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Kenmore 153.33062 Water Heater User Manual

1. instructions exactly a fire or explosion A This appliance has a pilot which is lighted by a C Use only your hand to push in or turn the gas control piezoelectric igniter When lighting the pilot follow these knob Never use tools If the knob will not push in or instructions exactly move by hand don t try to repair it call a qualified service B BEFORE LIGHTING smell all around the appliance area technician Force or attempted repair may result in a fire for gas Be sure to smell next to the floor because some or explosion gas is heavier than air and will settle on the floor D Do not use this appliance if any part has been under WHAT TO DO IF YOU SMELL GAS water Immediately call a qualified service technician to inspect the appliance Water heaters subjected to flood conditions or anytime the gas controls main burner or pilot have been submerged in water require replacement of the entire water heater E DO NOT USE THIS APPLIANCE IF THERE HAS BEEN AN IGNITION OF VAPORS Immediately call a qualified service Do not try to light any appliance Donot touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions aah i A Ifyou cannot reach you
2. ES O E ES O a a E E Sh ae wees E 6 YEAR LIMITED WARRANTY ON WATER HEATER on er aoc e For six years from the date of purchase if this water heater is installed and operated in a single family home in accordance with esl le the owner s manual instructions and all local applicable plumbing codes Sears will eat ne Es baal cn e Supply free water heater parts for those that are defective in material or workmanship ns Supply a free water heater for one that develops a leak eo a Sra ES For the second through the sixth year from purchase date you must pay the labor cost for installation of parts or water heater 55 eral see wien ee PEE n Esta SA E For commercial institutional industrial or residential use by two or more families the above limited warranty is only for two Ss ES years During the second year you must pay the labor cost for parts or water heater installation pang es eat ron 1 YEAR EXCLUSIVE KENMORE LABOR WARRANTY ES nel A i e ES For the first year from the date of purchase Sears will free of charge supply and install new water heater parts for defective ES ee ones or a new water heater for one that develops a leak ae a E tre WARRANTY SERVICE ES ae To obtain warranty service call 1 800 4 MY HOME 1 800 469 4663 ve ea 9 ES This warranty applies only while this product is in use in the United States i Goh This warranty gives you specific legal rights an
3. FIGURE 31 Testing the Igniter System Turn off the gas to the water heater at the manual gas shut off valve Watch the electrode tip while activating the igniter A visible spark should jump from the electrode To avoid shock do not touch the burner or any metal part on the pilot or pilot assembly If no spark is visible check the wire connections and make sure the electrode is not broken Replace the electrode if defective NOTE The electrode is part of the pilot assembly and cannot be replaced separately Dirt and rust on the pilot or electrode tip can prevent the igniter spark Wipe clean with a damp cloth and dry completely Rust can be removed from the electrode tip and metal surfaces by lightly sanding with an emery cloth or fine grit sandpaper Removing and Replacing the Gas Control Valve Thermostat IMPORTANT The gas control valve thermostat is a standard valve with a right hand thread thermocouple Use only factory authorized replacement parts Removing the Gas Control Valve Thermostat 1 Turn the gas control knob on the combination gas control valve thermostat clockwise to the OFF position NOTE Depress the dial stop on Robertshaw valves before turning the gas control knob See Lighting Instructions on the water heater 2 Turn off the gas at the manual shut off valve on the gas supply pipe Figure 3 3 Drain the water heater Refer to Draining section and follow the procedure 4 Disconnect the i
4. cleaning establishments or self service laundries with dry cleaning equipment it is imperative that the water heater or water heaters be installed so that combustion and ventilation air be taken directly from outdoors direct vent Propellants of aerosol sprays and volatile compounds cleaners chlorine based chemicals refrigerants etc in addition to being highly flammable in many cases will also change to corrosive hydrochloric acid when exposed to the combustion products of the water heater The results can be hazardous and also cause product failure Insulation Blankets Insulation blankets available to the general public for external use on gas water heaters are not necessary with Kenmore products The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters Your Kenmore water heater meets or exceeds the National Appliance Energy Conservation Act standards with respect to insulation and standby loss requirements making an insulation blanket unnecessary A WARNING 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
5. Number In Gallons On Tank 153 331020 8 203 mm 12 3 4 323 mm 3 4 Male 153 331050 11 279 mm 14 3 4 375 mm 3 4 Male Table 2 Expansion Tank Sizing Chart Inlet Water Heater Capacity Gallons Water 40 psi o eosi 2 2 5f 5 Power 2 2 5 55 sosi 2 5 5 5 5 Highest recorded inlet water pressure in a 24 hour period or regulated water pressure Expansion Tank Capacity Needed 26 NOTE Expansion tanks are pre charged with a 40 psi air charge If the inlet water pressure is higher than 40 psi the expansion tank s air pressure must be adjusted to match that pressure but must not be higher than 80 psi WATER HEATER 3 COLD WATER PRESSURE INLET FITTING REDUCING VALVE WITH BY PASS HOT INLET COLD WATER SHUT OFF 2 PRESSURE GAUGE RECOMMENDED INSTALLATION VERTICAL MOUNTING WATER HEATER COLD WATER INLET FITTING FLOOR CEILING JOIST ETC STRAPPING 3 PRESSURE REDUCING VALVE WITH BY PASS ran e Pa PRESSURE GAUGE INLET COLD WATER SHUT OFF a 1 EXPANSION TANK ALTERNATE RECOMMENDED INSTALLATION HORIZONTAL MOUNTING FIGURE 35 Strange Sounds Possible noises due to expansion and contraction of some metal parts during periods of heat up and cool down do nat represent harmful or dangerous conditions Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be c
6. TRATE DE INSTALAR U OPERAR ESTE CALENTADOR DE AGUA not use any phone in your building SI NO ENTIENDE LAS INSTRUCCIONES No hacer caso de esta J advertencia podr a originar lesiones graves o mortales immediately call your gas supplier froma neighbor s phone Follow the gas supplier s instructions 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 THE U S A 0609 www sears com PART NO 186190 002 SAFE INSTALLATION USE AND SERVICE Your safety and the safety of others is extremely important in the installation use and servicing of this water heater Many safety related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential 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 A DANGER situation which if not avoided will result in death or injury WARNING indicates a potentiall
7. The Master Protection Agreement also helps extend the life of your takes for you to schedule service You can call anytime day or night new product Here s what s included in the Agreement or schedule a service appointment online Expert Service by our 12 000 professional repair specialist Sears has over 12 000 professional repair specialists who have access to over 4 5 million quality parts and accessories That s the Unlimited service and no charge for parts and labor on all kind of professionalism you can count on to help prolong the life of your covered repairs new purchase for years to come Purchase your Master Protection Agreement today No lemon guarantee replacement of your covered product if four or more product failures occur within twelve months Some limitations and exclusions apply For prices and additional information call 1 800 827 6655 Product replacement if your covered product can t be fixed SEARS INSTALLATION SERVICE Annual Preventive Maintenance Check at your request no extra s charge For Sears professional Installation of home appliances garage door openers water heaters and other major home items in the U S A Fast help by phone phone support from a Sears technician all 1 800 4 MY HOME For in home major brand repair service Call 24 hours a day 7 days a week U S A and Canada SEARS 1 800 4 MY HOME 1 800 469 4663 www sears com The model number of
8. a concentration 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 an Anode Replacement Kit 9001453 and this Chlorination Treatment Anode replacement and chlorination of the tank are not covered by the water heater s limited warranty If the smelly water persists after the anode replacement and chlorination treatment it may be necessary to chlorinate or aerate your water supply to eliminate the problem Do not remove the anode leaving the tank unprotected By doing so all warranty on the water heater tank is voided AIR In Hot Water Faucets A WARNING Flammable hydrogen gases may be present Keep all ignition sources away from faucet when turning on hot water HYDROGEN GAS Hydrogen gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable and explosive To prevent the possibility of injury under these conditions
9. compressed air to clear any dust or debris that may have accumulated in the flame arrestor 3 Reassemble following the procedure under the Replacing the Burner Door Assembly section Replacing the Burner Door Assembly A WARNING Fire or Explosion Hazard _ Tighten both manifold door screws securely Remove any fiberglass between gasket and combustion chamber Replace viewport if glass is missing or damaged 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 A Read instruction manual before installing using or servicing water heater 1 O N gt 6 7 8 Check the door gasket for damage or imbedded debris prior to installation AWARNING Replace viewport if glass is missing or damaged Failure to do so can result in death explosion or fire Inspect the viewport for damage and replace as required Insert the burner door assembly into the combustion chamber and slide it completely forward Note When inserting the burner door assembly tip the burner end up slightly to ensure it engages with the burner bracket Inspect the door gasket and make sure there is no fiberglass insulation between the door gasket and the combustion chamber See Figure 30 Replace the two screws which secure the burner door assembly to the combustion
10. the water supply to the water heater at the water shut off valve or water meter Some installations require that the water be turned off to the entire house see Figures 2 and 4 FIGURE 4 When the water heater is drained disconnect the hose from f the drain valve Close the drain valve The water heater is now Check again to make sure the gas supply is OFF to the completely disconnected and ready to be removed Mineral water heater Then disconnect the gas supply connection from buildup or sediment may have accumulated in the old water the gas control valve heater This causes the water heater to be much heavier than normal and this residue if spilled out could cause staining ADANGER Burn hazard Hot water discharge Keep hands clear of drain valve discharge FIGURE 7 Facts to Consider About the Location Carefully choose an indoor location for the new water heater The placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance This water heater is not for use in manufactured mobile homes or outdoor installation Whether replacing an old water heater or putting the water heater in a new location the following critical points must be observed Select a location indoors as close as practical to the gas vent or chimney to which the water heater vent is going to be connected and as centralized with the w
11. 11 12 13 and 13A 11 The confined space shall be provided with two permanent openings one commencing within 12 inches 30 cm of the top and one commencing within 12 inches 30 cm from the bottom of the enclosure The openings shall communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors CHIMNEY OR GAS VENT VENTILATION LOUVERS SS EACH END OF ATTIC TT WATER HEATER rel Ii FURNACE INLET AIR DUCT ALT INLET AIR VENTILATION LOUVERS FIGURE 11 When directly communicating with the outdoors each opening shall have a minimum free area of 1 square inch per 4 000 Btu per hour 5 5 cm2 kW of total input rating of all equipment in the enclosure See Figure 11 When communicating with the outdoors through vertical ducts each opening shall have a minimum free area of 1 square inch per 4 000 BTU per hour 5 5 cm2 kW of total input rating of all equipment in the enclosure See Figure 12 e CHIMNEY OR GAS VENT VENTILATION LOUVERS Ss EACH END OF ATTIC AIR OUTLET WATER HEATER FURNACE INLET AIR DUCT ENDS 1 OR 30 cm ABOVE FLOOR FIGURE 12 When communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 square inch per 2 000 BTU per hour 11 cm kW of total input rating of all equipment in the enclosure See Figure 13 When ducts are used they shall be of th
12. Check all water piping and connections for leaks Repair as needed Venting VENT DAMPERS Any vent damper whether it is operated thermally or otherwise must be removed if its use inhibits proper drafting of the water heater Thermally Operated Vent Dampers Gas fired water heaters having thermal efficiency in excess of 80 may produce a relatively low flue gas temperature Such temperatures may not be high enough to properly open thermally operated vent dampers This would cause spillage of the flue gases and may cause carbon monoxide poisoning Vent dampers must bear evidence of certification as complying with the current edition of the American National Standard 15 ANSI 221 68 ANSI 221 66 67 respectively cover electrically and mechanically actuated vent dampers Before installation of any vent damper consult your local Sears Service Center or the local gas supplier for further information AWARNING Vent dampers must be certified in accordance with ANSI 221 68 Vent damper must permit proper drafting of water heater Install properly sized venting without venting Do not install outdoors Do not install without drafthood lf common vented install in accordance with NFPA 54 Be alert for obstructed or deterio rated vent system to avoid serious injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual To insure proper venting of this ga
13. Turn off the gas to the water heater at the manual gas shut off valve Figure 3 2 Turn the gas control knob on the combination gas control valve thermostat clockwise to the OFF position Figure 1 NOTE Depress the dial stop on Robertshaw valve before turning the gas control knob See Lighting Instructions on the water heater Remove the outer door Remove the two screws securing the burner door assembly to the combustion chamber Figure 24 GAS VALVE THERMOSTAT PIEZO IGNITER BUTTON THERMOCOUPLE MANIFOLD TUBE gt VIEWPORT Ey i PILOT 1 TUBE BURNER DOOR TWO PIECE WIRE SCREW 2 CONNECTOR FIGURE 24 5 Disconnect the thermocouple right hand thread pilot tube the igniter wire from the igniter button and manifold tube at the thermostat Figure 25 6 Grasp the manifold tube and push down slightly to free the manifold tube pilot tube and thermocouple 7 Carefully remove the burner door assembly from the combustion chamber Be sure not to damage internal parts ROBERTSHAW GAS VALVE 5 57 Q 4 You y YN Wy Sek op som ar I ka PILOT TUBE ae THERMOCOUPLE MANIFOLD TUBE FIGURE 25 21 Ultra Low NOx Natural Gas Burner Check the burner to see if it is dirty or clogged The burner may be cleaned with soft paint brush Figure 26 Do not use a wire brush or any too
14. and dilution of flue gases However in buildings of tight construction for example weather stripping heavily insulated caulked vapor barrier etc additional air may need to be provided using the methods described in Combustion Air and Ventilation for Appliances Located in Confined Spaces Combustion Air and Ventilation for Appliances Located in Confined Spaces CONFINED SPACE is a space whose volume is less than 50 cubic feet per 1 000 Btu per hour 4 8 m per kW of the aggregate input rating of all appliances installed in that space A ALL AIR FROM INSIDE BUILDINGS See Figure 9 on page 10 and Figure 10 below The confined space shall be provided with two permanent openings communicating directly with an additional room s of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination Each opening shall have a minimum free area of one square inch per 1 000 Btu per hour 22 cm kW of the total input rating of all gas utilization equipment in the confined space but not less than 100 square inches 645 cm One opening shall commence within 12 inches 30 cm of the top and one commencing within 12 inches 30 cm of the bottom of the enclosures CHIMNEY OR GAS VENT OPENINGS WATER HEATER FIGURE 10 B ALL AIR FROM OUTDOORS See Figures 9
15. bathtubs showers sink etc Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting ADANGER HOTTER WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes washing dish washing and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally handicapped If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at the hot water taps used by these people or at the water heater Mixing valves are available at plumbing supply or hardware stores Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat See Figures 21 and 22 Never a
16. 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 High Temperature Shut Off System This water heater is equipped with an automatic gas shutoff system This system works when high water temperatures are present The high temperature shutoff is built into the gas control valve It is non resettable If the high temperature shutoff activates the gas control valve must be replaced Turn OFF the entire gas supply to the water heater and contact your gas supplier TROUBLESHOOTING GUIDE BURNER WILL NOT IGNITE 1 Pilot not lit 1 Light pilot 2 Thermostat set too low 2 Turn temp dial to desired temperature 3 Nogas 3 Check with gas utility company 4 Dirt in the gas lines 4 Notify utility install trap in gas line 5 Pilot line clogged 5 Clean locate source and correct 6 Main burner line clogged 6 Clean locate source and correct 7 Non functioning thermocouple 7 Replace thermocouple 8 Non functioning thermostat 8 Replace thermostat 9 9 1 1 Heater installed in a confined area Provide fresh air ventilation SMELLY WATER Sulfides in the
17. Figure 1 for identification of components mentioned below Failure to follow these instructions can restrict the air flow required for proper combustion potentially resulting in fire asphyxiation serious personal injury or death Do not apply insulation to the top of the water heater as this will interfere with safe operation of the draft hood Do not cover the outer door thermostat or temperature 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 Do obtain new warning and instruction labels from Sears for placement on the blanket directly over the existing labels Do inspect the insulation blanket frequently to make certain it does not sag thereby obstructing combustion air flow Combustion Air and Ventilation for Appliances Located in Unconfined Spaces UNCONFINED SPACE is space whose volume is not less than 50 cubic feet per 1 000 Btu per hour 4 8 m per kW of the aggregate input rating of all appliances installed in that space Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors are considered a part of the unconfined space In unconfined spaces in buildings infiltration may be adequate to provide air for combustion ventilation
18. Gas Shut off Valve Q Temperature Pressure Relief Valve Ground Joint Union R Rating Plate INSTALL IN ACCORDANCE WITH LOCAL CODES T GAS CONTROL VALVE THERMOSTAT GAS CONG KNOB DRIP LEG AS REQUIRED BY LOCAL CODES TO VENT TERMINATION ON ROOF UNITROL WARNING READ ALL INSTRUCTIONS LBEFORE LIGHTING J TANK OR DEVICE IF WATER HEATER IS INSTALLED INA CLOSED WATER SYSTEM WATER TEMPERATURE ADJUSTING DIAL E gt d P VACUUM RELIEF q Ni D z wS gt J INSTALL PER y Se LOCAL CODES POSITION POSITION POSITION TOP VIEW V PILOT amp MAIN BURNER DISCHARGE PIPE MAIN BURNER PILOT TUBING Do not cap or plug A THERMOCOUPLE IGNITER ROD ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS FIGURE 1 7 INSTALLATION INSTRUCTIONS Removing the Old Water Heater 4 Attach a hose to the water heater Mwn0 gt gt drain valve and put the other end in a floor drain or outdoors Open the water heater drain valve Open a nearby hot water faucet which will relieve pressure in the water heater and speed draining The water passing out of the drain valve may be extremely hot To avoid being scalded make sure all connections are tight and that the water flow is directed away from any person see Figures 2 and 5 FIGURE 5 6 Disconnect the vent pipe from the draft hood wh
19. HEATERS HAVING A DIAMETER 19 05 mm OR 1 2 12 7 mm THREADED OR er 080 MOR LESS COPPER PLUMBING AND FLEXIBLE WATER i HEATER GAS CONNECTOR WITH FITTINGS Basic Tools Additional Tools Needed You may or may not need all these tools depending on your When Sweat Soldering type of installation These tools can be purchased at your local Tubing Cutters or Hacksaw Sears Store Propane Tank P Soft Solder Pipe Wrenches 2 14 356 mm Solder Flux Screwdriver Emery Cloth Tin Snips 6 1 82 m Tape or Folding Ruler Garden Hose Wire Brushes Drill Pipe Dope or Teflon Tape 7 PROPANE CHi C TUBING CUTTER TORCH SLOT HEAD SCREWDRIVER CE TIN SNIPS PHILLIPS SCREWDRIVER TEE C i HACKSAW EMERY CLOTH PIPE DOPE ROLL OF TEFLON SQUEEZE TUBE TAPE USE ONLY ON USE FOR WATER AND GAS WATER CONNECTIONS CONNECTIONS A gt 3 4 19 mm WIRE BRUSH VE O O ROLL OF LEAD FREE SOLDER GARDEN HOSE 6 FOOT TAPE PIPE WRENCH 1 2 13 mm WIRE BRUSH SOFT SOLDER FLUX TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER GAS MODELS A Vent Pipe J Drip Leg Sediment Trap S Flue Baffle B Drafthood K Inner Door T Gas Control Valve Thermostat C Anode L Outer door U Drain Valve D Hot Water Outlet M Union V Pilot and Main Burner E Outlet N Inlet Water Shut off Valve W Flue F Flexible Water Connections O Cold Water Inlet X Metal Drain Pan G Gas Supply P Inlet Dip Tube Y Piezo Igniter H Manual
20. IEF VALVE OPTIONAL TOP T amp P RELIEF VALVE NOT SHOWN q DISCHARGE PIPE Do not cap or plug DRAIN VALVE 6 MAXIMUM AIR GAP FLOOR DRAIN FIGURE 16 CAUTION Temperature pressure relief valve discharge pipe must terminate at adequate drain The Discharge Pipe Shall not be smaller in size than the outlet pipe size of the valve or have any reducing couplings or other restrictions Shall not be plugged or blocked Shall be of material listed for hot water distribution Shall be installed so as to allow complete drainage of both the temperature pressure relief valve and the discharge pipe Shall terminate a maximum of six inches above a floor drain or external to the building In cold climates it is recommended that the discharge pipe be terminated at an adequate drain inside the building Shall terminate at an adequate drain Shall not have any valve between the relief valve and tank Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk forscald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting ADANGER The temperature pressure relief valve must be manually operated at least once a year Caution s
21. Owner s Manual c Kenmore POWER MISER 6 ULTRA LOW NOx GAS WATER HEATER FOR POTABLE WATER HEATING ONLY NOT SUITABLE FOR SPACE HEATING NOT FOR USE IN MOBILE HOMES MODEL NO 153 330632 30 Gallon 153 330642 40 Gallon 153 330620 40 Gallon Short Safety Instructions 153 330652 50 Gallon Installation This water heater meets the new ANSI Z21 10 1 Operation e Care and Maintenance e Troubleshooting e Parts List For Your Safety AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER standard that deals with the accidental or unintended ignition of flammable vapors such as those emitted by gasoline AWARNING WARNING If the information in these Read and understand instruction A A i manual and safety messages instructions is not followed exactly a fire before installing operating or or explosion may result causing property servicing this water heater damage personal injury or death Failure to follow instructions and safety messages could result in death or serious injury Do not store or use gasoline or other Instruction manual must remain flammable vapors and liquids in the with water heater vicinity of this or any other appliance WHAT TO DOIF YOU SMELL GAS ADVERTENCIA e Donottry to light any appliance Si no puede leer o entender el ingl s y necesita el manual de Do not touch any electrical switch do instrucciones en espa ol puede solicitarlo al 1 800 821 2017 NO y i
22. a a a ii eee 28 30 PARTS ORDER Sorrento nda otto ote meta etn bos ato bull ceca teeth tn at 31 WARRAN Tas a e e dle tdo 32 CUSTOMER RESPONSIBILITIES Thank You for purchasing a Kenmore water heater Properly installed and maintained it should give you years of trouble free service lf you should decide that you want the new water heater professionally installed by Sears call 1 800 4 MY HOME They will arrange for prompt quality installation by Sears authorized contractors Abbreviations Found In This Instruction Manual CSA Canadian Standards Association ANSI American National Standards Institute NFPA National Fire Protection Association ASME American Society of Mechanical Engineers GAMA Gas Appliance Manufacturers Association This gas fired water heater is design certified by CSA INTERNATIONAL under American National Standard CSA Standard for Gas Water Heaters ANSI Z21 10 1 CSA 4 1 current edition Read the Safety Precautions section page 3 of this manual first and then the entire manual carefully If you don t follow the safety rules the water heater will not operate properly It could cause DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE This manual contains instructions for the installation operation and maintenance of the gas fired water heater It also contains warnings through out the manual that you must read and be aware of All warnings and all instructions are essential to the proper oper
23. al drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected Sensors mounted in the metal drain pan that turn off the water supply to the entire home when water is detected in the metal drain pan 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 A WARNING Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Avoid all ignition sources if you smell LP gas Do not expose water heater control to excessive gas pressure Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources away from faucets after extended period of non use e Read instruction manual before installing using or servicing water heater INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS VAPORS ARE LIKELY TO BE PRESENT OR STORED GARAGES STORAGE AND UTILITY AREAS ETC Flammable liquids such as gasoline solvents propane LP or butane etc and other substances such as adhesives etc emit flammable vapors which can be ignited by a gas water heater s pilot light or main burner The resulting flashback and fire can cause death or serious
24. 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 Be sure tank is completely filled with water before lighting and activating the water heater Follow the Operating Instructions f additional information is required contact Sears Service at 1 800 4 MY HOME 1 800 469 4663 TEFLON is a registered trademark of E I Du Pont De Nemours and Company 24 Housekeeping Vacuum around base of water heater for dust dirt and lint on a regular basis Fire and Explosion Hazard 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 Visibly inspect flame arrestor at least once every six months and clean if accumulated lint Can cause serious injury or death AT LEAST ONCE EVERY SIX MONTHS A VISUAL INSPECTION SHOULD BE MADE OF THE FLAME ARRESTOR CLEAN IF LINT ACCUMULATIONS ARE NOTICED INSTALLED IN SUITABLE AREA To insure sufficient ventilation and combustion air supply proper clearances from the water heater must be maintained See Facts to Consider About the Location section Combustible materials such as clothing cleaning materials or flammable liquids etc must not be placed against or adjacent to the water heater becaus
25. ater piping system as possible Selected location must provide adequate clearances for servicing and proper operation of the water heater CAUTION All water heaters eventually leak Donotinstall without adequate drainage Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak the flow will not cause damage to the structure For this reason it is not advisable to install the water heater in an attic or upper floor When such locations cannot be avoided a suitable metal drain pan should be installed under the water heater Metal drain pans are available at your local Sears or hardware store Such a drain pan must have a minimum length and width of at least 2 inches 51 mm greater than the water heater dimensions and must be piped to an adequate drain The pan must not restrict combustion air flow Water heater life depends upon water quality water pressure and the environment in which the water heater is installed Water heaters are sometimes installed in locations where leakage may result in property damage even with the use of a metal drain pan piped to a drain Unanticipated damage can be reduced or prevented by a leak detector or water shut off device used in conjunction with a piped metal drain pan These devices are available from some plumbing supply wholesalers and retailers and detect and react to leakage in various ways Sensors mounted in the met
26. ation of the water heater and your safety Since we cannot put everything on the first few pages READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER The installation must conform with these instructions and the local code authority having jurisdiction In the absence of local codes installations shall comply with the current edition of The National Fuel Gas Code ANSI 2223 1 NFPA 54 This publication is available from the Canadian Standards Association 8501 East Pleasant Valley Rd Cleveland Ohio 44131 or The National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 If after reading this manual you have any questions or do not understand any portion of the instructions call the Sears Service Center Carefully plan the place where you are going to put the water heater Correct combustion vent action and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and fires See figure 1 Examine the location to ensure the water heater complies with the Facts to Consider About the Location section in this manual For California installation this water heater must be braced anchored or strapped to avoid falling or moving during an earthquake See instructions for correct installation procedures Instructions may be obtained from the California Office of the State Architect 1102 Q Street Suite 5100 Sacramento CA 95811 Instructions can also be
27. burns to anyone in the area Even though this water heater is a flammable vapor ignition resistant water heater and is designed to reduce the chances of flammable vapors being ignited gasoline and other flammable substances should never be stored or used in the same vicinity or area containing a gas water heater or other open flame or spark producing appliance Also the water heater must be located and or protected so it is not subject to physical damage by a moving vehicle AWARNING For continued protection against risk of fire Do not install water heater on carpeted floor Do not operate water heater if flood damaged This water heater must not be installed directly on carpeting Carpeting must be protected by metal or wood panel beneath the appliance extending beyond the full width and depth of the appliance by at least 3 inches 76 2mm in any direction or if the appliance is installed in an alcove or closet the entire floor must be covered by the panel Failure to heed this warning may result in a fire hazard A WARNING Read instruction manual before installing using or servicing water heater Improper use may result in fire or explosion Maintain required clearances to combustibles Minimum clearances between the water heater and combustible surfaces are 0 inch at the sides and rear 4 inches 102 mm at the front and 6 inches 153 mm from the vent pipe see Figure 8 Clearance from the t
28. cal at the time of water heater installation The sediment trap shall be either a tee fitting with a capped nipple in the bottom outlet or other device recognized as an effective sediment trap If a tee fitting is used it shall be installed in conformance with one of the methods of installation shown in Figures 19 and 20 GROUND JOINT UNION OPTIONAL GAS CONTROL DRIP LEG SEDIMENT TRAP FIGURE 19 GAS PIPING WITH FLEXIBLE CONNECTOR GROUND JOINT UNION OPTIONAL BLACK PIPE GAS CONTROL DRIP LEG SEDIMENT TRAP FIGURE 20 GAS PIPING WITH ALL BLACK IRON PIPE TO GAS CONTROL OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE LIGHTING
29. cccnccccnnnnononononononcncnnnnnnnnnnnnnnnnnnnnnnnnonnnnn nr nn nanannnnnos 22 Cleaning the Combustion Chamber and Flame ArreStor ccccccccccccceeeceeeeeeeeeeesaeeeaeseeeaeeeeeeeeeeeeeeseseseeeseeeeeeeeeees 22 Replacing the Burner Door ASSeEMD iii A aaa ia 23 Piezoelectric Igniter ys Mgina a a a ayn aA 23 Testing MES LON ten SySteM ii A A neat rae oan 23 Removing and Replacing the Gas Control Valve Thermostat ccccccccccceeeeeeeeeeeeeeeeeeeaeaeaeaaaeaaeaeeeaeeseseeeeeeeenes 24 HOUSEKEEPING eet in dnn a A ee ed ht te ates 24 Anode Rod INSp6CtOn ii A en I es a eter es ones 24 Temperature Pressure Relief Valve Operation ccccccccccccecceceeeeeeeeeeeeeeaeseaeaeeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeseeeseeaeaeaeaaaea 25 DAIWA e gsc teed cet EE e ds 25 Drain Valve Washer Replacement iii TS deta Hane eee 25 SEICE cet ecco a a A e ahaha eased cs 25 TROUBLESHOOTING GUIDE iii e eee be ee ains 26 30 ACA SI ag ede teed cae abate ee ae eed 26 27 Thermal EXPANSION te csi seeks A ae eee eee 26 Strange SOUNGS A de 26 Drait Hood O DETAIL 26 CON ENS AMO e a li e e do o ae eh dt ds a dd 27 O A a a ak aah Staats MON cB dn setae balck e eatin yaaa Meta 27 OPE fatlonal CONGITNONS cs 000 A A te ee Bebe anche Dee A ee 27 SMe VOOM area a a Soe ede a a deacons vad adie eta aes 27 Al inv Flot Water Falces ia it od a 27 High Temperature Shut Off SySteM oaee eaa a eaaa aae nono aaa a Saa aa oaa ar N aiaa 27 TFROUDIESNOOTING MEMS mee
30. ce clogged 1 Clean locate source and correct 2 Low gas pressure 2 Check with gas utility company 3 Dirty pilot 3 Clean pilot Cold drafts Dirty burner screen 29 PILOT LIGHT TROUBLESHOOTING CHART Section A Pilot light will not light Section B Pilot light will not remain lit or repeatedly goes out Check the manual gas shut off valve to s the gas turned on NO see if itis in the open position if it is open YES then contact the gas utility company Make sure the thermocouple is securely Is the thermocouple securely connected to the gas control NO gt connected Finger tighten then give a additional 1 2 turn with a wrench valve thermostat While repeatedly depressing the igniter button hold down the reset button until the pilot is lit and NO mal intai maintains a stable flame then slowly release the reset button Have you bled all the air YES rom the pilot tube and gas supply line Test the thermocouple using the following procedure Disconnect the thermocouple from the gas control valve thermostat Using a multimeter with alligator clip leads vas attach the red lead to the body copper part of the thermocouple Attach the black lead to the end silver part of the thermocouple that connects to the gas control valve s the igniter producing a NO Follow the Testing the Igniter System thermostat Follow the instruction to light the pilot and watch the voltage readings on spa
31. chamber and tighten securely Once the burner door assembly is tightened visually inspect the door gasket between the burner door assembly 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 burner door assembly and the combustion chamber Reconnect the manifold tubing pilot tubing and thermocouple to the thermostat Do not cross thread or apply any thread sealant to these fittings The thermocouple nut should be started and turned all the way in by hand An additional 1 2 3 4 turn with a 7 16 open end wrench will then be sufficient to seat the lockwasher Reconnect the igniter wire Turn gas supply on and refer to the Operating Instructions 23 GAS CONTROL VALVE THERMOSTAT BURNER DOOR FIGURE 30 9 Check for leaks by brushing on an approved noncorrosive leak detection solution Bubbles will show a leak Correct any leak found 10 Replace the outer door 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 electrode should be centered between the pilot and thermocouple See Figure 31 Use only factory authorized piezoelectric igniter parts for replacement IGNITER BUTTON SNAP ON CONNECTOR WIRE A EA To ELECTRODE
32. d in the Troubleshooting Guide of this manual If a condition persists or you are uncertain about the operation of the water heater let the Sears Service Center check it out Contact Sears Service Center at 1 800 4 MY HOME 1 800 469 4663 TROUBLESHOOTING GUIDE Start Up Conditions Thermal Expansion CAUTION Avoid water heater damage Install thermal expansion tank or device if necessary Contact qualified installer or service agency As water is heated it expands thermal expansion In a closed system the volume of water will grow As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent temperature pressure relief valve operation water discharged from the valve due to excessive pressure build up The temperature pressure relief valve is not intended for the constant relief of thermal expansion This condition is not covered under the limited warranty A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank Table 1 Thermal Expansion Tank Specifications Model Capacity in Inches Fitting
33. d use of flammable vapor ignition resistant water heaters and have a thorough understanding of this instruction manual e Service Agency A service agency also must have ability equivalent to a licensed tradesman in the fields 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 the 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 Sears Roebuck and Co SAFETY PRECAUTIONS AWARNING Read and understand instruction manual and safety messages before installing operating or servicing this water heater Failure to follow instructions and safety messages could result in death or serious injury Instruction manual must remain with water heater ADANGER Water temperature over 125 F 52 C can cause severe burns instantly resulting in s
34. d you may also have other rights which vary from state to state 16 usd ne fats ay jen Sears Roebuck and Co Dept 817WA Hoffman Estates IL 60179 nee aca lees heii Km ai pei OO RR A eh DIAZ ag ps do s ROS OOO NE O ESAS w _ a A RE Ay PRA De ean RR a LR ERRE LEAR A O as TS E EOI 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 e i A charge will be made on service calls due to poor or incomplete installation These include a Adjusting thermostat c Leaks in pipes or fittings e Condensation b Lighting pilot d Improper venting MASTER PROTECTION AGREEMENTS Congratulations on making a smart purchase Your new Kenmore on products requiring in home repair plus convenient repair product is designed and manufactured for years of dependable scheduling operation But like all products it may require preventive maintenance i l A or repair from time to time That s when having a Master Protection Power surge protection against electrical damage due to power Agreement can save you money and aggravation fluctuations Rental reimbursement if repair of your covered product takes Purchase a Master Protection Agreement now and protect yourself A longer than promised from unexpected hassle and expense Once you purchase the Agreement a simple phone call is all that it
35. downloaded to your computer at WWW dsa dgs ca gov Pubs Complies with 10 ng J SCAQMD rule 1121 and districts having equivalent NOx requirements PRODUCT SPECIFICATIONS RECOVERY RATE GALS PER HOUR 90 F RISE TANK CAPACITY IN TYPE OF MODEL NUMBER GALS LTRS GAS 153 330632 114 NATURAL 153 330642 151 NATURAL 153 330620 151 NATURAL 153 330652 189 NATURAL INPUT RATE Btu hr 30 40 40 50 DIMENSIONS IN INCHES mm HEIGHT TO JACKET TOP 56 3 8 1 432 58 3 8 1 483 49 1 245 57 3 8 1 457 MINIMUM VENT PIPE INCHES DIAMETER INCHES mm 16 3 8 415 9 18 457 22 559 20 508 OR 4 102 OR 4 102 OR 4 102 3 3 3 3 76 OR 4 102 MATERIALS AND BASIC TOOLS NEEDED Materials Needed To simplify the installation Sears has available the installation parts shown below You may or may not need all of these materials depending on your type of installation da EDO OOOO Y E om E METAL DRAIN PANS AVAILABLE EXPANSION TANKS FOR 5 IN 20 508 mm DIAMETER THERMAL EXPANSION K FOR WATER HEATERS HAVING CONDITIONS AVAILABLE P A DIAMETER 18 457 mm OR IN 2 GALLONS LESS 24 610mm DIAMETER 7 6 LITERS AND FOR WATER HEATERS HAVING 5 GALLONS 16 9 LITERS A DIAMETER 22 559 mm OR LESS AND AVAILABLE IN 28 LOCAL SEARS STORE Noe cone wee 711 mm DIAMETER FOR WATER OR SERVICE CENTER c
36. e drain valve and terminate it to an adequate drain or external to the building 5 Open the water heater drain valve and allow all of the water to drain from the tank Flush the tank with water as needed to remove sediment 6 Close the drain valve refill the tank and restart the heater as directed in this manual If the water heater is going to be shut down for an extended period the drain valve should be left open IMPORTANT Condensation may occur when refi lling the tank and should not be confused with a tank leak Follow the lighting instructions in the Lighting section to restart the water heater Drain Valve Washer Replacement See Figure 34 Turn OFF gas supply to water heater Follow Draining instructions Turning counter clockwise N remove the cap e U N Unscrew the stem by turning it counter clockwise N and remove it from the drain valve body a Remove the bottom washer and put the new one in place 6 Re insert the stem into the drain valve body and retighten the cap to the body using a wrench DO NOT OVER TIGHTEN 7 Follow instructions in the Filling The Water Heater section 8 Check for leaks 9 Follow the lighting instructions in the Lighting section to restart the water heater CAP WASHER STEM SIS 7 SS A Ta WASHER FIGURE 34 Service Before calling for repair service read the Start Up Conditions and Operational Conditions foun
37. e same cross sectional area as the free area of the openings to which they connect The minimum short side dimension of rectangular air ducts shall not be less than 3 inches 76 2 mm See Figure 13 Le CHIMNEY OR GAS VENT Als INLET AIR DUCT FIGURE 13 Alternatively a single permanent opening may be used when communicating directly with the outdoors or with spaces that freely communicate with the outdoors The opening shall have a minimum free area of 1 square inch per 3 000 BTU per hour 8 3 cm kW of total input rating of all equipment in the enclosure See Figure 13A t CHIMNEY OR GAS VENT ALTERNATE OPENING LOCATION FIGURE 13A Louvers and Grilles In calculating free area consideration shall be given to the blocking effect of louvers grilles or screens protecting openings Screens used shall not be smaller than 1 4 inch 6 4 mm mesh Ifthe free area through a design of louver or grille is known it should be used in calculating the size opening required to provide the free area specified If the design and free area is not known it may be assumed that wood louvers will be 20 25 percent free area and metal louvers and grilles will have 60 75 percent free area Louvers and grilles shall be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation Special Conditions Created by Mechanical Exhausting or Fireplaces operation of
38. e they could catch on fire Anode Rod Inspection CAUTION Avoid water heater damage Inspection and replacement of anode rod required The anode rod is used to protect the tank from corrosion Most hot water tanks are equipped with an anode rod The submerged rod deteriorates to protect the tank Instead of corroding the tank water ions attack and eat away the anode rod This does not affect the water s taste or color The rod must be maintained to keep the tank in operating condition EXPOSED SUPPORT EXPOSED SUPPORT WIRE PITTED ANODE ROD 4 FIGURE 32 Anode deterioration depends on water conductivity not necessarily water condition A corroded or pitted anode rod indicates high water conductivity and should be checked and or replaced more often than an anode rod that appears to be intact Replacement of a depleted anode rod can extend the life of your water heater Inspection should be conducted by calling the Sears Service Center for an authorized contractor At a minimum the anode s should be checked annually after the warranty period Temperature Pressure Relief Valve Operation The temperature pressure relief valve must be manually operated at least once a year ADANGER Burn hazard Hot water discharge Keep clear of relief valve discharge outlet When checking the temperature pressure relief valve operation make sure that 1 no one i
39. e water heater 150 psi 1 035kPa and a discharge capacity not less than the water heater input rate as shown on the model rating plate For safe operation of the water heater the relief valve must not be removed from its designated opening nor plugged The temperature pressure relief valve must be installed directly into the fitting of the water heater designed for the relief valve Position the valve downward and provide tubing so that any discharge will exit only within 6 inches 153 mm above or at any distance below the structural floor see Figure 16 Be certain that no contact is made with any live electrical part The discharge opening must not be blocked or reduced in size under any circumstances Excessive length over 30 feet 9 14 m or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve No valve or other obstruction is to be placed between the relief valve and the tank Do not connect tubing directly to discharge drain unless a 6 inch air gap is provided To prevent bodily injury hazard to life or property damage the relief valve must be allowed to discharge water in quantities should circumstances demand Ifthe discharge pipe is not connected to a drain or other suitable means the water flow may cause property damage 14 HOT WATER COLD WATER OUTLET INLET L E mannan SHUTOFF 3 VALVE ay HOT COLD DRAFT HOOD TEMPERATURE PRESSURE REL
40. ere it connects to the water heater In most installations the vent pipe can be lifted off after any screw or other attached devices are removed Dispose of the draft hood The new water heater has a draft hood which must be used for proper operation If you have copper piping to the water heater the two copper water pipes can be cut with a hacksaw approximately four inches away from where they connect to the water heater see Figure 6 This will avoid cutting off pipes too short Additional cuts can be made later if necessary Disconnect the temperature pressure relief valve 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 2 C 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 FIGURE 6 If you have galvanized pipes to the water heater loosen the two galvanized pipes with a pipe wrench at the union in each line Also disconnect the piping remaining to the water heater see Figure 7 These pieces should be saved since they may be needed when reconnecting the new water heater Disconnect the temperature pressure relief valve drain line 2 Turn OFF
41. ess 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 Certain water conditions will cause a reaction between this rod and the water The most common complaint associated with the anode rod is one of a rotten egg smell This odor is derived from hydrogen sulfide gas dissolved in the water The smell is the result of four factors which must all be present for the odor to develop 27
42. evere injury or death Children the elderly and the physically or mentally disabled are athighestriskforscald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting 44 WARNING Fire Hazard For continued protection against risk of fire Do not install water heater on carpeted floor Do not operate water heater if flood damaged AWARNING Overheated water can cause water tank explosion Properly sized temperature and pressure relief valve must be installed in opening provided A WARNING Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Avoid all ignition sources if you smell LP gas Do not expose water heater control to excessive gas pressure Use only gas shown on rating plate Maintain required clearances to combustibles Keep ignition sources away from faucets after extended period of non use e Read instruction manual before installing using or servicing water heater A WARNING Breathing Hazard Carbon Monoxide Gas Install vent system in accordance with codes Do not operate water heater if flood damaged High altitude orifice must be installed for operation above 2 000 feet 610 m Do not operate if soot buildup Do not obstruct water heater air in
43. exhaust fans ventilation systems clothes dryers or fireplaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment 12 Water Piping Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting A DANGER HOTTER WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes washing dish washing cleaning and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally handicapped If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at the hot water taps used by these people or at the water heater Mixing valves are available at plumbi
44. g amount of noise and if left in 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 gt 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 the vicinity of water heater Chemical corrosion of flue and vent system can cause serious injury of death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual At least once a year a visual inspection should be made of the venting system You should look for 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 asphyxiation Chemical vapor corrosion of the flue and vent
45. gas L P gas The minimum inlet gas pressure listed on the rating plate is for the purpose of input adjustment If the gas control valve is subjected to pressures exceeding 1 2 pound per square inch 3 5kPa the damage to the gas control valve could result in a fire or explosion from leaking gas If the main gas line shutoff serving all gas appliances is used also turn OFF the gas at each appliance Leave all gas appliances shut OFF until the water heater installation is complete A gas line of sufficient size must be run to the water heater Consult the current edition of National Fuel Gas Code ANSI 2223 1 NFPA 54 and your gas supplier concerning pipe size There must be Areadily accessible manual shut off valve in the gas supply line serving the water heater Adrip leg sediment trap ahead of the gas control valve to help prevent dirt and foreign materials from entering the gas control valve A flexible gas connector or a ground joint union between the shut off valve and control valve to permit servicing of the unit Be sure to check all the gas piping for leaks before lighting the water heater Use a soapy water solution not a match or open flame Rinse off soapy solution and wipe dry The minimum inlet gas pressure shown on the rating plate is that which will permit firing at the rated input 44 WARNING High altitude orfice must be installed for operation above 2 000 feet 610 m Contact a qua
46. gniter wire from the igniter NOTE First remove the igniter from the bracket by depressing front and rear holding tabs and lift Next remove igniter bracket from the gas control valve thermostat Disconnect the thermocouple right hand threads pilot tube and manifold tube at the gas control valve thermostat Figure 25 5 Refer to Gas Piping section and disconnect the ground joint union in the gas piping Disconnect the remaining pipe from the gas control valve thermostat 6 To remove the gas control valve thermostat thread a correctly sized pipe into the inlet and use it to turn the gas control valve thermostat counterclockwise Do not use pipe wrench or equivalent to grip body Damage may result causing leaks Do not insert any sharp objects into the inlet or outlet connections Damage to the gas control valve thermostat may result Replacing the Gas Control Valve Thermostat To replace the gas control valve thermostat reassemble in reverse order When replacing the gas control valve thermostat thread a correctly sized pipe into the inlet and use it to turn the gas control valve thermostat clockwise DO NOT OVER TIGHTEN damage may result Be sure to use approved Teflon tape or pipe joint compound on the gas piping connections and fitting on the back of the gas control valve that screws into tank Be sure to remove the pilot ferrule nut from the new gas control valve thermostat Turn the gas supply on
47. h mortar mix cement A WARNING Flue gases may escape if vent pipe is not connected Do not store corrosive chemicals in vicinity of water heater Chemical corrosion of flue and vent system can cause serious injury or death Contact a qualified installer or service agency Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Failure to have required clearances between vent piping and combustible material will result in a fire hazard 16 Be sure vent pipe is properly connected to prevent escape of dangerous flue gases which could cause deadly asphyxiation Chemical vapor corrosion of the flue and vent system may occur if airfor 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 Gas Piping A WARNING Do not use water heater with any gas other than the gas shown on the rating plate Excessive pressure to gas control valve can cause serious injury or death Turn off gas lines during installation Contact qualified installer or service agency Make sure the gas supplied is the same type listed on the model rating plate The inlet gas pressure must not exceed 14 inch water column 3 5kPa for natural and propane
48. hat may have accumulated wait ten 10 minutes If you then smell gas STOP Follow B in the safety cn warning above If you do not smell gas go to the next iS step to ON TASA Cr ON 9 Set the temperature dial to 6 Turn the gas control knob SRA rl the desired setting counterclockwise m to PILOT 10 Replace the outer door TO TURN OFF GAS TO APPLIANCE Turn the temperature dial counterclockwise to its lowest setting 2 Turn the gas control knob clockwise B to the OFF position 18 Temperature Regulation Due to the nature of the typical gas water heater the water temperature in certain situations may vary up to 30F 16 7 C higher or lower at the point of use such as
49. he legs to top with sheet metal screws See Figure 17 Place the vent pipe over the draft hood With the vent pipe in position drill a small hole through both the vent pipe and draft hood Secure them together with a sheet metal screw Obstructed or deteriorated vent systems may present serious health risk or asphyxiation SHEET METAL SCREWS Four provided SS ac DRAFT HOOD JACKET TOP INSTALL THE DRAFT HOOD WITH THE FOUR SCREWS PROVIDED FIGURE 17 The vent pipe from the water heater must be no less than the diameter of the draft hood outlet on the water heater and must slope upward at least 1 4 inch per linear foot 21 mm per meter See Figure 18 TO CHIMNEY MIN 1 4 INCH RISE PER LINEAR FOOT 21 mm PER METER FIGURE 18 All vent gases must be completely vented to the outdoors of the structure dwelling Install only the draft hood provided with the new water heater and no other draft hood Vent pipes must be secured at each joint with sheet metal screws There must be a minimum of 6 inches 153 mm clearance between single wall vent pipe and any combustible material Fill and seal any clearance between single wall vent pipe and combustible material with mortar mix cement or other noncombustible substance For other than single wall follow vent pipe manufacturer s clearance specifications To insure a tight fit of the vent pipe in a brick chimney seal around the vent pipe wit
50. heated and increases the pressure of the water system If the relieving point of the water heater s temperature pressure relief valve is reached the valve will relieve the excess pressure The temperature pressure relief valve is not intended for the constant relief of thermal expansion This is an unacceptable condition and must be corrected It is recommended that any devices installed which could create a closed system have a by pass and or the system have an expansion tank to relieve the pressure built by thermal expansion in the water system Refer to the Thermal Expansion section under Troubleshooting Guide or contact local plumbing authority or local Sears Service Center on how to control this situation NOTE To protect against untimely corrosion of hot and cold water fittings it is strongly recommended that di electric unions or couplings be installed on this water heater when connected to copper pipe CAUTION Avoid water heater damage Install thermal expansion tank if necessary Do not apply heat to cold water inlet Contact qualified installer or Sears Service Center Figure 15 shows the typical attachment of the water piping to the water heater The water heater is equipped with 3 4 NPT water connections NOTE If using copper tubing solder tubing to an adapter before attaching the adapter to the cold water inlet connection Do not solder the cold water supply line directly to the cold water inle
51. hould be taken to ensure that 1 no one is in front of or around the outlet of the temperature pressure relief valve discharge line and 2 the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions and replace the temperature pressure relief valve with a new one Filling the Water Heater CAUTION Avoid water heater damage Fill tank with water before operating Never use this water heater unless it is completely full of water To prevent damage to the tank the tank must be filled with water Water must flow from the hot water faucet before turning ON gas to the water heater To fill the water heater with water Close the water heater drain valve by inserting a flat head screwdriver in the slot on the stem and turn to the right clockwise The drain valve is on the lower front of the water heater 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 insure 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
52. ings for make up air to enter the room YES Are the openings of sufficient size Correct size of openings to See Combustion Air and Ventilation section in o allow sufficient air Install correct size make up air openings per the NO gt Combustion Air and Ventilation section in this manual Check the water heater for a Flammable Vapor FV event Zz If the flame arrestor show signs of discoloration shut off the gas this manual for requirements 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 NOW Is there a furnace air handler in the same room as the water heater YES YES Does the return air duct for the furnace air handler draw its air from a separate location than the water heater See Facts to Consider About the Location section and the Combustion Air section Contact a local Heating Ventilation Air Conditioning amp Refrigeration authorized service provider Check the vent system for restrictions obstructions and check draft hood See Draft Hood NO the vent termination height Refer to Operation section in this manual the Installation Instructions section of YES this manual for specific requirements Is there proper drafting at the Remove the burner door assembly Is the flame arrestor and burner free from debris due to excessive lint dirt dust or oil YES Does the flame arrestor show signs of d
53. iscoloration NO YES Refer to the Service and Adjustment section of this manual for information on cleaning the flame arrestor and burner Shut off the gas supply to the water heater at the manual gas shut off valve then contact Sears Replace the gas control valve thermostat Service at 1 800 4 MY HOME 1 800 469 4663 This procedure requires the removal of water heater components 30 PARTSORDERLIST ORDER LIST POWER MISER 6 GAS WATER HEATER MODEL NO S Altemate anode location for top a for side T amp P AA TO tamos Heat Trap Hot Some Models 6 T amp PRelief Valve Located Top Or Side 9000071 9000071 9000728 9000071 8 Gas Control Valve Thermostat 9006438 9006439 9008440 9006439 9 Outer Door _____________ 700795 018 700795 018 700795 018 700795 018 Not Shown Includes Inner Door Gasket Flexible manifold tube sold as a separate part burner not included Now that you have purchased your gas water heater should a need MODEL NUMBER ever exist for repair parts or service simply contact any Sears Service SERIAL NUMBER Center or call 1 800 4 MY HOME 1 800 469 4663 Be sure to TYPE GAS NATURAL provide all pertinent facts when you call or visit PART DESCRIPTION WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE FOLLOWING INFORMATION THIS IS A REPAIR PARTS LIST NOT A PACKING LIST 31
54. l that may damage the burner screen Important Do not use the burner if the burner screen is damaged NOTE Damage may be rips or holes in the burner screen Discoloration is normal PILOT ASSEMBLY BURNER USE BRUSH ON THIS SURFACE FIGURE 26 Replacing the Pilot Assembly 1 Follow the instructions in Removing the Burner Door Assembly section to remove the assembly 2 Remove the retainer clip securing the two piece wire connector to the burner door assembly Note the orientation of the retainer clip Insert the tip of a large flat head screwdriver between the clip and the top of the two piece wire connector Carefully rotate the screwdriver to raise the clip lt may be necessary to remove the connector one side at a time See Figure 27 3 Locate where the thermocouple connects to the rear of the pilot assembly and pull the thermocouple tip from the rear of the pilot assembly 4 Remove the nut securing the pilot assembly to the burner and keep it for reuse later 5 Use a 1 2 open end wrench to loosen the nut securing the pilot tube to the pilot To prevent any bending use a pair of pliers to steady the pilot bracket o Remove the old pilot assembly including the igniter wire from the burner door assembly 7 Insert the pilot tube into the new pilot assembly Important The new pilot assembly comes with an orifice This orifice must be installed when replacing the pilot assembly IMPORTANT D
55. lified installer or service agency Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Water heaters covered in this manual have been tested and approved for installation at elevations up to 2 000 feet 610 m above sea level For installation above 2 000 feet 610 m the water heater s Btu input should be reduced at the rate of 4 percent for each 1 000 feet 305 m above sea level which requires replacement of the burner orifice in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 Contact your local gas supplier for further information Failure to replace the standard orifice with the proper high altitude orifice when installed at elevations above 2 000 feet 610 m could result in improper and inefficient operation of the appliance producing carbon monoxide gas in excess of the safe limits This could result in serious injury or death Contact your local gas supplier for any specific changes that may be required in your area A WARNING Use joint compound or tape compatible with propane Leak test before operating heater Disconnect gas piping and shut off valve before pressure testing system Use pipe joint compound or Teflon tape marked as being resistant to the action of petroleum Propane L P gases The appliance and its gas connection must be leak tested before placing the appliance in operation The appliance and its individ
56. llow 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 19 NOTE Awater 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 lt is adjustable and must be reset to the desired temperature setting for energy efficient operation at the minimum water temperature setting that meets your hot water needs To reduce the risk of scald injury 120 F 49 C is preferred starting point Some states have a requirement for a lower setting Align the index bar on the thermostat with the desired water temperature as shown in Figure 21 Turn the water temperature dial clockwise N to increase the temperature or counterclockwise N 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 Robertshaw Gas Valve Gas Control Knob 130 F Reset gt joo Button Dial Stop a Bar Temperature Dial FIGURE 21 Temperature Time to Produce 2nd amp 3rd Settings Degree Burns on Adult Skin 160 F 71 C About 1 2 second 150 F 66 C About 1 1 2 seconds ra FIGURE 22 SERVICE AND ADJUSTMENT Tank Sediment Cleaning Sediment build up on the tank bottom may create varyin
57. ng supply or hardware stores See Figure 14 Valves for reducing point of use temperature by mixing cold and hot water are also available Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat read the Temperature Regulation section in this manual HOT WATER OUTLET COLD WATER TO COLD WATER INLET ON HOT WATER WATER HEATER OUTLET ON WATER HEATER MIXING VALVE FIGURE 14 A WARNING Do nat connect to non potable water system This water heater shall not be connected to any heating systems or component s used with a non potable water heating appliance All piping components connected to this unit for space heating applications shall be suitable for use with potable water Toxic chemicals such as those used for boiler treatment shall not be introduced into this system Water supply systems may because of such events as high line pressure frequent cut offs or the effects of water hammer have installed devices such as pressure reducing valves check valves back flow preventers etc to control these types of problems When these devices are not equipped with an internal by pass and no other measures are taken the devices cause the water system to be closed As water is heated it expands thermal expansion and closed systems do not allow for the expansion of heated water The water within the water heater tank expands as it is
58. ning of the two piece wire connector Figure 27 NOTE The pilot tube should be located at the top followed by the igniter wire then the thermocouple See Replacing the Burner Door Assembly section PILOT IGNITER TUBE WIRE RETAINER CLIP TWO PIECE WIRE CONNECTOR MANIFOLD DOOR FIGURE 27 Cleaning the Pilot Assembly 1 2 Follow the procedure outlined in Removing the Burner Door Assembly Use a soft bristle brush to remove any debris that may have collected on the pilot Note Clean any debris found in the primary air supply hole on the pilot See Figure 28 Follow the steps in Replacing the Burner Door Assembly section to reassemble PRIMARY AIR SUPPLY HOLES PILOT BRACKET FIGURE 28 22 External Inspection amp Cleaning of the Flame Arrestor Although not likely to occur if debris collects on the flame arrestor use a vacuum compressed air or a soft bristle brush to remove it NOTE If unable to inspect or clean the flame arrestor from underneath follow the Cleaning the Combustion Chamber and Flame Arrestor section instructions Flashlight Mirror FIGURE 29 Cleaning the Combustion Chamber and Flame Arrestor 1 Follow procedure outlined in Removing the Burner Door Assembly section 2 Use a vacuum cleaner shop vac to remove all loose debris in the combustion chamber Figure 30 Use
59. nonenenononanncnononnnnnnnnnnononenenonns 11 Combustion Air and Ventilation Appliancesin Confined Spaces ooooncnnncononoconcnnnnnnnnncncnnnnnonnononennnnnnnnnnnnnnnnnnnnnnass 11 12 EIA ed lola AN A O E a RSA 12 13 T 8 P Valve and Pipe Insulation cccccccccccnncncncononocononenonononncnnncnnnnnnnnnononnnnnnnnnnnnnonenenennnnnnnnnnnnnnnnnnnnnninnnaninininnns 13 14 Temperature Pressure Relief Valve occcoocnocoooocononononononccnnncnnnnnnnnnononononnonnnnonenenenennnnnnnnnnnnnnonnnenoninanennnininnns 13 14 Filling the Water Hetero A rad 15 VENTING aa 15 16 Gas Pide iva aaa 16 17 SOMETA a iaa 17 OPERATING INSTRUCTIONS iii ais 18 19 Lighting amp Operating Laia ao aia iii 18 Temperature RE QUAtiON neii riian EK eE E E NS REEE NAAA ATE NEAT EAAS EAA ANEREN NEEE S EEEE leven 19 SERVICE AND ADJUSTMENT ans 20 22 Tank Sediment Cleaning 2 2 a LAEE EE S 20 Venting Systemi INSPECtON uisa iaa a aaaea a E aaaea arIa a iaaii anat 20 BUM NSpEctOM a a a aa iraa r ioia aaa aaas e aa Weeds waees aaa cave EIE aaaea E Di 20 Removing the Burner Door Assembly ccccccssssssececsececcneesssessenseansecsecuccusecseeseausaensesesceccessesesscanaasseseeeeesesseess 21 Ultra Low NOx Natural Gas Burner cevra ata a Aae AA Ane A nn nr rra nen nn nr nn nn RRE RR RR NEARE AE EANA 21 R pla cing the Pilot AsSSemDI yahene pna aaea a oil 21 Replacing the Thermocouple ea 22 External Inspection Cleaning of the Flame ArTestOT cocccccccccccc
60. o not operate this water heater without the orifice in place 8 Use a 1 2 open end wrench to tighten the nut securing the pilot tube to the pilot To prevent any bending use a pair of pliers to steady the pilot bracket 9 Use the nut removed in a previous step to secure the new pilot assembly to the burner Insert the igniter wire through the burner door and reconnect the thermocouple to the pilot assembly See Replacing the Thermocouple section 11 Reinstall the two piece wire connector NOTE The pilot tube must be at the top followed by the igniter wire then the thermocouple Follow the instructions in Replacing the Burner Door Assembly section to reinstall the assembly Replacing the Thermocouple 1 2 Remove the Burner Door Assembly as directed previously Remove the retainer clip from the back of the two piece wire connector and remove the two piece wire connector from the assembly Figure 27 Pull the thermocouple from the pilot assembly Figure 31 IMPORTANT Be careful not to bend or alter the position of the pilot assembly components 4 THERMOCOUPLE Push the new thermocouple through the holes in the pilot bracket Insert the thermocouple tube into the holes provided in the pilot assembly until it clicks into place Leave a small straight section entering and leaving the two piece wire connector section for easier removal service Position the new thermocouple through the ope
61. onsidered normal See Condensation section Draft Hood Operation Check draft hood operation by performing a worst case depressurization of the building With all doors and windows closed and with all air handling equipment and exhaust fans operating such as furnaces clothes dryers range hoods and bathroom fans a match flame should still be drawn into the draft hood of the water heater with its burner firing If the flame is not drawn toward the draft hood after 15 minutes of burner operation 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 Anew 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 products of combustion condense on the cooler tank surfaces and form drops of water which may fall onto the burner or other hot surfaces to produce a sizzling or frying noise Excessive condensation can cause pilot outage due to water running down the flue tube onto the main burner and putting out the pilot Because of the suddenn
62. op of the jacket is 8 inches 203 mm on most models Note that a lesser dimension may be allowed on some models refer to the label attached adjacent to the gas contro valve on the water heater TOP VIEW OF CLOSET WITH DOOR Ns AN TOP VIEW OF CLOSET WITHOUT DOOR 0 MIN Oo MIN EEEE KAEKA 104 mm 0 MIN FIGURE 8 A WARNING Breathing Hazard Carbon Monoxide Gas Install water heater in accordance with the instruction manual and NFPA 54 To avoid injury combustion and ventilation air must be taken from outdoors Do not place chemical emitting products near heater vapor water Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual A gas water heater cannot operate properly without the correct amount of air for combustion see Figure 9 Do not install in a confined area such as a closet unless you provide air as shown in the Locating The New Water Heater section Never obstruct the flow of ventilation air If you have any doubis or questions at all call your gas supplier Failure to provide the proper amount of combustion air can result in a fire or explosion and cause death serious bodily injury or property damage 10 12 MAX 30 cm RECTANGULAR 3 MIN AIR DUCT 76 2 mm AIR DUCT 12 MAX 30 cm FRONT VIEW OF DOOR FIGURE 9 If this water heater will be used in beauty shops barber shops
63. r gas supplier call the fire technician to inspect the appliance Water heaters department subjected to a flammable vapors ignition will show a discoloration on the air intake grid and require replacement of the entire water heater LIGHTING INSTRUCTIONS 7 Depress the reset button all the way in and IMMEDIATELY depress the igniter button until you hear a loud click Observe the pilot through the view port Do not release the reset button Repeat immediately if pilot does not light on the first try If the pilot does not light by the fourth attempt with the igniter repeat steps 4 7 Continue to hold the button for about 1 minute after the pilot is lit Release the reset button and it will pop back up Pilot should remain lit If the pilot light goes out repeat steps 3 7 before lighting the pilot 2 Remove the outer door 3 Turn the temperature dial counterclockwise A to its lowest setting IGNITER IMPORTANT If the pilot will not stay lit after several tries depress the dial stop and tum gas control knob to OFF then call your service technician or gas supplier IMPORTANT If the reset button see graphic at step 3 does not pop up when released stop and immediately shut off the gas at the line valve or tank Call your service technician or gas supplier 8 Turn the gas control knob gt Depress the dial stop and turn y gas control knob clockwise to the OFF position To clear any gas t
64. rk instructions in this manual the multimeter After 45 seconds the meter should read 12 millivolts DC or more YES y Follow the Replacing the Pilot Assembly Is the thermocouple fully s the pilot tube and or orifice Lig instructions found in this manual to access Does the thermocouple pass the test io gt seated in the pilot bracket ree from dirt and debris pilot tube and orifice Clean as needed and YES YES NO YES reinstall pilot tube and orifice Push the thermocouple Follow the Cleaning the Pilot Assembly Replace the thermocouple forward until it is fully seated in NO gt instructions found in this manual the pilot bracket and retest free from dirt and TES Follow the Replacing the Pilot Assembly Is the pilot tube and or orifice instructions found in this manual to access he pilot protected from cold Eliminate any drafts See the NO pilot tube and orifice Clean as needed and drafts that could prevent it Site Location instructions found reinstall pilot tube and orifice rom lighting in this manual YES SES instructions found in this manual Remove the burner door assembly Is the flame arrestor free from dirt or Clean the flame arrestor debris See Removing the Burner NO with a soft bristle brush Door Assembly section of the manual or vacuum cleaner for removal instructions YES Check for insufficient combustion air Are there open
65. s fired water heater the correct vent pipe diameter must be utilized Any additions or deletions of other gas appliances on a common vent with this water heater may adversely affect the operation of the water heater Consult your gas supplier if any such changes are planned For replacement heater installations where pre existing venting is used the venting must be inspected for obstructions and if deterioration is present it must be replaced For proper venting in certain installations a larger diameter vent pipe may be necessary Consult your local Sears Service Center or gas supplier to aid you in determining the proper venting for your water heater from the vent tables in the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 Periodically check the venting system for signs of obstruction or deterioration and replace if needed The combustion and ventilation air flow must not be obstructed The water heater with draft hood installed must be connected to a chimney or listed vent pipe system which terminates to the outdoors Never operate the water heater unless it is vented to the outdoors and has adequate air supply to avoid risks of improper operation explosion or asphyxiation For proper draft hood attachment the draft hood legs may be angled slightly inward Place the draft hood legs in the receiving holes on the top of the water heater The legs will snap in the holes to give a tight fit Secure t
66. s in front of or around the outlet of the temperature pressure relief valve discharge line and 2 that the water discharge will not cause any property damage as the water may be extremely hot see Figure 33 TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE FIGURE 33 If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions and replace the temperature 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 ADANGER Burn hazard Hot water discharge Keep hands clear of drain valve discharge It is recommended that the tank be drained and fl ushed every 6 months to remove sediment which may build up during operation 25 The water heater should be drained if being shut down during freezing temperatures To drain the tank perform the following steps 1 Turn off the gas to the water heater at the manual gas shut off valve 2 Open a nearby hot water faucet until the water is no longer hot 3 Close the cold water inlet valve 4 Connect a hose to th
67. sulation for T amp P valve and pipe connections from carton PIPE INSULATION FLUE PIPE a FIGURE 15A Fit pipe insulation over the incoming cold water line and the hot water line Make sure that the insulation is against the top cover of the heater 13 FitT amp P valve insulation over valve Make sure that the insulation does not interfere with the lever of the T amp P valve Secure all insulation using tape Temperature Pressure Relief Valve AA WARNING Temperature pressure relief valve must comply with ANSI Z21 22 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 This heater is provided with a properly certified combination temperature pressure relief valve by the manufacturer The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment as meeting the requirements for Relief Valves for Hot Water Supply Systems ANSI 221 22 and the code requirements of ASME If replaced the valve must meet the requirements of local codes but not less than a combination temperature and pressure relief valve certified as indicated in the above paragraph The valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of th
68. system may occur if air for combustion contains certain chemical vapors Spray can propellants cleaning solvents refrigerator and air conditioner refrigerants swimming pool chemicals calcium and sodium chloride waxes bleach and process chemicals are typical compounds which are potentially corrosive If when inspecting the vent system you find sooting or deterioration something is wrong Call the local gas supplier to correct the problem and clean or replace the flue and venting before resuming operation of the water heater Burner Inspection Flood damage to a water heater may not be readily visible or immediately detectable However over a period of time a flooded water heater will create dangerous conditions which can cause DEATH SERIOUS BODILY INJURY OR PROPERTY DAMAGE Contact a Sears Service Center to replace a flooded water heater Do not attempt to repair the unit It must be replaced At least once a year a visual inspection should be made of the main burner See Figure 23 CORRECT FLAME SOFT BLUE ca ee e A E a i E A E ZA HA Qu WWI Q FIGURE 23 Inspect burner flames through viewport Flames should be very small with a blue haze and small amounts of yellow or orange at the edges After several minutes of operation the burner screen may glow red If large flames are observed at anytime shut off unit and contact a Sears Service Center Removing the Burner Door Assembly 1
69. t It will harm the dip tube and damage the tank Look at the top cover of the water heater The water outlet is marked HOT Put two or three turns of Teflon tape around the threaded end of the threaded to sweat coupling and around both ends of the 3 4 NPT threaded nipple Using flexible connectors connect the hot water pipe to the hot water outlet on the water heater TEFLON is a registered trademark of E I Du Pont De Nemours and Company Look at the top of the water heater The cold water inlet is marked COLD Put two or three turns of Teflon tape around the threaded end of the threaded to sweat coupling and around both ends of the 3 4 NPT threaded nipple Using flexible connectors connect the cold water pipe to the cold water inlet of the water heater NOTE This water heater is super insulated to minimize heat loss from the tank Further reduction in heat loss can be accomplished by insulating the hot water lines from the water heater INSTALLATION COMPLETED USING INSTALLATION KIT FLEXIBLE WATER SHUTOFF CONNECTORS VALVE HOT WATER COLD WATER OUTLET A s INLET e die is las THREADED TO o THREADED TO SWEAT COUPLING SWEAT COUPLING 3 4 THREADED es THREADED COUPLING 5 COUPLING DRAFT HOOD A EI TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE Do not cap or plug 6 MAXIMUM z AIR GAP D FLOOR DRAIN FIGURE 15 T amp P Valve and Pipe Insulation Remove in
70. take with insulating jacket Do not place chemical vapor emitting products near water heater Gas and carbon monoxide detectors are available Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual Improper installation and use may result in property damage Do not operate water heater if flood damaged Inspect and replace anode Install in location with drainage Fill tank with water before operation Be alert for thermal expansion Refer to instruction manual for installation and service TABLE OF CONTENTS SAFE INSTALLATION USE AND SERVICE ic aaa 2 SAFETY PRECAUTIONS atte a anios 3 TABLE OF CONTENTS dt aten 4 CUSTOMER RESPONSIBILITIES aa 5 PRODUCT SPECIFICATIONS as 5 MATERIALS AND BASIC TOOLS NEEDED caia 6 Materials Nec dd e father O Orta AEE 6 BS e teh a na aN ite Nee ee o oe fae o ae haa o a o ec eo E 6 TYRIGAL INSTALLATION 222 satats ek elena nha as 7 INSTALLATION INSTRUCTIONS is 8 17 Removing the Old Water Heatter cccccccccccccccccecececseseeeueuseeesesseseseeeceeececececeeeeeesesesesassaseaeaeaeesecececeeeseseeeeeneenes 8 Facts to Consider About the LOCatiOn cccecceceeseenneceeceeeeeeeeeeecneeaeaeeaeceeeeeeeeecesecseeaaeaaeeeeeeeeeseeseesueaaeaeeeeeeeenegs 9 10 Insulation Blankets ise cigs seelsdaceds cekcees A ee ed 10 Combustion Air and Ventilation Appliances in Unconfined Spaces occccccccccccnnncocinccono
71. tat set too high Set temperature 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 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 air Provide ventilation to water heater RECOVERY Check flue way flue baffle and burner Flue clogged Clean flue locate source and correct Low gas pressure Check with gas utility company Improper calibration Replace thermostat Thermostat set too low Turn temperature dial to desired setting Water heater too small Install adequate heater Wrong piping connections Correct piping dip tube must be in cold inlet Wasted hot water Ad
72. ual shutoff valve shall be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 pound per square inch 3 5 kPa It shall be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 pound per square inch 3 5 kPa Connecting the gas piping to the gas control valve of the water heater can be accomplished by either of the two methods shown in Figures 19 and 20 TEFLON is a registered trademark of E I Du Pont De Nemours and Company 17 Sediment Traps 44 WARNING Contaminants in gas lines can cause fire or explosion Clean all installation gas piping before Install drip leg in accordance with NFPA 54 Contaminants in the gas lines may cause improper operation of the gas control valve that may result in fire or explosion Before attaching the gas line be sure that all gas pipe is clean on the inside To trap any dirt or foreign material in the gas supply line a drip leg sometimes called a sediment trap must be incorporated in the piping The drip leg must be readily accessible Install in accordance with the Gas Piping section Refer to the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 Asediment trap shall be installed as close to the inlet of the water heater as practi
73. vise customer Low gas pressure O Air for combustion obstructed 28 TROUBLESHOOTING GUIDE Continued DRIP FROM RELIEF VALVE 1 Excessive water pressure 1 Use a pressure reducing valve and relief valve Closed water system 2 See Thermal Expansion THERMOSTAT FAILS TO Non functioning thermostat 1 Replace thermostat SHUT OFF Improper calibration 2 Replace thermostat COMBUSTION ODORS Insufficient air 1 Provide ventilation to water heater Check flue way flue baffle and burner 2 Water heater flue or vent system blocked 2 Clean locate source and correct 3 Heater installed in a confined area Provide fresh air ventilation SMOKING AND CARBON 1 Flammable vapor incident 1 Call 1 800 4 MY HOME 1 800 469 4663 FORMATION SOOTING CONDENSATION 1 Temperature setting too low 1 Increase the temperature setting BURNER FLAME FLOATS 1 Orifice too large 1 Replace with correct orifice AND LIFTS OFF PORTS 2 High gas pressure 2 Check with gas utility company 3 Water heater flue or vent system blocked 3 Clean flue and burner locate source and correct 4 4 Locate source and correct 5 5 Clean burner screen See Ultra Low NOx Natural Gas Burner section of this manual FLAME BURNS AT ORIFICE 1 Non functioning thermostat 1 Replace thermostat 2 Low gas pressure 2 Check with gas utility company 3 Non functioning burner 3 Replace burner assembly PILOT FLAME TOO SMALL 1 Pilot line or orifi
74. water Replace the anode with a special anode Bleed the air from the gas line PILOT WILL NOT LIGHT Air in gas line 1 1 2 No gas 2 Check with gas utility company 3 Dirt in gas lines 3 Notify utility install dirt trap in gas line 4 Pilot line or orifice clogged 4 Clean locate source and correct 5 Cold drafts 5 Locate source and correct 6 Thermostat ECO switch open 6 Replace thermostat 7 Non functioning igniter 7 Replace igniter pilot assembly 8 Flammable vapor incident 8 Eliminate flammable vapor source s Call 1 800 4 MY HOME 1 800 469 4663 9 9 Check with gas utility company 1 10 See service and adjustment section for inspection and cleaning of flame arrestor amp burner 1 Pilot dirty 1 Clean pilot PILOT WILL NOT REMAIN LIT 1 Air in gas line eed the air from the gas line Dirt in gas lines otify utility install dirt trap in gas line Pilot line or orifice clogged lean locate source and correct Thermocouple connection loose e inger tighten then 1 2 turn with wrench Non functioning thermocouple eplace thermocouple Cold drafts Locate source and correct Flammable vapor incident A iminate flammable vapor source s Call 1 800 4 MY HOME 1 800 469 4663 Low gas pressure Check with gas utility company Air for combustion obstructed See service and adjustment section for inspection and cleaning of flame arrestor amp burner 10 Pilot dirty 10 Clean pilot HIGH OPERATION COSTS Thermos
75. y hazardous A WARNING situation which if not avoided could result in death or injury CAUTION indicates a potentially hazardous A CAUTION situation which if not avoided could result in minor or moderate injury CAUTION used without the safety alert CAUTION symbol indicates a potentially hazardous situation which if not avoided could result in property damage All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of 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 Installer A qualified installer 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 installer must also be familiar with the design features an
76. your water heater is found on the model rating plate on the front of the water heater Sears Roebuck and Co Hoffman Estates IL 60179 U S A

Kenmore 153.33062 Water Heater User Manual

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