Owner’s Manual
POWER MISER™ 6
GAS WATER HEATER
FOR POTABLE WATER HEATING ONLY.
NOT SUITABLE FOR SPACE HEATING.
NOT FOR USE IN MOBILE HOMES.
MODEL NO.
153.336162
153.336262
153.336362
153.336466
153.336566
153.336762
153.336862
153.336962
30 Gallon Short
40 Gallon Short
30 Gallon
40 Gallon
50 Gallon
30 Gallon Propane (L.P.)
40 Gallon Propane (L.P.)
50 Gallon Propane (L.P.)
• Safety Instructions
• Installation
• Operation
• Care and Maintenance
• Troubleshooting
• Parts List
For Your Safety
AN ODORANTISADDEDTOTHE GAS USED BYTHIS WATER HEATER.
C3 Technology® Gas Water Heaters meet
the new ANSI Z21.10.1 standard that deals
with the accidental or unintended ignition
of flammable vapors, such as those
emitted by gasoline.
ADVERTENCIA
Si no puede leer o entender el inglés y necesita el manual instructivo
y/o etiquetas en español puede obtenerlos llamando al
1-800-821-2017. NO TRATE DE INSTALAR O OPERAR ESTE
CALENTADOR DEAGUAsi no entiende la información en las etiquetas
o en el manual instructivo. No hacer caso de esta advertencia podría
resultarenlaMUERTEOGRAVESLESIONESCORPORALES.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A
PRINTED IN THE U.S.A 0705
PART NO. 184231-001
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SAFETY PRECAUTIONS
3
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TABLE OF CONTENTS
SAFE INSTALLATION, USEAND SERVICE ................................................................................................. 2
SAFETY PRECAUTIONS.............................................................................................................................. 3
TABLE OF CONTENTS ................................................................................................................................ 4
CUSTOMER RESPONSIBILITIES ................................................................................................................ 5
PRODUCT SPECIFICATIONS...................................................................................................................... 5
MATERIALS AND BASIC TOOLS NEEDED ................................................................................................. 6
Material Needed ...................................................................................................................................................... 6
Basic Tools ............................................................................................................................................................. 6
TYPICAL INSTALLATION............................................................................................................................... 7
INSTALLATION INSTRUCTIONS...............................................................................................................8-16
Removing the Old Water Heater .............................................................................................................................. 8
Facts to Consider About the Location ................................................................................................................ 9-10
Insulation Jackets ................................................................................................................................................. 10
CombustionAir and VentilationAppliances
in Unconfined Spaces............................................................................................................................................ 10
CombustionAir and VentilationAppliances
in Confined Spaces ...........................................................................................................................................11-12
Water Piping .................................................................................................................................................... 12-13
Temperature Pressure Relief Valve.................................................................................................................... 13-14
Filling the Water Heater......................................................................................................................................... 14
Venting ............................................................................................................................................................. 14-15
Gas Piping ....................................................................................................................................................... 15-16
Sediment Trap .................................................................................................................................................. 16-17
OPERATING INSTRUCTIONS ................................................................................................................ 18-19
Lighting & Operating Label .................................................................................................................................... 18
Temperature Regulation ......................................................................................................................................... 19
SERVICE AND ADJUSTMENT ............................................................................................................... 20-22
Tank (Sediment) Cleaning ...................................................................................................................................... 20
Venting System Inspection .................................................................................................................................... 20
Burner Inspection .................................................................................................................................................. 20
Burner Cleaning ..................................................................................................................................................... 20
Housekeeping .................................................................................................................................................. 20-21
Anode Rod Inspection ........................................................................................................................................... 21
Temperature-Pressure Relief Valve Operation ........................................................................................................ 21
Draining ............................................................................................................................................................ 21-22
Drain Valve Washer Replacement.......................................................................................................................... 22
Service .................................................................................................................................................................. 22
TROUBLESHOOTING GUIDE ................................................................................................................ 23-26
Start Up Conditions .............................................................................................................................................................23-25
Thermal Expansion........................................................................................................................................... 23
Strange Sounds ............................................................................................................................................... 23
Draft Hood Operation ................................................................................................................................... 23-24
Condensation ................................................................................................................................................... 24
Smoke/Odor ..................................................................................................................................................... 24
Operational Conditions ..................................................................................................................................... 24-25
Smelly Odor ..................................................................................................................................................... 24
Air in Hot Water Faucets.................................................................................................................................. 25
HighTemperature Shut-Off System .................................................................................................................. 24
Leakage Checkpoints ....................................................................................................................................... 25
Troubleshooting Items ........................................................................................................................................... 26
NOTES.................................................................................................................................................... 27-28
PARTS ORDER LIST ............................................................................................................................. 29-31
WARRANTY ................................................................................................................................................ 32
4
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CUSTOMER RESPONSIBILITIES
•
The installation must conform with these instructions and
the local code authority having jurisdiction. In the absence of
local codes, installations shall comply with the following:
Thank You for purchasing a Kenmore water heater. Properly
installed and maintained, it should give you years of trouble
free service. If you should decide that you want the new water
heater professionally installed by Sears call 1-800-4-MY-HOME®.
They will arrange for prompt, quality installation by Sears
authorized contractors.
In the United States: The National Fuel Gas Code ANSI
Z223.1/NFPA 54. This publication is available from the
Canadian Standards Association, 8501 East Pleasant Valley
Rd, Cleveland Ohio 44131, or The National Fire Protection
Association, 1 Batterymarch Park, Quincy, MA 02269.
Abbreviations Found In This Instruction Manual:
•
•
•
•
•
CSA - Canadian Standards Association
•
•
If after reading this manual you have any questions or do not
understand any portion of the instructions, call the Sears
Service Center.
ANSI - American National Standards Institute
NFPA - National Fire Protection Association
ASME - American Society of Mechanical Engineers
GAMA - Gas Appliance Manufacturers Association
Carefully plan the place where you are going to put the water
heater. Correct combustion, vent action, and vent pipe
installation are very important in preventing death from
possible carbon monoxide poisoning and fires. See
figure 1.
•
This gas-fired water heater is design certified by CSA
INTERNATIONAL under American National Standard/CSA
Standard for Gas Water Heaters ANSI Z21.10.1 • CSA 4.1
(current edition).
Examine the location to ensure the water heater complies
with the Facts to Consider About the Location section in this
manual.
•
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.
•
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 your local
dealer, wholesaler, public utilities or 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 through out the manual that you must
read and be aware of. All warnings and all instructions are
essential to the proper operation of the water heater and
your safety. Since we cannot put everything on the first few
pages, READ THE ENTIRE MANUALBEFOREATTEMPTING
TO INSTALLOR OPERATE THE WATER HEATER.
•
•
Massachusetts Code requires this water heater to be
installed in accordance with Massachusetts 248-CMR 2.00:
State Plumbing Code and 248-CMR 5.00.
Complies with SCAQMD rule #1121 and districts having
equivalent NOx requirements.
PRODUCT SPECIFICATIONS
RECOVERY
MINIMUM
DIMENSIONS
TANK
CAPACITY
IN GALS (LTRS)
TYPE
O F
GAS
INPUT RATE GALS.
VENT PIPE
INCHES
(mm)
DIAMETER IN INCHES (mm)
MODEL
NUMBER
RATE
PER HOUR
INCHES
(mm)
HEIGHT TO
JACKET TOP
(Btu/hr) @ 90°F RISE
153.336162
153.336262
153.336362
153.336466
153.336566
153.336762
153.336862
153.336962
30 (114)
40 (151)
30 (114)
40 (151)
50 (189)
30 (114)
40 (151)
50 (189)
NATURAL
NATURAL
NATURAL
NATURAL
NATURAL
PROPANE
PROPANE
PROPANE
32,000
35,500
35,500
35,500
35,500
35,500
35,500
35,500
30.6
35.4
34.9
35.4
35.4
34.9
35.4
35.4
3" (76) or 4" (102) 18 1/2" (470)
43 3/4" (1,111)
47 1/4" (1,200)
57 1/2” (1,461)
55 1/2" (1,410)
56 1/2” (1,435)
57 1/2” (1,461)
55 1/2” (1,410)
56 1/2” (1,435)
3" (76) or 4" (102)
3” (76)
20" (508)
16” (406)
3" (76)
18 1/2" (470)
20" (508)
3" (76)
3" (76)
16" (406)
3" (76)
18 1/2" (470)
20" (508)
3" (76)
5
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MATERIALS AND BASIC TOOLS NEEDED
Materials Needed
To simplify the installation Sears has available the installation parts shown below. You may or may not need all of these materials,
depending on your type of installation.
DRAIN PANS AVAILABLE IN 20”
EXPANSION TANKS FOR
THERMAL EXPANSION
CONDITIONS AVAILABLE
IN 2 GALLONS
(508 mm) DIAMETER FOR
WATER HEATERS HAVING A
DIAMETER 18” (457 mm) OR
LESS, 24” (610mm) DIAMETER
FOR WATER HEATERS HAVING
A DIAMETER 22” (559 mm) OR
LESS AND AVAILABLE IN 28”
(711 mm) DIAMETER FOR
WATER HEATERS HAVING A
DIAMETER 26” (660 mm) OR
LESS.
(7.6 LITERS) AND
5 GALLONS (18.9 LITERS)
CAPACITY HROUGH
LOCAL SEARS STORE OR
SERVICE CENTER.
WATER HEATER INSTALLATION KIT WITH
FLEXIBLE CONNECTORS FOR 3/4”
(19.05 mm) OR 1/2” (12.7 mm) THREADED OR
COPPER PLUMBING AND FLEXIBLE WATER
HEATER GAS CONNECTOR WITH FITTINGS.
Basic Tools
Additional Tools Needed
When Sweat Soldering
You may or may not need all these tools, depending on your
type of installation. These tools can be purchased at your local
Sears Store.
• Tubing Cutters or Hacksaw
• Propane Tank
• Soft Solder
• Solder Flux
• Emery Cloth
• Pipe Wrenches (2) 14” (356 mm)
• Screwdriver
• Tin Snips
• 6’ (1.82 m) Tape or Folding Ruler
• Garden Hose
• Wire Brushes
• Drill
• Pipe Dope or Teflon Tape
DRILL
PROPANE
TORCH
TUBING CUTTER
SLOT-HEAD SCREWDRIVER
PHILLIPS SCREWDRIVER
TIN SNIPS
ROLL OF
EMERY CLOTH
HACKSAW
PIPE DOPE
(SQUEEZE TUBE)
USE FOR WATER AND GAS
CONNECTIONS
ROLL OF TEFLON
TAPE (USE ONLY ON
WATER CONNECTIONS)
3/4” (19 mm) WIRE BRUSH
ROLL OF LEAD-FREE
SOFT SOLDER
SOLDER
FLUX
6 FOOT TAPE
GARDEN HOSE
PIPE WRENCH
1/2” (13 mm) WIRE BRUSH
6
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TYPICAL INSTALLATION
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A
B
C
D
E
F
G
H
I
Vent Pipe
Draft Hood
Anode
Hot Water Outlet
Outlet
Flexible Water Connections
Gas Supply
Manual Gas Shut-off Valve
Ground Joint Union
J
K
L
M
N
O
P
Drip Leg (Sediment Trap)
Inner Door
Outer door
S
T
U
V
W
X
Y
Flue Baffle
Thermostat
Drain Valve
Pilot and Main Burner
Flue
Drain Pan
Thermostat Shield (optional)
Piezo Igniter
Union
Inlet Water Shut-off Valve
Cold Water Inlet
Inlet Dip Tube
Temperature-Pressure Relief Valve
Rating Plate
Q
R
Z
AA Air Intake Screen
(T) THERMOSTAT
TO VENT TERMINATION
ON ROOF
Y
THERMOSTAT
COVER
(V) PILOT & MAIN BURNER
(OPTIONAL)
* ALL PIPING MATERIALS TO BE
SUPPLIED BY CUSTOMERS.
FIGURE1.
7
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INSTALLATION INSTRUCTIONS
4. Attach a hose to the water heater
Removing the Old Water Heater
drain valve and put the other end
in a floor drain or outdoors. Open
the water heater drain valve. Open
a nearby hot water faucet which will
relieve pressure in the water
heater and speed draining. The
water passing out of the drain valve
may be extremely hot. To avoid
being scalded, make sure all
connections are tight and that the
water flow is directed away from
any person, see Figures 2 and 5.
FIGURE5.
5. Disconnect the vent pipe from the draft hood where it connects
to the water heater. In most installations the vent pipe can
be lifted off after any screw or other attached devices are
removed. Dispose of the draft hood. The new water heater
has a draft hood which must be used for proper operation.
6. If you have copper piping to the water heater, the two copper
water pipes can be cut with a hacksaw approximately four
inches away from where they connect to the water heater,
see Figure 6. This will avoid cutting off pipes too short.
Additional cuts can be made later if necessary. Disconnect
the temperature-pressure relief valve drain line. When the
water heater is drained, disconnect the hose from the drain
valve. Close the drain valve. The water heater is now
completely disconnected and ready to be removed.
FIGURE2.
1. Turn “OFF” the gas supply to the
water heater.
If the main gas line Shut-off valve
serving all gas appliances is
used, also shut “OFF” the gas at
each appliance. Leave all gas
appliances shut “OFF” until the
water heater installation is
completed, see Figures 2 and 3.
FIGURE6.
FIGURE3.
FIGURE4.
If you have galvanized pipes to the water heater, loosen the
two galvanized pipes with a pipe wrench at the union in each
line. Also disconnect the piping remaining to the water heater,
see Figure 7. These pieces should be saved since they may
be needed when reconnecting the new water heater.
Disconnect the temperature-pressure relief valve drain line.
When the water heater is drained, disconnect the hose from
the drain valve. Close the drain valve. The water heater is
now completely disconnected and ready to be removed.
Mineral buildup or sediment may have accumulated in the
old water heater. This causes the water heater to be much
heavier than normal and this residue, if spilled out, could
cause staining.
2. Turn “OFF” the water supply to the
water heater at the water shut off
valve or water meter. Some
installations require that the water
be turned off to the entire house,
see Figures 2 and 4.
3. Check again to make sure the gas supply is “OFF” to the
water heater. Then disconnect the gas supply connection
from the gas control valve.
FIGURE7.
8
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• Devices that will turn off the gas supply to a gas water heater
while at the same time shutting off its water supply.
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.
Whether replacing an old water heater or putting the water heater
in a new location, the following critical points must be observed:
•
•
Select a location indoors as close as practical to the gas
vent or chimney to which the water heater vent is going to be
connected, and as centralized with the water piping system
as possible.
Selected location must provide adequate clearances for
servicing and proper operation of the water heater.
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS
(VAPORS) ARE LIKELY TO BE PRESENT OR STORED
(GARAGES, STORAGE AND UTILITY AREAS, ETC.):
Flammable liquids (such as gasoline, solvents, propane [LP or
butane, etc.] and other substances such as adhesives, etc.)
emit flammable vapors which can be ignited by a gas water
heater’s pilot light or main burner. The resulting flashback and
fire can cause death or serious burns to anyone in the area.
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.
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 Sears or hardware store. Such a drain
pan must have a minimum length and width of at least 2 inches
(51 mm) greater that 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.
This water heater must not be installed directly on carpeting.
Carpeting must be protected by metal or wood panel beneath
the appliance extending beyond the full width and depth of the
appliance by at least 3 inches (76.2 mm) 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.
• Sensors mounted in the drain pan that turn off the water supply
to the entire home when water is detected in the drain pan.
• Water supply shut-off devices that activate based on the water
pressure differential between the cold water and hot water
pipes connected to the water heater.
9
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Minimum clearances between the water heater and combustible
construction are inch at the sides and rear,
0
4 inches (102 mm) at the front, and 6 inches (153 mm) from the
vent pipe, see Figure 8. Clearance from the top of the jacket is 12
inches (305 mm) on most models. Note that a lesser dimension
may be allowed on some models, refer to the label attached
adjacent to the gas control valve on the water heater.
FIGURE9.
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 directly from outdoors (direct vent).
Propellants of aerosol sprays and volatile compounds,
(cleaners, chlorine based chemicals, refrigerants, etc.) in
addition to being highly flammable in many cases, will also
change to corrosive hydrochloric acid when exposed to the
combustion products of the water heater. The results can be
hazardous, and also cause product failure.
Insulation Blankets
Insulation blankets available to the general public for external
use on gas water heaters are not necessary with Kenmore
products. The purpose of an insulation blanket is to reduce the
standby heat loss encountered with storage tank heaters. Your
Kenmore water heater meets or exceeds the NationalAppliance
Energy Conservation Act standards with respect to insulation
and standby loss requirements, making an insulation blanket
unnecessary.
FIGURE8.
A gas water heater cannot operate properly without the correct
amount of air for combustion, see Figure 9. Do not install in a
confined area such as a closet, unless you provide air as shown
in the Locating The New Water Heater section. Never obstruct
the flow of ventilation air. If you have any 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.
WARNING
Should you choose to apply an insulation blanket to this heater,
you should follow these instructions (See Figure 1 for
identification of components mentioned below). Failure to follow
these instructions can restrict the air flow required for proper
combustion, potentially resulting in fire, asphyxiation, serious
personal injury or death.
10
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commence within 12 inches (30 cm) of the top and one
commencing within 12 inches (30 cm) of the bottom of the
enclosures.
•
•
•
•
•
•
Do not apply insulation to the top of the water heater, as this
will interfere with safe operation of the draft hood.
Do not cover the outer door, thermostat or temperature &
pressure relief valve.
Do not allow insulation to come within 2” (50.8 mm) of the
floor to prevent blockage of combustion air flow to the burner.
Do not cover the instruction manual. Keep it on the side of
the water heater or nearby for future reference.
Do obtain new warning and instruction labels from Sears
for placement on the blanket directly over the existing labels.
Do inspect the insulation blanket frequently to make certain
it does not sag, thereby obstructing combustion air flow.
Combustion Air and Ventilation for
FIGURE10.
Appliances Located in Unconfined Spaces
B. ALLAIR FROM OUTDOORS: (See Figures 9, 11,12 and 13)
UNCONFINED SPACE is space whose volume is not less than
50 cubic feet per 1,000 Btu per hour (4.8 m3 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.
The confined space shall be provided with two permanent
openings, one commencing within 12 inches (30 cm) of the
top and one commencing within 12 inches (30 cm) from the
bottom of the enclosure. The openings shall communicate
directly, or by ducts, with the outdoors or spaces (crawl or attic)
that freely communicate with the outdoors.
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 Combustion Air and Ventilation for Appliances
Located in Confined Spaces.
Combustion Air and Ventilation for
Appliances Located in Confined Spaces
CONFINED SPACE is a space whose volume is less than
50 cubic feet per 1,000 Btu per hour (4.8 m3 per kW) of the
aggregate input rating of all appliances installed in that space.
A. ALL AIR FROM INSIDE BUILDINGS:
(See Figure 9 on page 9 and Figure 10 below)
FIGURE11.
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
•
•
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.
When communicating with the outdoors through vertical
ducts, each opening shall have a minimum free area of
1 square inch per 4,000 BTU per hour (5.5 cm2/kW) of total
input rating of all equipment in the enclosure, see
Figure 12.
11
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Water Piping
FIGURE12.
HOTTER WATER CAN SCALD:
•
•
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 13.
Water heaters are intended to produce hot water. Water heated
to a temperature which will satisfy space heating, clothes
washing, dish washing, cleaning and other sanitizing needs
can scald and permanently injure you upon contact. Some
people are more likely to be permanently injured by hot water
than others. These include the elderly, children, the infirm, or
physically/mentally handicapped. If anyone using hot water in
your home fits into one of these groups or if there is a local
code or state law requiring a certain temperature water at the
hot water tap, then you must take special precautions. In
addition to using the lowest possible temperature setting that
satisfies your hot water needs, a means such as a *mixing
valve, shall be used at the hot water taps used by these people
or at the water heater. Mixing valves are available at plumbing
supply or hardware stores, see Figure 14 below. Valves for
reducing point of use temperature by mixing cold and hot water
are also available. Follow manufacturer’s instructions for
installation of the valves. Before changing the factory setting
on the thermostat, read the Temperature Regulation section in
this manual.
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
(76.2 mm), see Figure 13.
FIGURE13.
•
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.
FIGURE14.
•
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.
12
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This water heater shall not be connected to any heating systems
or component(s) used with a non-potable water heating
appliance.
•
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.
All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
NOTE: This water heater is super insulated to minimize
heat loss from the tank. Further reduction in heat loss
can be accomplished by insulating the hot water lines
from the water heater.
Toxic chemicals, such as those used for boiler treatment shall
not be introduced into this system.
Water supply systems may, because of such events as high
line pressure, frequent cut-offs or the effects of water hammer
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.
INSTALLATION COMPLETED USING
INSTALLATION KIT
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.
Refer to the Thermal Expansion section under Troubleshooting
Guide or contact local plumbing authority or local Sears Service
Center on how to control this situation.
NOTE: To protect against untimely corrosion of hot and cold
water fittings, it is strongly recommended that di-electric
unions or couplings be installed on this water heater when
connected to copper pipe.
FIGURE15.
T & P Valve and Pipe Insulation
Remove insulation for T & P valve and pipe connections from
carton.
Figure 15 shows the typical attachment of the water piping to
the water heater. The water heater is equipped with 3/4” NPT
water connections.
NOTE: If using copper tubing, solder tubing to an adapter
before attaching the adapter to the cold water inlet
connection. Do not solder the cold water supply line directly
to the cold water 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.
FIGURE15A.
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.
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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.
Temperature-Pressure Relief Valve
FIGURE16.
This heater is provided with a properly certified combination
temperature - pressure relief valve by the manufacturer.
The valve is certified by a nationally recognized testing
laboratory that maintains periodic inspection of production of
listed equipment as meeting the requirements for Relief Valves
and Automatic Gas Shut-off Devices for Hot Water Supply
Systems, ANSI Z21.22 and the code requirements of ASME.
If replaced, the valve must meet the requirements of local
codes, but not less than a combination temperature and
pressure relief valve certified as indicated in the above
paragraph.
The Discharge Pipe:
• Shall not be smaller in size than the outlet pipe size of the
valve, or have any reducing couplings or other restrictions.
The valve must be marked with a maximum set pressure not to
exceed the marked hydrostatic working pressure of the water
heater (150 psi = 1,035kPa) and a discharge capacity not less
than the water heater input rate as shown on the model rating
plate.
• 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.
For safe operation of the water heater, the relief valve must not
be removed from its designated opening nor plugged.
• Shall terminate at an adequate drain.
The temperature-pressure relief valve must be installed directly
into the fitting of the water heater designed for the relief valve.
Position the valve downward and provide tubing so that any
discharge will exit only within 6 inches (153 mm) above, or at
any distance below the structural floor, see Figure 16. Be certain
that no contact is made with any live electrical part. The
discharge opening must not be blocked or reduced in size
under any circumstances. Excessive length, over 30 feet
(9.14 m), or use of more than four elbows can cause restriction
and reduce the discharge capacity of the valve.
• Shall not have any valve between the relief valve and tank.
No valve or other obstruction is to be placed between the relief
valve and the tank. Do not connect tubing directly to discharge
drain unless a 6 inch air gap is provided. To prevent bodily
injury, hazard to life, or property damage, the relief valve must
be allowed to discharge water in quantities should
circumstances demand. If the discharge pipe is not connected
to a drain or other suitable means, the water flow may cause
property damage.
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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.
and mechanically actuated vent dampers). Before installation
of any vent damper, consult your local Sears Service Center or
the local gas supplier for further information.
If after manually operating the valve, it fails to completely reset
and continues to release water, immediately close the cold
water inlet to the water heater, follow the draining instructions,
and replace the temperature-pressure relief valve with a new
one.
Filling the Water Heater
Never use this water heater unless it is completely full of water.
To prevent damage to the tank, the tank must be filled with
water. Water must flow from the hot water faucet before turning
“ON” gas to the water heater.
To insure proper venting of this gas-fired water heater, the
correct vent pipe diameter must be utilized. Any additions or
deletions of other gas appliances on a common vent with this
water heater may adversely affect the operation of the water
heater. Consult your gas supplier if any such changes are
planned. For replacement heater installations where using pre-
existing venting, venting must be inspected for obstructions
and if deterioration is present, venting must be replaced.
To fill the water heater with water:
•
•
•
Close the water heater drain valve by turning the handle to
the right (clockwise). The drain valve is on the lower front of
the water heater.
For proper venting in certain installations, a larger diameter
vent pipe may be necessary. Consult your local Sears Service
Center or gas supplier to aid you in determining the proper
venting for your water heater from the vent tables in the current
edition of the National Fuel Gas Code ANSI Z223.1/NFPA 54.
Open the cold water supply valve to the water heater.
NOTE: The cold water supply valve must be left open when
the water heater is in use.
To insure complete filling of the tank, allow air to exit by
opening the nearest hot water faucet. Allow water to run
until a constant flow is obtained. This will let air out of the
water heater and the piping.
Periodically check the venting system for signs of obstruction
or deterioration and replace if needed.
The combustion and ventilation air flow must not be obstructed.
•
Check all water piping and connections for leaks. Repair
as needed.
The water heater with draft hood installed must be connected
to a chimney or listed vent pipe system, which terminates to
the outdoors. Never operate the water heater unless it is vented
to the outdoors and has adequate air supply to avoid risks of
improper operation, explosion or asphyxiation.
Venting
VENT DAMPERS - Any vent damper, whether it is operated
thermally or otherwise must be removed if its use inhibits proper
drafting of the water heater.
•
•
For proper draft hood attachment, the draft hood legs may
be angled slightly inward.
Place the draft hood legs in the receiving holes on the top of
the water heater. The legs will snap in the holes to give a
tight fit. Secure two legs to top with sheet metal screws.
Thermally Operated Vent Dampers: Gas-fired water heaters
having thermal efficiency in excess of 80% may produce a
relatively low flue gas temperature. Such temperatures may
not be high enough to properly open thermally operated vent
dampers. This would cause spillage of the flue gases and
may cause carbon monoxide poisoning.
•
Place the vent pipe over the draft hood. With the vent pipe in
position, drill a small hole through both the vent pipe and
draft hood. Secure them together with a sheet metal screw,
see Figure 17.
Vent dampers must bear evidence of certification as complying
with the current edition of the American National Standard
ANSI Z21.68 (ANSI Z21.66 & 67, respectively, cover electrically
Obstructed or deteriorated vent systems may present serious
health risk or asphyxiation.
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Be sure vent pipe is properly connected to prevent escape of
dangerous flue gases which could cause deadly asphyxiation.
Chemical vapor corrosion of the flue and vent system may
occur if 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.
Gas Piping
FIGURE17.
The vent pipe from the water heater must be no less than the
diameter of the draft hood outlet on the water heater and must
slope upward at least 1/4 inch per linear foot (21 mm per meter),
see Figure 18.
FIGURE18.
Make sure the gas supplied is the same type listed on the
model rating plate. The inlet gas pressure must not exceed
14 inch water column (3.5kPa) for natural and propane gas
(L.P.). The minimum inlet gas pressure listed on the rating
plate is for the purpose of input adjustment. If the gas control
valve is subjected to pressures exceeding 1/2 pound per square
inch (3.5kPa), the damage to the gas control valve could result
in a fire or explosion from leaking gas.
All vent gases must be completely vented to the outdoors of the
structure (dwelling). Install only the draft hood provided with
the new water heater and no other draft hood.
Vent pipes must be secured at each joint with sheet metal
screws.
There must be a minimum of 6 inches (153 mm) clearance
between single wall vent pipe and any combustible material.
Fill and seal any clearance between single wall vent pipe and
combustible material with mortar mix, cement, or other
noncombustible substance. For other than single wall, follow
vent pipe manufacturer’s clearance specifications. To insure
a tight fit of the vent pipe in a brick chimney, seal around the
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.
vent pipe with mortar mix cement.
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:
•
•
A readily accessible manual shut off valve in the gas supply
line serving the water heater, and
A drip leg (sediment trap) ahead of the gas control valve to
help prevent dirt and foreign materials from entering the
gas control valve.
•
A flexible gas connector or a ground joint union between the
shut off valve and control valve to permit servicing of the unit.
Be sure to check all the gas piping for leaks before lighting the
water heater. Use a soapy water solution, not a match or open
flame. Rinse off soapy solution and wipe dry.
The minimum inlet gas pressure shown on the rating plate is
that which will permit firing at the rated input.
Failure to have required clearances between vent piping and
combustible material will result in a fire hazard.
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Sediment Traps
Contaminants in the gas lines may cause improper operation
of the gas control valve that may result in fire or explosion.
Before attaching the gas line be sure that all gas pipe is clean
on the inside. To trap any dirt or foreign material in the gas
supply line, a drip leg (sometimes called a sediment trap)
must be incorporated in the piping. The drip leg must be readily
accessible. Install in accordance with the Gas Piping section.
Refer to the current edition of the National Fuel Gas Code,
ANSI Z223.1/NFPA54.
Water heaters covered in this manual have been tested and
approved for installation at elevations up to 7,700 feet (2,347m)
above sea level. For installation above 7,700 feet (2,347m),
the water heater’s Btu input should be reduced at the rate of 4
percent for each 1,000 feet (305 m) above sea level which
requires replacement of the burner orifice in accordance with
the National Fuel Gas Code ANSI Z223.1/NFPA 54. Contact
your local gas supplier for further information.
Failure to replace the standard orifice with the proper high
altitude orifice when installed at elevations above 7,700 feet
(2,347m) could result in improper and inefficient operation of
the appliance, producing carbon monoxide gas in excess of
the safe limits. This could result in serious injury or death.
Contact your local gas supplier for any specific changes that
may be required in your area.
A sediment trap shall be installed as close to the inlet of the
water heater as practical at the time of water heater installation.
The sediment trap shall be either a tee fitting with a capped
nipple in the bottom outlet or other device recognized as an
effective sediment trap. If a tee fitting is used, it shall be installed
in conformance with one of the methods of installation, shown
in Figures 19 and 20.
Use pipe joint compound or teflon tape marked as being
resistant to the action of petroleum (Propane [L.P.]) gases.
FIGURE19. GASPIPINGWITHFLEXIBLECONNECTOR.
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 19 and 20.
FIGURE 20. GAS PIPING WITH ALL
BLACK IRON PIPE TO GAS CONTROL.
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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.
BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATERANDAIR PURGED FROM ALL LINES.
A. This appliance has a pilot which is lit by a piezo electric
gas ignition system. Do not open the inner door of the
appliance and try to light the pilot by hand.
•
If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or turn
by hand, don’t try to repair it, call a qualified service
technician . Force or attempted repair may result in a fire
or explosion.
B. BEFORE LIGHTING smell all around the appliance area
for gas. Be sure to smell next to the floor because some
gas is heavier than air and will settle on the floor.
WHAT TO DO IFYOU SMELL GAS:
•
•
Do not try to light any appliance.
Do not touch any electric switch; do not use any phone
in your building.
Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
D. Do not use this appliance if any part has been under
water. Immediately contact a qualified installer or service
agency to replace a flooded water heater. Do not attempt
to repair the unit! It must be replaced!
•
LIGHTING INSTRUCTIONS
TOP KNOB
FIGURE “D”
1.
STOP! Read the safety information
above on this label.
2. Set the thermostat to lowest setting (PILOT LIGHTING).
Turn thermostat dial fully clockwise until it stops.
9. Once the pilot has been found, push the gas knob all the
way down. Immediately press the pilot igniter button rapidly
(4) to (5) times. If the pilot will not light, repeat step (3)
through (9).
10. Continue to hold the gas control knob down for about one
(1) minute after the pilot is lit. Release the gas control knob
and it will pop back up. Pilot should remain lit. If it goes out,
repeat step (3) through (9). It may take several minutes for
air to clear the lines before the pilot will light.
3. Push the gas control knob down slightly and turn clockwise
to “OFF”, SEE FIGURE “A”.
NOTE: Knob CANNOT be turned from “PILOT” to “OFF”
unless it is pushed down slightly. Do not force.
4. Remove the outer burner door located below the gas
control.
•
If knob does not pop up when released, stop and
immediately call your service technician or gas supplier.
If the pilot will not stay lit after several tries, turn the gas
5. Wait five (5) minutes to clear out any gas. If you then
•
smell gas,
STOP! Follow “B” in the safety information
control knob clockwise
to “OFF” and call your service
above on this label. If you don’t smell gas, go to next step.
6. This unit is equipped with a push button pilot igniter, which
is used to light the pilot. Locate the igniter on the gas
control.
technician or gas supplier. SEE FIGURE “A”.
11. Once the pilot flame is established replace the outer burner
door.
12. At arms length away, turn gas control knob
7. Turn gas control knob counterclockwise
to “PILOT”,
counterclockwise
to “ON”. SEE FIGURE “C”.
SEEFIGURE “B”.
13. Set thermostat to desired setting.
8. The pilot is located on the right side of the burner. It can be
located by looking through the glass view port while
pressing the piezo igniter button several times. Look for a
spark at the pilot location, FIGURE “D”.
DANGER: Hotter water increases the risk of
scald injury. Consult the instruction manual
before changing temperature.
TO TURN OFF GAS TO APPLIANCE
2. Push gas control knob down slightly and turn clockwise
to “OFF”. Do not force. SEE FIGURE “A”.
1. Set thermostat to the lowest setting (PILOT LIGHTING).
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Temperature Regulation
THE WATER HEATER SHOULD BE LOCATED IN AN AREA
WHERE THE GENERAL PUBLIC DOES NOT HAVE ACCESS.
IFASUITABLEAREAIS NOTAVAILABLE,ACOVER SHOULD BE
INSTALLED OVER THE THERMOSTAT TO PREVENT
TAMPERING. Suitable covers are available through the Sears
Service Center.
Due to the nature of the typical gas water heater, the water
temperature in certain situations may vary up to 30F° (16.7 C°)
higher or lower at the point of use such as, bathtubs, showers,
sink, etc.
Any water heater’s intended purpose is to heat water. Hot
water is needed for cleansing, cleaning, and sanitizing (bodies,
dishes, clothing). Untempered hot water can present a scald
hazard. Depending on the time element, and the people
involved (adults, children, elderly, infirm, etc.) scalding may occur
at different temperatures.
Never allow small children to use a hot water tap, or to draw
their own bath water. Never leave a child or handicapped person
unattended in a bathtub or shower.
NOTE: A water temperature range of 120°F-140°F (49°C-60°C)
is recommended by most dishwasher manufacturers.
The thermostat of this water heater has been factory set at its
lowest position (PILOT LIGHTING). It is adjustable and must
be reset to the desired temperature setting to reduce the risk of
scald injury. The mark ( ) indicative of approximately 120°F
(49°C) is preferred starting point. Some states have a
requirement for a lower setting.
Turn the water temperature dial clockwise (
the temperature, or counterclockwise (
temperature.
) to decrease
) to increase the
Should overheating occur or the gas supply fail to shut off, turn
off the manual gas control valve to the appliance.
HOTTER WATER CAN SCALD: Water heaters are intended to
produce hot water. Water heated to a temperature which will
satisfy space heating, clothes washing, dish washing, and
other sanitizing needs can scald and permanently injure you
upon contact. Some people are more likely to be permanently
injured by hot water than others. These include the elderly,
children, the infirm, or physically/mentally handicapped. If
anyone using hot water in your home fits into one of these
groups or if there is a local code or state law requiring a certain
temperature water at the hot water tap, then you must take
special precautions. In addition to using the lowest possible
temperature setting that satisfies your hot water needs, a
means such as a mixing valve, shall be used at the hot water
taps used by these people or at the water heater. Mixing valves
are available at plumbing supply or hardware stores. 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 Figures
21 and 22.
FIGURE21.
Temperature
Settings
Time to Produce 2nd & 3rd
Degree Burns on Adult Skin
VERYHOT=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)
About 1/2 second
About 1-1/2 seconds
Less than 5 seconds
About 30 seconds
More than 5 minutes
LOW = approx. 80°F (27°C)
- - - - - - - - - - - - - - - -
FIGURE22.
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SERVICE AND ADJUSTMENT
Tank (Sediment) Cleaning
Burner Inspection
Flood damage to a water heater may not be readily visible or
immediately detectable. However, over a period of time a
flooded water heater will create dangerous conditions which
can cause DEATH, SERIOUS BODILY INJURY, OR PROPERTY
DAMAGE. Contact a Sears Service Center to replace a flooded
water heater. Do not attempt to repair the unit! It must be
replaced!
Sediment build-up on the tank bottom may create varying
amount of noise, and if left in the tank will cause permanent
tank failure. In some water areas, you may not be able to drain
all sediment deposits by simply draining the tank. In these
cases Mag-Erad (part no. 23600) can be used to help remove
the sediment deposits. This may be ordered from the Sears
Service Center. For ordering, refer to the Parts Order List
section.
At least once a year a visual inspection should be made of the
main burner and pilot burner, see Figure 23.
Vent System Inspection
You should check for sooting. Soot is not normal and will impair
proper combustion.
Soot build-up indicates a problem that requires correction
before further use. Turn “OFF” gas to water heater and
leave off until repairs are made, because failure to correct the
cause of the sooting can result in a fire causing death, serious
injury, or property damage.
•
•
Flue gases may escape if vent pipe
is not connected.
Be alert for obstructed, sooted or
deteriorated vent system to avoid
serious injury or death.
•
•
Do not store corrosive chemicals
in vicinity of water heater.
Chemical corrosion of flue and vent
system can cause serious injury or
death
FIGURE23.
Burner Cleaning
At least once a year a visual inspection should be made of the
venting system. You should look for:
•
•
•
Obstructions which could cause improper venting. The
combustion and ventilation air flow must not be obstructed.
Damage or deterioration which could cause improper
venting or leakage of combustion products.
Rusted flakes around top of water heater.
Be sure the vent piping is properly connected to prevent escape
of dangerous flue gasses which could cause deadly
asphyxiation.
Obstructions and deteriorated vent systems may present
serious health risk or asphyxiation.
In the event your burner needs cleaning, following these
instructions:
Chemical vapor corrosion of the flue and vent system may
occur if air for combustion contains certain chemical vapors.
Spray can propellants, cleaning solvents, refrigerator and air
conditioner refrigerants, swimming pool chemicals, calcium
and sodium chloride, waxes, bleach and process chemicals
are typical compounds which are potentially corrosive.
If inspection of the burner shows that cleaning is required, turn
the gas control knob clockwise (
depressing slightly.
) to the “OFF” position,
NOTE: The knob cannot be turned from “PILOT” to “OFF”
unless knob is depressed slightly. DO NOT FORCE.
If when inspecting the vent system you find sooting or
deterioration, something is wrong. Call the local gas supplier
to correct the problem and clean or replace the flue and venting
before resuming operation of the water heater.
The burner needs to be removed for cleaning. Call the Sears
Service Center to remove and clean the burner and correct the
problem that required the burner to be cleaned.
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Housekeeping
Temperature-Pressure Relief Valve Operation
Vacuum around base of water heater for dust, dirt, and lint on a
regular basis.
The temperature-pressure relief valve must be manually
operated at least once a year.
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 24.
AT LEAST ONCE EVERY SIX MONTHS A
VISUAL INSPECTION SHOULD BE MADE OF
THE AIR INTAKE SCREEN. CLEAN IF LINT
ACCUMULATIONS ARE NOTICED.
INSTALLED IN SUITABLEAREA: 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 because they
could catch on fire.
FIGURE 24.
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.
Anode Rod Inspection
If the temperature-pressure relief valve on the appliance weeps
or discharges periodically, this may be due to thermal
expansion. You may have a check valve installed in the water
line or a water meter with a check valve. Consult the Sears
Service Center for further information. Do not plug the
temperature-pressure relief valve.
Draining
The anode rod is used to protect the tank from corrosion. Most
hot water tanks are equipped with an anode rod. The
submerged rod deteriorates to protect the tank. Instead of
corroding the tank, water ions attack and eat away the anode
rod. This does not affect the water’s taste or color. The rod
must be maintained to keep the tank in operating condition.
Anode deterioration depends on water conductivity, not
necessarily water condition. A corroded or pitted anode rod
indicates high water conductivity and should be checked and/
or replaced more often than an anode rod that appears to be
intact. Replacement of a depleted anode rod can extend the
life of your water heater. Inspection should be conducted by
calling the Sears Service Center for an authorized contractor. At
a minimum, the anode(s) should be checked annually after
the warranty period.
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.
1. Turn the gas control knob to the “OFF” position.
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2. CLOSE the cold water inlet valve to the water heater.
5. Screw the handle and cap assembly back into the drain
valve and retighten using a wrench. DO NOT OVER
TIGHTEN.
3. OPEN a nearby hot water faucet and leave open to allow for
draining.
6. Follow instructions in the Filling The Water Heater section.
4. Connect a hose to the drain valve and terminate to an
adequate drain.
7. Check for leaks.
8. Follow the lighting instructions in the Lighting section to
5. OPEN the water heater drain valve to allow for tank draining.
restart the water heater.
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 in the Lighting section to
restart the water heater.
FIGURE 25.
Drain Valve Washer Replacement
(See Figure 25)
Service
Before calling for repair service, read the Start Up Conditions
and Operational Conditions found in the Troubleshooting Guide
of this manual.
1. Turn “OFF” gas supply to water heater.
2. Follow “Draining” instructions.
If a condition persists or you are uncertain about the operation
of the water heater, let the Sears Service Center check it out.
3. Turning counter clockwise (
the screw handle.
), remove the hex cap below
Contact Sears Service Center at:
4. Remove the washer and put the new one in place.
1-800-4-MY-HOME® (1-800-469-4663).
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TROUBLESHOOTING GUIDE
NOTE: Expansion tanks are pre-charged with a 40 psi air
Start Up Conditions
charge. If the inlet water pressure is higher than 40 psi, the
expansion tank’s air pressure must be adjusted to match
that pressure, but must not be higher than 80 psi.
Thermal Expansion
Water supply system may, because of such events as high line
pressure, frequent cut-offs, and the effects of water hammer
have installed devices such as pressure reducing valves, check
valves, back flow preventers, etc., to control these types of
problems. When these devices are not equipped with an
internal by-pass, and no other measures are taken, the devices
cause the water system to be closed. As water is heated, it
expands (thermal expansion) and closed systems do not allow
for the expansion of heated water.
The water within the water heater tank expands as it is heated
and increases the pressure of the water system. If the relieving
point of water heater’s temperature-pressure relief valve is
reached, the valve will relief 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. Thermal expansion tanks are available from Sears
stores and through the Sears Service Centers. Contact the
local plumbing inspector, water supplier and/or the Sears
Service Center for assistance in controlling these situations,
see Figure 26.
Thermal Expansion Tank Specifications
FIGURE26.
Tank
Capacity
Dimensions
in Inches
Pipe
Fitting
Model
Strange Sounds
Number In Gallons Diameter
Length
On Tank
153.331020
153.331050
2
5
8 (203 mm) 12-3/4 (323 mm) 3/4” Male
11 (279 mm) 14-3/4 (375 mm) 3/4” Male
Possible noises due to expansion and contraction of some
metal parts during periods of heat-up and cool-down do not
represent harmful or dangerous conditions.
Expansion Tank Sizing Chart
Condensation causes sizzling and popping within the burner
area during heating and cooling periods and should be
considered normal. See Condensation section.
Inlet*
Water
Pressure 30
40psi
50psi
60psi
70psi
80psi
Water Heater Capacity (Gallons)
40
2
50
2
66
5
80
5
Expansion
Tank
Capacity
Needed
2
2
2
2
2
Draft Hood Operation
2
2
5
5
2
5
5
5
Check draft hood operation by performing a worst case
depressurization of the building. With all doors and windows
closed, and with all air handling equipment and exhaust fans
operating such as furnaces, clothes dryers, range hoods and
bathroom fans, a match flame should still be drawn into the
draft hood of the water heater with its burner firing. If the flame
2
5
5
5
5
5
5
5
*Highest recorded inlet water pressure in a 24 hour period or
regulated water pressure.
23
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is not drawn toward the draft hood, shut off water heater and
make necessary air supply changes to correct.
from hydrogen sulfide gas dissolved in the water. The smell is
the result of four factors which must all be present for the odor
to develop:
Condensation
•
•
•
a concentration of sulfate in the supply water.
little or no dissolved oxygen in the water.
Whenever the water heater is filled with cold water, some
condensate will form while the burner is on. A water heater
may appear to be leaking when in fact the water is condensation.
This usually happens when:
a sulfate reducing bacteria within the water heater. (This
harmless bacteria is non-toxic to humans.)
•
an excess of active hydrogen in the tank. This is caused by
the corrosion protective action of the anode.
•
•
A new water heater is filled with cold water for the first time.
Burning gas produces water vapor In water heaters,
particularly high efficiency models where flue temperatures
are lower.
Smelly water may be eliminated or reduced in some water
heater models by replacing the anode(s) with one of less active
material, and then chlorinating the water heater tank and all
hot water lines. Contact Sears Service for further information
concerning an Anode Replacement Kit #9001453 and this
Chlorination Treatment. Anode replacement and chlorination
of the tank are not covered by the water heater’s limited warranty.
•
Large amounts of hot water are used in a short time and the
refill water in the tank is very cold.
Moisture from the products of combustion condense on the
cooler tank surfaces and form drops of water which may fall
onto the burner or other hot surfaces to produce a “sizzling” or
“frying” noise.
If the smelly water persists after the anode replacement and
chlorination treatment, it may be necessary to chlorinate or
aerate your water supply to eliminate the problem.
Do not remove the anode leaving the tank unprotected. By
doing so, all warranty on the water heater tank is voided.
Excessive condensation can cause pilot outage due to water
running down the flue tube onto the main burner and putting
out the pilot.
“AIR” In Hot Water Faucets
Because of the suddenness and amount of water,
condensation water may be diagnosed as a “tank leak”. After
the water in the tank warms up (about 1-2 hours), the condition
should disappear.
Do not assume the water heater is leaking until there has
been enough time for the water in the tank to warm up.
An undersized water heater will cause more condensation.
The water heater must be sized properly to meet the family’s
demands for hot water including dishwashers, washing
machines and shower heads.
Excessive condensation may be noticed during the winter and
early spring months when incoming water temperatures are at
their lowest.
HYDROGEN GAS: Hydrogen gas can be produced in a hot
water system that has not been used for a long period of time
(generally two weeks or more). Hydrogen gas is extremely
flammable and explosive. To prevent the possibility of injury
under these conditions, we recommend the hot water faucet,
located farthest away, be opened for several minutes before
any electrical appliances which are connected to the hot water
system are used (such as a dishwasher or washing machine).
If hydrogen gas is present, there will probably be an unusual
sound similar to air escaping through the pipe as the hot water
faucet is opened. There must be no smoking or open flame
near the faucet at the time it is open.
Good venting is essential for a gas fired water heater to operate
properly as well as to carry away products of combustion and
water vapor.
Smoke Odor
It is not uncommon to experience a small amount of smoke
and odor during the initial start-up. This is due to burning off of
oil from metal parts, and will disappear in a short while.
High Temperature Shut-Off System
Operational Conditions
This water heater is equipped with an automatic gas shutoff
system. This system works when high water temperatures
are present. Turn “OFF” the entire gas supply to the water
heater. The high temperature shutoff is built into the gas control
valve. It is non-resettable. If the high temperature shutoff
activates, the gas control valve must be replaced. Contact your
gas supplier.
Smelly Odor
In each water heater there is installed at least one anode rod
(see parts section) for corrosion protection of the tank. Certain
water conditions will cause a reaction between this rod and
the water. The most common complaint associated with the
anode rod is one of a “rotten egg smell”. This odor is derived
24
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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.
Operational Conditions (Continued)
Leakage Checkpoints
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, see Figure 27.
A. Water at the draft hood is water vapor which has condensed
out of the combustion products. This is caused by a problem
in the vent. Contact 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.
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.
FIGURE27.
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 Installing the New Water Heater
section.
25
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TROUBLESHOOTING GUIDE (Continued)
These guidelines should be used by a qualified service agent. Call Sears Service at 1-800-4-MY-HOME® (1-800-469-4663)
for assistance. Inform the associate that this is a “Flammable Vapor Ignition Resistant” Product.
Problem
Cause
Solution
Improperly sealed, hot or cold supply connection,
relief valve, drain valve, or thermostat threads.
Leakage from other appliances or water lines.
Condensation of flue products.
Tighten threaded connections.
WATER LEAKS
Inspect other appliances near water heater.
Refer to CONDENSATION.
Thermal expansion in closed water system.
Improperly seated valve.
Install thermal expansion tank (DO NOT plug T&P valve).
Check relief valve for proper operation
(DO NOT plug T&P valve).
LEAKING T&P VALVE
SMELLY ODORS
High sulfate or mineral content in water supply.
Drain and flush heater thoroughly, then refill.
Bacteria in water supply.
Chlorinate or aerate water supply.
Refer to LIGHTING INSTRUCTIONS.
Turn on main gas shutoff valve.
Adjust igniter tip.
Gas control knob not positioned correctly.
Main gas supply off.
Igniter tip more than 1/8" from pilot hood.
Thermocouple malfunction.
Replace pilot assembly.
Thermocouple TCO malfunction.
Melted insulation on igniter wire or shorting
of igniter wire.
Replace pilot assembly.
Contact Sears Service to determine cause.
PILOT WILL NOT LIGHT
High ambient room temperature.
Contact Sears Service to determine cause.
Wire disconnected from spark igniter.
Broken electrode or electrical wire.
Piezo Igniter generator fails to operate or
malfunctions.
Reconnect wire connector to spark igniter.
Replace pilot assembly.
Replace Piezo Igniter generator.
Thermocouple TCO malfunction.
High ambient room temperature.
Replace pilot assembly.
Contact a service agency to
determine cause.
BURNER WILL NOT
STAY LIT
Dirty or clogged air intake screen.
Flame arrestor openings blocked.
Clean and reinstall air intake screen.
Contact Sears Service to
determine cause.
Defective Gas Control.
Replace Gas Control.
Dirty pilot burner.
Clean pilot assembly.
Dirty or clogged air intake screen.
Thermocouple tip is not in contact with pilot flame.
Thermocouple malfunction.
Thermocouple TCO malfunction.
Defective Gas Control.
Clean and reinstall air intake screen.
Insert thermocouple correctly.
Replace pilot assembly.
PILOT OUTAGE
Replace pilot assembly.
Replace Gas Control.
Heater not lit or thermostat not on.
Thermostat set too low.
Refer to LIGHTING INSTRUCTIONS.
Refer toTEMPERATURE REGULATION.
Reduce hot water use.
Heater undersized.
NOT ENOUGH
HOT WATER
Low gas pressure.
Contact your gas supplier.
Incoming water is unusually cold.
Leaking hot water pipes or fixtures.
High temperature limit switch activated.
Allow more time for heater to re-heat.
Have plumber check and repair leaks.
Contact Sears Service to
determine cause.
WATER TOO HOT
Thermostat set too high.
Refer toTEMPERATURE REGULATION.
Refer to CONDENSATION.
WATER HEATER SOUNDS
Condensation dripping on burner.
Sediment or calcium in bottom of heater tank.
Clean sediment from tank. Refer to DRAINING
instructions in Maintenance section of manual.
No adjustment available. Contact Sears Service
to determine cause.
SIZZLING - RUMBLING
SOOTING
Improper combustion.
Lack of supply air.
Improperly installed vent piping.
Downdraft.
Contact Sears Service to determine cause.
VENT GAS ODORS
Poor combustion.
26
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NOTES:
27
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NOTES:
28
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PARTS ORDER LIST
POWER MISER™ 6 GAS WATER HEATER
MODEL NO’S
153.336162
153.336262
153.336362
30 Gallon Short
40 Gallon Short
30 Gallon
3
BURNERASSEMBLY
Model Numbers
153.336262
9003406
9003889
9003485
9003385
9003457 (#37)
9003391
9003405
9000058
9001584
9003480
9003445
F145-1278
9003500
9003981
9003398
9003401
184231-001
23600
9003719
9003545
9003410
9003488
9000071
F145-1280
9003414
Key No. Part Description
153.336162
9003406
9003888
9003477
9003385
9003478 (#38)
9003391
9003405
9000058
9001584
9003999
9003445
F145-1278
9003500
9003981
9003400
9003401
184231-001
23600
153.336362
9003406
9003889
9003442
9003385
9003443 (#36)
9003390
9003405
9002402
9001584
9003969
9000275
F145-1278
9003463
9003981
9003399
9003401
184231-001
23600
1
2
Air Intake Screen
Anode Rod
3
4
BurnerAssembly
Burner Head**
5
6
7
Burner Orifice**
Burner Tube w/Rubber Boot**
Draft Hood
8
Drain Valve
9
Drain Valve Washer
Flue Baffle
10
11
12
13
*14
15
16
*17
*18
19
20
21
22
23
24
25
Flue Restrictor
Gas Control Valve
Inlet Tube
Inlet Tube Gasket
Inner Door**
Inner Door Gasket
Instruction Manual
Mag-Erad
Nipple w/Heat Trap
Outer Door
9003719
9003545
9003410
9003542
9000071
F145-1280
9003414
9003719
9003545
9003410
9003542
9000071
F145-1280
9003414
Piezo Igniter w/Bracket
PilotAssembly w/Grommet**
T& P Relief Valve
TemperatureAdjustment Knob
ViewportAssembly
* Not Shown. ** Includes Inner Door Gasket
Now that you have purchased your gas water heater, should a need
ever exist for repair parts or service, simply contact any Sears Service
Center or call 1-800-4-MY-HOME® (1-800-469-4663). Be sure to provide
all pertinent facts when you call or visit.
•
•
•
•
MODELNUMBER
SERIALNUMBER
TYPE GAS - NATURALOR PROPANE (L.P.)
PARTDESCRIPTION
WHEN ORDERING REPAIR PARTS,ALWAYS GIVETHE FOLLOWING
INFORMATION:
THIS ISAREPAIR PARTS LIST, NOT APACKING LIST.
29
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PARTS ORDER LIST
POWER MISER™ 6 GAS WATER HEATER
MODEL NO’S
153.336466
40 Gallon
153.336566
50 Gallon
3
BURNERASSEMBLY
Model Numbers
Key No. Part Description
153.336466
9003406
9003972
9003458
9003385
9003443 (#36)
9003391
9003405
9002402
9001584
9003970
9000275
F145-1278
9003463
9003981
9003400
9003401
184231-001
23600
153.336566
9003406
9003891
9003467
9003385
9003443 (#36)
9003389
9003405
9003482
9001584
9003989
9000275
F145-1278
9003473
9003981
9003398
9003401
184231-001
23600
1
2
Air Intake Screen
Anode Rod
3
4
BurnerAssembly
Burner Head**
5
6
7
Burner Orifice**
Burner Tube w/Rubber Boot**
Draft Hood
8
Drain Valve
9
Drain Valve Washer
Flue Baffle
10
11
12
13
*14
15
16
*17
*18
19
20
21
22
23
24
25
Flue Restrictor
Gas Control Valve
Inlet Tube
Inlet Tube gasket
Inner Door**
Inner Door Gasket
Instruction Manual
Mag-Erad
Nipple w/Heat trap
Outer Door
9003719
9003545
9003410
9003531
9000071
F145-1280
9003414
9003719
9003545
9003410
9003488
9000071
F145-1280
9003414
Piezo Igniter w/Bracket
PilotAssembly w/Grommet**
T & P Relief Valve
TemperatureAdjustment Knob
Viewport Assembly
* Not Shown. ** Includes Inner Door Gasket
Now that you have purchased your gas water heater, should a need
ever exist for repair parts or service, simply contact any Sears Service
Center or call 1-800-4-MY-HOME® (1-800-469-4663). Be sure to provide
all pertinent facts when you call or visit.
•
•
•
•
MODELNUMBER
SERIALNUMBER
TYPE GAS - NATURALOR PROPANE (L.P.)
PARTDESCRIPTION
WHEN ORDERING REPAIR PARTS,ALWAYS GIVETHE FOLLOWING
INFORMATION:
THIS ISA REPAIR PARTS LIST, NOTAPACKING LIST.
30
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PARTS ORDER LIST
POWER MISER™ 6 GAS WATER HEATER
MODEL NO’S
153.336762
153.336862
153.336962
30 Gallon Propane (L.P.)
40 Gallon Propane (L.P.)
50 Gallon Propane (L.P.)
3
BURNERASSEMBLY
Model Numbers
Key No. Part Description
153.336762
9003406
9003889
9003451
9003422
9003453 (#51)
9003454
9003405
9002402
9001584
9003969
9000275
F145-1279
9003463
9003981
9003399
9003401
184231-001
23600
153.336862
9003406
9003972
9003460
9003422
9003453 (#51)
9003392
9003405
9002402
9001584
9003970
9000275
F145-1279
9003463
9003981
9003400
9003401
184231-001
23600
153.336962
9003406
9003891
9003565
9003385
9003453 (#51)
9003389
9003405
9003482
9001584
9003989
9000275
F145-1279
9003473
9003981
9003398
9003401
184231-001
23600
1
2
Air Intake Screen
Anode Rod
3
4
BurnerAssembly
Burner Head**
5
6
7
Burner Orifice**
Burner Tube w/Rubber Boot**
Draft Hood
8
Drain Valve
9
Drain Valve Washer
Flue Baffle
10
11
12
13
*14
15
16
*17
*18
19
20
21
22
23
24
25
Flue Restrictor
Gas Control Valve
Inlet Tube
Inlet Tube Gasket
Inner Door**
Inner Door Gasket
Instruction Manual
Mag-Erad
Nipple w/Heat Trap
Outer Door
9003719
9003545
9003410
9003455
9000071
F145-1280
9003414
9003719
9003545
9003410
9003455
9000071
F145-1280
9003414
9003719
9003545
9003410
9004021
9000071
F145-1280
9003414
Piezo Igniter w/Bracket
PilotAssembly w/Grommet**
T& P Relief Valve
TemperatureAdjustment Knob
ViewportAssembly
* Not Shown. ** Includes Inner Door Gasket
Now that you have purchased your gas water heater, should a need
ever exist for repair parts or service, simply contact any Sears Service
Center or call 1-800-4-MY-HOME® (1-800-469-4663). Be sure to provide
all pertinent facts when you call or visit.
•
•
•
•
MODELNUMBER
SERIALNUMBER
TYPE GAS - NATURALOR PROPANE (L.P.)
PARTDESCRIPTION
WHEN ORDERING REPAIR PARTS,ALWAYS GIVE THE FOLLOWING
INFORMATION:
THIS IS AREPAIR PARTS LIST, NOTAPACKING LIST.
31
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6 - YEAR LIMITED WARRANTY ON WATER HEATER
For six years from the date of purchase, if this water heater is installed and operated in a single-family home in accordance with the
owner’s manual instructions and all local applicable plumbing codes, Sears will:
1. Supply free water heater parts for those that are defective in material or workmanship.
2. Supply a free water heater for one that develops a leak.
For the second through sixth year from the purchase date, you must pay the labor cost for installation of parts or water heater.
For commercial, institutional, industrial or residential use by two or more families, the above limited warranty is only for two years.
During the second year you must pay the labor cost for parts or water heater installation.
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.
WARRANTYSERVICE
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.817WA, 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
c. Condensation
b. Leaks in pipes or fittings
MASTERPROTECTIONAGREEMENTS
•
•
Power surge protection against electrical damage due to power
fluctuations.
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.
Rental reimbursement if repair of your covered product takes
longer than promised.
Once you purchase theAgreement, 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.
Purchase a Master ProtectionAgreement now and protect yourself from
unexpected hassle and expense.
Sears has over 12,000 professional repair specialists, 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!
The Master ProtectionAgreement also helps extend the life of your new
product. Here’s what’s included in theAgreement:
•
•
Expert Service by our 12,000 professional repair specialist.
Unlimited service and no charge for parts and labor on all covered
Some limitations and exclusions apply. For prices and additional
information call 1-800-827-6655.
repairs.
•
“No-lemon” guarantee - replacement of your covered product if
four or more product failures occur within twelve months.
SEARS INSTALLATION SERVICE
For Sears professional Installation of home appliances, garage door
openers, water heaters, and other major home items, in the U.S.A., call
1-800-4-MY-HOME®.
•
•
Product replacement if your covered product can’t be fixed.
Annual Preventive Maintenance Check at your request - no
extra charge.
•
Fast help by phone - phone support from a Sears technician on
products requiring in-home repair, plus convenient repair scheduling.
For in-home major brand repair service
Call 24 hours a day, 7 days a week (U.S.A. and Canada)
1-800-4-MY-HOME®
(1-800-469-4663)
The model number of your water heater is found on the model rating plate on the front of the water heater.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A
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