1 800 4 MY HOMES They will arrange for prompt quality installation by Sears authorized contractors Abbreviations Found In This Instruction Manual CSA Canadian Standards Association ANSI American National Standards Institute National Fire Protection Associati
20. 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 Z223 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 p MINIMUM SUPPORT STRAP MAINTAIN CLEARANCE TYPE B DOUBLE l WALL VENT PIPE MAINTAIN SPECIFIED VENT CLEARANCE CONNECTOR SLOPE UP 1 4 IN PER FT MINIMUM VERTICAL GAS VENT SYSTEM WITH TYPE B DOUBLE WALL VENT PIPE FIGURE 20 fm LISTED VENT A MAINTAIN SPECIFIED CLEARANCE SUPPORT STRAP MAINTAIN CLEARANCE VENT VENT CONNECTOR CONNECTOR SLOPE UP 1 4 IN PER FT MINIMUM UNUSED CHIMNEY FLUE OR MASONRY ENCLOSURE VENTING THROUGH A CHIMNEY WITH TYPE B DOUBLE WALL VENT PIPE FIGURE 241 x Maintain vent pipe clearance requirements to local state and or the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition xx NFPA 211 Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances states that these chimneys are intended to be installed in accordance with the installation instructions provided with each
21. follow the lighting instructions on the front of the water heater Is the base ring filter clean i e free of lint dust or debris Turn the gas control temperature knob to the NO pilot setting While repeatedly pressing the igniter button push in and hold the gas control temperature knob until the pilot is lit and maintains a stable flame status light will blink Once it maintains a stable flame release the gas control temperature knob Have you bled all the air YES from the pilot tube and gas supply line YES NO YES Is the igniter producing a spark Follow the Testing the Igniter YES Does the return air duct for the furnace air handler draw its air from a separate location than the water heater See the Set thermostat to desired temperature System section in this manual Location Requirements section and the Combustion Air Supply section Is there proper drafting at the drafthood See Checking theme NO Draft section in this manual Section B Pilot light repeatedly goes out Remove the burner door assembly Are the flame arrestor and burner free from debris due Refer to the Maintenance of your Water Heater section of this manual for information on cleaning NO Nou Are the combustion air supply and ventilation openings of sufficient size See Combustion Air Supply and Ventilation section in this manual for requirements YES
22. horizontal ducts The CONFINED fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors Attic or crawl pie spaces cannot be closed and must be properly ventilated to the 4000 BTUH outside Ductwork must be of the same cross sectional area as the REL 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 TS IRCH EER OPEN S R gt UL N 4000 BTUH FOUNDATION method in which the air is to be provided Refer to Table 3 to VENT calculate the minimum free area for each opening Figures 14 ALL AIR FROM OUTDOORS INLET AIR FROM VENTILATED CRAWL SPACE OUTLET AIR TO VENTILATED ATTIC FIGURE 14 Louvers and Grilles GABLE VENT P dd TO OUTDOORS In calculating free area for ventilation and combustion air supply openings consideration must be given to the blocking effect INSTALL ABOVE 4 INSULATION of protection louvers grilles and screens These devices can vag 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 15 16 and 17 are typical examples of each method CONFINED 1 SQ INCH design of louver or grille is known it should be used in SPACE BER 4006 calculating the specified free area of the
23. must be in cold inlet Leaking faucets Repair faucets Wasted hot water Advise customer Long runs of exposed piping Insulate piping Hot water piping in outside wall Insulate piping Low gas pressure Check with gas utility company SLOW HOT WATER Insufficient secondary air Provide ventilation to water heater Check flue RECOVERY way flue baffle and burner Water heater flue or vent system 2 Clean flue locate source and correct blocked Low gas pressure Check with gas utility company Improper calibration Replace thermostat Thermostat set too low Turn temperature dial to desired setting Water heater too small Install adequate heater Wrong piping connections Correct piping dip tube must be in cold inlet Wasted hot water Advise customer DRIP FROM RELIEF VALVE Excessive water pressure Use a pressure reducing valve and relief Heater stacking valve Closed water system 2 Lowerthe thermostat setting 3 See Closed System Thermal Expansion 37 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 2 Clean locate source and correct blocked Heater installed in a confined area 3 Provide fresh air ventilat
24. opening If the design 8 BTUH and free area are not known it can be assumed that most wood Nee UES louvers will allow 20 25 of free area while metal louvers and 1 SQ INCH PER 4000 BTUH 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 12 MAXIMUM Keep louvers and grilles clean and free of debris or other ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC obstructions FIGURE 15 17 1 SQ INCH PER 2000 BTUH wieni OUTLET OUTDOOR AIR DUCTS CONFINED SPACE 1 SQ INCH PER 2000 BTUH ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS FIGURE 16 ALTERNATIVE OPENING LOCATION 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 combustion is taken from the immediate water heater location or is ducted in from the outside see Combustion Air Supply and Ventilation This water heater must be properly vented for the removal of exhaust gases to the outside atmosphere Correct installation of the vent pipe system is mandatory for the proper and efficient operation of this water heater and is an important factor i
25. 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 f 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 Atemperature 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 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 Please note the following The s
26. thermostat Inspect flame coverage on thermopile 2 flashes Thermopile voltage low p 9 p Check inlet gas pressure Run open circuit thermopile output test and replace pilot assembly if output is below 350 mV Restart gas control valve If main burner turns on after restart replace 3 flashes Gas valve or tank sensor failure tank sensor If main burner does not turn on after restart replace gas valve assembly 4 flashes Gas control valve overheat failure Replace gas control valve thermostat pilot off or burner off Verify tank sensor is connected to electronic control module l Verify tank sensor is connected to the heater 5 flashes Lower tank sensor failure pilot on tank and burner off Run tank sensor calibration check Replace tank sensor and electronic control module Verify tank sensor is connected to electronic control module Verify tank sensor is connected to the heater 6 flashes Upper tank sensor failure pilot on tank Replace tank sensor and electronic control module 8 flashes Gas control valve failure pilot off Replace gas control valve thermostat and burner off 6 second solid light Pilot stays lit only when control knob Overheat failure Replace gas control valve followed by 4 flashes is depressed in PILOT position thermostat 6 second solid light Pilot stays lit only when control knob Electronic contro module failure Replace followed by 7 flashes is depressed in PILOT position
27. to the desired temperature setting to reduce the risk of scald injury The 120 F 49 C mark is the preferred starting point See Figure 28 on the next page Some states have a requirement for a lower setting Turn the water temperature dial clockwise N to increase the temperature or counterclockwise to decrease the temperature Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance GAS CONTROL TEMPERATURE KNOB SCALDING RISK INCREASES M WITH HOTTER WATER 2 STATUS p Time to Produce 2nd amp 3rd LM Burns on Adult Skin Temperature Settings 160 F 71 C Aboutli2second 1 2 second 150 F 66 About 1 1 2 seconds Ducem ran m 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 a higher thermostat setting may be required to meet the increased 24 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 Tank Sediment
28. 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 Ifthe water heater is located in an area that is subjected to lint and dirt it may be necessary to periodically clean the base ring filter and flame arrestor see External Inspection amp Cleaning of the Base Ring Filter also see Cleaning the Combustion Chamber and Flame Arrestor This water heater is not for use in manufactured mobile homes or outdoor installation NOTE This water heater must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition EXHAUST FAN i REVERSE FLOW OF GASES FIGURE 8 12 CAUTION Property Damage Hazard All water heaters eventually leak Donotinstall without adequate drainage IMPORTANT The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure Due to the normal corrosive action of water the tank will eventually leak after an extended period of time Also any external plumbing leak including those from improper installation may cause early failure of the tank due to corrosion if not repaired If the homeowner is uncomfortab
29. with gas utility company No gas Check with gas utility company Dirt in gas lines Notify utility install dirt trap in gas line Cold drafts Locate source and correct Thermostat ECO switch open Replace thermostat Pilot line or orifice clogged Clean locate source and correct Non functioning thermopile Replace thermopile Air for combustion obstructed See maintenance section for inspection and cleaning of flame arrester Flammable vapors incident Replace water heater eliminate flammable function actuated vapors source Contact Sears Service Base ring filter obstructed Inspect and clean base ring filter See External Cleaning amp Inspection of the Base Ring Filter HIGH OPERATION COSTS Thermostat set too high Settemperature dial to lower setting Sediment or lime in tank Drain flush provide water treatment if needed Water heater too small for job Install adequate heater Wrong piping connections Correct piping dip tube must be in cold inlet Leaking faucets Repair faucets Gas leaks Check with utility repair at once Wasted hot water Advise customer Long runs of exposed piping Insulate piping Hot water piping in exposed wall Insulate piping INSUFFICIENT HOT WATER 1 Thermostat set too low Turn temperature dial to desired setting Sediment or lime in tank Drain flush provide water treatment if needed Water heater too small Install adequate heater Wrong piping connections Correct piping dip tube
30. 8 It may take several minutes for air to clear the lines before the pilot will light e If the pilot will not stay lit after several tries turn the gas control knob counterclockwise 7 to OFF and call your service technician or gas supplier SEE FIGURE A 10 Once the pilot flame is established replace the outer burner door At arm s length away turn gas control knob clockwise to desired temperature setting SEE FIGURE C DANGER Hotter water increases the risk of scald injury Consult the instruction manual before changing temperature 11 Turn control thermostat knob fully counterclockwise 5 to OFF SEE FIGURE A 22 Checking the Draft A DANGER Burn harzard e Hot water discharge Keep clear of relief valve discharge outlet After successfully lighting the water heater allow the unitto 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 OPENING w 4 CA ed FIGURE 26 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 adjustment
31. Cleaning Sediment build up on the tank bottom may create varying amount of noise and if leftin the tank will cause permanent tank failure In some water areas you may not be able to drain all sediment deposits by simply draining the tank In these cases Mag Erad part no 23600 can be used to help remove the sediment deposits This may be ordered from the Sears Service Center For ordering refer to the Parts Order List section Vent System Inspection A WARNING Flue gases may escape if vent pipe is not connected Be alert for obstructed sooted or deteriorated vent system to avoid serious injury or death Do not store corrosive chemicals in vicinity of water heater Chemical corrosion of flue and vent system can cause serious injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual At least once a year a visual inspection should be made of the venting system You should look for Obstructions which could cause improper venting The combustion and ventilation air flow must not be obstructed Damage or deterioration which could cause improper venting or leakage of combustion products Rusted flakes around top of water heater Be sure the vent piping is properly connected to prevent escape of dangerous flue gasses which could cause deadly asphyxiation Obstructions and deteriorated vent systems may present serious health risk or asphyxiat
32. 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 All air from inside the building 2 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 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 TABLE 3 structure meets this requirement contact your local gas utility company or other qualified agency for a safety inspection Ea
33. E 1 800 469 4663 to request service Leakage Checkpoints 6 MAXIMUM AIR GAP DRAIN VALVE IS PARTIALLY HIDDEN BY DISCHARGE PIPE FIGURE 42 AWARNING Read and understand instruction manual and safetv messages before installing operating or servicing this water heater Failure to follow instructions and safetv 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 before the tank is completely full of water Never use this water heater unless it is completely filled with water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning gas to the water heater A Water at the draft hood is water vapor which has condensed out of the combustion products This is caused by a problem in the vent Contact a qualified technician B Condensation may be seen on pipes in humid weather or pipe connections may be leaking C The anode rod fitting may be leaking D Small amounts of water from temperature pressure relief valve may be due to thermal expansion or high water pressure in your area E The temperature pressure relief valve may be leaking at the tank fitting F Water from a drain valve may be due to
34. Fr r r SUPPORT EE PE 1 1 IT 2 FT MINIMUM ABOVE ANY OBJECT hrr r WITHIN 10FT HORIZONTALLY STRAP MAINTAIN CLEARANCE DO NOT EXTEND VENT BEYOND EDGE OF CHIMNEY 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 19 separation and maintain clearances to combustible materials Figures 20 and 21 IMPORTANT This gas vent must be terminated in a vertical position to facilitate the removal of the burnt gases An unused chimney flue or masonry enclosure may be used as a passageway for the installation of a gas vent Figure 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
35. Owner s Manual Kemmorej HvdroSense Gas Water Heater FOR POTABLE WATER HEATING ONLY NOT SUITABLE FOR SPACE HEATING NOT FOR USE IN MOBILE HOMES MODEL NO 153 331492 40 Gallon 153 331592 50 Gallon 5 ENERGY STAR This water heater complies with ANSI Z21 10 1 current edition regarding the accidental or unintended ignition of flammable vapors such as those emitted by gasoline AWARNING Read and understand instruction manual and safetv messages before installing operating or servicing this water heater Failure to follow instructions and safetv messages could result in death or serious injury Instruction manual must remain with water heater ADVERTENCIA Si no puede leer o entender el ingl s y necesita el manual de instrucciones en espa ol puede solicitarlo al 1 800 821 2017 NO TRATE DE INSTALAR U OPERAR ESTE CALENTADOR DE AGUA SI NO ENTIENDE LAS INSTRUCCIONES No hacer caso de esta advertencia podr a originar lesiones graves o mortales Safety Instructions e Installation Operation Care and Maintenance Troubleshooting Parts List For Your Safety AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER 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 othe
36. RE GAUGE ALTERNATE RECOMMENDED INSTALLATION HORIZONTAL MOUNTING FIGURE 41 Strange Sounds Possible noises due to expansion and contraction of some metal parts during periods of heat up and cool down do not represent harmful or dangerous conditions Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal See Condensation section Draft Hood Operation Check draft hood operation bv 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 drvers 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 A new water heater is filled with cold water for the first time Burning gas produces water vapor In water heaters particularly high efficiency models where flue temperatures are lower Large amounts of hot water are used in a short time and the refill water in the tank is very cold Moisture from the
37. SIZE Em 18 Vent onnectors c E 18 19 Chimney Connections si i 19 Vertical Exhaust Gas Vent 19 WATER SYSTEM PIPING iere en tiet etait o Barber 20 21 Piping iInstallatlon ie e trieste oae soles Eo f e D Lied i ta dave aer a 20 Closed System Thermal Expansions eet d ette Ssbbw 21 Temperature and Press re Relief Valve 3 uu gentes EE esee beet tee eive reip eosdebet 21 T amp P Relief Valve and 1 6 21 OPERATING YOUR WATER HEATER bii bom tes ut ta 22 24 Lighting InsStr ctions ois A A oerte eit ted e Erat ku e WE A 22 CHECKING the 23 B tn r Flameas xiii ssa i rt re e HERE BA a p A 23 Emergency SHUE DOWM eni dete utei quinis 23 Water Temperature Regulation 8 reset pases sss sanas adn na uaa 23 24 SERVICE AND ADJUSTMENT hin tet o eot eo ete tc torre Erie en eee be eee eue ole 25 27 Tank Sediment Clearing iecore Er pi a L a pede e b E rrt Pe Ve De mede ea din 25 Vent System INSPECTION Hs icc cetero tre voce e bt IN due Eo erga is 25 B rner INSPECTION ELTE 25 Burner Cleaning
38. TER AND FLAME ARRESTOR CLEAN IF LINT ACCUMULATIONS ARE NOTICED INSTALLED IN SUITABLE AREA To ensure sufficient ventilation and combustion air supply proper clearances from the water heater must be maintained See Installation Instructions Combustible materials such as clothing cleaning materials or flammable liquids etc must not be placed against or adjacent to the water heater because they could catch on fire Anode Rod Inspection CAUTION Avoid water heater damage Inspection and replacement of anode rod required The anode rod is used to protect the tank from corrosion Most hot water tanks are equipped with an anode rod The submerged rod deteriorates to protect the tank Instead of corroding the tank water ions attack and eat away the anode rod This does not affect the water s taste or color The rod must be maintained to keep the tank in operating condition Anode deterioration depends on water conductivity not necessarily water condition A corroded or pitted anode rod indicates high water conductivity and should be checked and or replaced more often than an anode rod that appears to be intact Replacement of a depleted anode rod can extend the life of your water heater Inspection should be conducted by calling the Sears Service Center for an authorized contractor At a minimum the anode s should be checked annually after the warranty period 26 Temperature Pressure Relief Valve Operation
39. ain 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 aconcentration of sulfate in the supply water little or no dissolved oxygen in the water a sulfate reducing bacteria within the water heater This harmless bacteria is non toxic to humans an excess of active hydrogen in the tank This is caused by the corrosion protective action of the anode Smelly water may be eliminated or reduced in some water heater models by replacing the anode s with one of less active material and then chlorinating the water heater tank and all hot water 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 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 WARNING
40. als that may contaminate the potable water supply must not be added to the piping system To protect against untimely corrosion of hot and cold water fittings it is strongly recommended that dielectric unions or couplings be installed on this water heater when connected to copper pipe 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 the harmful effects of thermal expansion Thermal expansion tanks are available from Sears stores and through the Sears Service Centers Contact the local plumbing inspector water supplier and or the Sears Service Center for assistance in controlling these situations For additional in
41. and damage The length of the vent connector cannot exceed 75 of the vertical vent height The vent connector must be accessible for cleaning inspection and replacement Vent connectors cannot pass through any ceiling floor firewall or fire partition It 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 The connector must be installed above the extreme bottom of the chimney to prevent potentially blocking the flue gases The connector must be firmly attached and sealed to prevent it from falling out 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 MNIMUM
42. and pressure relief valve should be used with your water heater Do not use an old or existing valve as it may be damaged or not adequate for the working pressure of the new water heater Do not place any valve between the relief valve and the tank The Temperature amp Pressure Relief Valve Must not be in contact with any electrical part Must be connected to an adequate discharge line Must not be rated higher than the working pressure shown on the rating plate of the water heater Discharge Line Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line Must not be capped blocked plugged or contain any valve between the relief valve and the end of the discharge line Must terminate a maximum of six inches above a floor drain or external to the building Must be capable of withstanding 250 F 121 C without distortion Must be installed to allow complete drainage of both the valve and discharge line T amp P Relief Valve and Pipe Insulation The 1 Locate the T amp P Relief Valve on the water heater 2 Locate the slit running the length of the insulation 3 Spread this slit open and slip it up under the T amp P Relief Valve See Figure 25 Apply gentle pressure to the insulation to ensure it is fully seated on the T amp P Relief Valve Once sealed secure the insulation with a section of tape IMPORTANT The insulation or tape should not block
43. ank should be installed on all closed systems to control the harmful effects of thermal expansion Thermal expansion tanks are available from Sears stores and through the Sears Service Centers Contact the local plumbing inspector water supplier and or the Sears Service Center for assistance in controlling these situations See Figure 41 TABLE 4 Thermal Expansion Tank Specifications Tank Dimensions Pipe Capacity in Inches Fitting In Gallons On Tank 153 331020 8 203 mm 12 3 4 323 mm 3 4 Male 153 331050 11 279 mm 14 3 4 375 mm 3 4 Male Model Number TABLE 5 Expansion Tank Sizing Chart Inlet Water Pressure 40psi Water Heater Capacitv Gallons Expansion Tank Capacitv 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 COLD WATER INLET FITTING 3 PRESSURE REDUCING VALVE WITH BY PASS 2 D INLET COLD WATER SHUT OFF HOT C COLD PRESSURE GAUGE RECOMMENDED INSTALLATION VERTICAL MOUNTING WATER HEATER COLD WATER INLET FITTING FLOOR CEILING JOIST ETC 3 PRESSURE REDUCING VALVE WITH BY PASS INLET COLD WATER SHUT OFF N 1 EXPANSION TANK 2 PRESSU
44. ble vapor ignition resistant water heaters and have a thorough understanding of this instruction manual Service Agency 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 strictly in accordance with the service guidelines provided by the manufacturer Gas Supplier The natural gas or propane utility or service who supplies gas for utilization by the gas burning appliances within this application The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the natural gas meter or propane storage tank of a building Many gas suppliers also offer service and inspection of appliances within the building AWARNING FIRE AND EXPLOSION HAZARD Can result in serious injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Storage of or use of gasoline or other flammable vapors or liquids in the Flammable Vapors vicinity of this or any other appliance can result in serious injury or death Read and follow water heater warnings and instructions Sears Roebuck and Co
45. ch 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 Based on total BTUH input rating for all utilizing equipment utilization equipment in the confined area but not less than 100 within the confined space square inches Figure 13 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 require each opening to have a minimum free area of 25 square inches Minimum free area 50 000 BTUH x 1 sq in 2000 BTUH 25 sq in Minimum Free Area of Permanent Openings for Ventilation and Combustion Air Supply All Air from Outdoors Only PERMANENT OPENINGS 1 SQUARE These openings connect directly with the outdoors through a ventilated attic a ventilated crawl space or through an outside MINIMUM wall 100 SQ IN Ses pe Consult the local codes of your area for specific ventilation and combustion air requirements INCH 1000 GABLE VENT TO OUTDOORS FIGURE 13 INSTALL ABOVE INSULATION DD bii Air from Outdoors Outdoor fresh air can be provided to a confined area either directly or by the use of vertical and
46. d 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 Figures 19 21 Install the vent connector avoiding unnecessary bends which create resistance to the flow of vent gases Install without dips or sags with an upward slope of at least 1 4 inch per foot Joints must be fastened by sheet metal screws or other approved means It must be supported to maintain clearances and prevent separation of joints
47. e Figure 10 may be used as a reference guide to locate the specific clearance locations A minimum of 24 inches of front clearance should be provided for inspection and service FRONT 247 MINIMUM FOR SERVICE FIGURE 10 Filling the Water Heater Never use this water heater unless it is completelv full of water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater To fill the water heater with water Close the water heater drain valve by turning the handle to the right clockwise The drain valve is on the lower front of the water heater Open the cold water supply valve to the water heater NOTE The cold water supply valve must be left open when the water heater is in use To ensure complete filling of the tank allow air to exit by opening the nearest hot water faucet Allow water to run until a constant flow is obtained This will let air out of the water heater and the piping Check all water piping and connections 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 in
48. e manifold burner assembly door to the combustion chamber and tighten securely Once the manifold burner assembly door is tightened visually inspect the door gasket between the manifold burner assembly door and the combustion chamber for spaces or gaps that would prevent a seal IMPORTANT Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber During the following procedure do not cross thread or apply any thread sealant to any of the fittings listed below First reconnect the manifold tubing to the gas control valve thermostat NOTE If a ferrule nut needs to be installed for the pilot tube locate the one provided with your parts kit Install it in the gas control valve thermostat at the pilot location hand tight only Next insert the pilot tube into the ferrule nut until it bottoms out NOTE Hold the tube in this position Tighten the ferrule nut with a wrench until the crimp connection seals to the pilot tube Continue to tighten until the nut is tight in the gas control valve thermostat Plug the thermopile plug into the gas control valve thermostat Also connect the two wire leads that go to the thermal switch if they had been removed Reconnect the igniter wire and tank sensor plugs Turn gas supply on and refer to the Lighting Instructions With the burner lit check the gas control valve thermostat supply line two piece wire connector mani
49. ent 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 37 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 replacement of the entire gas control valve thermostat If the ECO should activate the water heater cannot be used until the gas control valve thermostat is replaced by a qualified technician Contact Sears at 1 800 4 MY HOM
50. ey and aggravation The Master Protection Agreement also helps extend the life of your new product Here s what the Agreement includes Parts and labor needed to help keep products operating properly under normal use not just defects Our coverage goes well beyond the product warranty No deductibles no functional failure excluded from coverage real protection Expert service by 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 guarantee replacement of your covered product if four or more product failures occur within twelve months Product replacement if your covered product can t be fixed Annual Preventive Maintenance Check your request no extra charge Fast help by phone call it Rapid Resolution phone support from a Sears representative on all products Think of us as a talking owner s manual Power surge protection against electrical damage due to power fluctuations c Leaks in pipes or fittings 250 Food Loss Protection annually for any food spoilage that is the result of mechanical failure of any covered refrigerator or freezer Rental reimbursement if repair of your covered product takes longer than promised 10 discount off the regular price of any non
51. f petroleum Propane L P gases Adequate pipe size and approved pipe material An approved noncorrosive leak detection solution used to check all connections and fittings for possible gas leaks Correct any leak found INSTALLATION INSTRUCTIONS Open a nearby hot water faucet and leave it open to allow for draining Allow the hot water to run until water flowing from the faucet is 100 F or less Connect a hose to the drain valve Removing the Old Water Heater 1 and terminate to an adequate eae drain or outdoors Make sure all SHUT OFF VALVE 7 connections are tight and that the Tom DISCHARGE PIPE water flow is directed awav from people Open the drain valve rem and allow the tank to drain See UNION GAS CONTROL Figures 2 deg FIGURE 5 VALVE CHECK WITH THERMOSTAT LOCAL UTILITV FOR MINIMUM HEIGHT Disconnect the vent pipe from the draft hood where it connects 4 DRAIN VALVE 3 MINIMUM 1 6 MAXIMUM DRIP Leg 77 Y AIR GAP SUITABLE V DRAIN FIGURE 2 Turn OFF the gas supply to the water heater If the main gas line shutoff valve serving all gas appliances is used also shut OFF the gas at each appliance Leave all gas appliances shut OFF until the water heater installation is completed See Figures 2 and 3 Turn OFF the water supply to t
52. fold tube and pilot tube connections for leaks Check for leaks by brushing on an approved noncorrosive leak detection solution Bubbles forming indicate a leak Correct any leak found IMPORTANT All leaks must be fixed immediately Replace the outer door FLAME ARRESTOR BRACKET FIGURE 38 32 CLOSE UP INSIDE VIEW OF THE COMBUSTION CHAMBER BRACKET MANIFOLD TUBE FIGURE 39 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 40 Use only factory authorized piezoelectric igniter parts for replacement ELECTRONIC CONTROL MODULE PILOT ASSEMBLY PILOT THERMOPILE IGNITER BUTTON IGNITER WIRE PILOT BRACKET NOTE SPARK GAP DISTANCE MEASURED FROM ELECTRODE TIP TO PILOT FIGURE 40 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 t
53. formation see the Troubleshooting Guide later in this manual Temperature and Pressure Relief Valve AWARNING Temperature pressure relief valve must comply with ANSI Z21 22 CSA 4 4 and ASME code Properly sized temperature pressure relief valve must be installed in opening provided Can result in overheating and excessive tank pressure Can cause serious injury or death TEMPERATURE AND PRESSURE T amp P RELIEF VALVE OPTIONAL TOP T amp P RELIEF VALVE NOT SHOWN DISCHARGE PIPE DO NOT CAP OR PLUG DRAIN LINE 3 4 ID MINIMUM 1 MINIMUM e 6 MAXIMUM AIR GAP METAL DRAIN PAN i gt DRAIN FIGURE 24 21 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 Z21 22 The function of the temperature and pressure relief valve is to discharge water in large quantities in the event of excessive temperature or pressure developing in the water heater The valve s relief pressure must not exceed the working pressure of the water heater as stated on the rating plate IMPORTANT Only a new temperature
54. he 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 FVIR System Operational Checklist Manifold gasket properly sealed Viewport not damaged or cracked Flame arrestor free of debris and undamaged Two piece wire connector properly installed No leaks at pilot and manifold connection Manifold door screws securely tightened QUE a Depress the button on thermal switch TROUBLESHOOTING GUIDE Start Up Conditions Thermal Expansion CAUTION e Avoid water heater damage e 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 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 t
55. he water heater at the water shut off valve or water meter Some installations require that the water be turned off to the entire house See Figures 2 and 4 FIGURE 4 Check again to make sure the gas supply is OFF to the water heater Then disconnect the gas supply connection from the gas control valve ADANGER Burnhazard Hot water discharge Keep hands clear of drain valve discharge 11 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 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 reconnec
56. hnician Refer to the Draining and Flushing section 28 ELECTRONIC CONTROL MODULE LOCKING THERMOPILE SENSOR IGNITER GAS VALVE ASSEMBLY GAS VALVE ASSEMBLY FRONT VIEW WITH ELECTRONIC CONTROL MODULE REMOVED LOCKING LOCKING TAB TORX PILOT BURNER TAB SCREW TUBE TUBE FIGURE 31 29 MAINTENANCE OF YOUR WATER HEATER Replacement Parts IMPORTANT The following maintenance procedures are for the FVIR System components and should be performed by a qualified technician Replacement parts may be ordered from Sears Parts and Service Centers or by calling 1 800 4 MY HOME 1 800 469 4663 When ordering replacement parts always have the following information ready 1 model serial and product number 2 typeofgas 3 item number 4 parts description See the Parts Order List section for a list of available repair parts External Inspection amp Cleaning of the Base Ring Filter 1 Atleast annually check the base ring filter Figure 37 for any dust or debris that may have accumulated on the filter screen NOTE If the water heater is located in an area that is subjected to lint and dirt it may be necessary to check the base ring filter more frequently Follow the Lighting Instructions to turn off the water heater and allow it to cool for 10 minutes before attempting to clean the base ring filter 3 Use a vacuum cleaner with a hose attachment to remove any dust o
57. ich will satisfy space heating clothes washing dish washing and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally handicapped If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at the hot water taps used by these people or at the water heater Mixing valves are available at plumbing supply or hardware stores 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
58. ings Tank Sensor Upper and Lower 9006163 9006163 T amp P Relief Valve 9000728 9000728 Two Piece Wire Connector w Clip 9006794 9006794 MODEL NUMBER SERIAL NUMBER GAS NATURAL OR PROPANE L P PART DESCRIPTION THIS IS A REPAIR PARTS LIST NOT A PACKING LIST 40 09 NOTES 41 NOTES 42 NOTES 43 Get it fixed ati our home or ours Your Home For expert troubleshooting and home solutions advice manage f www managemyhome com For repair in your home of all major brand appliances lawn and garden equipment or heating and cooling systems no matter who made it no matter who sold it For the replacement parts accessories and owner s manuals that you need to do it yourself For Sears professional installation of home appliances and items like garage door openers and water heaters 1 800 4 MY HOME 1 800 469 4663 Call anytime day or night U S A and Canada www sears com www sears ca Our Home For repair of carry in items like vacuums lawn equipment and electronics call anytime for the location of your nearest Sears Parts amp Repair Service Center 1 800 488 1222 U S A 1 800 469 4663 Canada www sears com WWW Sears ca To purchase a protection agreement on a product serviced by Sears 1 800 827 6655 U S A 1 800 361 6665 Canada Para ped
59. ion Chemical vapor corrosion of the flue and vent system may occur if air for combustion contains certain chemical vapors Spray can propellants cleaning solvents refrigerator and air conditioner refrigerants swimming pool chemicals calcium and sodium chloride waxes bleach and process chemicals are typical compounds which are potentially corrosive If when inspecting the vent system you find sooting or deterioration something is wrong Call the local gas supplier to correct the problem and clean or replace the flue and venting before resuming operation of the water heater Burner Inspection Flood damage to a water heater may not be readily visible or immediately detectable However over a period of time a flooded water heater will create dangerous conditions which can cause DEATH SERIOUS BODILY INJURY OR PROPERTY DAMAGE Contact a Sears Service Center to replace a flooded water heater Do not attempt to repair the unit It must be replaced Atleast 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 Burne
60. ion SMOKING AND CARBON Insufficient secondary air Provide ventilation to water heater Check flue FORMATION SOOTING way flue baffle burner Low gas pressure 2 Water heater flue or vent system 3 blocked Thermostat not functioning properly 4 Replace thermostat 5 6 Check with gas utility company Clean locate source and correct Provide fresh air ventilation See Burner Flame Yellow Lazy Heater installed in a confined area Burner flame yellow lazy BURNER FLAME FLOATS Orifice too large 1 Replace with correct orifice AND LIFTS OFF PORTS High gas pressure 2 Check with gas utility company Water heater flue or vent system 3 Clean flue and burner locate source and correct blocked Cold drafts 4 Locate source and correct BURNER FLAME TOO HIGH 1 Orifice too large 1 Replace with correct orifice FLAME BURNS AT ORIFICE 1 Thermostat not functioning properly Replace thermostat 5 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 38 PILOT LIGHT TROUBLESHOOTING FLOWCHART Section A Pilot light will not light new installation Section C Pilot light will not remain lit Check for insufficient combustion air Is the manual gas shut off valve located in the supply line to the water heater in the on position Turn the manual gas shut off valve to the on position and
61. ir servicio de reparaci n Au Canada pour service en francais a domicilio y para ordenar piezas 1 800 LE FOYER 1 888 SU HOGAR 1 800 533 6937 1 888 784 6427 WWW sears ca Sears Registered Trademark M Trademark SM Service Mark of Sears Brands LLC Marca Registrada M Marca de F brica SM Marca de Servicio de Sears Brands LLC MC Marque de commerce MD Marque d pos e de Sears Brands LLC Sears Brands LLC
62. le 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 METAL DRAIN PAN PIPED TO AN ADEQUATE DRAIN 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 drain pan piped to a drain However unanticipated damage can be reduced or prevented by a leak detector or water shut off device used in conjunction with a piped drain pan These devices are available from some plumbing supply wholesalers and retailers and detect and react to leakage in various ways Sensors mounted in the drain pan that trigger an alarm or turn off the incoming water to
63. m Operational Checklist sibi b o ete Ed ek eee ro e er i rd 32 TROUBEESHOOTING GUIDE a en eee al Ltd eter Pes ee 33 35 Start Up Gondilloris ate tte ct et eed ere eire tti dient b B d LOL Io et redes ete tet ente deti 33 34 Operational Gonditlons e tee erat tie bet ee ite ved ee tie d tt 34 35 TROUBLESHOOTING CHART ctt eth ao eoi rete eerte eet edt 36 38 PILOT LIGHT TROUBLESHOOTING 39 PARTS ORDER tini ERR Esto rtt 40 PRODUCT WARRANTY new water heater for one that develops a leak States 12 YEAR LIMITED WARRANTY ON WATER HEATER For twelve years from date of purchase if this water heater is installed and operated in a single family home in accordance with the owner s manual instructions and all local applicable codes Sears will supply a free water heater for one that develops a leak For the second through twelfth year from purchase date you must pay the labor cost for installation of the water heater 3 YEAR LIMITED WARRANTY ON PARTS For three years from date of purchase if this water heater is installed and operated in a single family home in accordance with the owner s manual instructions and all local applicable codes if a part fails due to materials or workmanship Sears will supply a free replacement part After one year from purchase date y
64. march Park Quincy MA 02269 f after reading this manual you have any questions or do not understand any portion of the instructions call the Sears Service Center Carefully plan the place where you are going to 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 and 248 CMR 5 00 Complies with 40 Ng J NOx requirements of Texas and most California AQM Districts WARNING Use two or more people to move and install the water heater Failure to do so can result in injurv including back injurv IMPORTANT Do not remove anv permanent instructions labels or the data label from either the outside of the water heater or on the inside of water heater panels
65. n 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 2 Minimum Square BTUH Input Feet with 8 Ceiling 30 000 45 000 60 000 Typical Room with 8 Ceiling lt gt Co 75 000 90 000 105 000 6 28 37 46 56 5 1 5 9 3 7 Typical Room with 8 Ceiling 120 000 25 x 30 135 000 28 x 30 IMPORTANT The area must be open and be able to provide the proper air requirements to the water heater Areas that are being used for storage or contain large objects may not be suitable for water heater installation Water heaters installed in open spaces in buildings with unusually tight construction may still require outdoor air to function properly In this situation outside air openings should be sized the same as for a confined space Modern home construction usually requires supplying outside air into the water heater area
66. n 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 18 using the manufacturer s instructions and local codes rules or regulations IMPORTANT f 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 AC DRAFT HOOD 191 3 sLor x JACKET TOP INSTALL THE 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 hoo
67. ner compartment NOTE Be sure notto damage internal parts Removing the Burner from the Manifold Burner Assembly 1 Take off the burner by removing the two 2 screws located underneath the burner Check the burner to see if it is dirty or clogged The burner may be cleaned with soap and hot water Figure 34 BURNER BOTTOM VIEW FIGURE 34 Replacing the Pilot Pilot Tube Assembly 1 Remove the manifold assembly Manifold Burner Assembly See Removing the Remove the retainer clip from the back of the two piece wire connector using a flat blade screw driver then remove the two piece wire connector from the manifold door Figure 35 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 Remove the burner by removing the two 2 screws located beneath it Keep the screws for future use 11 12 13 14 Remove the screw that secures the pilot shield and pilot assembly to the pilot bracket Figure 35 Keep the screw for future use Loosen the nut securing the pilot tube to the pilot assembly NOTE To prevent any bending of the pilot bracket use pliers to hold the pilot assembly bracket while loosening the pilot nut Pull the pilot tube from the pilot assembly Figure 35 IMPORTANT Be careful not to bend or alter the position of the pilot assembly components Using the old pilot pilot tube assembly as
68. not operate if soot is present Use only gas shown on rating plate WIN 221 not obstruct water heater air intake Maintain required clearances to combustibles with insulating jacket Keep ignition sources away from faucets after extended Do not place chemical vapor emitting period of non use products near water heater Gas carbon monoxide detectors Read instruction manual before are available installing using or servicing water heater Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Improper installation and use may result in property damage Do not operate water heater if flood damaged Inspect and replace anode Install in location with drainage Fill tank with water before operation Be alert for thermal expansion Refer to instruction manual for installation and service TABLE OF CONTENTS SAFE INSTALLATION USE AND 2 OSAFETLY PREGAUTIONS oer tore eee tte 2 3 PRODUCT WARRANTY iter ete ettet tereti net 6 CUSTOMER RESPONSIBIELITIES 5 4o ott ti eter eot ee ad ete eot etu 7 PRODUGCT SPEGIFICATIONS i ette eh etae e e REDE ERU A tet ie uS 7 MATERIALS AND BASIC TOOLS NEEDEB nere ert e ERE vH Eee 8 TYIPICATEINS TAEEATION E 9 IMPORTANT INFORMATION ABOUT THIS WATER
69. ny AWARNING Explosion Hazard Replace view port if glass is missing or damaged Failure to do so can result in death explosion or fire 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 e Do not try to light any appliance eDo not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions GAS CONTROL FIGURE A PIEZO 5 IGNITOR STATUS OFF POSITION LED GAS CONTROL Turn gas control knob fullv counterclockwise 75 to OFF SEE FIGURE Remove the outer burner door located below the gas control Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above on this label If you dont smell gas em go to next step This unit is equipped with a push button pilot ignitor which is used to light the pilot Locate the ignitor on the gas control Turn gas control knob clockwise C to PILOT SEE FIGURE The pilot is located on the left side of the burner It can be located by looking thr
70. on ASME American Society of Mechanical Engineers 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 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 Battery
71. or cover the T amp P Relief Valve drain opening Also the insulation or tape should not block or hinder access to the T amp P Relief Valve manual relief lever 4 Next locate the hot water outlet amp cold water inlet pipes to the water heater 5 Selectone ofthe sections of pipe insulation and locate the slit that runs the length of the insulation 6 Spread the slit open at the base of the insulation and slip it over the cold water inlet pipe Apply gentle pressure along the length of the insulation to ensure it is fully seated around the cold water pipe Also ensure that the base of insulation is flush with the water heater Once seated secure the insulation with a section of tape T Repeat steps 5 through 6 for the hot water outlet pipe T amp P RELIEF VALVE INSULATION ejt MANUAL RELIEF LEVER T amp P RELIEF VALVE T amp P RELIEF VALVE DRAIN LINE FIGURE 25 OPERATING YOUR WATER HEATER Lighting Instructions Read and understand these directions thoroughly before attempting to light or re light the pilot Make sure the view port is not missing or damaged See Figure 33 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 compa
72. ot e Assembly AES Thermopile Connector FIGURE 36 31 Cleaning the Combustion Chamber and Flame arrestor 1 Follow procedure outlined in Removing the Manifold Burner Assembly 2 Use a vacuum cleaner shop vac to remove all loose debris in the combustion chamber Figure 37 Use compressed air to clear any dust or debris that may have accumulated in the flame arrestor COMBUSTION CHAMBER FLAME ARRESTOR FIGURE 37 3 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 two piece wire connector 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 installation Inspect the view port for damage and replace as required Insert the manifold burner assembly into the burner 11 compartment making sure that the tip of the manifold tube engages in the slot of the bracket inside the combustion chamber Figures 38 amp 39 Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion chamber Replace the two screws which secure th
73. ou must pay the labor cost for installation of the part 1 YEAR EXCLUSIVE KENMORE LABOR WARRANTY For the first year from the date of purchase Sears will free of charge supply and install new water heater parts for defective ones or a WARRANTY SERVICE To obtain warranty service call 1 800 4 MY HOME 1 800 469 4663 This warranty applies only while this product is in use in the United For commercial institutional industrial or residential use by two or more families the above limited warranty for tanks that leak is effective for two years from the date of purchase and the above limited parts warranty is effective for one year from the date of purchase This warranty gives you specific legal rights and you may also have other rights which vary from state to state Sears Roebuck and Co Dept 817 WA Hoffman Estates IL 60179 The price of your water heater does not include a free checkup service call On water heater installations arranged by Sears Sears warrants the installation A charge will be made on service calls due to poor or incomplete installation These include a Adjusting thermostat b Condensation Master Protection Agreements Congratulations on making a smart purchase Your new Kenmore product is designed and manufactured for years of dependable operation But like all products it may require preventive maintenance or repair from time to time That s when having a Master Protection Agreement can save you mon
74. ough the glass view port while pressing the piezo ignitor button several times Look for a spark at the pilot location Figure D Oncethe pilot has been found push the gas control knob all the way in toward the water heater Immediately STOP Read the safety information above on this label FIGURE B PILOT POSITION CONTROL KNOB FLAMMABLE BEFORE LIGHTING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES 1f you cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control 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 D Do not use this appliance if any part has been under water Immediately contact a qualified installer or service agency to replace a flooded water heater Do not attempt to repair the unit It must be replaced FIGURE MAIN BURNER 7 ON POSITION FIGURE D press the piezo ignitor button rapidiv 4 or 5 times If the pilot will not light repeated steps 2 through 8 9 Continue to hold the gas control knob in for about 30 seconds after the pilot is lit until the status L E D is flashing one flash every three seconds is normal Release the gas control knob and the pilot should remain lit If it goes out repeat steps 2 through
75. 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 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 metal parts and will disappear in a short while Operational Conditions Smelly Odor In each water heater there is installed at least one anode rod see parts section for corrosion protection of the tank Cert
76. r assembly to trip Is the water heater installed in a closet or other small enclosed space If so Are there openings for make up air to enter and exit the room area Are the openings of sufficient size Remember if there are other gas fired or air consuming appliances in the same room you need more make up air Refer to the Installation Instructions and Combustion Air Supply and Ventilation sections for specific requirements Make sure that fresh air is not taken from areas that contain negative pressure producing devices such as exhaust fans dryers fireplaces etc Is there a furnace air handler in the same room space as the water heater If so has a return air duct system been attached that exits the room If so check for leaks on the air duct system If no air duct system is present correct immediately by contacting a local Heating Ventilation Air Conditioning amp Refrigeration HVAC R authorized service provider Use a fresh air supply that is free of corrosive elements and flammable vapors 10 Fresh air openings must be sized correctly with consideration given to the blocking effect of louvers and grilles Ductwork must be the same cross sectional area as the openings Vent Pipe System Check for proper drafting at the water heater draft hood Refer to the Checking the Draft section of this manual for the test procedure If the procedure show
77. r 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 In the event your burner needs cleaning follow these instructions If inspection of the burner shows that cleaning is required turn the gas control knob counterclockwise to OFF position depressing slightly NOTE The knob cannot be turned from PILOT to OFF unless knob is depressed slightly DO NOT 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 ADANGER e 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 arrestor 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 FIL
78. r appliance WHAT DO IF YOU SMELL GAS e Donottry tolightany appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Sears Roebuck and Co Hoffman Estates IL 60179 U S A PRINTED IN U S A 1208 WWW Sears com PART NO 186422 001 SUPERSEDES 186422 000 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 Manv safetv related messages and instructions have been provided in this manual and on vour own water heater to warn vou 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 DANGER result in death or serious injury WARNING indicates a potentially haza
79. r debris that may have accumulated on the filter NOTE If unable to inspect or clean the base ring filter follow the Cleaning the Combustion Chamber and Flame arrestor instructions After the base ring filter has been cleaned follow the Lighting Instructions to return the water heater to service 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 Turn the temperature dial to the OFF position ELECTRONIC CONTROL MODULE l Q 8 PLUG PILOT MANIFOLD TUBE TUBE FIGURE 32 3 Remove the outer door Remove the two screws securing the manifold door assembly to the combustion chamber Figure 33 30 GAS CONTROL VALVE THERMOPILE THERMOSTAT PLUG PIEZO IGNITER BUTTON i 8 L MANIFOLD TUBE i THERMISTOR 577 WIRES THERMAL 7 SWITCH MANIFOLD DOOR TWO PIECE WIRE CONNECTOR MANIFOLD SCREWS 2 FIGURE 33 Disconnect the following from the gas control valve thermostat thermopile plug tank sensor plug igniter wire plug pilot tube and manifold tube See Figures 32 amp 33 Grasp the manifold tube and push down slightly to free the manifold and pilot tubes Carefully remove the manifold burner assembly from the bur
80. rdous situation which if not avoided could result WARNING in death or serious 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 safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances WARNING This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances included in the Act IMPORTANT DEFINITIONS Qualified Technician A qualified technician must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters The qualified technician must also be familiar with the design features and use of flamma
81. re or explosion Maintain required clearances to combustibles Keep combustibles such as boxes magazines clothes etc away from the water heater area Site Location Selectalocation near the center of the water piping system The water heater must be installed indoors and in a vertical position on a level surface DO NOT install in bathrooms bedrooms or any occupied room normally kept closed Locate the water heater as close to the chimney or gas vent as practical Consider the vent system piping and combustion air supply requirements when selecting the water heater location The venting system must be able to run from the water heater to termination with minimal length and elbows Locate the water heater near the existing gas piping If installing a new gas line locate the water heater to minimize the pipe length and elbows The water heater should be located in an area not subject to freezing temperatures Water heaters located in unconditioned spaces i e attics basements etc may require insulation of the water piping and drain piping to protect against freezing The drain and controls must be easily accessible for operation and service Maintain proper clearances as specified on the rating plate Do not locate the water heater near an air moving device The operation of air moving devices such as exhaust fans ventilation systems clothes dryers fireplaces etc can affect the proper operation of the
82. s nee ILLIUS UENIUNT 25 Ims 26 Inspection deos oie te eter iui e aea ve Dee fak i e er sae eu Pa eels 26 Temperature Pressure Relief Valve Operation 0 seen 26 Draining arid Flushing iesus Ea Vc E EE e Qr PL dudes 26 27 A 27 SERVICE INSTRUCTIONS FOR THE GAS CONTROL VALVE THERMOSTAT 28 29 MAINTENANCE YOUR WATER BIEBA TE a i ata adeb see t 30 32 Repla ement Parts sis e i ra 30 External Inspection amp Cleaning of the Base Ring 30 Removing the Manifold Burner 30 Removing the Burner from the Manifold Burner Assembly 30 Replacing the Pilot Pilot Tube en nene nennen 30 31 Cleaning the Combustion Chamber and 31 Replacing the Manifold Burner 31 32 Piezoele tric Igniter Systelm exerted eee d E Regex Drei n DERI RE E E AR e 32 Testing tne I niter System s s cti e em e tec eed LU RO ETE e ERE RD is 32 FVIR Syste
83. s 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 Z223 1 NFPA 54 current edition O Flue baffle properly positioned in the flue tube O Check the vent system for restrictions obstructions and checkthe venttermination 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 piping properly installed and free of leaks Heater completely filled with water Closed system pressure build up devices installed Tempering valve when applicable installed per manufacturers instructions See Water Temperature Regulation section Gas Supply and Piping Gas type is the same as that listed on the water heater rating plate Gas line equipped with shut off valve union and drip leg Use pipe joint compound or teflon tape marked as being resistant to the action o
84. s 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 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 23 Water Temperature Regulation Water temperature over 125 F 52 C can cause servere burns instantly resulting in severe injury or death ADANGER Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting Due to the nature of the typical gas water heater the water temperature in certain situations may vary up to 30 F 16 7 C higher or lower at the point of use such as bathtubs showers sink etc HOTTER WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature wh
85. 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 the thermostat dial to the OFF position This dial is located on the gas control valve thermostat Turn off the gas to the water heater at the manual gas shut off valve Open nearby hot water faucets and leave them open to allow for draining Allow the hot water to run until water flowing from the faucets is 100 F or less Close the cold water inlet valve Connect a hose to the drain valve and terminate it to an adequate drain or outdoors Make sure all connections are tight and that the water flow is directed away from people Open the water heater drain valve and allow all the water to drain from the tank Flush the tank with water as needed to remove sediment 27 T Close the drain valve refill the tank and restart the heater as directed under the Operating Your Water Heater section 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 section 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 Contac
86. stallation Checklist Water Heater Location Water heater location is important and can affect svstem performance Please check the following Installation area free of corrosive elements and flammable materials Centrally located with the water piping system For new installations Located as close to the gas piping and vent pipe system as possible Located indoors and in a vertical position Protected from freezing temperatures Proper clearances from combustible surfaces maintained and not installed directiv on a carpeted floor Provisions made to protect the area from water damage Metal drain pan installed and piped to an adequate drain Sufficient room to service the water heater See Clearances and Accessibility section of this manual Water heater not located near an air moving device Is the installed environment dirty excessive amounts of lint dirt dust etc If so the base ring filter located on the bottom of the water heater will need to be cleaned periodically Refer to the Maintenance of your Water Heater section of this manual for information on cleaning the base ring filter Combustion Air Supply and Ventilation Check for sufficient combustion air supply Insufficient air for the combustion of gas will result in the flame becoming lazy thereby allowing heat to build up in the combustion chamber This excessive heat will cause a thermal switch on the doo
87. structions 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 14 codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition Table 1 on the following page provides a sizing reference for commonly used gas pipe materials Consult the National Fuel Gas Code for the recommended gas pipe size of other materials Refer to Figure 11 for the items below 1 Install a readily accessible manual shut off valve 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
88. t Sears Service Center at 1 800 4 MY HOME 1 800 469 4663 SERVICE INSTRUCTIONS FOR THE GAS CONTROL VALVE THERMOSTAT Tools required D Installing a Gas Control Valve Thermostat Full Assembiv NOTE Ifthe electronic control module gas valve and backplate are not assembled assemble them before proceeding 3 16 slotted screwdriver A 1 T15 Torx Screwdriver 2 3 Open end wrenches 7 16 and 3 4 For these instructions please see Figure 31 1 lfitis not needed remove the metal gas valve nipple from the gas control valve thermostat It is screwed onto the B Removing the Electronic Control Module threaded plastic nipple of the gas control valve thermostat s 1 Turn the gas control temperature knob to the OFF position backplate IMPORTANT You can use the metal gas valve nipple that is already installed in the tank However if you need to 2 Turn off the gas at the manual shut off valve on the gas supply line Figure 11 install a new gas valve nipple drain the water heater before removing the old one from the tank 3 Disconnect the wire connectors from the piezo igniter tank sensors and thermopile mounted on the lower front of the Serew the new gas control valve into the tank opening then gas control valve assembly hand tighten it DO NOT OVER TIGHTEN or damage mav result Check for water leaks when vou are finished 4 Remove the torx screw located beside the pilot tube on the
89. ted from the gas supply piping system and the line capped Ifthe gas lines are to be tested at a pressure less than 14 W C the water heater must be isolated from the gas supply piping system by closing its manual shut off valve NOTE Air may be present in the gas lines and could prevent the pilot from lighting on initial start up The gas lines should be purged of air by a qualified technician after installation of the gas piping system While purging the gas piping system of air ensure that the fuel is not spilled in the area of the water heater installation or any source of ignition If the fuel is spilled while purging the piping system of air follow the WHAT TO DO IF YOU SMELL GAS instructions on the cover of this manual 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 Size in 10 40 50 60 1600 1100 Length of Pipe Feet 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 Cu Ft Per Hr Required Gas Input of Water Heater BTU HR Heating Value of Gas BTU FT The gas input of the water heater is marked on the water heater data plate The heating value of the gas BTU FT may be determined by consulting the local natural gas utility
90. the valve being slightly opened G The drain valve may be leaking at the tank fitting Combustion products contain water vapor which can condense on the cooler surfaces of the tank Droplets form and drip onto the burner or run on the floor This is common at the time of start up after installation and when incoming water is cold Water in the water heater bottom or on the floor may be from condensation loose connections or the relief valve DO NOT replace the water heater until a full inspection of all possible water sources is made and necessary corrective steps taken Leakage from other appliances water lines or ground seepage should also be checked To check where threaded portion enters tank insert cotton swab between jacket opening and fitting If cotton is wet follow draining instructions in the Draining and Flushing section and then remove fitting Put pipe dope or teflon tape on the threads and replace When you are finished follow the steps in Filling the Water Heater in the Installation Instructions earlier in this manual TROUBLESHOOTING CHART PROBLEM LED STATUS POSSIBLE CAUSE S CORRECTIVE ACTION GAS CONTROL VALVE THERMOSTAT OFF Electronic control module off or pilot Check wiring harness for proper connection flame off Ignite pilot flame 1 flash Electronic control module is powered Normal operation No action required and pilot lit Inspect thermopile connection to gas control valve
91. the water heater when water is detected Sensors mounted in the drain pan that turn off the water supply to the entire home when water is detected in the drain pan Water supply shut off devices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply Insulation Blankets Insulation blankets available to the general public for external 13 use on gas water heaters are not necessary with Kenmore products The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters Your Kenmore water heater meets or exceeds the National Appliance Energy Conservation Act standards with respect to insulation and standby loss requirements making an insulation blanket unnecessary A WARNING Breathing Hazard Carbon Monoxide Gas Do not obstruct water heater air intake with insulating blanket Gas and carbon monoxide detectors are available Install water heater in accordance with the instruction manual Breathing carbon monoxide can cause brain damage or death Always read 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
92. ting 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 water heater by shutting off the gas supply to the water heater s burner and pilot preventing re ignition of any remaining flammable vapors in the area This will not prevent a possible fire explosion if the igniter is depressed and flammable vapors have accumulated in the combustion chamber with the pilot light off If you suspect a flammable vapor incident has occurred do not use this appliance Do not attempt to light this appliance or depress the igniter button
93. tion N Cold Water Inlet W Metal Drain Pan F Gas Supply Piping O Inlet Dip Tube X Piezo Igniter G Manual Gas Shut off Valve P Temperature Pressure Relief Valve Y Base RingFilter H Ground Joint Union Q Rating Plate Drip Leg Sediment Trap R Flue Baffle INSTALLINACCORDANCE WITH LOCAL CODES DRIP LEG AS REQUIRED A S GAS CONTROL VALVE BY LOCAL CODES 2 THERMOSTAT GAS CONTROL THERMOSTAT KNOB TO VENT TERMINATION ON ROOF ad im GAS VALVE 1 n ASSEMBLY L l ELECTRONIC CONTROL MODULE V A INSTALL THERMAL EXPANSION A TANK OR DEVICE IF WATER v2 M HEATER IS INSTALLED IN A CLOSED WATER SYSTEM VACUUM RELIEF VALVE INSTALL PER Madre U MANIFOLD BURNER ASSEMBLY MAIN BURNER P PILOT TUBE MANIFOLD 00 3 L IGNITER WIRE DISCHARGE PIPE EN DO NOT CAP OR PLUG 6 MAXIMUM m AIR GAP FLOOR DRAIN ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS FIGURE 1 9 IMPORTANT INFORMATION ABOUT THIS WATER HEATER This gas water heater was manufactured to voluntarv safetv standards to reduce the likelihood of a flammable vapor ignition incident The new technologv used in meeting these standards makes this product more sensitive to installation errors Please review the following checklist and make anv required installation upgrades or changes Questions7 Contact Sears at 1 800 4 MV HOME 1 800 469 4663 In
94. ystem should be installed only with piping that is suitable for potable drinkable water such as copper CPVC or polybutylene This water heater must not be installed using iron piping or PVC water piping Use only pumps valves or fittings that are compatible with potable water 20 1 MINIMUM IN A CLOSED SYSTEM USEA p a THERMAL EXPANSION TANK COLD WATER SUPPLY TO FIXTURES N PRESSURE REDUCING VALVE c WITH BYPASS A 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 di DRAIN LINE 3 4 ID MINIMUM MASSACHUSETTS INSTALL A VACUUM RELIEF IN COLD WATER LINE PER SECTION 19 MGL 142 6 MAXIMUM AIR GAP FIGURE 22 4 TEMPERED WATER UNTEMPERED TO FIXTURES HOT WATER COLD H one OUTLET MIXING VALVE SET TO 120 F FOLLOW THE MIXING VALVE MANUFACTURER S INSTRUCTIONS FIGURE 23 It is recommend that only full flow ball or gate valves are used in water piping installations The use of valves that may cause excessive restriction to water flow is not recommended Use only 95 5 tin antimony or other equivalent solder Any lead based solder must not be used Piping that has been treated with chromates boiler seal or other chemicals must not be used Chemic

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