Kenmore THE ECONOMIZER 15333206 User Manual

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 ODORANT IS ADDED TO THE GAS USED BY THIS 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

resultar en la MUERTE O GRAVES LESIONES CORPORALES.

Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A

PRINTED IN THE U.S.A. 0308

www.se a1rs.com

PART NO. 185249-002

SAFETY PRECAUTIONS

TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE...................................................................................................................................... 2

SAFETY PRECAUTIONS................................................................................................................................................................... 3

TABLE OF CONTENTS...................................................................................................................................................................... 4

CUSTOMER RESPONSIBILITIES..................................................................................................................................................... 5

PRODUCT SPECIFICATIONS........................................................................................................................................................... 5

INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS ............................................................ 6

MATERIALS AND BASIC TOOLS NEEDED...................................................................................................................................... 7

TYPICAL INSTALLATION................................................................................................................................................................ 8-9

INSTALLATION INSTRUCTIONS ................................................................................................................................................. 9-22

Removing the Old Water Heater ................................................................................................................................................. 9

Facts to Consider About the Location ...................................................................................................................................10-11

Insulation Blankets.....................................................................................................................................................................11

Combustion Air and Ventilation for Appliances Located in Unconﬁned Spaces.........................................................................11

Combustion Air and Ventilation for Appliances Located in Conﬁned Spaces........................................................................11-12

Water Piping......................................................................................................................................................................... 13-14

Temperature-Pressure Relief Valve...................................................................................................................................... 14-15

Gas Piping................................................................................................................................................................................. 15

Sediment Traps......................................................................................................................................................................... 16

Filling the Water Heater............................................................................................................................................................. 16

Blower Assembly Installation................................................................................................................................................ 16-17

Vent Connections to Blower Assembly...................................................................................................................................... 18

Venting and Installation........................................................................................................................................................ 18-19

Condensation............................................................................................................................................................................ 18

Maximum Vent Lengths............................................................................................................................................................. 18

Venting ...................................................................................................................................................................................... 19

Vent Terminal Installation ..................................................................................................................................................... 19-20

Vertical Vent Through Roof ....................................................................................................................................................... 20

Vertical Vent Restrictions........................................................................................................................................................... 20

Vent Pipe Preparation .......................................................................................................................................................... 21-22

OPERATING INSTRUCTIONS.................................................................................................................................................... 23-24

Lighting and Operating Label.................................................................................................................................................... 23

Temperature Regulation............................................................................................................................................................ 24

FOR YOUR INFORMATION............................................................................................................................................................. 25

Start Up Conditions................................................................................................................................................................... 25

Operational Conditions.............................................................................................................................................................. 26

SERVICE AND ADJUSTMENT ................................................................................................................................................... 26-28

Venting System Inspection........................................................................................................................................................ 26

Burner Operation and Inspection ......................................................................................................................................... 26-27

Burner Cleaning ........................................................................................................................................................................ 27

Housekeeping ........................................................................................................................................................................... 27

Anode Rod Inspection............................................................................................................................................................... 27

Temperature-Pressure Relief Valve Operation..................................................................................................................... 27-28

Draining..................................................................................................................................................................................... 28

Drain Valve Washer Replacement............................................................................................................................................. 28

Service ...................................................................................................................................................................................... 28

LEAKAGE CHECKPOINTS.............................................................................................................................................................. 29

TROUBLESHOOTING GUIDELINES.......................................................................................................................................... 30-32

PARTS ORDER LIST ....................................................................................................................................................................... 33

WARRANTY..................................................................................................................................................................................... 36

CUSTOMER RESPONSIBILITIES

Thank You for purchasing a Kenmore water heater. Properly installed

2. The installation must conform with these instructions and the local code

authority having jurisdiction. In the absence of local codes, installations

shall comply with the National Fuel Gas Code ANSI Z223.1/NFPA

54 and the National Electrical Code, NFPA 70. These publications

are available from The National Fire Protection Association, 1

Batterymarch Park, Quincy, MA 02269.

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.

Abbreviations Found In This Instruction Manual:

• CSA - Canadian Standards Association

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 NFPA 70.

• ANSI - American National Standards Institute

• NFPA - National Fire Protection Association

• ASME - American Society of Mechanical Engineers

• GAMA - Gas Appliance Manufacturer’s Association

• 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.

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).

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.

PREPARING FOR THE INSTALLATION

Examine the location to ensure the water heater complies with the

“Facts to Consider About 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,

SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.

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 State Architect, 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 INSTALL OR OPERATE 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. For more information see next page.

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

PER HOUR

NUMBER

(Btu/hr)

40,000

@ 90°F RISE

(mm)

153.332040

153.332050

153.332060

153.332070

40 (151)

50 (189)

40 (151)

50 (189)

NATURAL

PROPANE

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)

INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS

For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed

in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by

the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above ﬁnished grade in the

area of the venting, including but not limited to decks and porches, the following requirements shall be satisﬁed:

INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas

fueled equipment, the installing plumber or gasﬁtter shall observe that a hard wired carbon monoxide detector with an alarm

and battery back-up is installed on the ﬂoor level where the gas equipment is to be installed. In addition, the installing plumber

or gasﬁtter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each

additional level of the dwelling, building or structure served by the sidewall horizontal vented gas fueled equipment. It shall

be the responsibility of the property owner to secure the services of qualiﬁed licensed professionals for the installation of hard

wired carbon monoxide detectors.

In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired

carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent ﬂoor level.

In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall

have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a bat-

tery operated carbon monoxide detector with an alarm shall be installed.

APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above

provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and CSA certiﬁed.

SIGNAGE Ametal or plastic identiﬁcation plate shall be permanently mounted to the exterior of the building at a minimum height

of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appli-

ance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW.

KEEP CLEAR OF ALL OBSTRUCTIONS.”

INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the

installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance

with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54

as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the

dwelling, building, or structure used in whole or in part for residential purposes.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product

Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with

the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall

include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of

a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the ﬂue gases,

but identiﬁes “special venting systems,” the following requirements shall be satisﬁed by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation

instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a

parts list and detailed installation instructions.

A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting

instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or

equipment at the completion of the installation.

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

EXPANSION TANKS FOR

THERMAL EXPANSION

CONDITIONS AVAILABLE

IN 2 GALLONS

20” (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

TIN SNIPS

PHILLIPS SCREWDRIVER

ROLL OF

HACKSAW

EMERY CLOTH

PIPE DOPE

(SQUEEZE TUBE)

USE FOR WATER AND GAS

CONNECTIONS

ROLL OF TEFLON

TAPE (USE ONLY ON

WATER CONNECTIONS)

3/4” (19 mm) WIRE BRUSH

ROLL OF LEAD-FREE

SOFT SOLDER

SOLDER

FLUX

6 FOOT TAPE

GARDEN HOSE

PIPE WRENCH

1/2” (13 mm) WIRE BRUSH

TYPICAL INSTALLATION

GET TO KNOW YOUR WATER HEATER - GAS MODELS

Vent Pipe–Exhaust

Vent Terminal

Hot Water Outlet

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

Air Intake Screen - Base Pan

AA Inner Door

B B Outer Door

CC HSI Burner Assembly

D D Air Intake Screen -

Blower Assembly

Inlet Dip Tube

Anode**

E E 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

SENSOR

PROPANE HOT SURFACE IGNITER & MAIN BURNER

HOT

SURFACE

IGNITOR

SENSOR

TEMPERATURE INDICATORS

*CAUTION: 115 VAC IN CONTROL HARNESS

AND INSIDE OUTER DOOR

TEMPERATURE ADJUSTMENT BUTTONS

GAS MODELS

WITH HOT SURFACE IGNITION

& 2”, 3” OR 4” PVC VENT CAPABILITY

FIGURE 1.

INSTALLATION INSTRUCTIONS

4. Attach a hose to the water heater drain

valve and put the other end in a ﬂoor

Removing the Old Water Heater

drain or outdoors. Open the water

heater drain valve. Open a nearby hot

water faucet which will relieve pressure

in the water heater and speed draining.

The water passing out of the drain valve

may be extremely hot. To avoid being

scalded, make sure all connections are

tight and that the water ﬂow is directed

away from any person, see Figures 2

and 5.

FIGURE 5.

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.

FIGURE 2.

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.

FIGURE 6.

If you have galvanized pipes to the water heater, loosen the two

galvanized pipes with a pipe wrench at the union in each line. Also

disconnect the piping remaining to the water heater, see Figure 7.

These pieces should be saved since they may be needed when

reconnecting the new water heater. Disconnect the temperature-

pressure relief valve drain line. When the water heater is drained,

disconnect the hose from the drain valve. Close the drain valve.

The water heater is now completely disconnected and ready to be

removed. Mineral buildup or sediment may have accumulated in the

old water heater. This causes the water heater to be much heavier

than normal and this residue, if spilled out, could cause staining.

FIGURE 3.

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.

FIGURE 4.

3. Check again to make sure the gas supply is “OFF” to the water heater.

Then disconnect the gas supply connection from the gas control

valve.

FIGURE 7.

FACTS TO CONSIDER ABOUT 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

occupants in the building and for the most economical use of the

appliance. This water heater is not for use in manufactured (mobile)

homes or outdoor installation.

FIGURE 8.

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

must be protected by metal or wood panel beneath the appliance

extending beyond the full width and depth of the appliance by at least

3” (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.

INSTALLATIONS INAREAS WHERE FLAMMABLE LIQUIDS (VAPORS)

ARE LIKELY TO BE PRESENT OR STORED (GARAGES, STORAGE

AND UTILITY AREAS, ETC.): Flammable liquids (such as gasoline,

solvents, propane (LP or butane, etc.) and other substances (such as

adhesives, etc.) emit ﬂammable vapors which can be ignited by a gas

water heater’s 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

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.

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.

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.

FIGURE 9.

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.

COMBUSTION AIR AND VENTILATION FOR APPLIANCES

LOCATED IN UNCONFINED SPACES

UNCONFINED SPACE is space whose volume is not less than

50 cubic feet per 1,000 Btu per hour (4.8 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

for Appliances Located in Conﬁned Spaces.”

FIGURE 10.

COMBUSTION AIR AND 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 ﬂammable

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.

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.

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.

A. ALL AIR 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.

FIGURE 14.

FIGURE 11.

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.

FIGURE 14A.

5. Alternatively a single permanent opening may be used when

communicating directly with the outdoors, or with spaces that freely

communicate with the outdoors. The opening shall have a minimum

free area of 1 square inch per 3,000 BTU per hour (8.3 cm²/kW) of

total input rating of all equipment in the enclosure. See Figure 14A.

6. 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.

FIGURE 12.

7. 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.

FIGURE 13.

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.

WATER PIPING

Toxic chemicals, such as those used for boiler treatment shall not be

introduced into this system.

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, should 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.

FIGURE 15.

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.

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 for Hot Water Supply

Systems, ANSI Z21.22 • CSA 4.4, and the code requirements of ASME.

If replaced, the valve must meet the requirements of local codes, but not

less than a combination temperature and pressure relief valve certiﬁed

as indicated in the above paragraph.

The valve must be marked with a maximum set pressure not to

exceed the marked hydrostatic working pressure of 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.

FIGURE 16.

For safe operation of the water heater, the relief valve must not be removed

from its designated opening nor plugged.

T & P Valve and Pipe Insulation (if supplied)

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.

Remove insulation for T & P valve and pipe connections from carton.

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.

FIGURE 17.

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.

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.

• 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.

A gas line of sufﬁcient size must be run to the water heater. Consult the

current edition of National Fuel Gas Code ANSI Z223.1/NFPA 54 and

your gas supplier concerning pipe size.

There must be:

• Shall not have any valve between the relief valve and tank.

• Areadily accessible manual shut off valve in the gas supply line serving

the water heater, and

• Adrip leg (sediment trap) ahead of the gas control valve to help prevent

dirt and foreign materials from entering the gas control valve.

• A ﬂexible gas connector or a ground joint union between the shut off

valve and control valve to permit servicing of the unit.

Be sure to check all the gas piping for leaks before lighting the water

heater. Use a soapy water solution, not a match or open ﬂame. Rinse

off soapy solution and wipe dry.

The 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.

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 Code ANSI Z223.1/NFPA 54. Contact your local

gas supplier for further information.

GAS PIPING

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

National Fuel Gas Code (ANSI Z223.1/ NFPA-54) whichever applies.

Copper and brass tubing and ﬁttings (except tin lined copper tubing)

shall not be used.

Use pipe joint compound or teﬂon tape marked as being resistant to the

action of petroleum [Propane (L.P.)] gases.

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.

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).

Connecting the gas piping to the gas control valve of the water heater

can be accomplished by either of the two methods shown in Figures

18 and 19.

FIGURE 18. GAS PIPING WITH

FLEXIBLE CONNECTOR.

FIGURE 20.

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/NFPA 54.

BLOWER ASSEMBLY INSTALLATION

SEQUENCE OF INSTALLATION

1. This power vented water heater comes with the blower assembly

installed.

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.

Asediment 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.

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. If the outer harness is not factory installed, make sure the ON/OFF

switch 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.

pipe is NOT ALLOWED. 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. That

length can be the minimum length required for the connection.

VENT CONNECTIONS TO BLOWER ASSEMBLY

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.

FIGURE 21.

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 Schedule 40 DWV 45° Vent Terminal must be used. For

your convenience, we have included a screen for both 3” and 4” Vent

Terminals.

VENTING AND 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 NOT connect 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 Deﬂection Temperature” (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, but not limited to ambient temperature and humidity of

installation 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). If you have condensate, then a 3/8” drain

hose can be connected 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.

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 3” Venting, the maximum equivalent feet of pipe allowed is

120 feet (36.6 m). This does not include the Vent Termination (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.

For 4” Venting, the maximum equivalent feet of pipe allowed is

160 feet (48.8 m). This does not include the Vent Termination (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.

Except where instructed in this manual, the mixing of 2”, 3” and 4” vent

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 TERMINAL INSTALLATIONS, 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 WIRING AND PIPING INSIDE

OF WALL.

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) WOODEN SIDE WALLS

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/NFPA 54, 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. In cold climates, it is recommended that vent termination not be

mounted directly above or within 3 feet (91 cm) horizontally from an oil

tank vent or gas meter to avoid potential freeze-up from condensation,

see Figure 23.

FIGURE 22.

Plan the vent system layout so that proper clearances are maintained

from plumbing and wiring.

FIGURE 23.

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

INSTALLATION AND MAXIMUM VENT LENGTHS, page 17.

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.

FIGURE 24.

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. Aproper ﬂashing or “BOOT” should

be used to seal the pipe where it exits the roof.

FIGURE 25.

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.).

The total vent system should not exceed that which is speciﬁed, see

VENTING AND INSTALLATION, page 17.

3. 3’ (0.9 m) above any forced air inlet located within 10’ (3.0 m).

All of the pipe should be secured as per the instructions in the instructions

in the VENTING AND INSTALLATION, page 17.

solvated with tetrahydrofuran (THF). Small quantities of dimethyl

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 or ABS cement to join PVC or CPVC pipe and

ﬁttings.

VENT PIPE PREPARATION

1. INITIAL PREPARATION

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: A dauber 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 CEMENT APPLICATIONS

2. SELECTION OF MATERIALS

Nominal Pipe

Size Brush Width

(INS.)

(IPS)

•

Cutting Device - Saw or Pipe Cutter

Deburring Tool, Knife, File, or Beveling Machine (2” and above)

Brush - Pure Bristle

1-1/2

1-1/2 - 2-1/2

*USE ONLY NATURAL BRISTLE

3. MAKING THE JOINT

A. Cutting

Rag - Cotton (Not Synthetic)

Primer and Cleaner

Solvent Cement - PVC for PVC Components and CPVC for CPVC

Components

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.

•

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.

A chemical 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

STEP A

B. Deburring

Use a knife, plastic pipe deburring tool, or ﬁle to remove burrs from

the end of small diameter pipe. Be sure to remove all burrs from

around the inside as well as the outside of the pipe. A slight chamfer

(bevel) of about 10°-15° should be added to the end to permit easier

insertion of the pipe into the end of the ﬁtting. Failure to chamfer the

edge of the pipe may remove cement from the ﬁtting socket, causing

the joint to leak.

STEP E

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. A good 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.

STEP B

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.

STEP F

Depth-of-entry

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

• Apply the solvent cement evenly and quickly around the outside

of the 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.

STEP G

OPERATING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING: If you do not follow these instructions exactly, a fire or

explosion may result causing property damage, personal injury

or loss of life.

FLAMMABLE

BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.

This appliance does not have a pilot. It is equipped with

an ignitiion device which automatically lights the

burner. Do not try to light the burner by hand.

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.

If you cannot reach your gas supplier, call the

fire department.

Use only your hand to push in the gas control but-

tons. Never use tools. If the control buttons will not

push in, don't try to repair them, call a qualified ser-

vice technician. Force or attempted repair may

result in a fire or explosion.

WHAT TO DO IF YOU SMELL GAS:

Do not try to light any appliance.

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 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

This appliance is equipped with a device

which automatically lights the burner.

DO NOT TRY TO LIGHT THE BURNER BY HAND.

VACATION

VERY

HOT

WARM

Wait five (5) minutes to

If you then smell gas,

clear out any gas.

STOP! Follow "B" in

COOLER

HOTTER

the safety information above on this label. If you

don't smell gas, go to the next step.

Turn on all electrical power to the appliance.

--------------

----------------------- ---------------------- ------------------------------

8. Set the ON/OFF switch on the control box to the

------------------------------------------------------

* -----------------------------------------------------------------------

* ----------------------------------------------------------

--------------------------------------------------------------------------------------

* ------------------------------------------------------------------------

-----------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------

--------------------------------------------------------

"ON" postition.

Set the thermostat to the desired setting by first

pressing the COOLER

and HOTTER

but-

tons together and holding for 1 second. Then press

the HOTTER button

10.WATER TEMPERATURE ADJUSTMENT is

STOP! Read the safety information above

on this label.

approximately 120^oF.

CAUTION: Hotter water increases the risk of

scald injury. Consult the instruction

manual before changing temperature.

If the appliance will not operate, follow the instruc-

tions "TO TURN OFF GAS TO APPLIANCE" and

call your technician or gas supplier.

Set the ON/OFF switch on the control box to the

"ON" position.

Set the thermostat to the lowest setting by first

pressing the COOLER

and HOTTER

but-

11.

tons together and holding for 1 second. Then press

the COOLER button

light appears.

until the Warm indicator

WARNING: TURN OFF ALL ELECTRIC

POWER BEFORE SERVICING.

Set the ON/OFF switch on the control box to the

"OFF" position.

TO TURN OFF GAS TO APPLIANCE

Set the thermostat to the lowest setting by first

pressing the COOLER and HOTTER but-

2. Set the ON/OFF switch on the control box to the

"OFF" postition.

Turn off all electrical power to the appliance if

service is to be performed.

tons together and holding for 1 second. Then press

the COOLER button

light appears.

until the Warm indicator

1. “Wake Up” the temperature indicators by holding down both “COOLER”

and “HOTTER” temperature adjustment buttons at the same time

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.

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.

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.

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.

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, should be used at the hot

water taps used by these people or at the water heater. Mixing valves

are available at plumbing supply or hardware stores, see Figure 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.

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.

The water heater should be located in an area where the general public

does not have access.

Time to Produce

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.

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

- - - - - - - - - - - - -

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.

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)

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:

WARM = approx. 80°F (27°C)

FIGURE 26.

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. A water 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

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.

Expansion

Tank

50psi

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

70psi

80psi

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.

THERMAL EXPANSION

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.

FIGURE 27.

STRANGE SOUNDS

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

SMELLY WATER

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.

HIGH WATER TEMPERATURE SHUT OFF SYSTEM

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.

Do not remove the anode leaving the tank unprotected. By doing

so, all warranty on the water heater tank is voided.

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 OPERATION AND INSPECTION

Flood damage to a water heater may not be readily visible or immediately

detectable. However, over a period of time a ﬂooded water heater will

create dangerous conditions which can cause DEATH, SERIOUS

BODILY INJURY, OR PROPERTY DAMAGE. Contact Sears Service

Center to replace a ﬂooded water heater. Do not attempt to repair the

unit! It must be replaced!

At least once a year a visual inspection should be made of the venting

system. You should look for:

1. Obstructions which could cause improper venting. The combustion

and ventilation air ﬂow must not be obstructed.

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 the Air 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.

FIGURE 29.

AT LEAST ONCE EVERY SIX MONTHS A VISUAL INSPECTION

SHOULD BE MADE OF THE AIR INTAKE SCREENS ON THE BASE

OF THE WATER HEATER AND THE BLOWER ASSEMBLY. 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.

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.

INSTALLED IN SUITABLE AREA: To insure sufﬁcient ventilation and

combustion air supply, proper clearances from the water heater must

be maintained. See “Facts to Consider About the Location” section.

Combustible materials such as clothing, cleaning materials, or ﬂammable

liquids, etc. must not be placed against or adjacent to the water heater

which can cause a ﬁre.

ANODE ROD INSPECTION

FIGURE 28.

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

Vacuum around base of water heater for dust, dirt, and lint on a regular basis.

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 plastic Air 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 the Air 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.

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

If the temperature-pressure relief valve on the appliance weeps or

discharges periodically, this may be due to thermal expansion. You

may have a check valve installed in the water line or a water meter

with a check valve. Consult your local water supplier or Sears Service

Center for further information. 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.

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).

4. Connect a hose to the drain valve and terminate to an adequate

drain.

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

Blower Assembly).

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.

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.

LED STATUS

PROBLEM

SOLUTION

1 Ensure the wall outlet (power supply) is properly

grounded.

The gas control valve has sensed

inadequate or no earth ground.

2 Ensure all ground connections/wires on the water

heater are securely connected.

1 Ensure the wall outlet/power supply is properly wired.

The gas control valve has sensed

reversed polarity in the 120 VAC

power supply.

2 Ensure all internal 120 VAC wiring connections and

wiring harness have no reversed wires. 120 VAC "hot"

wire must connect to the on/off switch.

Pressure switch circuit remaining

closed for more than 5 seconds

after heating cycle begins.

1 Ensure air pressure switch circuit wiring is correct and

the air pressure switch is not jumpered.

Blower may not start in this

condition.

2 Replace the air pressure switch.

1 Ensure the air pressure switch sensing tube is properly

connected at both ends and is not kinked or damaged.

2 Ensure the correct size of vent and intake air pipe (direct

vent products) was used per the installation instructions

in the manual that came with the water heater.

Pressure switch circuit remains

open longer than 5 seconds after

the blower is energized.

3 Ensure maximum number of elbows or maximum

equivalent feet of vent or intake air pipe has not been

exceeded per the installation instructions in the manual

that came with the water heater.

Blower may run continuously in

this condition.

4 Ensure there are no obstructions in the vent or intake

air pipe.

1 Check wiring to the hot surface igniter assembly -

replace igniter assembly if wiring is damaged or worn.

2 Check resistance of the igniter at igniter assembly plug

- should be between 11 and 18 ohms - replace igniter if

open or shorted.

The gas control valve has detected

an open igniter circuit.

3 Check igniter assembly plug and the socket on the

bottom of the gas control valve for good connection.

4 Replace igniter assembly if the plug is worn or

damaged.

5 Replace the gas control valve if the igniter assembly

socket on the bottom of the control is worn or damaged.

1 Gas supply is turned off - pressure is too low.

Ignition/ﬂame failure.

2 Ensure the ﬂame sensor is clean - use ﬁne steel wool

to clean the ﬂame sensor.

The gas control valve has reached

the maximum number or retries (3)

for ignition and is currently locked

out for one hour.

3 Manifold gas pressure to the burner is too low.

4 Check igniter assembly plug and the socket on the bottom

of the gas control valve for good connection. Replace

igniter assembly if the plug is worn or damaged replace

the gas control valve if socket is worn or damaged.

Cycle the power to the water heater

off and on to reset.

5 Replace igniter assembly.

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.

LED STATUS

PROBLEM

SOLUTION

1 Turn the power off for 10-20 seconds then on again to

clear these error codes.

The gas control valve has detected

a problem with the gas valve driver

circuit, internal microprocessor, or

other internal circuits.

2 If any of these error codes persist or cannot be cleared

- replace the gas control valve.

1 Turn the power off for 10-20 seconds then on again to

clear these error codes.

The gas control valve has sensed

main burner ﬂame out of proper

sequence.

2 Replace the gas control valve if this error code persists.

The gas control valve has detected

excessive water temperature in the

tank and has activated the ECO

(energy cut off) high temperature

limit.

1 Turn the power off for 10-20 seconds then on again to

clear these error codes.

2 Replace the gas control valve if the error code persists.

1 Press and release both temperature adjust buttons

several times - cycle water heater power off and on.

The gas control valve has detected

that one or both of the temperature

adjust buttons are stuck.

2 Replace the gas control valve if the error code persists.

The gas control valve has detected

the water temperature sensor

(located in the control valve's

immersion probe) is either open or

shorted.

1 Turn the power off for 10-20 seconds then on again to

clear these error codes.

2 Replace the gas control valve if the error code persists.

1 Ensure all FV sensor wiring is correct and the igniter

assembly plug and socket connections on the bottom

of the gas control valve are making good contact.

The gas control valve has detected

the FV (ﬂammable vapor) sensor is

either open or shorted.

2 Replace the FV sensor.

1 Do not touch any electrical switch, do not use any

phone in your building, and do not try to light any

appliance.

2 Smell around the water heater to ensure there are no

gas leaks at the gas control valve, in the supply gas

line(s), or any other type of ﬂammable vapor(s) in the

area.

The gas control valve has detected

the presence of ﬂammable vapors

from the FV (ﬂammable vapor)

sensor.

3 Carefully inspect the area surrounding the water heater

for any substances such as gasoline, paint, paint

thinners, varnish, or cleaners that could emit ﬂammable

vapors. Remove anything that can potentially emit

ﬂammable vapors from the area and store it properly in

a different location.

4 Call the technical information support phone number

shown on the water heater labeling for further

assistance.

1 On models equipped with a dilution air intake screen on

the blower assembly - check/clean this screen.

The gas control valve has detected

the air pressure switch circuit is

opening repeatedly during one

heating cycle.

2 On models equipped with a combustion air intake

screen on the base ring (bottom) of the water heater -

check/clean the screen.

LDO (Lint, Dust, and Oil) lockout

condition.

3 Ensure intake air screen(s) on models so equipped are

not obstructed.

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.

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.)

BURNER ASSEMBLY

OUTER DOOR

(ALTERNATE)

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

185249-002

9005967

9005968

9005969

9003977

185110-000

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

185249-002

9005967

9005968

9005969

9003977

185110-000

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

185249-002

9005967

9005968

9005969

9003977

185110-000

Burner Assembly

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

185249-002

9005967

9005968

9005969

9003977

185110-000

Burner Oriﬁce

Burner Tube

HSI Ignition Assembly

Inner Door

Inner Door Gasket

Flue Bafﬂe

Flue Restrictor

Blower Assembly

Air Intake Screen - Base Pan

Inlet Tube

Gas Control Valve

Drain Valve

Drain Valve Washer

Outer Door

Anode Rod

Temperature-Pressure Relief Valve

Viewport Assembly

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

Air Intake Screen - Blower Assembly

FV Sensor

FV Sensor Bracket

Nipple (cold inlet or hot outlet)

Blower Assembly Pressure Switch

* Not shown

Now that you have purchased your gas water heater, should

a need ever exist for repair parts or service, simply contact

any Sears Service Center or call 1-800-4-MY-HOME®

(1-800-469-4663).

WHEN ORDERING REPAIR PARTS,ALWAYS GIVE THE FOLLOWING

INFORMATION:

•

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 IS A REPAIR PARTS LIST, NOT A PACKING LIST.

NOTES:

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.

1 YEAR EXCLUSIVE KENMORE LABOR WARRANTY

For the ﬁrst year from the date of purchase, Sears will, free of charge, supply and install new water heater parts for defective ones

or a new water heater for one that develops a leak.

WARRANTY SERVICE

To obtain warranty service, call 1-800-4-MY-HOME^®(1-800-469-4663). This warranty applies only while this product is in use in the

United States.

This warranty gives you speciﬁc legal rights and you may also have other rights which vary from state to state.

SEARS, ROEBUCK AND CO., Dept. 817 WA, HOFFMAN ESTATES, IL 60179

The price of your water heater does not include a free checkup service call. On water heater installations arranged by Sears, Sears warrants

the installation.

A charge will be made on service calls due to poor or incomplete installation. These include:

a. Adjusting thermostat

b. Leaks in pipes or ﬁttings

c. Condensation

MASTER PROTECTION AGREEMENTS

•

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 ProtectionAgreement 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 ProtectionAgreement 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 ProtectionAgreement

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.

•

Product replacement if your covered product can’t be ﬁxed.

SEARS INSTALLATION SERVICE

Annual Preventive Maintenance Check at your request - no extra

charge.

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^®.

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)

www.sears.com

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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