Kenmore 153.33096, 153.33097 User Manual

Owner’s Manual

POWER MISER™ 9

ULTRA LOW NOx

GAS WATER HEATER

FOR POTABLE WATER HEATING ONLY.

NOT SUITABLE FOR SPACE HEATING.

NOT FOR USE IN MOBILE HOMES.

MODEL NO.

153.330960 40 Gallon

153.330970 50 Gallon

• Safety Instructions

• Installation

• Operation

• Care and Maintenance

• Troubleshooting

• Parts List

This water heater meets the new ANSI Z21.10.1 standard that deals with the accidental or unintended ignition of ﬂ ammable vapors, such as those emitted by gasoline.

For Your Safety

AN ODORANT IS ADDED T O THE GAS USED BY THIS WATER HEA TER.

ADVERTENCIA

Si no puede leer o entender el inglés y necesita el manual de instrucciones en español, puede solicitarlo al 1-800-821-2017. NO TRATE DE INSTALAR U OPERAR ESTE CALENTADOR DE AGUA SI NO ENTIENDE LAS INSTRUCCIONES. No hacer caso de esta advertencia podría originar lesiones graves o mortales.

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

PRINTED IN THE U.S.A 1208 PART NO. 315429-000

www.sears.com

SAFE INSTALLATION, USE AND SERVICE

Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.

Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use or service this water heater.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates an imminently hazardous

DANGER

WARNING

CAUTION

situation which, if not avoided, could result in death or injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert

CAUTION

All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and how to avoid the risk of injury.

symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage.

The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.

WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm.

This appliance can cause low-level exposure to some of the substances included in the Act.

IMPORTANT DEFINITIONS

• Gas Supplier: The natural gas or propane utility or service who supplies gas for utilization by the gas burning

appliances within this application. The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the natural gas meter or propane storage tank of a building. Many gas suppliers also offer service and inspection of appliances within the building.

SAFETY PRECAUTIONS

TABLE OF CONTENTS

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

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

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

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

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

MATERIALS AND BASIC TOOLS NEEDED ....................................................................................................................... 6

Materials Needed .....................................................................................................................................................6

Basic Tools................................................................................................................................................................6

TYPICAL INSTALLATION.......................................................................................................................................................... 7

INSTALLATION INSTRUCTIONS ......................................................................................................................................8-17

Removing the Old Water Heater ...............................................................................................................................8

Facts to Consider About the Location ..................................................................................................................9-10

Insulation Jackets ...................................................................................................................................................10

Combustion Air and Ventilation Appliances in Unconﬁ ned Spaces ........................................................................11

Combustion Air and Ventilation Appliancesin Conﬁ ned Spaces ........................................................................11-12

Water Piping ......................................................................................................................................................12-13

T & P Valve and Pipe Insulation ........................................................................................................................13-14

Temperature Pressure Relief Valve ...................................................................................................................13-14

Filling the Water Heater ..........................................................................................................................................15

Venting ...............................................................................................................................................................15-16

Gas Piping .........................................................................................................................................................16-17

Sediment Trap ........................................................................................................................................................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

Removing the Burner Door Assembly ....................................................................................................................21

Ultra Low NOx Natural Gas Burner ........................................................................................................................21

Replacing the Pilot Assembly .................................................................................................................................21

Replacing the Thermocouple ..................................................................................................................................22

External Inspection & Cleaning of the Flame Arrestor ............................................................................................22

Cleaning the Combustion Chamber and Flame Arrestor ........................................................................................22

Replacing the Burner Door Assembly .....................................................................................................................23

Piezoelectric Igniter System ...................................................................................................................................23

Testing the Igniter System ......................................................................................................................................23

Removing and Replacing the Gas Control Valve/Thermostat ................................................................................24

Housekeeping .........................................................................................................................................................24

Anode Rod Inspection ............................................................................................................................................24

Temperature-Pressure Relief Valve Operation .......................................................................................................25

Draining ..................................................................................................................................................................25

Drain Valve Washer Replacement ..........................................................................................................................25

Service ....................................................................................................................................................................25

TROUBLESHOOTING GUIDE ........................................................................................................................................26-30

Start Up Conditions ...........................................................................................................................................26-27

Thermal Expansion ...........................................................................................................................................26

Strange Sounds ................................................................................................................................................26

Draft Hood Operation ........................................................................................................................................26

Condensation ....................................................................................................................................................27

Smoke/Odor ......................................................................................................................................................27

Operational Conditions ...........................................................................................................................................27

Smelly Odor ......................................................................................................................................................27

Air in Hot Water Faucets ...................................................................................................................................27

High Temperature Shut-Off System ..................................................................................................................27

Troubleshooting Items .......................................................................................................................................28-30

PARTS ORDER LIST ................................................................................................................................................................31

WARRANTY.................................................................................................................................................................................32

CUSTOMER RESPONSIBILITIES

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.

Abbreviations Found In This Instruction Manual:

• CSA - Canadian Standards Association

• ANSI - American National Standards Institute

• NFPA - National Fire Protection Association

• ASME - American Society of Mechanical Engineers

• GAMA - Gas Appliance Manufacturers Association

• This gas-fired water heater is design certified by CSA

INTERNATIONAL under American National Standard/CSA Standard for Gas Water Heaters ANSI Z21.10.1 • CSA 4.1 (current edition).

• Read the “Safety Precautions” section, page 3 of this manual

ﬁ rst and then the entire manual carefully. If you don’t follow the safety rules, the water heater will not operate properly. It could cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.

This manual contains instructions for the installation, operation,

and maintenance of the gas-ﬁ red 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 ﬁ rst few pages, READ THE

ENTIRE MANUAL BEFORE A TTEMPTING T O INST ALL OR OPERATE THE WATER HEATER.

• The installation must conform with these instructions and the local code authority having jurisdiction. In the absence of local codes, installations shall comply with the current edition of The National Fuel Gas Code ANSI 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.

• If after reading this manual you have any questions or do not understand any portion of the instructions, call the Sears Service Center.

• Carefully plan the place where you are going to put the water heater. Correct combustion, vent action, and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and ﬁ res. See ﬁ gure 1.

Examine the location to ensure the water heater complies

with the Facts to Consider About the Location section in this manual.

• For California installation this water heater must be braced, anchored, or strapped to avoid falling or moving during an earthquake. See instructions for correct installation procedures. Instructions may be obtained from the California Ofﬁ ce of the State Architect, 400 P Street, Sacramento, CA

95814.

• Complies with 10 ng/J SCAQMD rule #1121 and districts having equivalent NOx requirements.

PRODUCT SPECIFICATIONS

RECOVERY

TANK

CAPACITY IN

MODEL NUMBER

153.330960 40 (151) NATURAL 40,000 41.0 3 (76) OR 4 (102) 20 (508) 58 3/8 (1,483)

153.330970 50 (189) NATURAL 40,000 41.0 3 (76) OR 4 (102) 22 (559) 57 3/8 (1,457)

GALS (LTRS)

TYPE OF

GAS

INPUT

RATE

(Btu/hr)

RATE GALS.

PER HOUR @

90°F RISE

MINIMUM

VENT PIPE

INCHES

(mm)

DIAMETER

INCHES

(mm)

DIMENSIONS IN

INCHES (mm)

HEIGHT TO

JACKET TOP

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.

EXPANSION TANKS FOR THERMAL EXPANSION CONDITIONS AVAILABLE IN 2 GALLONS (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 WATER HEATER GAS CONNECTOR WITH FITTINGS.

Basic Tools

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.

• Pipe Wrenches (2) 14” (356 mm)

• Screwdriver

• Tin Snips

• 6’ (1.82 m) Tape or Folding Ruler

• Garden Hose

• Drill

• Pipe Dope or Teﬂ on Tape

SLOT-HEAD SCREWDRIVER

DRILL

DRAIN PANS AVAILABLE IN 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 AV AILABLE IN 28” (711 mm) DIAMETER FOR WATER HEATERS HAVING A DIAMETER 26” (660 mm) OR LESS.

Additional Tools Needed When Sweat Soldering

• Tubing Cutters or Hacksaw

• Propane Tank

• Soft Solder

• Solder Flux

• Emery Cloth

• Wire Brushes

TUBING CUTTER

PROPANE

TORCH

PHILLIPS SCREWDRIVER

ROLL OF TEFLON

TAPE (USE ONLY ON

WATER CONNECTIONS)

GARDEN HOSE

6 FOOT TAPE

TIN SNIPS

PIPE DOPE

(SQUEEZE TUBE)

USE FOR WATER AND GAS

CONNECTIONS

PIPE WRENCH

3/4” (19 mm) WIRE BRUSH

1/2” (13 mm) WIRE BRUSH

HACKSAW

EMERY CLOTH

ROLL OF LEAD-FREE

SOFT SOLDER

ROLL OF

SOLDER

FLUX

TYPICAL INSTALLATION

GET TO KNOW YOUR WATER HEATER - GAS MODELS

A Vent Pipe

B Drafthood C Anode D Hot Water Outlet E Outlet F Flexible Water Connections G Gas Supply H Manual Gas Shut-off Valve I Ground Joint Union

* INSTALL IN ACCORDANCE WITH LOCAL CODES.

* DRIP LEG AS REQUIRED BY LOCAL CODES.

TO VENT TERMINATION

ON ROOF

INSTALL THERMAL EXPANSION

J Drip Leg (Sediment Trap) K Inner Door L Outer door M Union N Inlet Water Shut-off Valve O Cold Water Inlet P Inlet Dip Tube Q Temperature-Pressure Relief Valve R Rating Plate

TANK OR DEVICE IF WATER HEATER IS INSTALLED IN A

CLOSED WATER SYSTEM

S Flue Bafﬂ e T Thermostat U Drain Valve V Pilot and Main Burner W Flue X Drain Pan Y Piezo Igniter

(T) THERMOSTAT

GAS CONTROL KNOB

WATER TEMPERATURE

(ADJUSTING DIAL)

VACUUM RELIEF

*INSTALL PER

LOCAL CODES

VALVE

“OFF”

POSITION

“PILOT”

POSITION

TOP VIEW

“ON”

POSITION

(V) PILOT & MAIN BURNER

MAIN BURNER

PILOT BURNER

PILOT TUBING

BURNER

TUBE

THERMOCOUPLE

IGNITER ROD

* ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS.

FIGURE 1.

INSTALLATION INSTRUCTIONS

Removing the Old Water Heater

FIGURE 2.

1. Turn “OFF” the gas supply to the water heater.

If the main gas line shutoff valve

serving all gas appliances is used, also shut “OFF” the gas at each appliance. Leave all gas appliances shut “OFF” until the water heater installation is completed, see Figures 2 and 3.

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.

FIGURE 3.

FIGURE 4.

4. Attach a hose to the water heater drain valve and put the other end in a ﬂ oor 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 ﬂ ow is directed away from any person, see Figures 2 and 5.

FIGURE 5.

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.

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 7.

Facts to Consider About the Location

Carefully choose an indoor location for the new water heater. The placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance. This water heater is not for use in manufactured (mobile) homes or outdoor installation.

Whether replacing an old water heater or putting the water heater in a new location, the following critical points must be observed:

• Select a location indoors as close as practical to the gas vent or chimney to which the water heater vent is going to be connected, and as centralized with the water piping system as possible.

• 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 ﬂ ow will not cause damage to the structure. For this reason, it is not advisable to install the water heater in an attic or upper ﬂ oor. 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 than the water heater dimensions and must be piped to an adequate drain. The pan must not restrict combustion air ﬂ ow .

• Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply.

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 ﬂ ammable vapors which can be ignited by a gas water heater’s pilot light or main burner. The resulting ﬂ ashback and ﬁ re can cause death or serious burns to anyone in the area. Even though this water heater is a ﬂ ammable vapor ignition resistant water heater and is designed to reduce the chances of ﬂ ammable vapors being ignited, gasoline and other ﬂ ammable substances should never be stored or used in the same vicinity or area containing a gas water heater or other open ﬂ ame or spark producing appliance.

Also, the water heater must be located and/or protected so it is not subject to physical damage by a moving vehicle.

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. 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.

• 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.

This water heater must not be installed directly on carpeting. Carpeting must be protected by metal or wood panel beneath the appliance extending beyond the full width and depth of the appliance by at least 3 inches (76.2mm) in any direction, or if the appliance is installed in an alcove or closet, the entire ﬂ oor must be covered by the panel. Failure to heed this warning may result in a ﬁ re hazard.

Minimum clearances between the water heater and combustible construction are 0 inch at the sides and rear, 4 inches (102 mm) at the front, and 6 inches (153 mm) from the vent pipe, see Figure 8. Clearance from the top of the jacket is 8 inches (203 mm) on most models. Note that a lesser dimension may be allowed on some models, refer to the label attached adjacent to the gas control valve on the water heater.

FIGURE 8.

FIGURE 9.

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 ﬂ ammable in many cases, will also change to corrosive hydrochloric acid when exposed to the combustion products of the water heater. The results can be hazardous, and also cause product failure.

Insulation Blankets

Insulation blankets available to the general public for external use on gas water heaters are not necessary with Kenmore products. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. Your Kenmore water heater meets or exceeds the National Appliance Energy Conservation Act standards with respect to insulation and standby loss requirements, making an insulation blanket unnecessary.

A gas water heater cannot operate properly without the correct amount of air for combustion, see Figure 9. Do not install in a conﬁ ned area such as a closet, unless you provide air as shown in the Locating The New Water Heater section. Never obstruct the ﬂ ow 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 ﬁ re 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 identiﬁ cation of components mentioned below). Failure to follow these instructions can restrict the air ﬂ ow required for proper combustion, potentially resulting in ﬁ re, asphyxiation, serious personal injury or death.

• Do not apply insulation to the top of the water heater , as this will interfere with safe operation of the draft hood.

• Do not cover the outer door, thermostat or temperature & pressure relief valve.

• Do not allow insulation to come within 2” (50.8 mm) of the ﬂ oor to prevent blockage of combustion air ﬂ ow to the burner.

• Do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.

+ 22 hidden pages

Kenmore 153.33096, 153.33097 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual