Use & Care Guide
Model No.
153.332420 40 Gallon Tall
Kenmore
®
Gas Water Heater
For potable water heating only.
Not suitable for space heating.
Not for use in mobile homes.
INSTALLER: Affix these instructions to or near
the water heater.
OWNER: Retain these instructions for future
reference.
FOR YOUR SAFETY: An odorant is added to
the gas used by this water heater.
ADVERTENCIA
Si no puede leer o entender el inglés y necesita el manual de
instrucciones en español, puede solicitarlo al 1-800-821-2017. NO
TRATE DE INSTALAR U OPERAR ESTE CALENTADOR DE AGUA
SI NO ENTIENDE LAS INSTRUCCIONES. No hacer caso de esta
advertencia podría originar lesiones graves o mortales.
P/N 319357-000 (0810)
Sears Brands Management Corporation,
Hoffman Estates, IL 60179 U.S.A.
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Fire or Explosion Hazard
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Avoid all ignition sources if you smell Natural or LP gas.
Do not expose water heater control to excessive gas
pressure.
Use only gas shown on rating plate.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended
period of non-use.
Read instruction manual before
installing, using or servicing
water heater.
3
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TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE................................................................................................. 2
SAFETY PRECAUTIONS ........................................................................................................................... 2-3
PRODUCT WARRANTY ................................................................................................................................ 6
CUSTOMER RESPONSIBILITIES................................................................................................................. 7
PRODUCT SPECIFICATIONS ...................................................................................................................... 8
MATERIALS AND BASIC TOOLS NEEDED.................................................................................................. 9
TYPICAL INSTALLATION ............................................................................................................................ 10
IMPORTANT INFORMATION ABOUT THIS WATER HEATER....................................................................11
Installation Checklist ................................................................................................................................................11
INSTALLATION INSTRUCTIONS ........................................................................................................... 12-15
Removing the Old Water Heater............................................................................................................................. 12
Location Requirements........................................................................................................................................... 13
Site Location ........................................................................................................................................................... 13
Insulation Blankets.................................................................................................................................................. 14
Clearances and Accessibility ............................................................................................................................. 14-15
Filling the Water Heater.......................................................................................................................................... 15
GAS SUPPLY.......................................................................................................................................... 15-16
Gas Requirements.................................................................................................................................................. 15
Gas Piping .............................................................................................................................................................. 15
Gas Pressure.......................................................................................................................................................... 16
Gas Pressure Testing.............................................................................................................................................. 16
LP Gas Only............................................................................................................................................................ 16
COMBUSTION AIR SUPPLY & VENTILATION ...................................................................................... 17-20
Unconfined Space................................................................................................................................................... 17
Confined Space ...................................................................................................................................................... 17
All Air from Inside the Building........................................................................................................................... 17-18
All Air from Outdoors............................................................................................................................................... 18
Louvers and Grilles............................................................................................................................................ 18-19
Vent Pipe System ................................................................................................................................................... 19
Draft Hood Installation ............................................................................................................................................ 19
Vent Pipe Size ........................................................................................................................................................ 19
Vent Connectors ................................................................................................................................................ 19-20
Chimney Connection............................................................................................................................................... 20
Vertical Exhaust Gas Vent ...................................................................................................................................... 20
WATER SYSTEM PIPING....................................................................................................................... 21-22
Piping Installation.................................................................................................................................................... 21
Closed System/Thermal Expansion........................................................................................................................ 22
Temperature and Pressure Relief Valve................................................................................................................. 22
T&P Relief Valve and Pipe Insulation........................................................................................................................ 22
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OPERATING YOUR WATER HEATER...................................................................................................23-25
Lighting Instructions................................................................................................................................................ 23
Checking the Draft.................................................................................................................................................. 24
Burner Flames ........................................................................................................................................................ 24
Emergency Shut Down........................................................................................................................................... 24
Water Temperature Regulation.......................................................................................................................... 24-25
SERVICE AND ADJUSTMENT ............................................................................................................... 26-28
Vent System Inspection .......................................................................................................................................... 26
Burner Inspection.................................................................................................................................................... 26
Burner Cleaning...................................................................................................................................................... 26
Housekeeping......................................................................................................................................................... 27
Anode Rod Inspection ............................................................................................................................................ 27
Temperature-Pressure Relief Valve Operation ....................................................................................................... 27
Draining and Flushing........................................................................................................................................ 27-28
Service.................................................................................................................................................................... 28
MAINTENANCE OF YOUR WATER HEATER........................................................................................ 29-32
Replacement Parts ................................................................................................................................................. 29
External Inspection & Cleaning of the Base-Ring Filter ......................................................................................... 29
Removing the Manifold/Burner Assembly............................................................................................................... 29
Removing the Burner from the Manifold/Burner Assembly .................................................................................... 29
Replacing the Thermocouple............................................................................................................................. 29-30
Replacing the Pilot/ Pilot Tube Assembly ............................................................................................................... 30
Cleaning the Combustion Chamber and Flame-arrestor........................................................................................ 30
Replacing the Manifold/Burner Assembly............................................................................................................... 31
Piezoelectric Igniter System ................................................................................................................................... 31
Testing the Igniter System ...................................................................................................................................... 32
Removing and Replacing the Gas Control Valve/Thermostat................................................................................ 32
FVIR System Operational Checklist ....................................................................................................................... 32
TROUBLESHOOTING GUIDE................................................................................................................ 33-35
Start Up Conditions............................................................................................................................................ 33-34
Operational Conditions ...................................................................................................................................... 34-35
TROUBLESHOOTING CHART............................................................................................................... 36-37
PILOT LIGHT TROUBLESHOOTING FLOWCHART................................................................................... 38
PARTS ORDER LIST.............................................................................................................................. 40-41
5
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PRODUCT WARRANTY
3 - YEAR LIMITED WARRANTY ON WATER HEATER
For three years from the date of purchase, if this water heater is installed and operated in a single-family home in accordance with the
owner’s manual instructions and all local applicable plumbing codes, Sears will:
1. Supply free water heater parts for those that are defective in material or workmanship.
2. Supply a free water heater for one that develops a leak.
For the second through third year from the purchase date, you must pay the labor cost for installation of parts or water heater.
For commercial, institutional, industrial or residential use by two or more families, the above limited warranty is only for two years. During
the second year you must pay the labor cost for parts or water heater installation.
If governmental regulations prohibit Sears from furnishing a comparable model replacement water heater under this warranty, Sears will
furnish a new water heater of comparable output as permitted by such governmental regulations; however, the Owner will be charged
for the additional cost associated with the changes made to the replacement water heater design to comply with such governmental
regulations.
Replacements and/or repairs furnished under this warranty do not carry a new warranty, and are only covered by the unexpired portion
of the original warranty.
1 - YEAR EXCLUSIVE KENMORE LABOR WARRANTY
For the first year from the date of purchase, Sears will, free of charge, supply and install new water heater parts for defective ones or a
new water heater for one that develops a leak.
WARRANTY SERVICE
To obtain warranty service, call 1-800-4-MY-HOME® (1-800-469-4663).
This warranty applies only while this product is in use in the United States.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
SEARS BRANDS MANAGEMENT CORPORATION, Hoffman Estates, IL 60179
The price of your water heater does not include a free checkup service call. On water heater installations arranged by Sears, Sears
warrants the installation.
A charge will be made on service calls due to poor or incomplete installation. These include:
a. Adjusting thermostat
b. Condensation
c. Leaks in pipes or fittings
Master Protection Agreements
Congratulations on making
a
smart purchase. Your new
•
$250 Food Loss Protection annually for any food spoilage
that is the result of mechanical failure of any covered
refrigerator or freezer.
Kenmore® product is designed and manufactured for years
of dependable operation. But like all products, it may require
preventive maintenance or repair from time to time. That’s when
having a Master Protection Agreement can save you money and
aggravation.
•
•
Rental reimbursement if repair of your covered product takes
longer than promised.
10% discount off the regular price of any non-covered repair
service and related installed parts.
The Master Protection Agreement also helps extend the life of your
new product. Here’s what the Agreement* includes:
Once you purchase the Agreement, a simple phone call is all that it
takes for you to schedule service. You can call anytime day or night,
or schedule a service appointment online.
•
Parts and labor needed to help keep products operating
properly under normal use, not just defects. Our coverage
goes well beyond the product warranty. No deductibles, no
functional failure excluded from coverage— real protection.
The Master Protection Agreement is a risk free purchase. If you
cancel for any reason during the product warranty period, we
will provide a full refund. Or, a prorated refund anytime after the
product warranty period expires. Purchase your Master Protection
Agreement today!
•
Expert service by a force of more than 10,000 authorized
Sears service technicians, which means someone you can
trust will be working on your product.
•
•
Unlimited service calls and nationwide service, as often as
you want us, whenever you want us.
Somelimitationsandexclusionsapply. Forpricesandadditional
information in the U.S.A. call 1-800-827-6655.
“No-lemon” guarantee – replacement of your covered product
if four or more product failures occur within twelve months.
* Coverage in Canada varies on some items. For full details,
call Sears Canada at 1-800-361-6665.
•
•
Product replacement if your covered product can’t be fixed.
Annual Preventive Maintenance Check at your request – no
Sears Installation Service
extra charge.
For Sears professional installation of home appliances, garage door
•
•
Fast help by phone – we call it Rapid Resolution – phone
support from a Sears representative on all products. Think of
us as a “talking owner’s manual.”
openers, water heaters, and other major home items, in the U.S.A.
or Canada call 1-800-4-MY-HOME®
.
Power surge protection against electrical damage due to
power fluctuations.
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CUSTOMER RESPONSIBILITIES
Thank You for purchasing a Kenmore water heater. Properly installed
•
Massachusetts Code requires this water heater to be installed in
accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5.00.
and maintained, it should give you years of trouble free service. If
you should decide that you want the new water heater professionally
®
installed by Sears call 1-800-4-MY-HOME . They will arrange for
prompt, quality installation by Sears authorized contractors.
•
Complies with 40 Ng/J NOx requirements of Texas and most
California AQM Districts.
Abbreviations Found In This Instruction Manual:
•
•
•
•
•
CSA - Canadian Standards Association
WARNING
ANSI - American National Standards Institute
NFPA - National Fire Protection Association
ASME - American Society of Mechanical Engineers
GAMA - Gas Appliance Manufacturers Association
Excessive Weight Hazard
Use two or more people to move and install the water heater.
Failure to do so can result in injury (including back injury).
Important Information About This Water Heater:
IMPORTANT: Do not remove any permanent instructions, labels, or
the data label from either the outside of the water heater or on the
inside of water heater panels.
This gas water heater was manufactured to voluntary safety
standards to reduce the likelihood of a flammable vapor ignition
incident. New technology used in meeting these standards makes this
product more sensitive to installation errors or improper installation
environments. Please review the Installation Checklist found at the
end of the installation instructions section and make any required
installation upgrades or changes.
•
•
•
•
Remove exterior packaging and place installation components
aside.
Inspect all parts for damage prior to installation and
start-up.
This manual contains instructions for the installation, operation,
and maintenance of the gas-fired water heater. It also contains
warnings through out the manual that you must read and be aware
of. All warnings and all instructions are essential to the proper
operation of the water heater and your safety. Since we cannot put
everything on the first few pages, READ THE ENTIRE MANUAL
BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER
HEATER.
Completely read all instructions before attempting to assemble
and install this product.
After installation, dispose of/recycle all packaging materials.
•
The installation must conform with these instructions and the
local code authority having jurisdiction. In the absence of local
codes, installations shall comply with the following:
In the United States: The National Fuel Gas CodeANSI Z223.1/
NFPA 54. This publication is available from the Canadian
StandardsAssociation, 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 Installation Instructions section in this manual.
For California installation, this water heater must be braced,
anchored, or strapped to avoid falling or moving during an
earthquake. See instructions for correct installation procedures.
Instructions may be obtained from California’s Office of the
State Architect, 1102 Q Street, Suite 5100, Sacramento, CA
95811. Instructions can also be downloaded to your computer
7
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PRODUCT SPECIFICATIONS
MODEL
NUMBER
TANK CAPACITY
IN GALS (LTRS)
TYPE
OF
GAS
INPUT
RATE
RECOVERY
RATE GALS.
PER HOUR
@ 90°F RISE
MINIMUM
VENT PIPE
DIA. INCHES
(mm)
DIAMETER
INCHES
(mm)
DIMENSIONS
INCHES (mm)
HEIGHT TO
(Btu/hr)
JACKET TOP
153.332420
40 (151)
Natural
35,500
36.34
3 (76) or 4 (102)
18 (457)
58.14 (1477)
8
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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.
METAL DRAIN PANS
AVAILABLE IN 20” (508
mm) DIAMETER FOR
EXPANSION TANKS FOR
THERMAL EXPANSION
CONDITIONS AVAILABLE
IN 2 GALLONS
WATER HEATERS HAVING A
DIAMETER 18” (457 mm) OR
LESS, 24” (610mm) DIAMETER
FOR WATER HEATERS HAVING
A DIAMETER 22” (559 mm)
OR LESS AND AVAILABLE IN
28” (711 mm) DIAMETER FOR
WATER HEATERS HAVING A
DIAMETER 26” (660 mm) OR
LESS.
(7.6 LITERS) AND
5 GALLONS (18.9 LITERS)
CAPACITY THROUGH
LOCAL SEARS STORE
OR SERVICE CENTER.
WATER HEATER INSTALLATION KIT
WITH FLEXIBLE CONNECTORS FOR 3/4”
(19.05 mm) COPPER PLUMBINGAND FLEXIBLE
GAS CONNECTOR WITH FITTINGS.
BASIC TOOLS
ADDITIONAL TOOLS NEEDED
WHEN SWEAT SOLDERING
You may or may not need all these tools, depending on your
type of installation. These tools can be purchased at your local
Sears Store.
• Tubing Cutters or Hacksaw
• Propane Torch
• Soft Solder
• Solder Flux
• Emery Cloth
• Pipe Wrenches (2) 14” (356 mm)
• Screwdriver
• Tin Snips
• 6’ (1.82 m) Tape or Folding Ruler
• Garden Hose
• Wire Brushes
• Drill
• Pipe Dope or Teflon Tape
DRILL
PROPANE
TORCH
TUBING CUTTER
SLOT-HEAD SCREWDRIVER
TIN SNIPS
PHILLIPS SCREWDRIVER
ROLL OF
HACKSAW
EMERY CLOTH
PIPE DOPE
(SQUEEZE TUBE)
USE FOR WATER AND GAS
CONNECTIONS
ROLL OF TEFLON
TAPE (USE ONLY ON
WATER CONNECTIONS)
3/4” (19 mm) WIRE BRUSH
ROLL OF LEAD-FREE
SOFT SOLDER
SOLDER
FLUX
6 FOOT TAPE
GARDEN HOSE
PIPE WRENCH
1/2” (13 mm) WIRE BRUSH
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TYPICAL INSTALLATION
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A
B
C
D
E
F
G
H
I
Vent Pipe
Draft Hood
J
K
L
M
N
O
P
Inner Door
Outer Door
Union
Inlet Water Shut-off Valve
Cold Water Inlet
Inlet Dip Tube
Temperature-Pressure Relief Valve
Rating Plate
S
T
U
V
W
X
Y
Gas Control Valve/Thermostat
Drain Valve
Pilot and Main Burner
Flue
Metal Drain Pan
Piezo Igniter
Base-Ring Filter
Anode (Not Shown)
Hot Water Outlet
Insulation
Gas Supply Piping
Manual Gas Shut-off Valve
Ground Joint Union
Drip Leg (Sediment Trap)
Q
R
Flue Baffle
* INSTALLINACCORDANCE
WITH LOCAL CODES.
* DRIP LEG AS REQUIRED
BY LOCAL CODES.
(S) GAS CONTROL VALVE/
THERMOSTAT: WHITE-RODGERS
GAS CONTROL KNOB
TO VENT
TERMINATION ON
ROOF
INSTALL THERMAL EXPANSION
TANK IF WATER HEATER IS
INSTALLED IN A CLOSED
WATER SYSTEM
A
WATER TEMPERATURE DIAL
(ADJUSTING DIAL)
L
M
N
B
D
VACUUM RELIEF
VALVE
*INSTALL PER
LOCAL CODES
O
“OFF”
POSITION
“PILOT”
POSITION
“ON”
POSITION
TOP VIEW
P
E
R
(U) MANIFOLD/BURNER ASSEMBLY
MAIN BURNER
THERMOCOUPLE
PILOT TUBE
IGNITER WIRE
Q
MANIFOLD TUBE
F
MANIFOLD DOOR
G
DISCHARGE PIPE
(DO NOT CAP OR PLUG.)
H
X
V
S
T
U
6” MAXIMUM
AIR GAP
I
FLOOR DRAIN
Y
W
J
K
* ALL PIPING MATERIALS TO BE
SUPPLIED BY CUSTOMERS.
FIGURE 1.
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IMPORTANT INFORMATION ABOUT THIS WATER HEATER
This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident.
The new technology used in meeting these standards makes this product more sensitive to installation errors. Please review the
following checklist and make any required installation upgrades or changes.
Questions? Contact Sears at 1-800-4-MY-HOME (1-800-469-4663).
Installation Checklist
□
□
Fresh air openings must be sized correctly with consideration
given to the blocking effect of louvers and grilles.
Water Heater Location
Ductwork must be the same cross-sectional area as the
openings.
Water heater location is important and can affect system
performance. Please check the following:
Vent Pipe System
□
□
Installation area free of corrosive elements and flammable
materials.
Check for proper drafting at the water heater draft hood. Refer
to the “Checking the Draft” section of this manual for the test
procedure. If the procedure shows insufficient draft is present,
please check the following:
Centrally located with the water piping system (For new
installations). Located as close to the gas piping and vent
pipe system as possible.
□
□
Draft hood properly installed.
□
□
□
□
Located indoors and in a vertical position. Protected from
freezing temperatures.
Vent connectors securely fastened with screws and
supported properly to maintain six inch clearance.
Proper
clearances
from
combustible
surfaces
maintained and not installed directly on a carpeted floor.
□
□
Vent connector made of approved material and sized
correctly.
Provisions made to protect the area from water damage.
Metal drain pan installed and piped to an adequate drain.
Vent pipe system installed according to all local and state
codes or, in the absence of local and state codes, the
“National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current
edition.
Sufficient room to service the water heater. See Clearances
and Accessibility section of this manual.
□
□
Water heater not located near an air moving device.
Is the installed environment dirty (excessive amounts of
lint, dirt, dust, etc.)? If so, the base-ring filter located on
the bottom of the water heater will need to be cleaned
periodically. Refer to the “Maintenance of your Water
Heater” section of this manual for information on cleaning
the base-ring filter.
□
□
Flue baffle properly positioned in the flue tube.
Check the vent system for restrictions/obstructions and
check the vent termination height. Refer to the “Combustion
Air Supply and Ventilation” section of this water heater
manual for specific requirements.
□
Recheck for sufficient combustion air supply.
Combustion Air Supply and Ventilation
Water System Piping
Check for sufficient combustion air supply. Insufficient air for
the combustion of gas will result in the flame becoming “lazy”,
thereby allowing heat to build up in the combustion chamber.
This excessive heat will cause a thermal switch on the door
assembly to trip. Is the water heater installed in a closet or other
small, enclosed space? If so:
□
Temperature and pressure relief valve properly installed with
a discharge line run to an open drain and protected from
freezing.
□
□
□
□
All piping properly installed and free of leaks.
Heater completely filled with water.
□
□
Are there openings for make-up air to enter and exit the
room/area?
Closed system pressure build-up devices installed.
Mixing valve (when applicable) installed per manufacturer’s
instructions (See “Water Temperature Regulation” section).
Are the openings of sufficient size? Remember, if there
are other gas-fired or air-consuming appliances in the
same room, you need more make-up air. Refer to the
“Installation Instructions” and “Combustion Air Supply and
Ventilation” sections for specific requirements.
Gas Supply and Piping
□
Gas type is the same as that listed on the water heater rating
plate.
□ Make sure that fresh air is not taken from areas that contain
negative pressure producing devices such as exhaust fans,
dryers, fireplaces, etc.
□
□
Gas line equipped with shut-off valve, union, and drip leg.
Use pipe joint compound or teflon tape marked as being
resistant to the action of petroleum [Propane (L.P.)] gases.
□
Is there a furnace/air handler in the same room space as
the water heater? If so, has a return air duct system been
attached that exits the room? If so, check for leaks on the
air duct system. If no air duct system is present, correct
immediately by contacting a local Heating, Ventilation, Air-
Conditioning & Refrigeration (HVAC-R) authorized service
provider.
□
□
Adequate pipe size and approved pipe material.
An approved noncorrosive leak detection solution used
to check all connections and fittings for possible gas leaks.
Correct any leak found.
□
Use a fresh air supply that is free of corrosive elements and
flammable vapors.
11
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INSTALLATION INSTRUCTIONS
4.
Attach a hose to the water heater
Removing the Old Water Heater
drain valve and put the other end
in a floor drain or outdoors. (See
Figures 2 and 5.) Open the water
heater drain valve. The water
passing out of the drain valve
may be extremely hot. To avoid
being scalded, make sure all
connections are tight and that the
water flow is directed away from
any person.
5
2
6
1
MANUAL GAS
SHUT-OFF VALVE
GROUND
JOINT
UNION
FIGURE 5.
DISCHARGE PIPE
CHECK WITH
(DO NOT CAP
OR PLUG)
LOCAL UTILITY
FOR MINIMUM HEIGHT
5.
6.
Disconnect the vent pipe from the draft hood where it connects
to the water heater. In most installations the vent pipe can
be lifted off after any screw or other attached devices are
removed. Dispose of the draft hood. The new water heater
has a draft hood which must be used for proper operation.
3
4
3” MINIMUM
6” MAXIMUM
AIR GAP
DRIP LEG
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.
SUITABLE
DRAIN
FIGURE 2.
1.
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 3.
FIGURE 6.
2.
Open a nearby hot water faucet
until the water is no longer hot.
When the water has cooled, turn
“OFF”thewatersupplytothewater
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.
If you have galvanized pipes to the water heater, loosen
the two galvanized pipes with a pipe wrench at the union in
each line. Also disconnect the piping remaining to the water
heater. See Figure 7. These pieces should be saved since
they may be needed when reconnecting the new water heater.
Disconnect the temperature-pressure relief valve drain line.
When the water heater is drained, disconnect the hose from
the drain valve. Close the drain valve. The water heater
is now completely disconnected and ready to be removed.
Mineral buildup or sediment may have accumulated in the
old water heater. This causes the water heater to be much
heavier than normal and this residue, if spilled out, could
cause staining.
FIGURE 4.
3.
Check again to make sure the gas supply is “OFF” to the water
heater. Then disconnect the gas supply connection from the
gas control valve.
FIGURE 7.
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area of the water heater, leave the area immediately and call
the fire department from a neighbor’s home. Do not attempt to
clean the spill until all ignition sources have been extinguished.
Location Requirements
WARNING
WARNING
Carbon Monoxide Poisoning Hazard
Do not install in a mobile home.
Fire or Explosion Hazard
• Read instruction manual before installing, using or
servicing water heater.
Doing so can result in carbon monoxide poisoning and death.
• Improper use may result in fire or explosion.
• Maintain required clearances to combustibles.
The FVIR System is designed to reduce the risk of flammable
vapor-related fires. The patented system protects your family by
trapping the burning vapors within the water heater combustion
chamber through the special flame-arrestor. The burning vapors
literally “burn themselves out” without escaping back into the
room. In the event of a flammable vapor incident, the FVIR
System disables the water heater by shutting off the gas supply
to the water heater’s burner and pilot, preventing re-ignition
of any remaining flammable vapors in the area. This will not
prevent a possible fire/explosion if the igniter is depressed
and flammable vapors have accumulated in the combustion
chamber with the pilot light off. If you suspect a flammable
vapor incident has occurred, do not use this appliance. Do not
attempt to light this appliance, or depress the igniter button
if you suspect flammable vapors have accumulated inside or
outside the appliance. Immediately call a qualified technician to
inspect the appliance. Water heaters subjected to a flammable
vapors incident will show a discoloration on the flame-arrestor
and require replacement of the entire water heater.
Keep combustibles such as boxes, magazines, clothes, etc.
away from the water heater area.
Site Location
•
•
Select a location near the center of the water piping system.
The water heater must be installed indoors and in a vertical
position on a level surface. DO NOT install in bathrooms,
bedrooms, or any occupied room normally kept closed.
Locate the water heater as close to the chimney or gas
vent as practical. Consider the vent system piping and
combustion air supply requirements when selecting the
water heater location. The venting system must be able
to run from the water heater to termination with minimal
length and elbows.
•
•
Locate the water heater near the existing gas piping. If
installing a new gas line, locate the water heater to minimize
the pipe length and elbows.
WARNING
The water heater should be located in an area not subject
to freezing temperatures. Water heaters located in
unconditioned spaces (i.e., attics, basements, etc.) may
require insulation of the water piping and drain piping
to protect against freezing. The drain and controls must
be easily accessible for operation and service. Maintain
proper clearances as specified on the rating plate.
•
Do not locate the water heater near an air-moving device.
The operation of air-moving devices such as exhaust fans,
ventilation systems, clothes dryers, fireplaces, etc., can
affect the proper operation of the water heater. Special
attention must be given to conditions these devices may
create. Flow reversal of flue gases may cause an increase
of carbon monoxide inside of the dwelling (Figure 8).
FLAMMABLES
Flammable Vapors
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
•
•
If the water heater is located in an area that is subjected to
lint and dirt, it may be necessary to periodically clean the
base-ring filter and flame-arrestor (see External Inspection
& Cleaning of the Flame-arrestor).
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other
appliance. Storage of or use of gasoline or other
flammable vapors or liquids in the vicinity of this or any
other appliance can result in serious injury or death.
This water heater is not for use in manufactured (mobile)
homes or outdoor installation.
NOTE: This water heater must be installed according to all local
and state codes or, in the absence of local and state codes, the
“National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edition.
Read and follow water heater warnings and instructions.
Do not use or store flammable products such as gasoline,
solvents, or adhesives in the same room or area near the
water heater. If such flammables must be used, all gas burning
appliances in the vicinity must be shut off and their pilot lights
extinguished. Open the doors and windows for ventilation while
flammable substances are in use.
EXHAUST FAN
REVERSE FLOW
OF GASES
If flammable liquids or vapors have spilled or leaked in the
FIGURE 8
13
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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.
IMPORTANT: The water heater should be located in an area
where leakage of the tank or connections will not result in damage
to the area adjacent to the water heater or to lower floors of the
structure. Due to the normal corrosive action of water, the tank will
eventually leak after an extended period of time. Also any external
plumbing leak, including those from improper installation, may
cause early failure of the tank due to corrosion if not repaired. If
the homeowner is uncomfortable with making the repair a qualified
technician should be contacted. A suitable metal drain pan should
be installed under the water heater as shown below, to help protect
the property from damage which may occur from condensate
formation or leaks in the piping connections or tank. The pan must
limit the water level to a maximum depth of 1-3/4” and be two inches
wider than the heater and piped to an adequate drain. NOTE: The
pan must not restrict combustion air flow. Locate the water heater
near a suitable indoor drain. Outside drains are subject to freezing
temperatures which can obstruct the drain line. The piping should
be at least 3/4” ID and pitched for proper drainage.
WARNING
Should you choose to apply an insulation blanket to this
heater, you should follow these instructions (See Figure 1
for identification of components mentioned below). Failure to
follow these instructions can restrict the air flow required for
proper combustion, potentially resulting in fire, asphyxiation,
serious personal injury or death.
•
•
•
Do not apply insulation to the top of the water heater, as
this will interfere with safe operation of the draft hood.
METAL
DRAIN
PAN
Do not cover the outer door, thermostat or temperature &
pressure relief valve.
PIPED TO AN
ADEQUATE DRAIN
Do not allow insulation to come within 2” (50.8 mm) of
the floor to prevent blockage of combustion air flow to the
burner.
AT LEAST 2” GREATER THAN THE
DIAMETER OF THE WATER HEATER.
FIGURE 9.
•
•
Do not cover the instruction manual. Keep it on the side of
the water heater or nearby for future reference.
Water heater life depends upon water quality, water usage,
water temperature and the environment in which the water
heater is installed. Water heaters are sometimes installed in
locations where leakage may result in property damage, even
with the use of a metal drain pan piped to a drain. However,
unanticipated damage can be reduced or prevented by a leak
detector or water shut-off device used in conjunction with a
piped metal drain pan. These devices are available from some
plumbing supply wholesalers and retailers, and detect and react
to leakage in various ways:
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.
Clearances and Accessibility
•
•
•
•
Sensors mounted in the metal drain pan that trigger an
alarm or turn off the incoming water to the water heater
when water is detected.
NOTE: Minimum clearances from combustible surfaces are
stated on the label adjacent to the gas control valve/thermostat
of the water heater. The water heater is certified for installation
on a combustible floor.
Sensors mounted in the metal drain pan that turn off the
water supply to the entire home when water is detected in
the drain pan.
•
IMPORTANT: If installing over carpeting, the carpeting
must be protected by a metal or wood panel beneath the
water heater. The protective panel must extend beyond the
full width and depth of the water heater by at least three
inches (76.2mm) in any direction; or if in an alcove or closet
installation, the entire floor must be covered by the panel.
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.
•
Figure 10 may be used as a reference guide to locate the
specific clearance locations. A minimum of 24 inches of
front clearance should be provided for inspection and
service.
Insulation Blankets
Insulation blankets available to the general public for external
14
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•
•
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.
VENT
TOP
TO
CEILING
BACK
SIDES
To ensure complete filling of the tank, allow air to exit by
opening the nearest hot water faucet. Allow water to run until
a constant flow is obtained. This will let air out of the water
heater and the piping.
FRONT
24” MINIMUM
FOR SERVICE
SIDES
TOP
VIEW
•
Check all water piping and connections for leaks. Repair as
needed.
FIGURE 10.
Filling the Water Heater
Never use this water heater unless it is completely full of water.
To prevent damage to the tank, the tank must be filled with water.
Water must flow from the hot water faucet before turning “ON” gas
to the water heater. To fill the water heater with water:
•
Close the water heater drain valve by turning the handle to
the right (clockwise). The drain valve is on the lower front of
the water heater.
GAS SUPPLY
codes or, in the absence of local and state codes, the “National
Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edition.
WARNING
Tables 1 and 2 on the following page provide a sizing reference
for commonly used gas pipe materials. Consult the “National
Fuel Gas Code” for the recommended gas pipe size of other
materials.
NOTE: Use pipe joint compound or teflon tape marked as being
resistant to the action of petroleum [Propane (L.P.)] gases.
(See Figure 11.)
1. Install a readily accessible manual shut-off valve in the gas
supply line as recommended by the local utility. Know the
location of this valve and how to turn off the gas to this unit.
2. Install a drip leg (if not already incorporated as part of
the water heater) as shown. The drip leg must be no less
than three inches long for the accumulation of dirt, foreign
material, and water droplets.
3. Install a ground joint union between the gas control valve/
thermostat and the manual shut-off valve. This is to allow
easy removal of the gas control valve/ thermostat.
4. Turn the gas supply on and check for leaks. Test all
connections by brushing on an approved noncorrosive
leak-detection solution. Bubbles will show a leak. Correct
any leak found.
Explosion Hazard
Use a new CSA approved gas supply line.
Install a shut-off valve.
•
•
•
Do not connect a natural gas water heater to an
L.P. gas supply.
•
•
Do not connect an L.P. gas water heater to a
natural gas supply.
Failure to follow these instructions can result in
death, explosion, or carbon monoxide poisoning.
MANUAL GAS
SHUT-OFF VALVE
Gas Requirements
IMPORTANT: Read the rating plate to be sure the water heater
is made for the type of gas you will be using in your home. This
information will be found on the rating plate located near the
gas control valve/thermostat. If the information does not agree
with the type of gas available, do not install or light. Call your
dealer.
GROUND
JOINT
UNION
CHECK WITH
LOCAL UTILITY
FOR MINIMUM HEIGHT
NOTE: An odorant is added by the gas supplier to the gas used
by this water heater. This odorant may fade over an extended
period of time. Do not depend upon this odorant as an indication
of leaking gas.
3” MINIMUM
6” MAXIMUM
DRIP LEG
AIR GAP
Gas Piping
SUITABLE DRAIN
FIGURE 11.
The gas piping must be installed according to all local and state
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the fuel is not spilled in the area of the water heater installation,
or any source of ignition. If the fuel is spilled while purging the
piping system of air follow the “WHAT TO DO IF YOU SMELL
GAS” instructions on the cover of this manual.
Gas Pressure
WARNING
LP Gas Only
WARNING
Explosion Hazard
•
•
Gas leaks can not always be detected by smell.
Gas suppliers recommend that you use a gas
detector approved by UL or CSA.
Explosion Hazard
•
•
For more information, contact your gas supplier.
Have a qualified person make sure L.P. gas pressure
does not exceed 13” water column.
If a gas leak is detected, follow the “What to do if you
smell gas” instructions on the cover of this manual.
Examples of a qualified person include: licensed
plumbers, authorized gas company personnel, and
authorized service personnel.
IMPORTANT:The gas supply pressure must not exceed the maximum
supply pressure as stated on the water heater’s rating plate. The
minimum supply pressure is for the purpose of input adjustment.
Failure to do so can result in death, explosion, or
fire.
Gas Pressure Testing
IMPORTANT: This water heater and its gas connection must be
leak tested before placing the appliance in operation.
Liquefied petroleum gas is over 50% heavier than air and in
the occurrence of a leak in the system, the gas will settle at
floor level. Basements, crawl spaces, closets and areas below
ground level will serve as pockets for the accumulation of gas.
Before lighting an L.P. gas water heater, smell all around the
appliance at floor level. If you smell gas, follow the instructions
as given in the warning on the front page.
•
If the code requires the gas lines to be tested at a pressure
exceeding 14” W.C., the water heater and its manual shut-off
valve must be disconnected from the gas supply piping system
and the line capped.
•
If the gas lines are to be tested at a pressure less than 14” W.C.,
the water heater must be isolated from the gas supply piping
system by closing its manual shut-off valve.
When your L.P. tank runs out of fuel, turn off the gas at all
gas appliances including pilot lights. After the tank is refilled,
all appliances must be re-lit according to their manufacturer’s
instructions.
NOTE: Air may be present in the gas lines and could prevent the
pilot from lighting on initial start-up. The gas lines should be purged
of air by a qualified technician after installation of the gas piping
system. While purging the gas piping system of air, ensure that
16
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COMBUSTION AIR SUPPLY & VENTILATION
TABLE 3
WARNING
120,000
135,000
750
844
25 x 30
28 x 30
Carbon Monoxide Warning
Follow all the local and state codes or, in the absence of
local and state codes, the “National Fuel Gas Code”,
ANSI Z223.1 (NFPA 54)- current edition to properly
install vent system.
IMPORTANT:
•
•
•
The area must be open and be able to provide the proper
air requirements to the water heater. Areas that are being
used for storage or contain large objects may not be
suitable for water heater installation.
Failure to do so can result in death, explosion, or
carbon monoxide poisoning.
Water heaters installed in open spaces in buildings with
unusually tight construction may still require outdoor air
to function properly. In this situation, outside air openings
should be sized the same as for a confined space.
IMPORTANT: Air for combustion and ventilation must not
come from a corrosive atmosphere. Any failure due to corrosive
elements in the atmosphere is excluded from warranty
coverage.
Modern home construction usually requires supplying
outside air into the water heater area.
The following types of installation (not limited to the following)
will require outdoor air for combustion due to chemical exposure
and may reduce but not eliminate the presence of corrosive
chemicals in the air:
Confined Space
For the correct and proper operation of this water heater,
ample air must be supplied for the combustion, ventilation, and
dilution of flue gases. Small enclosures and confined areas
must have two permanent openings so that sufficient fresh air
can be drawn from outside of the enclosure. One opening shall
be within 12 inches of the top and one within 12 inches of the
bottom of the enclosure as shown in Figure 12.
•
•
•
•
•
beauty shops
photo processing labs
buildings with indoor pools
water heaters installed in laundry, hobby, or craft rooms
water heaters installed near chemical storage areas
Combustionairmustbefreeofacid-formingchemicalssuchassulfur,
fluorine, and chlorine. These elements are found in aerosol sprays,
detergents, bleaches, cleaning solvents, air fresheners, paint, and
varnish removers, refrigerants, and many other commercial and
household products. When burned, vapors from these products
form highly corrosive acid compounds. These products should not
be stored or used near the water heater or air inlet.
The size of each opening (free area) is determined by the total
BTUH input of all gas utilization equipment (i.e., water heaters,
furnaces, clothes dryers, etc.) and the method by which the air
is provided. The BTUH input can be found on the water heater
rating plate. Additional air can be provided by two methods:
1. All air from inside the building.
2. All air from outdoors.
Combustion and ventilation air requirements are determined by
the location of the water heater. The water heater may be located
in either an open (unconfined) area or in a confined area or small
enclosure such as a closet or small room. Confined spaces are
areas with less than 50 cubic feet for each 1,000 BTUH of the total
input for all gas-using appliances.
12” MAXIMUM
CLOSET
OR
Unconfined Space
PERMANENT
OPENINGS TO
THE OUTSIDE OR
ADDITIONAL
ROOMS WITHIN
THE BUILDING
OTHER
CONFINED
SPACE
A water heater in an unconfined space uses indoor air for
combustion and requires at least 50 cubic feet for each 1,000
BTUH of the total input for all gas appliances. The table below
shows a few examples of the minimum square footage (area)
required for various BTUH inputs.
TABLE 3
Minimum Square
Typical Room
BTUH Input
Feet with
8’ Ceiling
188
with 8’ Ceiling
12” MAXIMUM
FIGURE 12.
30,000
45,000
60,000
75,000
90,000
105,000
9 x 21
14 x 20
15 x 25
15 x 31
20 x 28
20 x 33
281
All Air from Inside the Building
375
When additional air is to be provided to the confined area
from additional room(s) within the building, the total volume of
the room(s) must be of sufficient size to properly provide the
necessary amount of fresh air to the water heater and other
469
563
657
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gas utilization equipment in the area. If you are unsure that the
structure meets this requirement, contact your local gas utility
company or other qualified agency for a safety inspection.
Each of the two openings shall have a minimum free area of 1
square inch per 1,000 BTUH of the total input rating of all gas
utilization equipment in the confined area, but not less than 100
square inches (Figure 13).
TABLE 4
Minimum Free Area of Permanent Openings for Ventilation
and Combustion Air Supply - All Air from Outdoors Only.
Based on total BTUH input rating for all utilizing equipment
within the confined space.
Minimum Free Area
Per Opening (sq. in.)
Reference
Drawing
Opening Source
*Direct to outdoors 1 sq. in, per 4000 BTUH
Figure 14
Figure 15
Figure 16
Figure 17
Vertical Ducts
Horizontal Ducts
Single Opening
1 sq. in, per 4000 BTUH
1 sq. in, per 2000 BTUH
1 sq. in, per 3000 BTUH
CONFINED
SPACE
Example: A water heater with an input rating of 50,000 BTUH using
horizontal ducts would require each opening to have a minimum free
area of 25 square inches.
Minimum free area = 50,000 BTUH x 1 sq. in. / 2000 BTUH = 25 sq.
in.
PERMANENT
OPENINGS
These openings connect directly with the outdoors through a
ventilated attic, a ventilated crawl space, or through an outside
wall.
1 SQUARE
INCH/1000
BTUH
(MINIMUM
100 SQ. IN.)
*
Consult the local codes of your area for specific ventilation and
combustion air requirements.
GABLE VENT
TO OUTDOORS
FIGURE 13.
INSTALL ABOVE
INSULATION
All Air from Outdoors
Outdoor fresh air can be provided to a confined area either
directly or by the use of vertical and horizontal ducts. The
fresh air can be taken from the outdoors or from crawl or attic
spaces that freely communicate with the outdoors. Attic or crawl
spaces cannot be closed and must be properly ventilated to the
outside.
CONFINED
OUTLET
SPACE
AIR TO
ATTIC 1 SQ.
INCH PER
4000 BTUH
INLET AIR FROM
THE CRAWL SPACE
ALTERNATE
AIR INLET
Ductwork must be of the same cross-sectional area as the
free area of the opening to which they connect. The minimum
dimension of rectangular air ducts cannot be less than three
inches.
1 SQ. INCH PER
4000 BTUH
OPEN
FOUNDATION
VENT
The size of each of the two openings is determined by the
method in which the air is to be provided. Refer to Table 4 to
calculate the minimum free area for each opening. Figures 14,
15, 16 and 17 are typical examples of each method.
ALL AIR FROM OUTDOORS: INLET AIR FROM VENTILATED
CRAWL SPACE/OUTLET AIR TO VENTILATED ATTIC
FIGURE 14.
Louvers and Grilles
GABLE VENT
TO OUTDOORS
In calculating free area for ventilation and combustion air supply
openings, consideration must be given to the blocking effect
of protection louvers, grilles, and screens. These devices can
reduce airflow, which in turn may require larger openings to
achieve the required minimum free area. Screens must not be
smaller than 1/4” mesh. If the free area through a particular
design of louver or grille is known, it should be used in
calculating the specified free area of the opening. If the design
and free area are not known, it can be assumed that most wood
louvers will allow 20 - 25% of free area while metal louvers and
grilles will allow 60 - 75% of free area.
INSTALL ABOVE
INSULATION
OUTLET AIR
TO ATTIC
1 SQ. INCH
PER 4000
BTUH
CONFINED
SPACE
INLET AIR DUCT
1 SQ. INCH PER
4000 BTUH
Louvers and grilles must be locked open or interconnected with
the equipment so that they are opened automatically during
equipment operation.
12” MAXIMUM
Keep louvers and grilles clean and free of debris or other
obstructions.
ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC
FIGURE 15.
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using the manufacturer’s instructions and local codes, rules, or
regulations.
1 SQ. INCH PER
2000 BTUH
IMPORTANT: If you lack the necessary skills required to
properly install this venting system, you should not proceed, but
get help from a qualified technician.
OUTLET
CONFINED
SPACE
Draft Hood Installation
OUTDOOR
AIR DUCTS
SHEET METAL SCREWS (FOUR PROVIDED)
DRAFT HOOD
LEGS
INLET
LEGS
1 SQ. INCH PER
2000 BTUH
SLOT
SLOT
JACKET TOP
ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS
INSTALL THE DRAFT HOOD WITH
THE FOUR SCREWS PROVIDED.
FIGURE 16.
FIGURE 18.
Align the legs of the draft hood with the slots provided. Insert
the legs and secure the draft hood to the water heater’s top
with the four screws provided as shown in Figure 18. Do not
alter the draft hood in any way. If you are replacing an existing
water heater, be sure to use the draft hood supplied with this
water heater.
ALTERNATIVE
OPENING
LOCATION
1 SQ. INCH
CONFINED
PER 3000 BTUH
SPACE
Vent Pipe Size
It is important that you follow the guidelines in these instructions
for sizing a vent pipe system. If a transition to a larger vent size
is required, the vent transition connection must be made at the
draft hood outlet.
Vent Connectors
ALL AIR FROM OUTDOORS - USING A SINGLE PERMANENT OPENING
1. Type B, Double wall, U.L. Listed Vent Pipe.
2. Single wall Vent Pipe.
FIGURE 17.
Maintain the manufacturer’s specified minimum clearance from
combustible materials when using type B double wall vent
pipe.
Vent Pipe System
This water heater uses a non-direct, single-pipe vent system
to remove exhaust gases created by the burning of fossil fuels.
Air for combustion is taken from the immediate water heater
location or is ducted in from the outside (see “Combustion Air
Supply and Ventilation”).
Vent connectors made of type B, double wall vent pipe material
may pass through walls or partitions constructed of combustible
material if the minimum listed clearance is maintained.
Maintain a six inch minimum clearance from all combustible
materials when using single wall vent pipe.
This water heater must be properly vented for the removal of
exhaust gases to the outside atmosphere. Correct installation
of the vent pipe system is mandatory for the proper and efficient
operation of this water heater and is an important factor in the
life of the unit.
IMPORTANT: Single wall vent pipe cannot be used for water
heaters located in attics and may not pass through attic spaces,
crawl spaces or any confined or inaccessible location. A single
wall metal vent connector cannot pass through any interior
wall.
The vent pipe must be installed according to all local and state
codes or, in the absence of local and state codes, the “National
Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edition. The
vent pipe installation must not be obstructed so as to prevent
the removal of exhaust gases to the outside atmosphere.
When installing a vent connector, please note the following
(See Figures 19-21):
•
•
•
Install the vent connector avoiding unnecessary bends,
which create resistance to the flow of vent gases.
Install without dips or sags with an upward slope of at least
1/4-inch per foot.
IMPORTANT: The use of vent dampers is not recommended
by the manufacturer of this water heater. Although some vent
dampers are certified by CSA International, this certification
applies to the vent damper device only and does not mean they
are certified for use on this water heater.
Joints must be fastened by sheet metal screws or other
approved means. It must be supported to maintain
clearances and prevent separation of joints and damage.
•
The length of the vent connector cannot exceed 75% of the
vertical vent height.
U.L. recognized fuel gas and carbon monoxide (CO) detectors
are recommended in all applications and should be installed
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•
•
•
The vent connector must be accessible for cleaning,
inspection, and replacement.
separation, and maintain clearances to combustible materials
(Figures 20 and 21).
Vent connectors cannot pass through any ceiling, floor,
firewall, or fire partition.
IMPORTANT: This gas vent must be terminated in a vertical
position to facilitate the removal of the burnt gases.
It is recommended (but not mandatory) that a minimum 12
inches of vertical vent pipe be installed on the draft hood
prior to any elbow in the vent system.
An unused chimney flue or masonry enclosure may be used as a
passageway for the installation of a gas vent (Figure 21).
Common (combined) venting is allowable with vertical type B
vent systems and lined masonry chimneys as long as proper
draft for the water heater is established under all conditions of
operation. CAUTION: DO NOT common vent this water heater
with any power vented appliance.
IMPORTANT: Existing vent systems must be inspected for
obstructions, corrosion, and proper installation.
Chimney Connection
Figures 19-21 are examples of vent pipe system installations
and may or may not be typical for your specific application.
Consult the “National Fuel Gas Code”, NFPA 54, ANSI Z223.1-
current edition and the guidelines set forth by prevailing local
codes.
IMPORTANT: Before connecting a vent to a chimney, make sure
the chimney passageway is clear and free of obstructions. The
chimney must be cleaned if previously used for venting solid
fuel appliances or fireplaces. Also consult local and state codes
for proper chimney sizing and application or, in the absence
of local and state codes, the “National Fuel Gas Code”, ANSI
Z223.1(NFPA 54)-current edition.
LISTED VENT CAP
•
The connector must be installed above the extreme bottom
of the chimney to prevent potentially blocking the flue
gases.
2 FT. MINIMUM ABOVE ANY OBJECT
WITHIN 10 FT. HORIZONTALLY
3 FT. MINIMUM
SUPPORT
STRAP
•
•
•
The connector must be firmly attached and sealed to
prevent it from falling out.
*MAINTAIN
CLEARANCE
TYPE B DOUBLE
WALL VENT PIPE
To aid in removing the connector, a thimble or slip joint may
be used.
**MAINTAIN
SPECIFIED
CLEARANCE
The connector must not extend beyond the inner edge of
the chimney as it may restrict the space between it and the
opposite wall of the chimney (Figure 19).
VENT
CONNECTOR
SLOPE UP
1/4 IN. PER FT.
MINIMUM
LISTED LINED
CHIMNEY
2 FT. MINIMUM ABOVE ANY OBJECT
WITHIN 10FT. HORIZONTALLY
VERTICAL GAS VENT SYSTEM WITH
TYPE B DOUBLE WALL VENT PIPE.
3 FT. MINIMUM
SUPPORT
STRAP
MAINTAIN
CLEARANCE*
FIGURE 20.
SEAL
DO NOT EXTEND
VENT BEYOND EDGE
OF CHIMNEY
LISTED VENT CAP
MAINTAIN MANUFACTURER’S
SPECIFIED MINIMUM CLEARANCE
**MAINTAIN
SPECIFIED
CLEARANCE
SLOPE
UP 1/4 IN.
PER FT.
VENT
CONNECTOR
SUPPORT
STRAP
MINIMUM
*MAINTAIN
CLEARANCE
SEAL
CHIMNEY TERMINATION VENT SYSTEM
FIGURE 19.
VENT CONNECTOR
VENT
CONNECTOR
SLOPE UP
1/4 IN. PER FT.
MINIMUM
Do not terminate the vent connector in a chimney that has not
been certified for this purpose. Some local codes may prohibit
the termination of vent connectors in a masonry chimney.
UNUSED CHIMNEY
FLUE OR MASONRY
ENCLOSURE
Vertical Exhaust Gas Vent
VENTING THROUGH A CHIMNEY WITH
TYPE B DOUBLE WALL VENT PIPE.
Vertical exhaust gas vents must be installed with U.L. listed type B
vent pipe according to the vent manufacturer’s instructions and the
terms of its listing.
FIGURE 21.
Maintain vent pipe clearance requirements to local, state and/or the
“National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edition.
It must be connected to the water heater’s draft hood by a
listed vent connector or by directly originating at the draft hood
opening.
*
NFPA 211, Standard for Chimneys, Fireplaces, Vents, and Solid
**
Fuel-Burning Appliances states that these chimneys are intended to
be installed in accordance with the installation instructions provided
with each chimney support assembly. Minimum air space clearance to
combustible materials should be maintained as marked on the chimney
sections.
Vertical gas vents must terminate with a listed cap or other roof
assembly and be installed according to their manufacturer’s
instructions.
Gas vents must be supported to prevent damage, joint
20
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WATER SYSTEM PIPING
IN A CLOSED SYSTEM USE A
THERMAL EXPANSION TANK
Piping Installation
COLD WATER SUPPLY TO FIXTURES
Piping, fittings, and valves should be installed according to the
installation drawing (Figure 22). If the indoor installation area
is subject to freezing temperatures, the water piping must be
protected by insulation.
PRESSURE REDUCING VALVE
WITH BYPASS
COLD WATER
INLET
HOT WATER
OUTLET
COLD WATER INLET VALVE
(SHUT-OFF VALVE)
The water supply pressure should not exceed 80 psi. If this
occurs, a pressure reducing valve with a bypass may need to
be installed in the cold water inlet line. This should be placed
on the supply to the entire house in order to maintain equal hot
and cold water pressures.
TEMPERATURE AND PRESSURE (T&P)
RELIEF VALVE (OPTIONAL TOP T&P
RELIEF VALVE NOT SHOWN)
DISCHARGE PIPE
(DO NOT CAP OR PLUG)
MASSACHUSETTS: INSTALL
IMPORTANT: Heat cannot be applied to the water fittings on
the heater as they may contain nonmetallic parts. If solder
connections are used, solder the pipe to the adapter before
attaching the adapter to the hot and cold water fittings.
A VACUUM RELIEF IN COLD
WATER LINE PER SECTION
19 MGL 142.
DRAIN LINE
3/4” ID
MINIMUM
1” MINIMUM
METAL
DRAIN PAN
6” MAXIMUM
AIR GAP
IMPORTANT: Always use a good grade of joint compound and
be certain that all fittings are drawn up tight.
DRAIN
1. Install the water piping and fittings as shown in Figure 22.
Connect the cold water supply (3/4” NPT) to the cold water
inlet fitting. Connect the hot water supply (3/4” NPT) to the
hot water outlet fitting.
FIGURE 22.
TEMPERED WATER
TO FIXTURES
UNTEMPERED
HOT WATER
COLD
WATER
INLET
IMPORTANT: Some models may contain energy saving heat
traps to prevent the circulation of hot water within the pipes. Do
not remove the inserts within the heat traps.
2. The installation of unions in both the hot and cold water
supply lines is recommended for ease of removing the
water heater for service or replacement.
HOT
WATER
OUTLET
3. The manufacturer of this water heater recommends
installing a mixing valve or an anti-scald device in the
domestic hot water line as shown in Figure 23. These
valves reduce the point-of-use temperature of the water
by mixing cold and hot water and are readily available for
use.
MIXING VALVE
(SET TO 120°F)
4. If installing the water heater in a closed water system,
install an expansion tank in the cold water line as specified
under “Closed System/Thermal Expansion.”
FOLLOW THE MIXING
VALVE MANUFACTURER’S
INSTRUCTIONS
5. Install a shut-off valve in the cold water inlet line. It
should be located close to the water heater and be easily
accessible. Know the location of this valve and how to shut
off the water to the heater.
FIGURE 23.
Please note the following:
•
The system should be installed only with piping that is
suitable for potable (drinkable) water such as copper, CPVC,
or polybutylene. This water heater must not be installed
using iron piping or PVC water piping.
6. A temperature and pressure relief valve must be installed
in the opening marked “Temperature and Pressure
(T & P) Relief Valve” on the water heater. A discharge line
must be added to the opening of the T&P Relief Valve.
Follow the instructions under “Temperature and Pressure
Relief Valve.”
•
•
Use only pumps, valves, or fittings that are compatible with
potable water.
7. After piping has been properly connected to the water
heater, remove the aerator at the nearest hot water faucet.
Open the hot water faucet and allow the tank to completely
fill with water. To purge the lines of any excess air, keep
the hot water faucet open for 3 minutes after a constant
flow of water is obtained. Close the faucet and check all
connections for leaks.
It is recommend that only full flow ball or gate valves are used
in water piping installations. The use of valves that may cause
excessive restriction to water flow is not recommended.
•
•
•
Use only 95/5 tin-antimony or other equivalent solder. Any
lead based solder must not be used.
Piping that has been treated with chromates, boiler seal, or
other chemicals must not be used.
Chemicals that may contaminate the potable water supply
must not be added to the piping system.
21
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For protection against excessive pressures and temperatures,
a temperature and pressure relief valve must be installed in the
opening marked “T & P RELIEF VALVE.” (See Figure 24). This
valve must be design certified by a nationally recognized testing
laboratory that maintains periodic inspection of the production
of listed equipment or materials as meeting the requirements
for Relief Valves for Hot Water Supply Systems, ANSI Z21.22.
The function of the temperature and pressure relief valve is to
discharge water in large quantities in the event of excessive
temperature or pressure developing in the water heater. The
valve’s relief pressure must not exceed the working pressure of
the water heater as stated on the rating plate.
Closed System/Thermal Expansion
IMPORTANT: Only a new temperature and pressure relief valve
should be used with your water heater. Do not use an old or
existing valve as it may be damaged or not adequate for the
working pressure of the new water heater. Do not place any
valve between the relief valve and the tank.
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.
The Temperature & Pressure Relief Valve:
•
•
•
Must not be in contact with any electrical part.
Must be connected to an adequate discharge line.
Must not be rated higher than the working pressure shown
on the rating plate of the water heater.
The Discharge Line:
•
•
•
Must not be smaller than the pipe size of the relief valve or
have any reducing coupling installed in the discharge line.
Must not be capped, blocked, plugged or contain any valve
between the relief valve and the end of the discharge line.
Must terminate a maximum of six inches above a floor
drain or external to the building. In cold climates, it is
recommended that the discharge line be terminated at an
adequate drain inside the building.
A properly sized thermal expansion tank should be installed
on all closed systems to control the harmful effects of thermal
expansion. Thermal expansion tanks are available from Sears
stores and through the Sears Service Centers. Contact the
local plumbing inspector, water supplier and/or the Sears
Service Center for assistance in controlling these situations.
(For additional information, see the Troubleshooting Guide later
in this manual.)
•
•
Must be capable of withstanding 250°F (121°C) without distortion.
Must be installed to allow complete drainage of both the
valve and discharge line.
Temperature and Pressure Relief Valve
T&P Relief Valve and Pipe Insulation
1. Locate the temperature and pressure relief valve on the water
heater (also known as a T&P relief valve). See Figure 25.
2. Locate the slit running the length of the T&P relief valve
insulation.
3. Spread the slit open and fit the insulation over the T&P relief
valve. See Figure 25. Apply gentle pressure to the insulation
to ensure that it is fully seated on the T&P Relief Valve. Once
seated, secure the insulation with duct tape, electrical tape,
or equivalent. IMPORTANT: The insulation and tape must not
block the discharge opening or hinder access to the manual
relief lever (Figure 25). Ensure a discharge pipe is installed
into the T&P valve discharge opening per the instructions in
this manual.
Explosion Hazard
• Temperature-pressure relief
valve must comply with ANSI
Z21.22-CSA 4.4 and ASME
code.
• Properly sized temperature-
pressure relief valve must be
installed in opening provided.
• Can result in overheating
and excessive tank pressure.
• Can cause serious injury or
death.
4. Locate the hot water (outlet) & cold water (inlet) pipes to the
water heater.
5. Locate the slit running the length of a section of pipe insulation.
6. Spread the slit open and slip the insulation over the cold water
(inlet) pipe. Apply gentle pressure along the length of the
insulation to ensure that it is fully seated around the pipe. Also,
ensure that the base of the insulation is flush with the water
heater. Once seated, secure the insulation with duct tape,
electrical tape, or equivalent.
TEMPERATURE AND PRESSURE (T&P)
RELIEF VALVE (OPTIONAL TOP T&P
RELIEF VALVE NOT SHOWN)
7. Repeat steps 5 and 6 for the hot water (outlet) pipe.
8. Add additional sections of pipe insulation as needed.
DISCHARGE PIPE
(DO NOT CAP OR PLUG)
T&P RELIEF VALVE INSULATION
MANUAL RELIEF
LEVER
DRAIN LINE
3/4” ID
MINIMUM
1” MINIMUM
T&P RELIEF
VALVE
METAL
DRAIN PAN
6” MAXIMUM
AIR GAP
T&P RELIEF VALVE
DRAIN LINE
DRAIN
FIGURE 24.
FIGURE 25.
22
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OPERATING YOUR WATER HEATER
Lighting Instructions
WARNING
Read and understand these directions thoroughly before
attempting to light or re-light the pilot. Make sure the view port
is not missing or damaged. (See Figure 32.) Make sure the
tank is completely filled with water before lighting the pilot.
Check the rating plate near the gas control valve/thermostat for
the correct gas. Do not use this water heater with any gas other
than the one listed on the rating plate. If you have any questions
or doubts, consult your gas supplier or gas utility company.
Explosion Hazard
Replace view port if glass is missing
or damaged.
Failure to do so can result in death,
explosion or fire.
FOR YOUR SAFETY READ BEFORE LIGHTING
If you do not follow these instructions exactly, a
WARNING:
fire or explosion may result causing property damage, personal
injury or loss of life.
FLAMMABLE
BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES
C.Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or
turn by hand, don't try to repair it, call a qualified
service technician. Force or attempted repair may
result in a fire or explosion.
A. This appliance has a pilot which is lit by a piezo-
electric spark gas ignition system. Do not open
the inner door of the appliance and try to light
the pilot by hand.
smell all around the appliance
B.BEFORE LIGHTING
D.Do not use this appliance if any part has been under
water. Immediately contact a qualified installer or
service agency to replace a flooded water heater.
area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will
settle on the floor.
Do not attempt to repair the unit! It must be replaced!
E. DO NOT USE THIS APPLIANCE IF THERE HAS
BEEN AN IGNITION OF VAPORS. Immediately
call a qualified service technician to inspect the
appliance. Water heaters subjected to a
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electric switch; do not use any
phone in your building.
Immediately call your gas supplier from a neighbor's
phone. Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the fire
department.
flammable vapors ignition will show a
discoloration on the air intake grid and require
replacement of the entire water heater.
LIGHTING INSTRUCTIONS
GAS CONTROL
MAIN BURNER
FIGURE 'A'
FIGURE 'B'
FIGURE 'C'
KNOB
PIL0T
120° MARK
PIEZO
IGNITOR
PILOT
PILOT
PILOT
THERMOSTAT
DIAL
PILOT
"OFF" POSITION
"PILOT" POSITION
"ON" POSITION
THERMOCOUPLE
GAS CONTROL
FIGURE "D"
TOP KNOB
9.
STOP! Read the safety information
1.
Once the pilot has been found, push the gas knob
all the way down. Immediately press the pilot ignitor
button rapidly (4) to (5) times. If the pilot will not
light, repeat step (3) through (9).
Continue to hold the gas control knob down for about
one (1) minute after the pilot is lit. Release the gas
above on this label.
2.Set the thermostat to lowest setting(PILOT LIGHTING).
Turn thermostat dial fully clockwise until it stops.
3.Push the gas control knob down slightly and turn
clockwise to "OFF". SEE FIGURE 'A'.
NOTE: Knob cannot be turned from "PILOT" to "OFF"
unless knob is pushed down slightly. Do not force.
Remove the outer burner door located below
the gas control.
10.
control knob and it will pop back up. Pilot should
remain lit. If it goes out , repeat step (3) through (9). It
may take several minutes for air to clear the lines
before the pilot will light.
4.
If knob does not pop up when released, stop and
immediately call your service technician or gas
Wait ten (10) minutes to clear out any gas. If you
5.
supplier.
then smell gas,
safety information
you don't smell gas,
STOP! Follow "B" in the
above on this label. If
go to next step.
If the pilot will not stay lit after several tries,
turn the gas control knob clockwise to 'OFF' and
call your service technician or gas supplier.
SEE FIGURE 'A'
6. This unit is equipped with a push button pilot ignitor,
which is used to light the pilot. Locate the ignitor
on the gas control.
11. Once the pilot flame is established replace the
outer burner door.
12.
7. Turn gas control knob counterclockwise
At arm's length away, turn gas control knob
to "PILOT". SEE FIGURE 'B'.
counterclockwise
to 'ON'. SEE FIGURE 'C'.
8. The pilot is located on the left side of the burner. It
can be located by looking through the glass view port
while pressing the piezo ignitor button several times.
Look for a spark at the pilot location, Figure "D".
13.
Set thermostat to desired setting.
DANGER: Hotter water increases the risk of
scald injury. Consult the instruction
manual before changing temperature.
TO TURN OFF GAS TO APPLIANCE
1.Set the thermostat to lowest setting
(PILOT LIGHTING).
2. Push gas control knob down slightly and turn clock-
wise to 'OFF'. Do not force. SEE FIGURE 'A'.
23
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Checking the Draft
Water Temperature Regulation
Water temperature over 125°F (52°C)
can cause servere burns instantly
resulting in severe injury or death.
WARNING
Burn Hazard
Children, the elderly, and the
physically or mentally disabled are at
highest risk for scald injury.
Do not touch vent.
Feel water before bathing or
showering.
Doing so can result in burns.
Temperature limiting valves are
available.
Read instruction manual for safe
temperature setting.
After successfully lighting the water heater, allow the unit to operate
for 15 minutes and check the draft hood relief opening for proper
draft (Figure 26). Make sure all other appliances in the area are
operating and all doors are closed when performing the draft test.
Pass a match flame around the relief opening of the draft hood. A
steady flame drawn into the opening indicates proper draft.
Due to the nature of the typical gas water heater, the water
temperature in certain situations may vary up to 30°F (16.7 °C)
higher or lower at the point of use such as, bathtubs, showers,
sink, etc.
DRAFT HOOD
RELIEF
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. See Figure 23. Follow
manufacturer’s instructions for installation of the valves. Before
changing the factory setting on the thermostat, see Figure 28.
Using the lowest hot water temperature that meets your needs
will also provide the most energy efficient operation of the water
heater.
OPENING
MATCH
FIGURE 26.
If the flame flutters or is blown out, combustion products are
escaping from the relief opening. If this occurs, do not operate the
water heater until proper adjustments or repairs are made to the
vent pipe system and/or air supply requirements.
Burner Flames
Inspect the burner flames through the viewport and compare
them to the drawing in Figure 27. A properly operating burner
should produce a soft blue flame. Blue tips with yellow inner
cones are satisfactory. The tips of the flame may have a slight
yellow tint. The flame should not be all yellow or have a sharp
blue-orange color. Contaminated air may cause an orange
colored flame. Contact a qualified technician if the flame is not
satisfactory.
Never allow small children to use a hot water tap, or to draw
their own bath water. Never leave a child or handicapped
person unattended in a bathtub or shower.
NOTE: A water temperature range of 120°F-140°F (49°C-60°C)
is recommended by most dishwasher manufacturers.
The thermostat of this water heater has been factory set at its
lowest position. It is adjustable and must be reset to the desired
temperature setting to reduce the risk of scald injury. The
mark is indicative of approximately 120°F (49°C) and is the
preferred starting point. See Figure 28 on the next page. Some
states have a requirement for a lower setting.
Turn the water temperature dial clockwise (
the temperature, or counterclockwise (
temperature.
) to decrease
) to increase the
FIGURE 27.
Emergency Shut Down
Should overheating occur or the gas supply fail to shut off, turn
off the manual gas control valve to the appliance.
IMPORTANT: Should overheating occur or the gas supply fails
to shut off, turn off the water heater’s manual gas control valve
and call a qualified technician.
24
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GAS CONTROL KNOB
(OFF-PILOT-ON)
Water
Temperature
°F
Time for 1st
Degree Burn
(Less Severe Burns)
Time for Permanent Burns
2nd & 3rd Degree
(Most Severe Burns)
110
116
116
122
131
140
149
154
(normal shower temp.)
(pain threshold)
35 minutes
INDEX BAR
155°F
150°F
45 minutes
5 minutes
25 seconds
5 seconds
2 seconds
1 second
1 minute
5 seconds
140°F
2 seconds
1 second
instantaneous
120°F
130°F
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978)
TEMPERATURE DIAL
TEMPERATURES SHOWN ARE APPROXIMATES AND MAY VARY.
FIGURE 28.
NOTE: During low demand periods when hot water is not
being used, a lower thermostat setting will reduce energy
losses and may satisfy your normal hot water needs. If hot
water use is expected to be more than normal, a higher
thermostat setting may be required to meet the increased
demand. When leaving your home for extended periods
(vacations, etc.) turn the temperature dial to its lowest
setting. This will maintain the water at low temperatures with
minimum energy losses and prevent the tank from freezing
during cold weather.
25
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SERVICE AND ADJUSTMENT
At least once a year, a visual inspection should be made of the
main burner and pilot burner. See Figure 29.
Vent System Inspection
You should check for sooting. Soot is not normal and will impair
proper combustion.
Soot build-up indicates a problem that requires correction before
further use. Turn “OFF” gas to water heater and leave off until
repairs are made, because failure to correct the cause of the
sooting can result in a fire causing death, serious injury, or
property damage.
FIGURE 29.
Burner Cleaning
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 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 inspection of the burner shows that cleaning is required, turn
the gas control knob clockwise (
depressing slightly.
) to the “OFF” position,
NOTE: The knob cannot be turned from “PILOT” to “OFF”
unless knob is depressed slightly. DO NOT FORCE.
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.
The burner needs to be removed for cleaning. Call the Sears
Service Center to remove and clean the burner and correct the
problem that required the burner to be cleaned.
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!
26
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Anodedeteriorationdependsonwaterconductivity,notnecessarily
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.
Housekeeping
Vacuum around base of water heater for dust, dirt, and lint on
a regular basis.
Fire and Explosion Hazard
Temperature-Pressure Relief Valve Operation
Do not obstruct combustion air
openings at the bottom of the
water heater.
The temperature-pressure relief valve must be manually
operated at least once a year.
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.
Burn hazard
At least annually, check the
base-ring filter and flame arrester
for any dust, lint, or debris that
may have accumulated. Clean
as necessary.
Hot water discharge.
Keep clear of relief valve
discharge outlet.
Can cause serious injury or death.
When checking the temperature-pressure relief valve operation,
make sure that (1) no one is in front of or around the outlet of
the temperature-pressure relief valve discharge line, and (2)
that the water discharge will not cause any property damage, as
the water may be extremely hot. See Figure 30.
AT LEAST ANNUALLY, A VISUAL INSPECTION SHOULD BE
MADE OF THE BASE-RING FILTER AND FLAME ARRESTER.
CLEAN IF LINT ACCUMULATIONS ARE NOTICED.
INSTALLED IN SUITABLEAREA:To ensure sufficient ventilation
and combustion air supply, proper clearances from the water
heater must be maintained. See “Installation Instructions.”
Combustible materials such as clothing, cleaning materials, or
flammable liquids, etc. must not be placed against or adjacent
to the water heater because they could catch on fire.
Anode Rod Inspection
FIGURE 30.
If after manually operating the valve, it fails to completely reset
and continues to release water, immediately close the manual
gas shut-off valve and the cold water inlet valve and call the
Sears Service Center.
If the temperature-pressure relief valve on the appliance
weeps or discharges periodically, this may be due to thermal
expansion. You may have a check valve installed in the
water line or a water meter with a check valve. Consult the
Sears Service Center for further information. Do not plug the
temperature-pressure relief valve.
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.
Draining and Flushing
It is recommended that the tank be drained and flushed
every 6 months to remove sediment which may build up during
FIGURE 29B.
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operation. The water heater should be drained if being shut
down during freezing temperatures. To drain the tank, perform
the following steps:
If the water heater is going to be shut down for an extended
period, the drain valve should be left open.
IMPORTANT: Condensation may occur when refilling the tank
and should not be confused with a tank leak.
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.
Service
3. Close the cold water inlet valve.
Before calling for repair service, please read the Troubleshooting
Guide in this manual.
4. Connect a hose to the drain valve and terminate it to an
adequate drain or external to the building.
If a condition persists or you are uncertain about the operation
of the water heater, let the Sears Service Center check it out.
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.
Contact Sears Service Center at:
6. Close the drain valve, refill the tank, and restart the heater
as directed in this manual.
1-800-4-MY-HOME® (1-800-469-4663).
28
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MAINTENANCE OF YOUR WATER HEATER
Replacement Parts
GAS CONTROL VALVE/
THERMOSTAT
PIEZO
IGNITER
BUTTON
IMPORTANT: The following maintenance procedures are for
the FVIR System components and should be performed by a
qualified technician.
MANIFOLD
TUBE
PILOT
TUBE
THERMOCOUPLE
THERMAL
SWITCH
ReplacementpartsmaybeorderedfromSearsPartsandService
Centers or by calling 1-800-4-MY-HOME (1-800-469-4663).
When ordering replacement parts, always have the following
information ready:
VIEW PORT
MANIFOLD
DOOR
MANIFOLD
SCREWS (2)
MANIFOLD
COMPONENT BLOCK
1. model, serial, and product number
2. type of gas
3. item number
FIGURE 32.
4. parts description
See the Parts Order List section for a list of available repair parts.
6. Disconnect the thermocouple (right-hand thread), pilot tube,
the igniter wire from the igniter button, the two connectors
attached to the thermal switch, and manifold tube at the gas
control valve/thermostat. (Figures 31 & 32.) NOTE: L.P. Gas
systems use reverse (left-hand) threads on the manifold tube.
External Inspection & Cleaning of the
Base-Ring Filter
7. Grasp the manifold tube and push down slightly to free the
manifold, pilot tube, and thermocouple.
1. At least annually, check the base-ring filter (Figure 38) for
any dust or debris that may have accumulated on the filter
screen. NOTE: If the water heater is located in an area that
is subjected to lint and dirt, it may be necessary to check
the base-ring filter more frequently.
8. Carefully remove the manifold/burner assembly from the
burner compartment. NOTE: Be sure not to damage internal
parts.
Removing the Burner from the Manifold/
Burner Assembly
2. Follow the Lighting Instructions to turn off the water heater
and allow it to cool for 10 minutes before attempting to clean
the base-ring filter.
Natural Gas (Low Nox) & L.P. Gas Burner
3. Use a vacuum cleaner with a hose attachment to remove
any dust or debris that may have accumulated on the filter.
NOTE: If unable to inspect or clean the base-ring filter, follow
the “Cleaning the Combustion Chamber and Flame-arrestor”
instructions.
1. Take off the burner by removing the two (2) screws located
underneath the burner.
2. Check the burner to see if it is dirty or clogged. The burner
may be cleaned with soap and hot water (Figure 33).
4. After the base-ring filter has been cleaned, follow the
Lighting Instructions to return the water heater to service.
PILOT ASSEMBLY
(BOTTOM VIEW)
SCREWS
Removing the Manifold/Burner Assembly
1. Turn off the gas supply to the water heater at the manual
gas shut-off valve. This valve is typically located beside the
water heater (Figure 11). Note the position of the shut-off
valve in the open/on position then proceed to turn it off.
BURNER
(BOTTOM VIEW)
2. On the lower front of the water heater, locate the gas control
valve/thermostat (see Figure 32). Before performing any
maintenance, it is important to turn the temperature dial on
the gas control valve/thermostat to its lowest setting.
FIGURE 33.
Replacing the Thermocouple
3. On top of the gas control valve/thermostat, turn the gas
control knob to the “OFF” position.
1. Remove the manifold/burner assembly as directed previously.
2. Lift the retainer clip straight up from the back of the manifold
component block (using a flat-blade screwdriver), then
remove the manifold component block from the manifold
door (Figure 34.)
WHITE RODGERS GAS VALVE
PILOT
TUBE
3. Remove the burner. See “Removing the Burner from the
Manifold/Burner Assembly.”
THERMOCOUPLE
MANIFOLD TUBE
4. Pull the thermocouple from the pilot assembly (Figure 35).
IMPORTANT: Be careful not to bend or alter the position of the
pilot assembly components.
FIGURE 31.
5. Insert the thermocouple tip into the holes provided in the
pilot bracket until it clicks into place. NOTE: The base
of the thermocouple must be flush with the base of the
pilot bracket.
4. Remove the outer door.
5. Remove the two screws securing the manifold door
assembly to the combustion chamber (Figure 32).
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6. Position the new thermocouple through the bottom opening
of the manifold component block (Figure 34). Be sure
igniter wire is positioned through the small opening of the
manifold component block.
8. Connect the new pilot tube and tighten the nut securing it to
the pilot assembly. IMPORTANT: Keep the pilot orifice in
the pilot when making the connection. Do not operate the
water heater without the pilot orifice installed.
7. Re-attach the burner. Note the orientation of the burner
(Figure 33.)
9. Install the thermocouple, making sure that it is fully seated.
10. Attach the pilot assembly to the pilot bracket and secure using
the screw removed earlier.
8. See “Replacing the Manifold/Burner Assembly.”
FERRULE NUT
11. Re-attach the burner. Note the orientation of the burner
(Figure 33.)
THERMOCOUPLE
IGNITER WIRE
PILOT
PILOT BRACKET
12. Position the new pilot tube through the largest opening of
the manifold component block. NOTE: The largest opening
should be located at the top position. The igniter wire
should be located in the middle opening and thermocouple
in the bottom opening. (Figure 37)
OTHER FITTINGS
NOT SHOWN
FOR CLARITY
RETAINER
CLIP
MANIFOLD TUBE
PILOT TUBE
MANIFOLD/BURNER
DOOR OPENING
MANIFOLD
COMPONENT BLOCK
FIGURE 34.
PILOT TUBE
IGNITER WIRE
THERMOCOUPLE
FIGURE 35.
MANIFOLD COMPONENT BLOCK
FIGURE 37.
Replacing the Pilot/ Pilot Tube Assembly
13. Reposition the manifold component block in the manifold
door opening and secure it with the retainer clip.
1. Remove the manifold/burner assembly. See “Removing
the Manifold/Burner Assembly.”
14. Carefully bend the new pilot tube and thermocouple to
match the bend of the manifold tube. NOTE: When bending,
DO NOT crimp or crease the pilot tube or thermocouple.
(Figure 34)
2. Lift the retainer clip straight up from the back of the manifold
component block (using a flat-blade screwdriver), then
remove the manifold component block from the manifold
door (Figure 34.)
15. Before you proceed to the next step, install the new brass
ferrule nut in the gas control valve/thermostat’s pilot tube
opening. HAND TIGHTEN ONLY.
IMPORTANT: Be careful not to bend or alter the position of the
pilot tube. It will be used as a bending template for the new
pilot assembly.
16. See “Replacing the Manifold/Burner Assembly.”
3. Take off the burner by removing the two (2) screws located
underneath the burner. See Figure 33.
Cleaning the Combustion Chamber and
Flame-arrestor
4. Remove and keep the screw securing the pilot assembly to
the pilot bracket. (Figure 36)
5. Remove and keep the old pilot tube and thermocouple.
1. Follow procedure outlined in “Removing the Manifold/
Burner Assembly.”
6. Using the old pilot tube as a guide, bend the new pilot tube
to match the old one. NOTE: Make only the bends closest
to the pilot before going to the next step. (Figure 36)
2. Use a vacuum cleaner/shop vac to remove all loose debris
in the combustion chamber (Figure 38). Use compressed
air to clear any dust or debris that may have accumulated
in the flame-arrestor.
COMBUSTION CHAMBER
FLAME ARRESTOR
SCREW
DOOR GASKET
OLD PILOT ASSEMBLY
OTHER FITTINGS
NOT SHOWN
FOR CLARITY
PILOT TUBE
IGNITER WIRE
FIRST BEND(S)
BASE-RING
FILTER
THERMOCOUPLE
FIGURE 36.
FIGURE 38.
3. Reassemble by following the procedure under “Replacing
the Manifold/Burner Assembly.”
7. Route the new pilot tube, thermocouple, and igniter wire
through the manifold/burner door opening. (Figure 34)
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control valve/thermostat. Finally, start the thermocouple nut
and turn it all the way in by hand. An additional quarter turn
with a 3/8” open-end wrench will then be sufficient to seat
the lockwasher. When you are finished, connect the two
wire leads that go to the thermal switch.
Replacing the Manifold/Burner Assembly
WARNING
7. Reconnect the igniter wire.
8. Turn gas supply on and refer to the Lighting Instructions.
9. With the burner lit, check the gas control valve/thermostat
supply line, manifold component block, manifold tube,
and pilot tube connections for leaks. Check for leaks by
brushing on an approved noncorrosive leak detection
solution. Bubbles forming indicate a leak. Correct any leak
found. IMPORTANT: All leaks must be fixed immediately.
Explosion Hazard
•
•
Tighten both manifold door screws securely.
Remove any fiberglass between gasket
and combustion chamber.
10. Replace the outer door.
BRACKET
FLAME ARRESTOR
•
•
Replace viewport if glass is missing or
damaged.
DOOR GASKET
Replace manifold component block if missing
or removed.
•
•
Replace door gasket if damaged.
Failure to follow these instructions can result
in death, explosion, or fire.
TIP
1. Check the door gasket for damage or imbedded debris
prior to installation.
FIGURE 39.
2. Inspect the view port for damage and replace as required.
CLOSE-UP INSIDE VIEW OF
THE COMBUSTION CHAMBER.
3. Insert the manifold/burner assembly into the burner
compartment, making sure that the tip of the manifold tube
engages in the slot of the bracket inside the combustion
chamber (Figures 39 & 40).
SLOT
TIP
BRACKET
4. Inspect the door gasket and make sure there is no
fiberglass insulation between the gasket and the
combustion chamber.
MANIFOLD TUBE
FIGURE 40.
5. Replace the two screws, which secure the manifold/
burner assembly door to the combustion chamber and
tighten securely. Once the manifold/burner assembly door
is tightened, visually inspect the door gasket between
the manifold/burner assembly door and the combustion
chamber for spaces or gaps that would prevent a seal.
IMPORTANT: Do not operate the water heater if the door
gasket does not create a seal between the manifold door
and the combustion chamber.
Piezoelectric Igniter System
The piezoelectric igniter system consists of the igniter button,
electrode, and wire. The pilot is ignited by an electric spark
generated when the igniter button is pressed. The spark gap
of 0.125 inch is set when the electrode is installed at the factory.
(Figure 41). Use only factory authorized piezoelectric igniter
parts for replacement.
6. During the following procedure, do not cross-thread or
apply any thread sealant to any of the fittings listed below.
First, reconnect the manifold tubing to the gas control valve/
thermostat. NOTE: L.P. gas systems use reverse (left-hand)
threads on the manifold tube.
IGNITER
BUTTON
THERMOCOUPLE
PILOT
NOTE: If a ferrule nut needs to be installed for the pilot
tube, locate the one provided with your parts kit. Install it in
the gas control valve/thermostat at the pilot location, hand
tight only.
.125” *
WIRE
TO
ELECTRODE
PILOT
BRACKET
TIP
ELECTRODE
Next, insert the pilot tube into the ferrule nut until it bottoms
out. NOTE: Hold the tube in this position. Tighten the ferrule
nut with a wrench until the crimp connection seals to the
pilot tube. Continue to tighten until the nut is tight in the gas
SNAP-ON CONNECTOR
* NOTE: SPARK GAP DISTANCE MEASURED FROM ELECTRODE TIP TO PILOT.
FIGURE 41.
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2. Reconnect the gas piping to the gas control valve/
thermostat. NOTE: Use an approved Teflon tape or pipe
compound on the gas piping connections.
Testing the Igniter System
Turn off the gas to the water heater at the manual gas shut-off
valve. Watch the electrode tip while activating the igniter. A
visible spark should jump from the electrode. To avoid shock,
do not touch the burner or any metal part on the pilot or pilot
assembly. If no spark is visible, check the wire connections
and make sure the electrode is not broken. Replace the igniter
if defective. Dirt and rust on the pilot or electrode tip can
prevent the igniter spark. Wipe clean with a damp cloth and dry
completely. Rust can be removed from the electrode tip and
metal surfaces by lightly sanding with an emery cloth or fine
grit sandpaper.
3. Attach the igniter and bracket to the new gas control valve/
thermostat, clipping it at the back edge of thermostat and
snapping it into place. NOTE: Do not use the (pilot) ferrule
nut supplied with the new gas control valve/thermostat,
unless the existing nut is not usable. Reconnect the pilot
tube, manifold tube, thermocouple, igniter wire, and thermal
switch wires. NOTE: L.P. gas systems use reverse (left-
hand) threads on the manifold tube.
4. Fill the tank completely with water. NOTE: To purge the
lines of any excess air, keep the hot water faucet open for
3 minutes after a constant flow of water is obtained.
Removing and Replacing the Gas Control
Valve/Thermostat
5. Turn on the gas supply and test the gas supply connections
by brushing on an approved noncorrosive leak detection
solution. Bubbles forming indicate a leak. Correct any leak
found.
IMPORTANT: This water heater has a resettable thermal
switch installed. Do not attempt to disable or modify this feature
in any way. Use only factory authorized replacement parts.
6. Check the operation of the burner by following the lighting
instructions on the front of the water heater. With the
burner lit, check the gas control valve/thermostat supply
line, manifold tube and pilot tube connections for leaks.
Removing the Gas Valve:
1. Turn off the gas supply to the water heater at the manual gas
shut-off valve. This valve is typically located beside the water
heater. Note the position of the shut-off valve in the open/on
position then proceed to turn it off (Figure 11).
7. Verify proper operation and then replace the outer door.
8. If additional information is required, contact Residential
Technical Assistance by referencing the number on the water
heater.
TEFLON® is a registered trademark of E.I. Du Pont De Nemours
and Company.
2. On the lower front of the water heater, locate the gas control
valve/thermostat (see Figure 32). Before performing any
maintenance, it is important to turn the temperature dial on
the gas control valve/thermostat to its lowest setting.
FVIR System Operational Checklist
3. On top of the gas control valve/thermostat, turn the gas
control knob to the “OFF” position. See Lighting Instructions
on the water heater.
1. Manifold gasket properly sealed.
2. Viewport not damaged or cracked.
4. Drain the water heater. Refer to the section of “Draining
and Flushing” section and follow the procedure.
3. Flame-arrestor free of debris and undamaged.
4. Manifold component block properly installed.
5. No leaks at pilot and manifold connection.
6. Manifold door screws securely tightened.
7. Depress the button on the thermal switch.
5. Disconnect the igniter wire from the igniter. NOTE: There are
two types of igniters. If you have the square igniter, slide the
igniter bracket backwards away from the gas valve to remove
it. If you have the round igniter, first remove the igniter from the
bracket by depressing front and rear holding tabs and lift. Next,
remove the igniter bracket from the gas valve. Disconnect the
thermocouple (right-hand threads), pilot tube, and manifold
tube at the gas control valve/thermostat (Figure 31). NOTE:
L.P. gas systems use reverse (left-hand) threads on the
manifold tube. Also, disconnect the thermal switch wires.
6. Refer to “Gas Piping” section (Figure 11) and disconnect
the ground joint union in the gas piping. Disconnect the
remaining pipe from the gas control valve/thermostat.
7. To remove the gas control valve/thermostat, thread a
correctly sized pipe into the inlet and use it to turn the gas
control valve/thermostat (counterclockwise.) Do not use a
pipe wrench or equivalent to grip body. Damage may result,
causing leaks.
Donotinsertanysharpobjectsintotheinletoroutletconnections.
Damage to the gas control valve/thermostat may result.
Replacing the Gas Valve:
1. To replace the gas control valve/thermostat, reassemble
in reverse order. When replacing the gas control valve/
thermostat, thread a correctly sized pipe into the inlet and use
it to turn the gas valve (clockwise.) DO NOT OVER TIGHTEN
or damage may result. NOTE: Use an approved TEFLON®
tape or pipe compound only on the threaded section of the
gas control valve/thermostat that screws into the tank.
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TROUBLESHOOTING GUIDE
NOTE: Expansion tanks are pre-charged with a 40 psi air
Start Up Conditions
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.
Thermal Expansion
As water is heated, it expands (thermal expansion). In a closed
system, the volume of water will grow. As the volume of water
grows, there will be a corresponding increase in water pressure
due to thermal expansion. Thermal expansion can cause
premature tank failure (leakage). This type of failure is not
covered under the limited warranty. Thermal expansion can also
cause intermittent temperature-pressure relief valve operation:
water discharged from the valve due to excessive pressure
build up. The temperature-pressure relief valve is not intended
for the constant relief of thermal expansion. This condition is not
covered under the limited warranty.
A properly sized thermal expansion tank should be installed
on all closed systems to control the harmful effects of thermal
expansion. Thermal expansion tanks are available from Sears
stores and through the Sears Service Centers. Contact the local
plumbing inspector, water supplier and/or the Sears Service
Center for assistance in controlling these situations. See
Figure 42.
Table 5: Thermal Expansion Tank Specifications
Tank
Capacity
Dimensions
in Inches
Pipe
Fitting
FIGURE 42.
Model
Number
In Gallons Diameter
Length
On Tank
153.331020
153.331050
2
5
8 (203 mm) 12-3/4 (323 mm) 3/4” Male
11 (279 mm) 14-3/4 (375 mm) 3/4” Male
Strange Sounds
Possible noises due to expansion and contraction of some
metal parts during periods of heat-up and cool-down do not
represent harmful or dangerous conditions.
Table 6: Expansion Tank Sizing Chart
Condensation causes sizzling and popping within the burner
area during heating and cooling periods and should be
considered normal. See “Condensation” section.
Inlet*
Water
Pressure
40psi
Water Heater Capacity (Gallons)
30
2
40
2
50
2
66
5
82
5
Expansion
Tank
Draft Hood Operation
50psi
2
2
2
5
5
Capacity
Needed
60psi
70psi
80psi
2
2
2
2
2
5
5
5
5
5
5
5
5
5
5
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
*Highest recorded inlet water pressure in a 24 hour period or regulated
water pressure.
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drawn toward the draft hood, shut off water heater and make
necessary air supply changes to correct.
result of four factors which must all be present for the odor to
develop:
•
•
•
a concentration of sulfate in the supply water.
Condensation
little or no dissolved oxygen in the water.
a sulfate reducing bacteria within the water heater. (This
harmless bacteria is non-toxic to humans.)
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:
•
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
concerningthischlorinationtreatmentandananodereplacement
kit #9001453. (For short heaters, use anode replacement
kit #9006299.) Anode replacement and chlorination of the tank
are not covered by the water heater’s limited warranty.
•
A new water heater is filled with cold water for the first
time.
•
Burning gas produces water vapor In water heaters,
particularly high efficiency models where flue temperatures
are lower.
•
Large amounts of hot water are used in a short time and the
refill water in the tank is very cold.
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.
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.
Do not remove the anode, leaving the tank unprotected. By
doing so, all warranty on the water heater tank is voided.
Excessive condensation can cause pilot outage due to water
running down the flue tube onto the main burner and putting
out the pilot.
“AIR” In Hot Water Faucets
Because of the suddenness and amount of water, condensation
water may be diagnosed as a “tank leak”. After the water in
the tank warms up (about 1-2 hours), the condition should
disappear.
Do not assume the water heater is leaking until there has been
enough time for the water in the tank to warm up.
An undersized water heater will cause more condensation.
The water heater must be sized properly to meet the family’s
demandsforhotwaterincludingdishwashers, washingmachines
and shower heads.
Excessive condensation may be noticed during the winter and
early spring months when incoming water temperatures are at
their lowest.
HYDROGEN GAS: Hydrogen gas can be produced in a hot water
system that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely flammable and
explosive. To prevent the possibility of injury under these conditions,
we recommend the hot water faucet, located farthest away, be
opened for several minutes before any electrical appliances which are
connected to the hot water system are used (such as a dishwasher
or washing machine). If hydrogen gas is present, there will probably
be an unusual sound similar to air escaping through the pipe as the
hot water faucet is opened. There must be no smoking or open flame
near the faucet at the time it is open.
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.
Safety Shut-off and Thermal Switch
Operational Conditions
This water heater is designed to automatically shut-off in the
event of the following:
Smelly Odor
1. The pilot flame is extinguished for any reason.
2. The water temperature exceeds 195°F (91°C).
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
3. Excessive build up of dust on the base ring filter or flame
arrestor. See Maintenance of your Water Heater Section.
4. The ignition of flammable vapors.
A thermocouple is used to determine if a pilot flame is present,
and will shut off the gas supply to the main burner and the pilot
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if the flame is absent. This unit is also equipped with a thermal
switch, designed to shut off the gas supply in the event the
water heater has been exposed to flammable vapors (e.g.,
spilled gasoline), poor combustion caused by a blocked vent or
insufficient combustion air. If the thermal switch opens:
1. Check the flame-arrestor for signs of high temperature (blue
or black discoloration). See Figure 38.
2. If there are signs of high temperature or that the thermal switch
has opened, inspect your installation for problems with venting,
combustion air supply, or a possible flammable vapor event.
(See “Pilot Light Troubleshooting Flowchart” section.) Correct
any issues prior to resetting the thermal switch. If you suspect
a flammable vapor incident has occurred, do not use this
appliance. Immediately call a qualified technician to inspect
the appliance. Water heaters subjected to a flammable vapors
ignition will require replacement of the entire water heater.
Read this manual first. Then, before checking the water heater,
make sure the gas supply has been turned “OFF”, and never
turn the gas “ON” before the tank is completely full of water.
3. Reset the thermal switch by depressing the small button in the
center of the thermal switch. Follow the Lighting Instructions
found on the front of your water heater. A high temperature
limit switch or ECO (Energy Cut Off) in the tank is used to
shut off the unit if the water temperature exceeds 195°F
(91°C). The ECO is a single-use switch, which, if activated,
requires complete replacement of the entire gas control valve/
thermostat. If the ECO should activate, the water heater cannot
be used until the gas control valve/thermostat is replaced by
a qualified technician. Contact Sears at 1-800-4-MY-HOME
(1-800-469-4663) to request service.
Never use this water heater unless it is completely filled with
water. To prevent damage to the tank, the tank must be filled
with water. Water must flow from the hot water faucet before
turning “ON” gas to the water heater.
A. Water at the draft hood is water vapor which has condensed
out of the combustion products. This is caused by a
problem in the vent. Contact a qualified technician.
B. *Condensation may be seen on pipes in humid weather or
pipe connections may be leaking.
C. *The anode rod fitting may be leaking.
D. Small amounts of water from temperature-pressure relief
valve may be due to thermal expansion or high water
pressure in your area.
Leakage Checkpoints
A
C
E. *The temperature-pressure relief valve may be leaking at
the tank fitting.
B
E
D
F. Water from a drain valve may be due to the valve being
slightly opened.
G. *The drain valve may be leaking at the tank fitting.
H. Combustion products contain water vapor which can
condense on the cooler surfaces of the tank. Droplets form
and drip onto the burner or run on the floor. This is common
at the time of start-up after installation and when incoming
water is cold.
I. Water in the water heater bottom or on the floor may be
from condensation, loose connections, or the relief valve.
DO NOT replace the water heater until a full inspection
of all possible water sources is made and necessary
corrective steps taken.
Leakage from other appliances, water lines, or ground seepage
should also be checked.
H
G
*
To check where threaded portion enters tank, insert cotton
swab between jacket opening and fitting. If cotton is wet, follow
draining instructions in the “Draining and Flushing” section and
then remove fitting. Put pipe dope or teflon tape on the threads
and replace. When you are finished, follow the steps in “Filling
the Water Heater” in the Installation Instructions earlier in this
manual.
I
F
6” MAXIMUM
AIR GAP
FIGURE 43.
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TROUBLESHOOTING CHART
PROBLEM
POSSIBLE CAUSE(S)
CORRECTIVE ACTION
1. Light pilot
BURNER WILL NOT IGNITE 1. Pilot not lit
2. Thermostat set too low
2. Turn temp. dial to desired temperature
3. Check with gas utility company
4. Notify utility-install trap in gas line
5. Clean, locate source and correct
6. Clean, locate source and correct
7. Replace thermocouple
3. No gas
4. Dirt in the gas lines
5. Pilot line clogged
6. Main burner line clogged
7. Non-functioning thermocouple
8. Non-functioning thermostat
9. Heater installed in a confined area
8. Replace thermostat
9. Provide fresh air ventilation
SMELLY WATER
1. Sulfides in the water
1. Replace the anode with a special anode
BURNER FLAME YELLOW- 1. Insufficient secondary air
1. Provide ventilation to water heater
2. Check with gas utility company
LAZY
2. Low gas pressure
3. Water heater flue or vent system
blocked
4. Main burner line clogged
5. Heater installed in a confined area
6. Obstruction in main burner orifice
3. Clean, locate source and correct
4. Clean, locate source and correct
5. Proper fresh air ventilation
6. Clean or replace orifice
PILOT WILL NOT LIGHT OR 1. Non-functioning igniter
1. Replace igniter pilot assembly
REMAIN LIT
2. The thermal switch tripped
2. See Pilot Light Troubleshooting Flowchart section
3. Wire lead connection at thermal switch 3. Remove and reconnect the wire leads at
loose
thermal switch, confirm connections are tight
and not loose
4. Thermocouple connection loose
5. Air in gas line
4. Finger tighten; then 1/4 turn with wrench
5. Bleed the air from the gas line
6. Check with gas utility company
7. Check with gas utility company
8. Notify utility-install dirt trap in gas line
9. Locate source and correct
6. Low gas pressure
7. No gas
8. Dirt in gas lines
9. Cold drafts
10. Thermostat ECO switch open
11. Pilot line or orifice clogged
12. Non-functioning thermocouple
13. Air for combustion obstructed
10. Replace thermostat
11. Clean, locate source and correct
12. Replace thermocouple
13. See maintenance section for inspection and
cleaning of flame arrester
14. Flammable vapors incident, FVIR 14. Replace water heater, eliminate flammable
function actuated
15. Base-ring filter obstructed
vapors source. Contact Sears Service.
15. Inspect and clean base-ring filter. See “External
Cleaning & Inspection of the Base-Ring Filter.”
HIGH OPERATION COSTS
1. Thermostat set too high
2. Sediment or lime in tank
3. Water heater too small for job
4. Wrong piping connections
5. Leaking faucets
1. Set temperature dial to lower setting
2. Drain/flush-provide water treatment if needed
3. Install adequate heater
4. Correct piping-dip tube must be in cold inlet
5. Repair faucets
6. Gas leaks
6. Check with utility-repair at once
7. Advise customer
8. Insulate piping
9. Insulate piping
7. Wasted hot water
8. Long runs of exposed piping
9. Hot water piping in exposed wall
INSUFFICIENT HOT WATER 1. Thermostat set too low
2. Sediment or lime in tank
3. Water heater too small
1. Turn temperature dial to desired setting
2. Drain/flush-provide water treatment if needed
3. Install adequate heater
4. Wrong piping connections
5. Leaking faucets
4. Correct piping-dip tube must be in cold inlet
5
Repair faucets
6. Wasted hot water
6. Advise customer
7. Long runs of exposed piping
8. Hot water piping in outside wall
9. Low gas pressure
7. Insulate piping
8. Insulate piping
9. Check with gas utility company
SLOW HOT WATER
RECOVERY
1. Insufficient secondary air
1. Provide ventilation to water heater. Check flue
way, flue baffle, and burner
2. Water heater flue or vent system 2. Clean flue, locate source and correct
blocked
3. Low gas pressure
4. Improper calibration
5. Thermostat set too low
6. Water heater too small
7. Wrong piping connections
8. Wasted hot water
3. Check with gas utility company
4. Replace thermostat
5. Turn temperature dial to desired setting
6. Install adequate heater
7. Correct piping-dip tube must be in cold inlet
8. Advise customer
DRIP FROM RELIEF VALVE 1. Excessive water pressure
2. Heater stacking
1. Use a pressure reducing valve and relief
valve
2. Lower the thermostat setting
3. See “Closed System/Thermal Expansion”
3. Closed water system
36
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TROUBLESHOOTING CHART (CONTINUED)
PROBLEM
POSSIBLE CAUSE(S)
CORRECTIVE ACTION
THERMOSTAT FAILS TO
SHUT-OFF
1. Thermostat not functioning properly
2. Improper calibration
1. Replace thermostat
2. Replace thermostat
COMBUSTION ODORS
1. Insufficient secondary air
1. Provide ventilation to water heater. Check flue
way, flue baffle, and burner
2. Water heater flue or vent system 2. Clean, locate source and correct
blocked
3. Heater installed in a confined area
3. Provide fresh air ventilation
SMOKING AND CARBON
FORMATION (SOOTING)
1. Insufficient secondary air
1. Provide ventilation to water heater. Check flue
way, flue baffle, burner
2. Low gas pressure
3. Water heater flue or vent system 3. Clean, locate source and correct
blocked
4. Thermostat not functioning properly
5. Heater installed in a confined area
6. Burner flame yellow-lazy
2. Check with gas utility company
4. Replace thermostat
5. Provide fresh air ventilation
6. See “Burner Flame Yellow-Lazy”
CONDENSATION
1. Temperature setting too low
1. Increase the temperature setting. Refer to the
“Condensation” sub-section of this manual’s
Troubleshooting Guide.
BURNER FLAME FLOATS
AND LIFTS OFF PORTS
1. Orifice too large
1. Replace with correct orifice
2. High gas pressure
2. Check with gas utility company
3. Water heater flue or vent system 3. Clean flue and burner-locate source and correct
blocked
4. Cold drafts
4. Locate source and correct
BURNER FLAME TOO HIGH 1. Orifice too large
1. Replace with correct orifice
FLAME BURNS AT ORIFICE 1. Thermostat not functioning properly
2. Low gas pressure
1. Replace thermostat
2. Check with gas utility company
PILOT FLAME
TOO SMALL
1. Pilot line or orifice clogged
2. Low gas pressure
1. Clean, locate source and correct
2. Check with gas utility company
37
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PILOT LIGHT TROUBLESHOOTING FLOWCHART
Check Draft. (See “Checking the
Draft” section of this manual.)
Does pilot light go out when
button is released?
NO
YES
Test the thermocouple using the following
procedure: Disconnect the thermocouple from the
gas control valve/thermostat. Using a multimeter
with alligator clip leads, 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/thermostat. Follow the instruction to light
the pilot and watch the voltage readings on the
multimeter. After 45 seconds the meter should
read 12 millivolts DC or more.
Are the wires from the gas
control valve/thermostat firmly
connected to the switch?
Has the thermal switch
tripped?
Secure connections
and attempt a relight.
NO
NO
YES
YES
Are the wires damaged
and/or frayed?
Is the thermocouple
connection loose?
NO
NO
YES
YES
Check for insufficient
combustion air.
Tighten the connection
Does the thermocouple pass the test?
Replace the gas control
valve/thermostat.
Replace the thermocouple.
NO
YES
Is the base-ring filter clean (i.e., free
of lint, dust, or debris)?
Inspect and clean the base-ring filter. Refer to the “External
Inspection & Cleaning of the Base-Ring Filter” section of this manual.
NO
YES
Are there openings
for make-up air to
enter the room?
Install correct size make-up air openings per
the “Combustion Air Supply and Ventilation”
section in this manual.
NO
YES
Are the openings of sufficient size?
See “Combustion Air Supply and Ventilation”
section in this manual for requirements.
Correct size of openings to
allow sufficient air.
NO
YES
Is there a furnace/air
handler in the same room as
the water heater?
NO
YES
Does the return air duct for the furnace/air handler draw
its air from a separate location than the water heater?
See the “Location Requirements” and “Combustion Air
Supply and Ventilation” sections in this manual.
Contact a local Heating, Ventilation, Air
Conditioning & Refrigeration authorized
service provider.
NO
YES
Check the vent system for restrictions/obstructions and check the vent
termination height. Refer to the “Installation Instructions” section of this
manual for specific requirements.
Is there proper drafting at the
draft hood? See “Checking the
Draft” section in this manual.
NO
NO
YES
Is the flame-arrestor free from
debris due to excessive lint, dirt,
dust or oil?
Refer to the “Maintenance of Your Water Heater” section of this
manual for information on cleaning the flame-arrestor.
YES
Check the water heater for a Flammable Vapor (FV) event. Note: it may be
necessary to remove the manifold door assembly to visually inspect the water
heater. Reference the “Maintenance of your Water Heater” section of this
manual for removal instructions.
Is the pilot tube
damaged?
Does the flame
arrestor show signs
of discoloration and/
or debris?
Is the igniter wire insulation burnt or
show signs of discoloration?
NO
NO
THERMAL
SWITCH
YES
YES
YES
Shut-off the gas supply to the water
heater at the manual gas shut-off
valve, then contact Sears Service at
1-800-4-MY-HOME (1-800-469-4663).
FIGURE 44.
38
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NOTES
39
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PARTS ORDER LIST
Kenmore 36 GAS WATER HEATER
MODEL NUMBER
5
12
12
8
1
153.332420
40 Gallon Tall (Natural)
16
3
7
4
9
14
17
6
19
11
15
18
2
13
Model Numbers
Key No. Part Description
153.332420
9003944
1
Anode Rod
2
3
4
5
Base-Ring Filter
Burner Head
Burner Orifice
Draft Hood
9006616
9006136
9006699
9006647
6
Drain Valve
9002402
7
8
9
Gas Control Valve/Thermostat
Inlet Tube w/ Gasket
Inner Door Gasket
F145-1555
9006690
9006141
10
11
Instruction Manual *
319357-000
Manifold Door Assembly - Contains:
Manifold Tube, Gasket, Door, Pilot Tube,
Thermocouple, Manifold Component Block
w/ Clip, Thermal Switch, Burner Head,
Burner Orifice, and Pilot Assembly.
9006617
12
13
14
15
Nipple w/Heat Trap
Outer Door
Piezo Igniter w/ Clip
Pilot Assembly w/ Tubing and
Fittings
9003719
9006648
9006143
9006666
16
17
18
19
T & P Relief Valve
Temperature Adjustment Knob
Thermocouple
9000071
F145-1280
9000056
9006449
Manifold Component Block w/ Clip
* Not Shown.
•
•
•
•
MODEL NUMBER
SERIAL NUMBER
Now that you have purchased your gas water heater, should
a need ever exist for repair parts or service, simply contact
any Sears Service Center or call 1-800-4-MY-HOME®
(1-800-469-4663). Be sure to provide all pertinent facts when
you call or visit.
TYPE GAS - NATURAL OR PROPANE (L.P.)
PART DESCRIPTION
THIS IS A REPAIR PARTS LIST, NOT A PACKING LIST.
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE
FOLLOWING INFORMATION:
40
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NOTES
41
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Get it fixed, at your home or ours!
Your Home
For troubleshooting, product manuals and expert advice:
For repair – in your home – of all major brand appliances,
lawn and garden equipment, or heating and cooling systems,
no matter who made it, no matter who sold it!
For the replacement parts, accessories and
owner’s manuals that you need to do-it-yourself.
For Sears professional installation of home appliances
and items like garage door openers and water heaters.
1-800-4-MY-HOME® (1-800-469-4663)
Call anytime, day or night (U.S.A. and Canada)
Our Home
For repair of carry-in items like vacuums, lawn equipment,
and electronics, call anytime for the location of your nearest
Sears Parts & Repair Service Center
1-800-488-1222 (U.S.A.)
1-800-469-4663 (Canada)
To purchase a protection agreement on a product serviced by Sears:
1-800-827-6655 (U.S.A.)
1-800-361-6665 (Canada)
Para pedir servicio de reparación
a domicilio, y para ordenar piezas:
Au Canada pour service en français:
1-800-LE-FOYERMC
1-888-SU-HOGAR®
(1-800-533-6937)
(1-888-784-6427)
® Registered Trademark / TM Trademark of KCD IP, LLC in the United States, or Sears Brands, LLC in other countries
® Marca Registrada / TM Marca de Fábrica de KCD IP, LLC en Estados Unidos, o Sears Brands, LLC in otros países
MC Marque de commerce / MD Marque déposée de Sears Brands, LLC
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