Owner’s Manual
THE ECONOMIZER™ 6
GAS WATER HEATER
POWER VENTED GAS MODELS
WITH HOT SURFACE IGNITION
FOR POTABLE WATER HEATING ONLY.
NOT SUITABLE FOR SPACE HEATING.
NOT FOR USE IN MOBILE HOMES.
• Safety Instructions
• Installation
• Operation
MODEL NO.
• Care and Maintenance
• Troubleshooting
• Parts List
153.332040
153.332050
153.332060
153.332070
40 Gallon Nat
50 Gallon Nat
40 Gallon LP
50 Gallon LP
For Your Safety
AN ODORANTISADDEDTOTHE GAS USED BYTHIS WATER HEATER.
C3 Technology® Gas Water Heaters meet
the new ANSI Z21.10.1 standard that deals
with the accidental or unintended ignition
of flammable vapors, such as those
emitted by gasoline.
ADVERTENCIA
Si no puede leer o entender el inglés y necesita el manual instructivo
y/o etiquetas en español puede obtenerlos llamando al
1-800-821-2017. NO TRATE DE INSTALAR O OPERAR ESTE
CALENTADOR DEAGUAsi no entiende la información en las etiquetas
o en el manual instructivo. No hacer caso de esta advertencia podría
resultarenlaMUERTEOGRAVESLESIONESCORPORALES.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A
PRINTED IN THE U.S.A. 0905
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PART NO. 185249-000
SAFETY PRECAUTIONS
3
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TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE.................................................................................................................................... 2
SAFETY PRECAUTIONS ................................................................................................................................................................. 3
TABLE OF CONTENTS .................................................................................................................................................................... 4
CUSTOMER RESPONSIBILITIES ................................................................................................................................................... 5
PRODUCT SPECIFICATIONS ......................................................................................................................................................... 5
MATERIALS AND BASIC TOOLS NEEDED .................................................................................................................................... 6
TYPICAL INSTALLATION .................................................................................................................................................................. 7
INSTALLATION INSTRUCTIONS .............................................................................................................................................. 8-21
Removing the Old Water Heater ............................................................................................................................................. 8
Facts to Consider About the Location .............................................................................................................................. 9-10
Insulation Blankets................................................................................................................................................................. 10
Combustion Air and Ventilation for Appliances Located in Unconfined Spaces ............................................................. 10
Combustion Air and Ventilation for Appliances Located in Confined Spaces ............................................................10-11
Water Piping ...................................................................................................................................................................... 12-13
Temperature-Pressure Relief Valve ............................................................................................................................... 13-14
Gas Piping......................................................................................................................................................................... 14-15
Sediment Traps ...................................................................................................................................................................... 15
Filling the Water Heater ......................................................................................................................................................... 15
Blower Assembly Installation .......................................................................................................................................... 15-16
Vent Connections to Blower Assembly ................................................................................................................................. 17
Venting and Installation ......................................................................................................................................................... 17
Condensation ......................................................................................................................................................................... 17
Maximum Vent Lengths .......................................................................................................................................................... 17
Venting ..................................................................................................................................................................................... 18
Vent Terminal Installation ................................................................................................................................................ 18-19
Vertical Vent Through Roof..................................................................................................................................................... 19
Vertical Vent Termination Restrictions .................................................................................................................................. 19
Vent Pipe Preparation ...................................................................................................................................................... 20-21
OPERATING INSTRUCTIONS................................................................................................................................................. 22-23
Lighting and Operating Label ............................................................................................................................................... 22
Temperature Regulation ........................................................................................................................................................ 23
FOR YOUR INFORMATION ...................................................................................................................................................... 24-25
Start Up Conditions .......................................................................................................................................................... 24-25
Operational Conditions.......................................................................................................................................................... 25
SERVICE AND ADJUSTMENT ................................................................................................................................................. 25-27
Venting System Inspection .................................................................................................................................................... 25
Burner Operation and Inspection ................................................................................................................................... 25-26
Burner Cleaning ..................................................................................................................................................................... 26
Housekeeping ........................................................................................................................................................................ 26
Anode Rod Inspection ............................................................................................................................................................ 26
Temperature-Pressure Relief Valve Operation ............................................................................................................. 26-27
Draining ................................................................................................................................................................................... 27
Drain Valve Washer Replacement ........................................................................................................................................ 27
Service ..................................................................................................................................................................................... 27
LEAKAGE CHECKPOINTS ............................................................................................................................................................ 28
TROUBLESHOOTING GUIDELINES ...................................................................................................................................... 29-30
REPAIR PARTS LIST ...................................................................................................................................................................... 31
WARRANTY ..................................................................................................................................................................................... 32
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CUSTOMER RESPONSIBILITIES
2. The installation must conform with these instructions and the local
Thank You for purchasing a Kenmore water heater. Properly installed
and maintained, it should give you years of trouble free service. If you
should decide that you want the new water heater professionally
installed by Sears call 1-800-4-MY-HOME®. They will arrange for prompt,
quality installation by Sears authorized contractors.
code authority having jurisdiction. In the absence of local codes,
installationsshallcomplywiththeNationalFuelGasCodeANSIZ223.1/
NFPA54andtheNationalElectricalCode, NFPA70.Thesepublications
are available from The National Fire Protection Association, 1
Batterymarch Park, Quincy, MA02269.
Abbreviations Found In This Instruction Manual:
• CSA- Canadian StandardsAssociation
3. The water heater when installed must be grounded in accordance
with the local codes, or in the absence of local codes, the National
Electrical Code NFPA70.
• ANSI -American National Standards Institute
• NFPA- National Fire ProtectionAssociation
• ASME -American Society of Mechanical Engineers
• GAMA- GasAppliance Manufacturer’sAssociation
• UL - Underwriters Laboratories Inc.
4. If after reading this manual you have any questions or do not
understand any portion of the instructions, call the local gas utility or
the Sears Service Center.
5. 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.
This gas-fired water heater is listed by Underwriters Laboratories Inc.
underAmerican National Standard/CSAStandard for Gas Water Heaters
ANSI Z21.10.1 • CSA 4.1 (current edition).
PREPARING FOR THE INSTALLATION
Examine the location to ensure the water heater complies with the
“Facts to ConsiderAbout the Location” section in this manual.
1. Read the “Safety Precautions” section, page 3 of this manual first
and then the entire manual carefully. If you don’t follow the safety
rules, the water heater will not operate properly. It could cause
DEATH, SERIOUSBODILYINJURYAND/ORPROPERTYDAMAGE.
6. 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 Office of the StateArchitect, 400 P Street,
Sacramento, CA 95814.
This manual contains instructions for the installation, operation, and
maintenance of the gas-fired water heater. It also contains warnings
throughout 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 INSTALLOROPERATE THE WATER HEATER.
7. 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.
8. Complies with SCAQMD rule #1121 and districts having equivalent
NOx requirements.
PRODUCT SPECIFICATIONS
TANK
CAPACITY
IN GALS.
(LTRS)
RECOVERY
MINIMUM
VENT PIPE
INCHES
(mm)
INPUT
RATE
RATE GALS.
DIAMETER
INCHES
DIMENSIONS IN
INCHES (mm) HEIGHT
TO JACKET TOP
55 (1,397)
MODEL
TYPE OF
GAS
PERHOUR
NUMBER
(Btu/hr)
40,000
40,000
40,000
40,000
@ 90°F RISE
(mm)
153.332040
153.332050
153.332060
153.332070
40 (151)
50 (189)
40 (151)
50 (189)
NATURAL
NATURAL
PROPANE
PROPANE
44
44
44
44
2 (51)
18 1/2 (470)
20 (508)
2 (51)
56 3/4 (1,441)
2 (51)
18 1/2 (470)
20 (508)
55 (1,397)
2 (51)
56 3/4 (1,441)
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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.
DRAIN PANS AVAILABLE IN 20”
EXPANSION TANKS FOR
THERMAL EXPANSION
CONDITIONS AVAILABLE
IN 2 GALLONS
(508 mm) DIAMETER FOR
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) OR 1/2” (12.7 mm) THREADED OR
COPPER PLUMBING AND 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 Tank
• 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
PHILLIPS SCREWDRIVER
TIN SNIPS
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
6
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TYPICAL INSTALLATION
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A
B
C
D
E
F
G
H
J
Vent Pipe–Exhaust
Vent Terminal
K
L
Hot Water Outlet
V
W
X
Y
Z
Drip Leg (Sediment Trap)
Drain Valve
Gas Valve-Thermostat
Drain Pan
Outlet Receptacle (115 VAC)
Temperature-Pressure Relief Valve
Flue
Flue Baffle Assembly**
Insulation
Control Harness
Rating Plate
Gas Supply
Manual Gas Shut-off Valve
Ground Joint Union
Vent Adapter-Rubber Boot
Blower Assembly
Cold Water Inlet
Inlet Water Shut-off Valve
Union
M
N
O
P
Q
R
S
T
Air Intake Screen - Base Pan
AA Inner Door
BB Outer Door
CC HSI Burner Assembly
DD Air Intake Screen -
Blower Assembly
Inlet Dip Tube
Anode**
U
EE FV Sensor Assembly
* ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS.
** LOCATED UNDER THE BLOWER ASSEMBLY.
NATURAL HOT SURFACE IGNITER & MAIN BURNER
HOT
SURFACE
IGNITOR
SENS
PROPANE HOT SURFACE IGNITER & MAIN BURNER
HOT
SURFACE
IGNITOR
SENSOR
TEMPERATURE INDICATORS
*CAUTION: 115 VAC IN CONTROL HARNESS
AND INSIDE OUTER DOOR
T
GAS MODELS
WITH HOT SURFACE IGNITION
& 2", 3" OR 4" PVC VENT CAPABILITY
FIGURE1.
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INSTALLATION INSTRUCTIONS
4. Attach a hose to the water heater drain
Removing the Old Water Heater
valve and put the other end in a floor
drain or outdoors. Open the water
heater drain valve. Open a nearby hot
water faucet which will relieve
pressure in the water heater and speed
draining. The water passing out of the
drain valve may be extremely hot. To
avoid being scalded, make sure all
connections are tight and that the water
flow is directed away from any person,
see Figures 2 and 5.
FIGURE5.
5. Disconnect the vent pipe from the blower assembly 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. Make sure
existing vent complies with maximum and minimum vent lengths on
page 17.
6. 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.
FIGURE2.
1. Turn “OFF” the gas supply to the water
heater.
If the main gas line Shut-off 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.
FIGURE6.
FIGURE3.
FIGURE4.
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.
2. Turn “OFF” the water supply to the
water heater at the water shut off
valve or water meter. Some
installations require that the water be
turned off to the entire house, see
Figures 2 and 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.
FIGURE7.
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FACTS TO CONSIDERABOUT THE LOCATION
Carefully choose an indoor location for the new water heater, because
the placement is a very important consideration for the safety of the
occupantsinthebuildingandforthemosteconomicaluseoftheappliance.
This water heater is not for use in manufactured (mobile) homes
or outdoor installation.
FIGURE8.
Whether replacing an old water heater or putting the water heater in a
new location, the following critical points must be observed:
1. Select a location indoors as close as practical to the vent terminal or
location to which the water heater vent piping is going to be connected,
and as centralized with the water piping system as possible.
2. Selected location must provide adequate clearances for servicing
and proper operation of the water heater.
Installation of the water heater must be accomplished in such a manner
that if the tank or any connections should leak, the flow will not cause
damage to the structure. For this reason, it is not advisable to install the
water heater in an attic or upper floor. When such locations cannot be
avoided, a suitable drain pan should be installed under the water heater.
Drain pans are available at your local hardware store. Such a drain pan
must have a minimum length and width of at least 2" (5.1 cm) greater than
the water heater dimensions and must be piped to an adequate drain.
The pan must not restrict combustion air flow.
Also, the water heater must be located and/or protected so it is not
subject to physical damage by a moving vehicle.
Water heater life depends upon water quality, water pressure and the
environment in which the water heater is installed. Water heaters are
sometimes installed in locations where leakage may result in property
damage, even with the use of a drain pan piped to a drain. However,
unanticipated damage can be reduced or prevented by a leak detector or
water shut-off device used in conjunction with a piped drain pan. These
devices are available from some plumbing supply wholesalers and
retailers, and detect and react to leakage in various ways:
• Sensors mounted in the drain pan that trigger an alarm or turn off the
incoming water to the water heater when leakage is detected.
• Sensors mounted in the drain pan that turn off the water supply to the
entire home when water is detected in the drain pan.
This water heater must not be installed directly on carpeting. Carpeting
mustbeprotectedbymetalorwoodpanelbeneaththeapplianceextending
beyond the full width and depth of the appliance by at least 3" (7.6 cm) in
any direction, or if the appliance is installed in an alcove or closet, the
entire floor must be covered by the panel. Failure to heed this warning
may result in a fire hazard.
• 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.
INSTALLATIONSINAREASWHEREFLAMMABLELIQUIDS(VAPORS)
ARELIKELYTOBEPRESENTORSTORED(GARAGES,STORAGEAND
UTILITYAREAS, ETC.): Flammable liquids (such as gasoline, solvents,
propane (LP or butane, etc.) and other substances (such as adhesives,
etc.) emit flammable vapors which can be ignited by a gas water heater’s
hot surface igniter or main burner. The resulting flashback and fire can
cause death or serious burns to anyone in the area. This water heater is
equipped with a FV sensor for detecting the presence of flammable
vapors, see Figure 8. When the sensor detects those vapors, the unit
will shut down and not operate. Should this happen, please refer to the
troubleshooting guide on pages 29-30. Even though this water heater is
a flammable vapors ignition resistant water heater and is designed to
reduce the chances of flammable vapors being ignited, gasoline and
other flammable substances should never be stored or used in the same
vicinity or area containing a gas water heater or other open flame or
spark producing appliance.
Minimum clearances between the water heater and combustible
construction are 0 inch at the sides and rear, 5" (12.7 cm) from the front
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flammable in many cases, will also react to form corrosive hydrochloric
acid when exposed to the combustion products of the water heater.
The results can be hazardous, and also cause product failure.
and 12" (30.5 cm) from the top. (Standard clearance.) If clearances
stated on the heater differ from standard clearances, install water heater
according to clearances stated on the heater.
INSULATION BLANKETS
Adequate clearance for servicing this appliance should be considered
before installation, such as changing the anodes, etc.
Insulation blankets are available to the general public for external use
on gas water heaters but are not necessary with Kenmore products.
The purpose of an insulation blanket is to reduce the standby heat loss
encountered with storage tank heaters. Your Kenmore water heater
meets or exceeds the National Appliance Energy Conservation Act
standards with respect to insulation and standby loss requirements,
making an insulation blanket unnecessary.
A minimum clearance of 5" (12.7 cm) must be allowed for access to
replaceable parts such as the thermostats, drain valve and relief valve.
When installing the heater, consideration must be given to proper location.
Location selected should be as close to the wall as practicable and as
centralized with the water piping system as possible.
FIGURE9.
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions (For identification of components
mentioned below, see Figure 1). 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 blower assembly.
• Do not cover the outer door, thermostat or temperature & pressure
relief valve.
• Do not allow insulation to come within 2" (5.1 cm) of the floor to
prevent blockage of combustion air flow to the burner.
• Do not cover the instruction manual. Keep it on the side of the
water heater or nearby for future reference.
• Do obtain new warning and instruction labels from Sears
for placement on the blanket directly over the existing labels.
• Do inspect the insulation blanket frequently to make certain it
does not sag, thereby obstructing combustion air flow.
A gas water heater cannot operate properly without the correct amount
of air for combustion. Do not install in a confined area such as a closet,
unless you provide air as shown in the “Facts to Consider About the
Location” section. Never obstruct the flow of ventilation air. If you
have any doubts or questions at all, call your gas supplier. Failure to
provide the proper amount of combustion air can result in a fire or
explosion and cause death, serious bodily injury, or property damage.
COMBUSTIONAIRAND VENTILATION FOR
APPLIANCES LOCATED IN UNCONFINED SPACES
UNCONFINED SPACE is space whose volume is not less than
50 cubic feet per 1,000 Btu per hour (4.8 cubic meters per kW) of the
aggregate input rating of all appliances installed in that space. Rooms
communicating directly with the space in which the appliances are
installed, through openings not furnished with doors, are considered a
part of the unconfined space.
In unconfined spaces in buildings, infiltration may be adequate to provide
air for combustion, ventilation and dilution of flue gases. However, in
buildings of tight construction (for example, weather stripping, heavily
insulated, caulked, vapor barrier, etc.), additional air may need to be
provided using the methods described in “CombustionAir and Ventilation
forAppliances Located in Confined Spaces.”
FIGURE10.
COMBUSTIONAIRAND VENTILATION FOR
APPLIANCES LOCATED IN CONFINED SPACES
If this water heater will be used in beauty shops, barber shops, cleaning
establishments, or self-service laundries with dry cleaning equipment,
it is imperative that the water heater or water heaters be installed so
that combustion and ventilation air be taken from outside these areas.
CONFINED SPACE is a space whose volume is less than 50 cubic feet
per 1,000 Btu per hour (4.8 cubic meters per kW) of the aggregate
input rating of all appliances installed in that space.
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorine based chemicals, refrigerants, etc.) in addition to being highly
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Chemical vapor corrosion of the flue, blower assembly 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.
2. When communicating with the outdoors through vertical ducts, each
opening shall have a minimum free area of 1 square inch per 4,000
Btu per hour (5.5 cm2/kW) of total input rating of all equipment in the
enclosure, see Figure 13.
3. When communicating with the outdoors through horizontal ducts,
each opening shall have a minimum free area of 1 square inch per
2,000 Btu per hour (11 cm2/kW)) of total input rating of all equipment
in the enclosure, see Figure 14.
A. ALLAIR FROM INSIDE BUILDINGS: (See Figure 10 and 11)
The confined space shall be provided with two permanent openings
communicating directly with an additional room(s) of sufficient volume
so that the combined volume of all spaces meets the criteria for an
unconfined space. The total input of all gas utilization equipment installed
in the combined space shall be considered in making this determination.
Each opening shall have a minimum free area of one square inch per
1,000 Btu per hour (22 cm2/kW) of the total input rating of all gas utilization
equipment in the confined space, but not less than 100 square inches
(645 cm2). One opening shall commence within 12 inches
(31 cm) of the top and one commencing within 12 inches (31 cm) of the
bottom of the enclosures.
FIGURE13.
4. When ducts are used, they shall be of the same cross-sectional
area as the free area of the openings to which they connect. The
minimum short side dimension of rectangular air ducts shall not be
less than 3 inches (7.6 cm), see Figure 14.
FIGURE11.
B. ALL AIR FROM OUTDOORS: (See Figures 12, 13 and 14)
The confined space shall be provided with two permanent openings,
one commencing within 12 inches (31 cm) of the top and one
commencing within 12 inches (31 cm) from the bottom of the enclosure.
The openings shall communicate directly, or by ducts, with the outdoors
or spaces (crawl or attic) that freely communicate with the outdoors.
1. When directly communicating with the outdoors, each opening shall
have a minimum free area of 1 square inch per 4,000 Btu per hour
(5.5 cm2/kW) of total input rating of all equipment in the enclosure,
see Figure 12.
FIGURE14.
5. Louvers and Grilles: In calculating free area, consideration shall be
given to the blocking effect of louvers, grilles or screens protecting
openings. Screens used shall not be smaller than 1/4 inch
(6.4 mm) mesh. If the free area through a design of louver or grille
is known, it should be used in calculating the size opening required
to provide the free area specified. If the design and free area is not
known, it may be assumed that wood louvers will be 20-25 percent
free area and metal louvers and grilles will have 60-75 percent free
area. Louvers and grilles shall be fixed in the open position or
interlocked with the equipment so that they are opened automatically
during equipment operation.
6. Special Conditions Created by Mechanical Exhausting or Fireplaces:
operation of exhaust fans, ventilation systems, clothes dryers or
fireplaces may create conditions requiring special attention to avoid
unsatisfactory operation of installed gas utilization equipment.
FIGURE12.
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Toxic chemicals, such as those used for boiler treatment shall not be
introduced into this system.
WATER PIPING
When the system requires water at temperatures higher than required
for domestic water purposes, a tempering valve must be installed. Please
refer to Figure 15 for suggested piping arrangement.
Water supply systems may, because of such events as high line
pressure, frequent cut-offs, the effects of water hammer among others,
have installed devices such as pressure reducing valves, check valves,
back flow preventers, etc. to control these types of problems. When
these devices are not equipped with an internal by-pass, and no other
measures are taken, the devices cause the water system to be closed.
As water is heated, it expands (thermal expansion) and closed systems
do not allow for the expansion of heated water.
The water within the water heater tank expands as it is heated and
increases the pressure of the water system. If the relieving point of the
water heater’s temperature-pressure relief valve is reached, the valve
will relieve the excess pressure. The temperature-pressure relief
valve is not intended for the constant relief of thermal
expansion. This is an unacceptable condition and must be corrected.
It is recommended that any devices installed which could create a closed
system have a by-pass and/or the system have an expansion tank to
relieve the pressure built by thermal expansion in the water system.
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.
HOTTER WATER CAN SCALD:
Water heaters are intended to produce hot water. Water heated to a
temperature which will satisfy space heating, clothes washing, dish
washing, cleaning and other sanitizing needs can scald and permanently
injure you upon contact. Some people are more likely to be permanently
injured by hot water than others. These include the elderly, children, the
infirm, or physically/mentally handicapped. If anyone using hot water in
your home fits into one of these groups or if there is a local code or state
law requiring a certain temperature water at the hot water tap, then you
must take special precautions. In addition to using the lowest possible
temperature setting that satisfies your hot water needs, a means such
as a *mixing valve, shall be used at the hot water taps used by these
people or at the water heater, see Figure 15. Valves for reducing point
of use temperature by mixing cold and hot water are also available:
NOTE: To protect against untimely corrosion of hot and cold
water fittings, it is strongly recommended that di-electric unions
or couplings be installed on this water heater when connected
to copper pipe.
Figure 16 shows the typical attachment of the water piping to the water
heater. The water heater is equipped with 3/4 inch NPT water
connections.
FIGURE15.
Consult Sears Service Center. Follow manufacturer’s instructions for
installation of the valves. Before changing the factory setting on the
thermostat, read the “Temperature Regulation” section in this manual.
NOTE: If using copper tubing, solder tubing to an adapter before
attaching the adapter to the cold water inlet connection. Do not
solder the cold water supply line directly to the cold water inlet.
It will harm the dip tube and damage the tank.
•
Look at the top cover of the water heater. The water outlet is marked
“HOT”. Put two or three turns of teflon tape around the threaded end
of the threaded-to-sweat coupling and around both ends of the 3/4”
NPT threaded nipple. Using flexible connectors, connect the hot water
pipe to the hot water outlet on the water heater.
•
Look at the top of the water heater. The cold water inlet is marked
“COLD”. Put two or three turns of teflon tape around the threaded
end of the threaded-to-sweat coupling and around both ends of the
3/4” NPT threaded nipple. Using flexible connectors, connect the cold
water pipe to the cold water inlet of the water heater.
This water heater shall not be connected to any heating system or
component or used as a non-potable water heating appliance.
All piping components connected to this unit shall be suitable for use
with potable water.
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TEMPERATURE-PRESSURE RELIEF VALVE
INSTALLATION COMPLETED USING INSTALLATION KIT
This heater is provided with a properly certified combination
temperature - pressure relief valve by the manufacturer.
The valve is certified by a nationally recognized testing laboratory that
maintains periodic inspection of production of listed equipment of
materials as meeting the requirements for Relief Valves and Automatic
Gas Shut-off Devices for Hot Water Supply Systems,ANSI Z21.22 • CSA
4.4, and the code requirements ofASME.
If replaced, the valve must meet the requirements of local codes, but not
less than a combination temperature and pressure relief valve certified
as indicated in the above paragraph.
The valve must be marked with a maximum set pressure not to exceed
the marked hydrostatic working pressure of the water heater
(150 psi = 1,035 kPa) and a discharge capacity not less than the water
heater input rate as shown on the model rating plate.
FIGURE16.
T & P Valve and Pipe Insulation (if supplied)
Remove insulation for T & P valve and pipe connections from carton.
For safe operation of the water heater, the relief valve must not be
removed from its designated opening nor plugged.
The temperature-pressure relief valve must be installed directly into the
fitting of the water heater designed for the relief valve. Position the valve
downward and provide tubing so that any discharge will exit only within
6 inches (15.2 cm) above, or at any distance below the structural floor.
Be certain that no contact is made with any live electrical part. The
discharge opening must not be blocked or reduced in size under any
circumstances. Excessive length, over 30 feet (9.14 m), or use of more
than four elbows can cause restriction and reduce the discharge
capacity of the valve, see Figures 16 or 20.
No valve or other obstruction is to be placed between the relief valve
and the tank. Do not connect tubing directly to discharge drain unless a
6" (15.2 cm) air gap is provided. To prevent bodily injury, hazard to life,
or property damage, the relief valve must be allowed to discharge water
in quantities should circumstances demand. If the discharge pipe is not
connected to a drain or other suitable means, the water flow may cause
property damage.
FIGURE17.
Fit pipe insulation over the incoming cold water line and the hot water
line. Make sure that the insulation is against the top cover of the heater.
Fit T & P valve insulation over valve. Make sure that the insulation does
not interfere with the lever of the T & P valve.
Secure all insulation using tape.
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If the main gas line Shut-off serving all gas appliances is used, also
turn “off” the gas at each appliance. Leave all gas appliances shut
“off” until the water heater installation is complete.
The Discharge Pipe:
• Shall not be smaller in size than the outlet pipe size of the valve, or
have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
A gas line of sufficient size must be run to the water heater. Consult
the current edition of National Fuel Gas CodeANSI Z223.1/NFPA54 and
your gas supplier concerning pipe size.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both the
temperature-pressure relief valve, and the discharge pipe.
• Shall terminate at an adequate drain.
There must be:
• Shall not have any valve between the relief valve and tank.
• A readily accessible manual shut off valve in the gas supply line
serving the water heater, and
• A drip leg (sediment trap) ahead of the gas control valve to help
prevent dirt and foreign materials from entering the gas control valve.
• A flexible gas connector or a ground joint union between the shut off
valve and control valve to permit servicing of the unit.
Be sure to check all the gas piping for leaks before lighting the water
heater. Use a soapy water solution, not a match or open flame. Rinse
off soapy solution and wipe dry.
The temperature-pressure relief valve must be manually operated at least
once a year. Caution should be taken to ensure that (1) no one is in front
of or around the outlet of the temperature-pressure relief valve discharge
line, and (2) the water manually discharged will not cause any bodily injury
or property damage because the water may be extremely hot.
If after manually operating the valve, it fails to completely reset and
continues to release water, immediately close the cold water inlet to
the water heater, follow the draining instructions, and replace the
temperature-pressure relief valve with a new one.
GAS PIPING
Water heaters covered in this manual have been tested and approved
for installation at elevations up to 7,700 feet (2,347 m) above sea level.
When installed at elevations above 7,700 feet (2,347 m), input rating
should be reduced at the rate of 4 percent for each 1,000 feet (305 m)
above sea level which requires replacement of the burner orifice in
accordance with National Fuel Gas CodeANSI Z223.1/NFPA 54. Contact
your local gas supplier for further information.
Failure to replace the standard orifice with a high altitude orifice when
installed at elevations above 7,700 feet (2,347 m) could result in
improper and inefficient operation of the appliance, producing carbon
monoxide gas in excess of safe limits. This could result in serious
injury or death. Contact your gas supplier for any specific changes
which may be required in your area.
Make sure the gas supplied is the same type listed on the model rating
plate. The inlet gas pressure must not exceed 14 inch water column (3.5
kPa) for natural and propane gas (L.P.). The minimum inlet gas pressure
shown on the rating plate is that which will permit firing at rated input.
All gas piping must comply with local codes and ordinances or with the
NationalFuelGasCode(ANSIZ223.1/NFPA-54)whicheverapplies.Copper
andbrasstubingandfittings(excepttinlinedcoppertubing)shallnotbeused.
If the gas control valve is subjected to pressures exceeding 1/2 psi
(3.5 kPa), the damage to the gas control valve could result in a fire or
explosion from leaking gas.
Use pipe joint compound or teflon tape marked as being resistant to the
action of petroleum [Propane (L.P.)] gases.
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The appliance and its gas connection must be leak tested before placing
the appliance in operation.
The appliance and its individual Shut-off valve shall be disconnected
from the gas supply piping system during any pressure testing of that
system at test pressures in excess of 1/2 pound per square inch
(3.5 kPa). It shall be isolated from the gas supply piping system by
closing its individual manual Shut-off valve during any pressure testing
of the gas supply piping system at test pressures equal to or less than
1/2 pound per square inch (3.5 kPa).
Connectingthegaspipingtothegascontrolvalveofthewaterheatercanbe
accomplished by either of the two methods shown in Figures 18 and 19.
FIGURE 18. GAS PIPING WITH
FLEXIBLECONNECTOR.
FIGURE20.
FILLING THE WATER HEATER
FIGURE 19. GAS PIPING WITH ALL
BLACK IRON PIPE TO GAS CONTROL.
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.
SEDIMENT TRAPS
To fill the water heater with water:
1. 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.
2. 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.
3. To insure complete filling of the tank, allow air to exit by opening the
nearest hot water faucet. Allow water to run until a constant flow
is obtained. This will let air out of the water heater and the piping.
4. Check all water piping and connections for leaks. Repair as needed.
Contaminants in the gas lines may cause improper operation of the gas
control valve that may result in fire or explosion. Before attaching the
gas line be sure that all gas pipe is clean on the inside. To trap any dirt
or foreign material in the gas supply line, a drip leg (sometimes called a
sediment trap) must be incorporated in the piping. The drip leg must be
readily accessible. Install in accordance with the “Gas Piping” section.
Refer to the current edition of the National Fuel Gas Code,
ANSI Z223.1/NFPA54.
BLOWERASSEMBLYINSTALLATION
SEQUENCEOFINSTALLATION
1. Thispowerventedwaterheatercomeswiththeblowerassemblyinstalled.
2
After the unit is set in place, make sure the blower assembly is still
mounted securely and the air intake screen of the blower assembly
is installed in the dilution air opening. Also make sure the drain port
of the rubber boot vent adapter is capped off. Lastly, make sure
there is no damage to the blower.
A sediment trap shall be installed as close to the inlet of the water
heater as practical at the time of water heater installation. The sediment
trap shall be either a tee fitting with a capped nipple in the bottom outlet
or other device recognized as an effective sediment trap. If a tee fitting
is used, it shall be installed in conformance with one of the methods of
installation shown in Figures 18 and 19.
3. Make sure there is no packing material in the discharge of the
blower or the intake of the dilution air restrictor, see Figure 21.
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4. Make sure that the plastic tubing is still attached from the air pressure
switch to the port on the blower housing. Make sure the plastic
tubing is not folded anywhere between the pressure switch and
the blower housing.
7. Do not plug in power cord until vent system is completely installed.
This power vent heater operates on 110-120 Vac, therefore a
grounded outlet must be within reach of the six (6) foot (1.8 m)
flexible power cord supplied with the unit (see Figure 1). The power
cord supplied may be used only where local codes permit. If local
codes do not permit the use of a flexible power supply cord:
5. Make sure the ON/OFF switch is in the OFF position and that the
outer harness is connected from the blower control box to the
connector on the bottom side of the gas valve.
a.) Make sure the unit is unplugged from wall outlet. Remove screws
and open panel on front of control box.
6. Iftheouterharnessisnotfactoryinstalled, makesuretheON/OFFswitch
is in the OFF position and then connect the harness from the blower
control box to the connector on the bottom side of the gas valve.
b.) Cut the flexible power cord, leaving enough to be able to make
connections and remove the strain relief fitting from box.
c.) Install suitable conduit fitting in side of enclosure and then follow
(d.) and (e.) below.
d.) Splice field wiring into existing wiring using code authorized method
(wire nuts, etc.).
e.) Be certain that neutral and live connections are not reversed when
making these connections.
f.) Close panel on the side of control box, make sure that access panel
is secured shut.
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Except where instructed in this manual, the mixing of 2", 3" and 4" vent
pipe is NOTALLOWED. If 2" pipe is to be used, then a 2" to 3" bell reducer
is recommended. Figure 21 shows the recommended location for the
bell reducer. If the bell reducer is located at the rubber boot on the
blower assembly, then a short section of 3" vent pipe needs to be
installed in the rubber boot for proper connection of the 2" to 3" bell
reducer.Thatlengthcanbetheminimumlengthrequiredfortheconnection.
VENT CONNECTIONS TO BLOWERASSEMBLY
Figure 21 shows the optimal placement of the 2" to 3" or 3" to 4" reducer;
however, the vent can be reduced at any point in the vent system as long
as the maximum vent length is not exceeded.
If 4" pipe is to be used, then a 3" to 4" bell reducer is recommended.
Figure 21 shows the recommended location for the bell reducer. If the
bell reducer is located at the rubber boot on the blower assembly, then
a short section of 3" vent pipe needs to be installed in the rubber boot
for proper connection of the 3" to 4" bell reducer. That length can be
the minimum length required for the connection.
The water heaters covered by this manual are supplied with a 2" Schedule
40 PVC 22.5° Vent Terminal. If you decide to vent with 3" or 4" pipe, a
Schedule40DWV45°VentTerminalmustbeused. Foryourconvenience,
we have included a screen for both 3" and 4" Vent Terminals.
FIGURE21.
VENTINGAND INSTALLATION
Plan the layout of the vent system from the vent termination to the water
heater considering all of the 90° and 45° elbows plus the number of feet
of pipe that would be needed to install the total vent system. The water
heater must be vented to the outdoors as described in these instructions.
DO NOTconnect this water heater to an existing vent or chimney. It must
be vented separately from all other appliances. Nonmetallic vent may be
used if it has “Heat DeflectionTemperature” (HDT@66 psi) or 455 kPa of
at least 157°F or 69°C. Typical nonmetallic vent materials meeting this
requirement are: PVC (Schedule 40,ASTM D-1785), Coex Cellular Core
(Schedule 40,ASTM F-441), CPVC (Schedule 40,ASTM D-2846),ABS
(Schedule 40,ASTM D-2661). The fittings, other than the supplied Vent
Termination should be equivalent to the following: PVC (Schedule 40,
DWV,ASTM D-2665), CPVC (Schedule 40, DWV, ASTM F-438),ABS
(Schedule 40 DWV,ASTM D-2661).
The vent piping should be connected to the blower with a rubber
adapter and secured with hose clamps. The adapter and clamps are
provided with the heater.
Even though the flue gas temperature leaving the blower is between
140°F (69°C) and 175°F (79°C), some installations will have water
vapor condense in the vent piping. If this occurs, then adequate means
of draining and disposing of the condensate needs to be made by
the installer.
CONDENSATION
Condensate formation does not occur in all installations of power vented
water heaters, but should be protected against on installations where it
can form in the venting system. Condensation in the venting system of
power vented water heaters is dependent upon installation conditions
including, butnotlimitedtoambienttemperatureandhumidityofinstallation
location, ambient temperature and humidity of venting space, vent
discharge and slope, and product usage. In certain conditions, installations
in unconditioned space or having long horizontal or vertical vent runs
may accumulate condensate. In these conditions, the vent pipe should
be sloped downward away from the blower assembly 1/4" (6.4 mm) per
five feet (1.5 m) of pipe but not more than 1 1/2" (3.8 cm) in the total vent
length. If the vent piping is vented level or sloped upwards away from
the blower assembly, then adequate means for draining and disposing
of the condensate needs to be made by the installer (if condensate is
detected). Ifyouhavecondensate, thena3/8"drainhosecanbeconnected
to the built-in drain port of the rubber boot on the blower assembly. For
your convenience, the rubber boot is supplied with a removable cap on
the built-in drain port. Prior to operating the water heater, make sure the
removable cap is installed on the drain port (if a drain hose is not needed).
The cement used should be as recommended by the vent pipe
manufacturer. See the instructions on pages 20 and 21 for the proper
method of cutting and cementing the PVC pipe and fittings.
The unit may be vented horizontally through a wall or vertically through
the roof. Pipe runs must be adequately supported along both vertical
and horizontal runs as follows:
• For Schedule 40, 2" PVC,ABS, Coex Cellular Core vent pipe: Every
3 feet (0.9 m).
• For Schedule 40, 3" PVC,ABS, Coex Cellular Core vent pipe: Every
3.5 feet (1.1 m).
• For Schedule 40, 4" PVC,ABS, Coex Cellular Core vent pipe: Every
4 feet (1.2 m).
• For Schedule 40, 2" CPVC vent pipe: Every 5 feet (1.5 m).
• For Schedule 40, 3" CPVC vent pipe: Every 6 feet (1.8 m).
• For Schedule 40, 4" CPVC vent pipe: Every 6.5 feet (2.0 m).
MAXIMUM VENT LENGTHS
40,000 BTU Units:
It is imperative that the first hanger (or support) be located on the horizontal
run immediately adjacent to the first 90-degree elbow from the vertical
rise. Support method used should isolate the vent pipe from the floor
joists or other structural members to prevent the transmission of noise
and vibration. Do not support, pin, or otherwise secure the venting
system in a way that restricts the normal thermal expansion and
contraction of the chosen venting material.
For 2" Venting, the maximum equivalent feet of pipe allowed
is 40 feet (12.2 m). This does not include the supplied vent termination
for the water heater. For the 2" venting, one 90° elbow is approximately
equal to 5 feet (1.5 m). One 45° elbow is approximately equal to 2.5
feet (0.8 m). It is recommended that at least 2 feet (0.6 m) of spacing
be used in between all 45° elbows and all 90°elbows.
For 3" Venting, the maximum equivalent feet of pipe allowed
is 120 feet (36.6 m). This does not include the VentTermination (supplied
locally) for the water heater. For the 3" venting, one 90° elbow is
approximately equal to 5 feet (1.5 m). One 45° elbow is approximately
equal to 2.5 feet (0.8 m). It is recommended that at least 2 feet (0.6 m)
of spacing be used in between all 45° elbows and all 90°elbows.
If the water heater is being installed as a replacement for an existing
power vented heater in pre-existing venting, a thorough inspection of
the existing venting system must be performed prior to any installation
work. Verify that the correct material as detailed above has been
used, and that the minimum or maximum vent lengths and terminal
location as detailed in this manual have been met. Carefully inspect the
entire venting system for any signs of cracks or fractures, particularly
at the joints between elbows and other fittings and the straight runs of
vent pipe. Check the system for signs of sagging or other stresses in
the joints as a result of misalignment of any components in the system.
If any of these conditions are found, they must be corrected in
accordance with the venting instructions in this manual before
completing the installation and putting the water heater into service.
For 4" Venting, the maximum equivalent feet of pipe allowed
is 160 feet (48.8 m). This does not include the VentTermination (supplied
locally) for the water heater. For the 4" venting, one 90° elbow is
approximately equal to 8 feet (2.4 m). One 45° elbow is approximately
equal to 4 feet (1.2 m). It is recommended that at least 2 feet (0.6 m) of
spacing be used in between all 45° elbows and all 90°elbows.
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Vent pipes serving power vented appliances are classified by building
codes as “vent connectors”. Required clearances from combustible
materials must be provided in accordance with information in this manual
under FACTS TO CONSIDER ABOUT THE LOCATION and VENT
TERMINALINSTALLATIONS, and with the National Fuel Gas Code and
local codes.
VENTING
VENT TERMINAL INSTALLATION
1. After the point of termination has been determined, use the cover
plate as a template to mark the hole for the vent pipe to insert
through the wall. BEWARE OF CONCEALED WIRINGAND PIPING
INSIDE OFWALL.
2. If the Vent Terminal is being installed on the outside of a finished
wall, it may be easier to mark both the inside and outside wall.
Align the holes by drilling a hole through the center of the template
from the inside through to the outside. The template can now be
positioned on the outside wall using the drilled hole as a centering
point for the template.
3. A) MASONRY SIDE WALLS
Chisel an opening approximately one half inch larger than the
marked circle.
B) WOODENSIDEWALLS
Drill a pilot hole approximately one quarter inch outside of the
marked circle. This pilot hole is used as a starting point for a
saws-all or sabre saw blade. Cut around the marked circle staying
approximately one quarter inch outside of the line. (This will allow
the vent pipe to easily slide through the opening. The resulting
gap will be covered up by the vent terminal cover plates.) Repeat
this step on inside wall if necessary.
4. When the vent piping cannot pass through an outside wall at a
height greater than or equal to 12" above the ground (or above
snow accumulation level), then the installation can be modified as
shown below.
The vent system must terminate so that proper clearances are
maintained as cited in local codes or the current edition of the National
Fuel Gas Code, ANSI Z223.1/NFPA54, 7.3.4e and 7.8a,b, as follows:
1. The exit terminals of a mechanical vent system shall be not less
than 7 feet (2.13 m) above grade when located adjacent to public
walkways, see Figure 23.
2. A venting system shall terminate at least 3 feet (91 cm) above any
forced air inlet located within 10 feet (3.1 m), see Figure 23.
3. The venting system shall terminate at least 4 feet (1.2 m) below, 4
feet (1.2 m) horizontally from or, 12 in. (30 cm) above any door,
window or gravity air inlet into any building.
The manufacturer also recommends that the vent termination should
not be installed closer than 3 feet (91 cm) from an inside corner of an
L shaped structure and not be less than 12 in. (30 cm) above grade.
The vent shall terminate a minimum of 12'' (30.5 cm) above expected
snowfall level to prevent blockage of vent termination, see Figure 23.
4. Incoldclimates, itisrecommendedthatventterminationnotbemounted
directlyaboveorwithin3feet(91cm)horizontallyfromanoiltankventor
gasmetertoavoidpotentialfreeze-upfromcondensation, seeFigure23.
Plan the vent system layout so that proper clearances are maintained
from plumbing and wiring.
FIGURE22.
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FIGURE23.
This unit can vent through 2", 3" or 4" nonmetallic pipe and fittings.
VERTICAL VENT TERMINATION RESTRICTIONS
The vent pipe installation can be started from either the blower discharge
or the termination wall. Keep in mind the total vent system (pipe and
elbows) when installing the vent system, see VENTING AND
INSTALLATIONANDMAXIMUMVENTLENGTHS, page17.
1. Minimum of twelve 12" (30.5 cm) above the roof or twelve 12"
(30.5 cm) above the anticipated snow level. Provide proper support
for all pipe protruding through the roof.
FIGURE24.
The vent terminal should be kept as close as possible to the outside
wall, but you need to allow at least 1.5" (3.8 cm) of pipe past the wall,
for the wall flange and vent terminal to mount on the pipe.
Before the vent terminal is installed, caulk (not supplied) around the pipe
on the exterior wall and install the optional wall flange. The flange can be
held to the outside wall by placing some of the caulking on the back of the
flange. The wall flange is supplied for decorative purposes only and is
not a requirement for the vent termination (if not needed by the installer).
VERTICAL VENT THROUGH ROOF
This unit is approved for venting through the roof with the type vent
terminal that is included with the unit. A proper flashing or “BOOT”
should be used to seal the pipe where it exits the roof.
FIGURE25.
The total vent system should not exceed that which is specified, see
VENTINGANDINSTALLATION, page 17.
2. 4' (1.2 m) from or 1' (0.3 m) above any gable, dormer, or other roof
structure with access to interior of building (i.e.-vent, window etc.).
All of the pipe should be secured as per the instructions in the instructions
in the VENTINGAND INSTALLATION, page 17.
3. 3' (0.9 m) above any forced air inlet located within 10' (3.0 m).
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formamide (DMF) may be included to act as a retarding agent to extend
curing time. Select the proper cement; Schedule 40 cement should be
used for Schedule 40 pipe. Never use all-purpose cements, commercial
glues and adhesives orABS cement to joinPVCorCPVC pipe and fittings.
VENT PIPE PREPARATION
1. INITIALPREPARATION
A. Make sure the solvent cement you are planning to use is
designed for the specific application you are attempting.
B. Know the physical and chemical characteristics and limitations
of the PVC and CPVC piping materials that you are about to use.
C. Know the reputation of your manufacturer and their products.
D. Know your own qualifications or those of your contractor.
The solvent welding technique of joining PVC and CPVC pipe
is a specialized skill just as any other pipe fitting technique.
APPLICATORS
E. Closely supervise the installation and inspect the finished
job before start-up.
Select a suitable pure bristle type paint brush. Use a proper width
brush or roller to apply the primer and cement (see chart below).
Speedy application of cement is important due to its fast drying
characteristics. IMPORTANT NOTE:Adauber type applicator should
only be used on pipe sizes 2" and below. For larger diameter pipe, a
brush or roller must be used.
F. Contact the manufacturer, supplier, or competent consulting
agency if you have any questions about the application or
installation of PVC and CPVC pipe.
G. Take the time and effort to do a professional job. Shortcuts
will only cause you problems and delays in start-up. By far,
the majority of failures in PVC and CPVC systems are the
result of shortcuts and/or improper joining techniques.
RECOMMENDED BRUSH* SIZE FOR PRIMER
AND CEMENTAPPLICATIONS
Nominal Pipe
Size Brush Width
2. SELECTION OF MATERIALS
(IPS)
(INS.)
2
3
1-1/2
1-1/2 - 2-1/2
•
•
•
•
•
•
Cutting Device - Saw or Pipe Cutter
Deburring Tool, Knife, File, or Beveling Machine (2" and above)
Brush - Pure Bristle
*USEONLYNATURALBRISTLE
Rag - Cotton (Not Synthetic)
3. MAKING THE JOINT
Primer and Cleaner
A. Cutting
Pipe must be squarely cut to allow for the proper interfacing of the
pipe end and the fitting socket bottom. This can be accomplished
with a miter box saw or wheel type cutter. Wheel type cutters are
not generally recommended for larger diameters since they tend to
flare the corner of the pipe end. If this type of cutter is used, the
flare on the end must be completely removed.
Solvent Cement - PVC for PVC Components and CPVC for CPVC
Components
•
•
Containers - Metal or Glass to hold Primer and Cement. Select the
type of PVC or CPVC materials to be used on the basis of their
application with respect to chemical resistance, pressure rating,
temperature characteristics, etc.
NOTE: Power saws should be specifically designed to cut plastic pipe.
Insertion Tool - Helpful for larger diameter pipe and fittings 6 inches
(15.2 cm) and above.
PRIMER
It is recommended that Tetrahydrofuran (THF) be used to prepare the
surfaces of pipe and fittings for solvent welding. Do not use water,
rags, gasoline or any other substitutes for cleaning PVC or CPVC
surfaces.Achemical cleaner such as MEK may be used.
CEMENT
The cement should be a bodied cement of approximately 500 to 1600
centipoise viscosity containing 10-20% (by weight) virgin PVC material
solvated with tetrahydrofuran (THF). Small quantities of dimethyl
STEP A
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B. Deburring
Useaknife, plasticpipedeburringtool, orfiletoremoveburrsfromtheend
ofsmalldiameterpipe. Besuretoremoveallburrsfromaroundtheinside
as well as the outside of the pipe. Aslight chamfer (bevel) of about 10°-
15° should be added to the end to permit easier insertion of the pipe into
theendofthefitting. Failuretochamfertheedgeofthepipemayremove
cementfromthefittingsocket, causingthejointtoleak.
STEPE
F. Joint assembly
Working quickly, insert the pipe into the fitting socket bottom and
give the pipe or fitting a 1/4 turn to evenly distribute the cement. Do
not continue to rotate the pipe after it has hit the bottom of the fitting
socket. Agood joint will have sufficient cement to make a bead all
the way around the outside of the fitting hub. The fitting will have a
tendency to slide back while the cement is still wet so hold the joint
together for about 15 seconds.
STEPB
C. Test dry fit of the joint
Tapered fitting sockets are designed so that an interfaced fit should
occur when the pipe is inserted about 1/3 to 2/3 of the way into the
socket. Occasionally, when pipe fitting dimensions are at the
tolerance extremes, it will be possible to fully insert dry pipe to the
bottom of the fitting socket. When this happens, a sufficient quantity
of cement must be applied to the joint to fill the gap between the pipe
and fitting. The gap must be filled to obtain a strong, leak-free joint.
D. Inspection, cleaning, priming
Visually inspect the inside of the pipe and fitting sockets and remove
all dirt, grease or moisture with a clean dry rag. If wiping fails to
clean the surfaces, a chemical cleaner must be used. Check for
possible damage such as splits or cracks and replace if necessary.
Depth-of-entry
STEPF
Marking the depth of entry is a way to check if the pipe has reached
the bottom of the fitting socket in Step F. Measure the fitting depth
and mark this distance on the pipe O.D. You may want to add
several inches to the distance and make a second mark as the
primer and cement will most likely destroy your first one.
G. Cleanup and joint movement
Remove all excess cement from around the pipe and fitting with a
dry cotton rag. This must be done while the cement is still soft.
The joint should not be disturbed immediately after the cementing
procedure, and sufficient time should be allowed for proper curing
of the joint. Exact drying time is difficult to predict because it depends
on variables such as temperature, humidity and cement integrity.
For more specific information, you should contact your solvent
cement manufacturer.
Apply primer to the surface of the pipe and fitting socket with a natural
bristle brush. This process softens and prepares the PVC or CPVC for
the solvent cementing step. Move quickly and without hesitation to the
cementing procedure while the surfaces are still wet with primer.
E. Application of solvent cement
• Applythesolventcementevenlyandquicklyaroundtheoutsideofthe
pipe at a width a little greater than the depth of the fitting socket.
• Apply a light coat of cement evenly around the inside of the
fitting socket. Avoid puddling.
• Apply a second coat of cement to the pipe end.
STEPG
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OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal injury or loss of
life.
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATERANDAIR PURGED FROMALL LINES.
A. This appliance does not have a pilot. It is equipped with
an ignition device which automatically lights the burner.
Do NOT try to light the burner by hand.
B. BEFORE OPERATING smell all around the appliance area
for gas. Be sure to smell next to the floor because some
gas is heavier than air and will settle on the floor.
WHAT TO DO IFYOU SMELLGAS:
•
If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push in the gas control buttons.
Never use tools. If the control buttons will not push in,
don’t try to repair them, call a qualified service technician.
Force or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under
water. Immediately contact a qualified installer or service
agency to replace a flooded water heater. Do not attempt
to repair the unit! It must be replaced!
•
•
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.
•
OPERATING INSTRUCTIONS
4. This appliance is equipped with a device which
automatically lights the burner.
DONOTTRYTOLIGHTTHEBURNERBYHAND.
5. Wait five (5) minutes
If you then smell gas,
to clear out any gas.
STOP! Follow “B” in the
safety information above on this label. If you don’t smell
gas, go to the next step.
6. Turn on all electrical power to the appliance.
7. Set thermostat to desired setting by first pressing the
COOLER
and HOTTER
buttons together and
holding for 1 second. Then press the HOTTER
button.
8. If the appliance will not operate, follow the instructions
“TO TURN OFF GAS TO APPLIANCE” and call your
technician or gas supplier.
1.
STOP! Read the safety information above,
on this label.
9. WATERTEMPERATUREADJUSTMENT
is approximately 120°F.
2. Set the thermostat to the lowest setting by first pressing
the COOLER and HOTTER buttons together and
CAUTION: Hotter water increases the risk
of scald injury. Consult the instruction
manual before changing temperature.
holding for 1 second. Then press the COOLER
until the WARM indicator light appears.
button
3. Set the “ON/OFF” switch on the blower control box to the
“OFF” position.
WARNING: TURN OFFALLELECTRIC
POWERBEFORESERVICING
TO TURN OFF GAS TOAPPLIANCE
1. Set the thermostat to the lowest setting by first pressing the COOLER
and HOTTER
buttons together and holding
for 1 second. Then press the COOLER button until the WARM indicator light appears.
2. Set the ON/OFF switch on the blower control box to the “OFF” position.
3. Turn off all electric power to the appliance if service is to be performed.
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The water heater should be located in an area where the general
public does not have access.
TEMPERATURE REGULATION
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.
The water temperature setting was factory set at the lowest
temperature; Pressing the “COOLER”
button decreases temperature
and pressing the “HOTTER” button increases the temperature.
Any water heater’s intended purpose is to heat water. Hot water is
needed for cleansing, cleaning, and sanitizing (bodies, dishes, clothing).
Untempered hot water can present a scald hazard. Depending on the
time element, and the people involved (adults, children, elderly, infirm,
etc.) scalding may occur at different temperatures.
Setting the water heater temperature at 120°F (49°C) (Approx. “
mark on temperature setting of gas valve) will reduce the risk of scalds.
Some states require settings at specific lower temperatures.
”
To avoid any unintentional changes in water temperature settings, the
control has a tamper resistant feature for changing the temperature
setting. To change the temperature setting follow these instructions:
It is recommended that lower water temperatures be used to avoid the
risk of scalding. It is further recommended, in all cases, that the water
temperature be set for the lowest temperature which satisfies your
hot water needs. This will also provide the most energy efficient
operation of the water heater.
1. “Wake Up” the temperature indicators by holding down both
“COOLER” and “HOTTER” temperature adjustment buttons at the
same time for one second, see Figure 26. One or two of the
temperature indicators will light up. These indicators will only remain
on for 30 seconds if no further buttons are pressed.After 30 seconds
the control will go back to “Sleep” mode.
Figure 26 shows the approximate water temperatures produced at
various thermostat settings. Short repeated heating cycles caused by
small hot water uses can cause temperatures at the point of use to
exceed the thermostat setting by up to 30°F (17°C). If you experience
this type of use you should consider using lower temperature settings
to reduce scald hazards.
2. Release both of the temperature adjustment buttons.
a. To decrease the temperature press and release the “COOLER”
button until the desired setting is reached.
Valves for reducing the point-of-use temperature by mixing cold and
hot water are available, see Figure 15.Also available are inexpensive
devices that attach to faucets to limit hot water temperatures. Contact
a licensed plumber or the local plumbing authority.
b. To increase the temperature press and release the “HOTTER”
button until the desired setting is reached.
NOTE: Holding down the button will not continue to lower or raise the
temperature setting. The button must be pressed and released for
each temperature change desired.
Should overheating occur or the gas supply fail to shut off, turn off the
manual gas control valve to the appliance.
HOT 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, shall 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 15.
Follow manufacturer’s instructions for installation of the valves. Before
changing the factory setting on the thermostat, read the “Temperature
Regulation” section in this manual, see Figure 26.
Time to Produce
Display
A B C
2nd and 3rd Degree
Burns on Adult Skin
About 1/2 seconds
About 1-1/2 seconds
Less than 5 seconds
About 30 seconds
More than 5 minutes
- - - - - - - - - - - - -
Temperature Setting
C-Flashing = approx. 160°F (71°C)
C = approx. 150°F (66°C)
B = approx. 140°F (60°C)
A = approx. 130°F (54°C)
= approx. 120°F (49°C)
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.
WARM = approx. 80°F (27°C)
FIGURE26.
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FOR YOUR INFORMATION
START UP CONDITIONS
Thermal Expansion Tank Specifications
Tank
Capacity
Dimensions
in Inches
Pipe
Fitting
CONDENSATE
Model
Whenever the water heater is filled with cold water, some condensate
will form while the burner is on.Awater heater may appear to be leaking
when in fact the water is condensate. This usually happens when:
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
a. A new water heater is filled with cold water for the first time.
b. Burning gas produces water vapor in water heaters, particularly
high efficiency models where flue temperatures are lower.
c. Large amounts of hot water are used in a short time and the refill
water in the tank is very cold.
Expansion Tank Sizing Chart
Inlet*
Water
Pressure
40psi
Water Heater Capacity (Gallons)
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.
30
2
40
2
50
2
66
5
80
5
Expansion
Tank
50psi
2
2
2
5
5
Because of the suddenness and amount of water, condensate water
may be diagnosed as a “tank leak”.After the water in the tank warms
up (about 1-2 hours), the condition should disappear.
Capacity
Needed
60psi
2
2
5
5
5
70psi
2
2
5
5
5
80psi
2
5
5
5
5
Do not assume the water heater is leaking until there has been enough
time for the water in the tank to warm up.
*Highest recorded inlet water pressure in a 24 hour period or
regulated water pressure.
An undersized water heater will cause more condensation. The water
heater must be sized properly to meet the family’s demands for hot
water including dishwashers, washing machines and shower heads.
NOTE: Expansion tanks are pre-charged with a 40 psi air
charge. If the inlet water pressure is higher than 40 psi, the
expansion tank’s air pressure must be adjusted to match
that pressure, but must not be higher than 80 psi.
Excessive condensate may be noticed during the winter and early
spring months when incoming water temperatures are at their lowest.
Good venting is essential for a gas fired water heater to operate properly
as well as to carry away products of combustion and water vapor.
SMOKE/ODOR
It is not uncommon to experience a small amount of smoke and odor
during the initial start-up. This is due to burning off of oil from metal
parts, and will disappear in a short while.
THERMALEXPANSION
Water supply systems may, because of such events as high line
pressure, frequent cut-offs, the effects of water hammer among
others, have installed devices such as pressure reducing valves, check
valves, back flow preventers, etc. to control these types of problems.
When these devices are not equipped with an internal by-pass, and no
other measures are taken, the devices cause the water system to be
closed.As water is heated, it expands (thermal expansion) and closed
systems do not allow for the expansion of heated water.
The water within the water tank expands as it is heated and increases
the pressure of the water system. If the relieving point of the water
heater’s temperature-pressure relief valve is reached, the valve will
release the excess pressure. The temperature-pressure relief
valve is not intended for the constant relief of thermal
expansion. This is an unacceptable condition and must be corrected.
It is recommended that any devices installed which could create a
closed system have a by-pass and/or the system have an expansion
tank or device to relieve the pressure built by thermal expansion in the
water system. Expansion tanks are available through Sears stores
and Sears Service Centers. Contact Sears Service Center for
assistance in controlling these situations, see Figure 27.
FIGURE27.
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Do not remove the anode leaving the tank unprotected. By
doing so, all warranty on the water heater tank is voided.
STRANGESOUNDS
Possible noises due to expansion and contraction of some metal parts
during periods of heat-up and cool-down do not necessarily represent
harmful or dangerous conditions.
“AIR” IN HOT WATER FAUCETS
Condensation causes sizzling and popping within the burner area during
heating and cooling periods and should be considered normal. See
“Condensate” in this section.
OPERATIONAL CONDITIONS
SMELLYWATER
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” in the hot water. The smell is a result of four factors
which must all be present for the odor to develop:
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.
a. A concentration of sulfate in the supply water.
b. Little or no dissolved oxygen in the water.
c. A sulfate reducing bacteria which has accumulated within the water
heater (this harmless bacteria is nontoxic to humans).
d. 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 water lines. Contact
Sears Service Center for further information concerning Anode
Replacement Kit #9001453 and this chlorination treatment. Anode
replacement and chlorination of the tank are not covered by the water
heater’s limited warranty.
HIGHWATERTEMPERATURESHUTOFFSYSTEM
This water heater is equipped with an automatic gas shut-off system.
This system works when high water temperatures are present. Turn
“OFF” the entire gas supply to the water heater. The high temperature
shut-off is built into the gas control valve. It is non-resettable. If the high
temperature shut-off activates, the gas control valve must be replaced.
Contact your gas supplier or Sears Service Center.
If the smelly water persists after the anode replacement and chlorination
treatment, we can only suggest that chlorination or aeration of the
water supply be considered to eliminate the water problem.
SERVICE AND ADJUSTMENT
2. Damage or deterioration which could cause improper venting or
leakage of combustion products.
VENTING SYSTEM INSPECTION
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 after inspection of the vent system you found sooting or deterioration,
something is wrong. Call the local gas utility to correct the problem and
clean or replace the flue and venting before resuming operation of the
water heater.
BURNER OPERATIONAND INSPECTION
Flood damage to a water heater may not be readily visible or immediately
detectable. However, overaperiodoftimeafloodedwaterheaterwillcreate
dangerousconditionswhichcancauseDEATH,SERIOUSBODILYINJURY,
ORPROPERTYDAMAGE.ContactSearsServiceCentertoreplaceaflooded
waterheater. Donotattempttorepairtheunit!Itmustbereplaced!
At least once a year a visual inspection should be made of the venting
system. You should look for:
1. Obstructions which could cause improper venting. The combustion
and ventilation air flow must not be obstructed.
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At least once a year a visual inspection should be made of the main
burner and the hot surface igniter assembly for proper flame
characteristics and ignition sequences. This can be done by removing
the Outer Door and viewing the main burner operation through the
Viewport on the Inner Door, see Figure 1. The main burner should
provide complete combustion of gas, ignite rapidly, give reasonably
quiet operation, and cause no excessive flame lifting from the burner
ports. If the proper flame characteristics are not evident (see Figure
28), make sure that the flow of combustion and ventilation air is not
blocked on theAir Intake Screen at the base of the water heater (see
Figure 29), the Lint screen on the blower assembly (see Figure 1), and
in the venting system.
FIGURE29.
AT LEAST ONCE EVERY SIX MONTHS A VISUAL INSPECTION
SHOULD BE MADE OF THEAIR INTAKE SCREENS ON THE BASE
OF THE WATER HEATERAND THE BLOWERASSEMBLY. CLEAN
IF LINT ACCUMULATIONS ARE NOTICED.
You should also check for sooting. Soot is not normal and will impair
proper combustion. A visual inspection of the main burner and HSI
igniter assembly should also be done at least once a year, see
Figure 28.
INSTALLED IN SUITABLE AREA: To insure sufficient ventilation and
combustion air supply, proper clearances from the water heater must
be maintained. See “Facts to ConsiderAbout the Location” section.
Combustible materials such as clothing, cleaning materials, or flammable
liquids, etc. must not be placed against or adjacent to the water heater
which can cause a fire.
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.
ANODE ROD INSPECTION
FIGURE28.
BURNER CLEANING
In the event your burner or burner air openings require cleaning, turn
the blower switch to the “OFF” position and allow the burner to cool.
Call Sears Service Center to remove and clean the burner and correct
the problem that required the burner to be cleaned.
The anode rod is used to protect the tank from corrosion. Most hot
water tanks are equipped with an anode rod. The submerged rod
sacrifices itself 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.
HOUSEKEEPING
Vacuumaroundbaseofwaterheaterfordust, dirt, andlintonaregularbasis.
Anode deterioration depends on water conductivity, not necessarily
water condition. Acorroded 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 a qualified technician, and at a minimum should be
checked annually after the warranty period.
TEMPERATURE-PRESSURE
RELIEF VALVE OPERATION
This water heater unit is supplied with a plasticAir Intake Screen that will
filter and prevent lint build-up on the bottom of the flame arrestor of this
heater.To prevent the lint build-up on the arrestor, the lint screen must be
installed on the Base Pan with the “arrows” pointing upwards as shown
in Figure 29. If theAir Intake Screen is missing from this heater, please
contact Sears Service Center for a replacement part.
The temperature-pressure relief valve must be manually operated at
least once a year.
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5. OPEN the water heater drain valve to allow for tank draining.
NOTE: If the water heater is going to be shut down and
drained for an extended period, the drain valve should be
left open with hose connected allowing water to terminate
to an adequate drain.
6. CLOSE the drain valve.
7. Follow instructions in the “Filling The Water Heater” section.
8. Follow the lighting instructions on the label or see page 22 under
“Operating Instructions” to restart the water heater.
FIGURE 30.
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.
DRAIN VALVE WASHER REPLACEMENT
(See Figure 31)
1. Turn “OFF” gas supply to water heater.
2. Follow “Draining” instructions.
If after manually operating the valve, it fails to completely reset and
continues to release water, immediately close the cold water inlet to
the water heater, follow the draining instructions, and replace the
temperature-pressure relief valve with a new one.
3. Turning counterclockwise (
screw handle.
), remove the hex cap below the
Ifthetemperature-pressurereliefvalveontheapplianceweepsordischarges
periodically, this may be due to thermal expansion. You may have a check
valveinstalledinthewaterlineorawatermeterwithacheckvalve. Consult
yourlocalwatersupplierorSearsServiceCenterfor furtherinformation. Do
not plug the temperature-pressure relief valve.
4. Remove the washer and put the new one in place.
5. Screw the handle and cap assembly back into the drain valve and
retighten using a wrench. DO NOT OVER TIGHTEN.
6. Follow instructions in the “Filling The Water Heater” section.
7. Check for leaks.
DRAINING
8. Follow the lighting instructions in the “Operating Instructions” section
to restart the water heater.
The water heater should be drained if being shut down during freezing
temperatures. Also periodic draining and cleaning of sediment from the
tank may be necessary.
FIGURE 31.
1. Set the blower switch to the “OFF” position.
SERVICE
2. CLOSE the cold water inlet valve to the water heater.
3. OPEN a nearby hot water faucet and leave open to allow for draining.
4. Connect a hose to the drain valve and terminate to an adequate drain.
If a condition persists or you are uncertain about the operation of the
water heater contact Sears Service Center at 1-800-MY-HOME®
(1-800-469-4663).
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LEAKAGE CHECKPOINTS
Use this guide to check a “Leaking” water heater. Many suspected
“Leakers” are not leaking tanks. Often the source of the water can be
found and corrected.
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.
If you are not thoroughly familiar with gas codes, your water heater, and
safety practices, contact Sears Service Center to check the water heater.
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 blower assembly is water vapor which has condensed
out of the combustion products. This is caused by a problem in the
vent. Contact the gas utility.
B. *Condensation may be seen on pipes in humid weather or pipe
connections may be leaking.
C. *The anode rod fitting may be leaking (anode is located under the
BlowerAssembly).
D. Small amounts of water from temperature-pressure relief valve
may be due to thermal expansion or high water pressure in your
area.
E. *The temperature-pressure relief valve may be leaking at the tank
fitting.
F. Water from a drain valve may be due to the valve being slightly
opened.
G. *The drain valve may be leaking at the tank fitting.
H. Combustion products contain water vapor which can condense on
the cooler surfaces of the tank. Droplets form and drip onto the
burner or run on the floor. This is common at the time of start-up
after installation and when incoming water is cold.
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.
*
To check where threaded portion enters tank, insert cotton swab
between jacket opening and fitting. If cotton is wet, follow “Draining”
instructions in the “Periodic Maintenance” section and then remove
fitting. Put pipe dope or teflon tape on the threads and replace.
Then follow “Filling the Water Heater” instructions in the “Installation
Instructions” section.
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TROUBLESHOOTING GUIDELINES
These guidelines should be used by a qualified service agent. Call Sears Service at 1-800-4-MY-HOME® (1-800-469-4663)
for assistance. Inform the associate that this is a “Flammable Vapor Ignition Resistant” Product.
PROBLEM
SOLUTION
LED STATUS
An open earth ground circuit to the
ignition system.
1. Check that the earth ground connection is
properly connected.
A
B C
2. Check that the ground conductor on the
water heater is properly connected.
Wiring error or a high resistance to
earth ground.
1. Check for proper connection of line
neutral and hot wires.
2. Check that the water heater is securely
connected to earth ground.
A
A
B C
B C
Pressure switch remained closed longer
than 5 seconds after the call for
heat began.
1. Pressure switch wiring is incorrect.
2. Replace pressure switch.
Pressure switch remained open longer
than 5 seconds after the combustion
blower was energized.
1. Pressure switch wiring is incorrect.
2. Pressure switch tubing not connected
correctly.
A
A
B C
B C
3. Air intake or exhaust obstructed.
Error in the hot surface ignitor circuit.
System in lockout.
1. Check that all wiring is correct and secure.
2. Replace hot surface ignitor.
1. Gas supply is off or too low to operate.
2. Hot surface ignitor not positioned
correctly.
A
B C
3. Low voltage to the water heater.
4. Electric polarity to unit is incorrect - test
and correct.
A
A
A
B C
B C
B C
Problem in the gas valve driver circuit.
Problem with the internal circuit.
Problem with the internal circuit.
1. Turn power to the water heater off for
10 seconds and the back on.
2. Replace gas control valve.
1. Turn power to the water heater off for
10 seconds and then back on.
2. Replace gas control valve.
1. Turn power to the water heater off for
10 seconds and then back on.
2. Replace gas control valve.
A
A
B C
B C
Flame signal sensed out of
proper sequence.
1. Replace gas control valve.
ECO activated.
1. Replace gas control valve.
A
A
A
B C
B C
B C
One of the temperature adjust
buttons stuck closed.
1. Press and release each of the buttons
once.
2. Replace gas control valve.
Water temperature sensor is
either open or short circuited.
1. Check that all wiring is correct and secure.
2. Replace gas control valve.
Unit shuts down and in lockout.
1. Clean and reinstall the air intake screen.
2. Clean and reinstall the lint screen on the
Blower assembly.
A
A
B C
B C
Unit shuts down.
1. Check for correct wiring to FV sensor.
2. Check for open circuits to FV sensor.
3. Replace FV sensor.
Unit shuts down and in lockout.
29
1. FV sensor detected presence of flammable vapors.
2. Contact Sears Service Center to determine cause.
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TROUBLESHOOTING GUIDELINES
These guidelines should be utilized by a qualified service agent. When calling for service notify the service agent
that this is a “Flammable Vapor Ignition Resistant” Product.
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REPAIR PARTS LIST
THE ECONOMIZER™ 6 GAS WATER HEATER
MODEL NO’S
40 Gallon Natural Gas
153.332040
153.332050
153.332060
153.332070
50 Gallon Natural Gas
40 Gallon Propane (L.P.)
50 Gallon Propane (L.P.)
BURNERASSEMBLY
OUTER DOOR
(ALTERNATE)
1
16
Model Numbers
153.332050
Key No. Part Description
153.332040
9005938
9003385
9005950(#32)
9005951
9005958
9003400
9003401
9005959
9003445
9004316
9003406
9003447
9005962
9002402
9001584
9005966
9003972
9000071
9003414
9002846
9002847
9002848
9002850
185249-000
9005967
9005968
9005969
9003977
153.332060
9005943
9005948
9003495(#50)
9005954
9005958
9003398
9003401
9005959
9003445
9004316
9003406
9003447
9005963
9002402
9001584
9005966
9003972
9000071
9003414
9002846
9002847
9002848
9002850
185249-000
9005967
9005968
9005969
9003977
153.332070
9005944
9005948
9003495(#50)
9005955
9005958
9003398
9003401
9005959
9003445
9004316
9003406
9002547
9005963
9002402
9001584
9005966
9003891
9000071
9003414
9002846
9002847
9002848
9002850
185249-000
9005967
9005968
9005969
9003977
1
2
BurnerAssembly
Burner Head
9005939
9003385
9005950(#32)
9005952
9005958
9003400
9003401
9005959
9003445
9004316
9003406
9002547
9005962
9002402
9001584
9005966
9003891
9000071
9003414
9002846
9002847
9002848
9002850
185249-000
9005967
9005968
9005969
9003977
3
Burner Orifice
4
Burner Tube
5
6
HSI IgnitionAssembly
Inner Door
7
Inner Door Gasket
8
Flue Baffle
9
Flue Restrictor
10
11
12
13
14
15
16
17
18
19
20
BlowerAssembly
Air Intake Screen - Base Pan
Inlet Tube
Gas Control Valve
Drain Valve
Drain Valve Washer
Outer Door
Anode Rod
Temperature-Pressure Relief Valve
ViewportAssembly
20" Dia. Drain Pan w/Side Drain (optional)
22" Dia. Drain Pan w/Side Drain (optional)
24" Dia. Drain Pan w/Side Drain (optional)
28" Dia. Drain Pan w/Side Drain (optional)
Instruction Manual
*21
22
23
Air Intake Screen - BlowerAssembly
FV Sensor
24
FV Sensor Bracket
25
Nipple (cold inlet or hot outlet)
* Not shown
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE
FOLLOWING INFORMATION:
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).
•
•
•
•
MODEL NUMBER
TYPE GAS (NATURAL OR PROPANE (L.P.)
SERIAL NUMBER
Be sure to provide all pertinent facts when you call or visit.
PART DESCRIPTION
The model number of your Gas Water Heater will be found
on the rating place located above the gas control valve.
THIS ISAREPAIR PARTS LIST, NOTAPACKING LIST.
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6 YEAR LIMITED WARRANTY ON WATER HEATER
For six years from date of purchase, if this water heater is installed and operated in a single-family home in accordance with the
owner’s manual instructions and all local applicable plumbing codes, Sears will supply a free water heater for one that develops
a leak.
For the second through sixth year from purchase date, you must pay the labor cost for installation of 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 water heater installation.
1YEAR 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, ROEBUCKAND CO., Dept. 817 WA, HOFFMAN ESTATES, IL60179
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. Leaks in pipes or fittings
c. Condensation
MASTERPROTECTIONAGREEMENTS
•
Fast help by phone - phone support from a Sears technician on
products requiring in-home repair, plus convenient repair scheduling.
Congratulations on making a smart purchase. Your new Kenmore®
product is designed and manufactured for years of dependable
operation. But like all products, it may require preventive maintenance
or repair from time to time. That’s when having a Master Protection
Agreement can save you money and aggravation.
•
•
Power surge protection against electrical damage due to power
fluctuations.
Rental reimbursement if repair of your covered product takes
longer than promised.
Purchase a Master Protection Agreement now and protect yourself
from unexpected hassle and expense.
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 on-line.
The Master Protection Agreement also helps extend the life of your
new product. Here’s what’s included in the Agreement:
Sears has over 12,000 professional repair specialist, who have access
to over 4.5 million quality parts and accessories. That’s the kind of
professionalism you can count on to help prolong the life of your new
purchase for years to come. Purchase your Master Protection
Agreement today!
•
•
Expert Service by our 12,000 professional repair specialists.
Unlimited service and no charge for parts and labor on all
covered repairs.
Some limitations and exclusions apply. For prices and
additional information call 1-800-827-6655.
•
“No-lemon” guarantee - replacement of your covered product if
four or more product failures occur within twelve months.
SEARS INSTALLATION SERVICE
•
•
Product replacement if your covered product can’t be fixed.
For Sears professional installation of home appliances, garage door
openers, water heaters and other major home items, in the U.S.A., call
1-800-4-MY-HOME®.
Annual Preventive Maintenance Check at your request - no
extra charge.
For in-home major brand repair service
Call 24 hours a day, 7 days a week (U.S.A. and Canada)
1-800-4-MY-HOME®
(1-800-469-4663)
The model number of your water heater is found on the model rating plate on the front of the water heater
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
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