Kenmore 153.331350, 153.331360 User Manual
Use & Care Guide
Model No.
153.331350
153.331360
40 U.S. Gal (151 Litres)
50 U.S. Gal (189 Litres)
LLC
I<enmore
°a
For potable water heating only.
Not for use in mobile homes.
INSTALLER: Affix these instructions to or near
the water heater.
OWNER: Retain these instructions for future
reference.
FOR YOUR SAFETY: An odorant is added to
the gas used by this water heater.
lllillll{II'II_111LAll
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
m Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance,
P/N 324086-000 (1302)
Sears Brands Management Corporation,
Hoffman Estates, IL 60179 U.S.A.
www.kenmore.com
www.sears.com
®
-- WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do
not use any phone in your building.
• Immediately call your gas supplier
from a neighbor's phone. Follow the
gas supplier's instructions.
• If you cannot reach your gas supplier,
call the fire department.
m lnstallation and service must be
performed by a qualified installer,
service agency or the gas supplier.
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 injury 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
__..-'
Read and understand instruction
manual and safety messages
before installing, operating or
servicing thiswater heater.
Failure to follow instructions and
safety messages could result in
death or serious injury.
Instruction manual must remain with
water heater.
Water temperature over 125°F
(52°C) can cause severe burns
instantly resulting in severe injury or
death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting valves are
available.
Read instruction manual for safe
temperature setting.
Fire Hazard
For continued protection against
riskoffire:
• De not install water heater on
carpeted floor.
• Do not operate water heater if
flood damaged.
J
Explosion Hazard
• Overheated water can cause
water tankexplosion.
• Properly sized temperature
and pressure relief valve
must be installed in opening
provided.
ImproperInstallation,useand servicemay result
in property damage.
• Do not operate water heater if flood damaged.
• Inspect anode rods regularly, replace when significantly depleted.
• Install in location with drainage.
• Fill tank with water before operation.
• Properly sized thermal expansion tanks are required on all
closed water systems.
Refer to this manual for installation and service.
• Before servicing the water heater, make sure the bbwer
assembly is unplugged or the electrical supply to the
water heater istumed "OFF".
• Label all wires prior to disconnection when servicing
controls. Wiring error can cause improperand dangerous
operation. Verify proper operation after servicing.
• Failure to do this could res,ult in death, serious bedil_
injury, or property damage.
Breathing Hazard - Carbon Monoxide Gas
• Install vent system in accordance with codes.
• Do not operate water heater if flood damaged.
• For operation above 10,100' (3,079 m), a high
altitude orifice must be installed.
• Do not operate if soot buildup is present.
• Do not obstruct water heater air intake with
insulating jacket.
• Do not obstruct blower air intake.
• Do not place chemical vapor emitting products
near water heater.
• Gas and carbon monoxide detectors are
available.
• No vent damper installation is compatible with
this power vented water heater.
Breathing carbon monoxide can cause brain damage or death•
Always read and understand instruction manual.
Flammable Vapors
Fire or Explosion Hazard
• Do not store or use gasoline or other flammable vapors
and liquids inthe vicinity of this or any other appliance.
• Avoid all ignition sources if you smell gas.
• Do not expose water heater control to excessive gas
pressure.
• Use only gas shown on rating plate.
• Maintain required clearances to combustibles.
• Keep ignition sources away from faucets after extended
period of non-use.
installing, using or servicing
Read instruction manual before ,_
water heater.
iq_uVapors from flammable
s may explode and
catch fire causing death or
severe burns.
Do not use or store
flammable products such as
gasoline, solvents or adhe-
sives in the same room or
area near the water heater.
Water heater has a main
burner and hot surface igniter.
The hot surface igniter:
1. can be triggered at any
time and
2. the hot surface will ignite
flammable vapors.
Vapors:
1. cannot be seen,
2. are heavier than air,
Keep flammable products:
1. far away from heater,
2. in approved containers,
3. tightly closed and
4. out of children's reach.
3. go a long way on the floor
and
4. can be carried from other
rooms to the the
electodes by air currents.
Installation: Do not install the water heater where flammable
products will be stored or used.
SAFE INSTALLATION, USE AND SERVICE 2
SAFETY PRECAUTIONS 3
TABLE OF CONTENTS 5
PRODUCT WARRANTY 6
CUSTOMER RESPONSIBILITIES 7
Qualified Installer Or Service Agency ........... 8
Preparing For The Installation ................. 8
PRODUCT SPECIFICATIONS 9
INSTALLATION REQUIREMENTS FOR THE
COMMONWEALTH OF MASSACHUSETTS 9
MATERIALS AND BASIC TOOLS NEEDED 11
TYPICAL INSTALLATION 12
Get To Know Your Water Heater - Gas Models... 12
IMPORTANT INFORMATION ABOUT THIS WATER
HEATER 14
Installation Checklist ....................... 14
INSTALLATION INSTRUCTIONS 15
Removing the Old Water Heater .............. 15
Facts To Consider About The Location ......... 16
Storage Of Flammable Liquids ............... 17
Clearances To Combustibles ................ 17
Floors With Carpeting ...................... 18
Clearance For Servicing .................... 18
Insulation Blankets ........................ 19
GAS SUPPLY 20
Gas Piping .............................. 20
Sediment Traps/Dirt Leg .................... 21
High Altitude Installation .................... 21
COMBUSTION AIR SUPPLY & VENTILATION 22
Air Requirements ......................... 22
Unconfined Space ......................... 22
Unusually Tight Construction ................ 22
Confined Space .......................... 22
Direct Vent Appliances ..................... 22
Exhaust Fans ............................ 22
Fresh Air Openings For Confined Spaces ...... 22
All Air From Inside Buildings ................. 23
All Air From Outdoors ...................... 23
Chemical Vapor Corrosion .................. 24
VENTING 25
Exhaust Venting .......................... 25
Planning The Vent System .................. 25
High Ambient Temperature Installations ........ 26
Polypropylene Vent Systems ................ 26
Condensate .............................. 27
Venting Terminations and Sizing .............. 27
Vent Screen Installation .................... 28
Important Notes and Warnings ............... 28
Termination Clearances Sidewall Power Vent ... 29
Calculating Equivalent Feet ................. 30
Vent Pipe Preparation ...................... 31
Venting Installation ........................ 33
Vent Pipe Connection To Blower .............. 35
Different Coupling Installations According To Vent
Sizes ................................... 35
Blower Exhaust Direction ................... 36
Blower Assembly Installation ................ 36
WATER SYSTEM PIPING 37
Water Piping ............................. 37
Mixing Valve Usage ........................ 38
Closed Water Systems ..................... 39
Thermal Expansion ........................ 39
Temperature-Pressure Relief Valve ........... 39
T&P Valve Discharge Pipe Requirements ....... 40
Temperature-Pressure Relief Valve and Pipe
Insulation ................................ 40
Filling The Water Heater .................... 41
ELECTRICAL SUPPLY 42
Electrical Requirements & Wiring Diagram ...... 42
SAFETY LOCKOUTS 44
System Status LED Indicator Light ............ 44
High Limit Controls (Energy Cut Off) ........... 44
Thermostat/Water Temperature .............. 44
Blower High Limit Switch ................... 44
Blower Air Pressure Switch .................. 44
Flammable Vapor Sensor ................... 44
LIGHTING INSTRUCTIONS 45
OPERATING YOUR WATER HEATER 46
Water Heater Operation .................... 46
Temperature Regulation .................... 46
Gas Control Valve/thermostat ................ 47
SERVICE AND ADJUSTMENT 48
General Upkeep .......................... 48
Venting System Inspection .................. 48
Blower Maintenance ....................... 48
Cleaning The Blower ....................... 48
Burner Operation And Inspection ............. 49
Combustion Chamber And Burner Cleaning ..... 50
Housekeeping ............................ 50
Anode Rod Inspection ...................... 50
Anode Rod .............................. 51
Removing Anode Rod ...................... 51
Installing Anode Rod ....................... 51
Temperature-Pressure Relief Valve Test ........ 52
Draining And Flushing ...................... 52
To Drain The Water Heater Storage Tank ....... 53
To Flush The Water Heater Storage Tank ....... 53
Service ................................. 53
TROUBLESHOOTING GUIDE 54
Start Up Conditions ........................ 54
Condensate .............................. 54
Thermal Expansion ........................ 54
Smoke/Odor ............................. 55
Strange Sounds .......................... 55
Operational Conditions ..................... 55
Smelly Water ............................. 55
"Air" In Hot-water Faucets ................... 56
Leakage Checkpoints ...................... 57
TROUBLESHOOTING CHECKLIST 58
Resetting The Heater Control ................ 61
Lockouts ................................ 61
Soft Lockout ............................. 61
Hard Lockout ............................. 61
Ignition State And Timing ................... 61
System Status And Error Codes .............. 62
Reading The LED Flash Sequence ............ 62
Corrective Actions ......................... 63
PARTS ORDER LIST 66
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:
. Supply free water heater parts for those that are defective in material or workmanship.
• Supply a free water heater for one that develops a tank 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.
If governmental regulations prohibit Sears from furnishing a comparable model replacement water heater under this warranty, Sears will
furnish a new water heater of comparable output as permitted by such governmental regulations; however, the Owner will be charged
for the additional cost associated with the changes made to comply with such governmental regulations.
Replacements furnished under this warranty do not carry a new warranty; and are only covered by the unexpired portion of the original
warranty•
1 - YEAR EXCLUSIVE KENMORE LABOR WARRANTY
For the first year from the date of purchase, Sears will, free of charge, supply and install new water heater parts for defective ones or a
new water heater for one that develops a leak.
WARRANTY SERVICE
To obtain warranty service, call 1-8O0-4-MY-HOME ®(1-800-469-4663).
This warranty applies only while this product is in use in the United States.
This warranty gwes you specific lega/rights, and you may also have other rights which vary from state to state.
SEARS BRANDS MANAGEMENT CORPORATION, Hoffman Estates, IL 60179
The price of your water heater does not include a free checkup service call. On water heater installations arranged by Sears, Sears
warrants the installation.
A charge will be made on service calls due to poor or incomplete installation. These include:
a. Adjusting thermostat b. Condensation c. Leaks in pipes or fittings
Master Protection Agreements
Congratulations on making a smart purchase. Your new 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.
The Master Protection Agreement also helps extend the life of your
new product. Here's what the Agreement* includes:
• Parts and labor needed to help keep products operating
properly under normal use, not just defects. Our coverage
goes well beyond the product warranty. No deductibles, no
functional failure excluded from coverage-- real protection.
• Expert service by a force of more than 10,000 authorized
Sears service technicians, which means someone you can
trust will be working on your product.
• Unlimited service calls and nationwide service, as often as
you want us, whenever you want us.
• "No-lemon" guarantee - replacement of your covered product
if four or more product failures occur within twelve months.
• Product replacement if your covered product can't be fixed.
• Annual Preventive Maintenance Check at your request - no
extra charge.
• Fast help by phone - we call it Rapid Resolution - phone
support from a Sears representative on all products. Think of
us as a "talking owner's manual."
• Power surge protection against electrical damage due to
power fluctuations.
• $250 Food Loss Protection annually for any food spoilage
that is the result of mechanical failure of any covered
refrigerator or freezer.
• Rental reimbursement if repair of your covered product takes
longer than promised.
• 10% discount off the regular price of any non-covered repair
service and related installed parts.
Once you purchase the Agreement, a simple phone call is all that it
takes for you to schedule service. You can call anytime day or night,
or schedule a service appointment online.
The Master Protection Agreement is a risk free purchase. If you
cancel for any reason during the product warranty period, we
will provide a full refund. Or, a prorated refund anytime after the
product warranty period expires. Purchase your Master Protection
Agreement today!
Some limitations and exclusions apply. For prices and
additional information in the U.S.A. call 1-800-827-6665.
* Coverage in Canada varies on some items. For full details,
call Sears Canada at 1-800-361-6665.
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.
or Canada call 1-800-4-MY-HOME <"_.
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
• UL- Underwriters Laboratories Inc.
• AHRI -Air Conditioning, Heating and Refrigeration
Institute.
• LLC- Low Lead Content
This gas-fired water heater is design certified by
CSA International, under Water Heater Standard
ANSI Z21.10.1 • CSA 4.1 (current edition).
• Carefully plan the place where you are going
to put the water heater. Correct combustion,
vent action, and vent pipe installation are very
important in preventing death from possible
carbon monoxide poisoning and fires. See
Figure 1.
• Examine the location to ensure the water heater
complies with the Installation Instructions section
in this manual.
For California installation, this water heater
must be braced, anchored, or strapped to avoid
falling or moving during an earthquake. See
instructions for correct installation procedures.
Instructions may be obtained from California's
Office of the State Architect, 1102 Q Street,
Suite 5100, Sacramento, CA 95811. Instructions
can also be downloaded to your computer at
www.dsa.dgs.ca.gov/Pubs.
• 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 40 Ng/J NOx requirements of
Texas and most California AQM Districts.
This water heater has been developed to heat
potable water for normal residential demands
and may also be used in combination with space
heating applications. It is not designed to be
solely used in space heating (hydronic heating)
applications. Do not install this heater in space
heating (hydronic heating) only applications.
This manual contains instructions for the
installation, operation, and maintenance of the
gas-fired water heater. It also contains warnings
through out the manual that you must read and
be aware of. All warnings and all instructions are
essential to the proper operation of the water heater
and your safety. Since we cannot put everything on
the first few pages, READ THE ENTIRE MANUAL
BEFORE ATTEMPTING TO INSTALL OR
OPERATE THE WATER HEATER.
• If after reading this manual you have any
questions or do not understand any portion of
the instructions, call the Sears Service Center.
Excessive Weight Hazard
Use two or more people to move and install
water heater.
Failure to do so can result in back or
other injury.
IMPORTANT: Do not remove any permanent
instructions, labels, or the data label from either the
outside of the water heater or on the inside of water
heater panels.
• Remove exterior packaging and place
installation components aside.
• Inspect all parts for damage prior to installation
and start-up.
• Completely read all instructions before
attempting to assemble and install this product.
• After installation, dispose of/recycle all
packaging materials.
Qualified Installer Or Service Agency
Installation and service of this water heater requires
ability equivalent to that of a Qualified Agency
(as defined by ANSI below) in the field involved.
Installation skills such as plumbing, air supply,
venting, gas supply and electrical supply are
required in addition to electrical testing skills when
performing service.
ANSI Z223.1 2006 Sec. 3.3.83: "Qualified Agency"
-"Any individual, firm, corporation or company
that either in person or through a representative
is engaged in and is responsible for (a) the
installation, testing or replacement of gas piping
or (b) the connection, installation, testing, repair
or servicing of appliances and equipment; that
is experienced in such work; that is familiar with
all precautions required and that has complied
with all the requirements of the authority having
jurisdiction."
If you are not qualified (as defined by ANSI above)
and licensed or certified as required by authority
having jurisdiction to perform a given task, do not
attempt to perform any of the procedures described
in this manual. If you do not understand the
instructions given in this manual do not attempt to
perform any procedures outlined in this manual.
Preparing For The Installation
1. Read the "Safety Precautions" section of this
manual first and then entire manual carefully.
If you don't follow safety rules, the water
heater will not operate properly. Itcould cause
DEATH, SERIOUS BODILY INJURY AND/OR
PROPERTY DAMAGE.
This manual contains instructions for
installation, operation, and maintenance of the
gas-fired water heater. Italso contains warnings
throughout the manual that you must read
and be aware of. All warnings and instructions
are essential to proper operation of the water
heater and your safety. Since we cannot put
everything on the first few pages, READ
ENTIRE MANUAL BEFORE ATTEMPTING
TO INSTALL OR OPERATE THE WATER
HEATER.
, The installation must conform with these
instructions and local code authority having
jurisdiction. In absence of local codes,
installation must comply with current editions
of the National Fuel Gas Code, ANSI Z223.1/
NFPA 54 and National Electrical Code, NFPA
70. All documents are available from:
CSA International,
8501 East Pleasant Valley Road,
Cleveland, Ohio, United States
44131-5575.
NFPA documents are also available from:
National Fire Protection Association,
1 Batterymarch Park,
Quincy, MA 02269.
The water heater, when installed, must be
electrically grounded in accordance with the
local codes or in the absence of local codes:
the National Electrical Code (NFPA 70).
3. If after reading this manual you have any
questions or do not understand any portion
of the instructions, call the local gas utility or
the manufacturer whose name appears on the
rating plate.
4. 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
Figures 11 and 12). Examine the location to
ensure the water heater complies with the
"Facts To Consider About The Location" section
in this manual.
5. Complies with California Health and Safety
code 116875 (known as AB-1953) and with
weighted average maximum of 0.25% lead.
153.331350 40 (151) NATURAL 50,000 55.9 2 (51) 20 (508) 59 1/8 (1,502)
153.331360 50 (189) NATURAL 50,000 55.9 2 (51) 22 (559) 58 3/4 (1,492)
COMMONWEALTH OF MASSACHUSETTS
For all side wall terminated, horizontally vented power vent, direct vent and power direct vent gas fueled
water heaters installed in every dwelling, building or structure used in whole or in part for residential
purposes, including those owned or operated by the Commonwealth and where the side wall exhaust
vent termination is less than seven (7) feet above finished grade in the area of the venting, including but
not limited to decks and porches, the following requirements shall be satisfied:
INSTALLATION OF CARBON MONOXIDE DETECTORS
At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber
or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up
is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber
or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm
is installed on each additional level of the dwelling, building or structure served by the sidewall horizontal
vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of
qualified licensed professionals for the installation of hard wired carbon monoxide detectors.
In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an
attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the
next adjacent floor level.
In the event that the requirements of this subdivision can not be met at the time of completion of
installation, the owner shall have a period of thirty (30) days to comply with the above requirements
provided that during said thirty (30) day period, a battery operated carbon monoxide detector with an
alarm shall be installed.
APPROVED CARBON MONOXIDE DETECTORS
Each carbon monoxide detector as required in accordance with the above provisions shall comply with
NFPA 720 and be ANSI/UL 2034 listed and CSA certified.
SIGNAGE
A metal or plastic identification plate shall be permanently mounted to the exterior of the building
at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for
the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size
no less than one- half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL
OBSTRUCTIONS."
INSPECTION
The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not
approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and
signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1through 4.
EXEMPTIONS
Thefollowingequipmentisexemptfrom248CMR5.08(2)(a)1through4:
1. TheequipmentlistedinChapter10entitled"EquipmentNotRequiredToBeVented"inthemost
currenteditionof NFPA54asadoptedbytheBoard;and
2. ProductApprovedsidewallhorizontallyventedgasfueledequipmentinstalledinaroomorstructure
separatefromthedwelling,building,orstructureusedinwholeorinpartforresidentialpurposes.
MANUFACTURERREQUIREMENTS-GASEQUIPMENTVENTINGSYSTEMPROVIDED
WhenthemanufacturerofProductApprovedsidewallhorizontallyventedgasequipmentprovidesa
ventingsystemdesignorventingsystemcomponentswiththeequipment,theinstructionsprovidedbythe
manufacturerforinstallationoftheequipmentandtheventingsystemshallinclude:
1. Detailedinstructionsfortheinstallationoftheventingsystemdesignortheventingsystem
components;and
2. Acompletepartslistfortheventingsystemdesignorventingsystem.
MANUFACTURERREQUIREMENTS-GASEQUIPMENTVENTINGSYSTEMNOTPROVIDED
WhenthemanufacturerofProductApprovedsidewallhorizontallyventedgasfueledequipmentdoes
notprovidethepartsforventingthefluegases,butidentifies"specialventingsystems,"thefollowing
requirementsshallbesatisfiedbythemanufacturer:
1. Thereferenced"specialventingsystem"instructionsshallbeincludedwiththeapplianceor
equipmentinstallationinstructions;and
2. The"specialventingsystems"shallbeProductApprovedbytheBoard,andtheinstructionsforthat
systemshallincludea partslistanddetailedinstallationinstructions.
AcopyofallinstallationinstructionsforallProductApprovedsidewallhorizontallyventedgasfueled
equipment,allventinginstructions,allpartslistsforventinginstructions,and/orallventingdesign
instructionsshallremainwiththeapplianceorequipmentatthecompletionoftheinstallation.
10
MATERIALS NEEDED
To simplify the installation, Sears has available the installation parts shown below. You may or may not need all of these materials,
depending on your type of installation.
METAL DRAIN PANS AVAILABLE IN THE
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"
(t9.05 ram) COPPER PLUMBING AND FLEXIBLE
GAS CONNECTOR WITH FITTINGS.
FOLLOWING SIZES:
• 20" (508 ram) DIAMETER FOR WATER
HEATERS HAVING A DIAMETER OF
18" (457 ram) OR LESS.
• 24" (610ram) DIAMETER FOR WATER
HEATERS HAVING A DIAMETER 22"
(559 ram) OR LESS.
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 Teflon ® Tape DRILL
SLOT-HEAD SCREWDRIVER
PHILLIPS SCREWDRIVER
ROLL OF TEFLON ® (SQUEEZE TUBE)
TAPE (USE ONLY ON USE FOR WATER AND GAS
WATER CONNECTIONS) CONNECTIONS
GARDEN HOSE 6 FOOT TAPE PIPE WRENCH
TIN SNIPS
ADDITIONAL TOOLS NEEDED
WHEN SWEAT SOLDERING
Tubing Cutters or Hacksaw
Propane Torch
Soft Solder
Solder Flux
Emery Cloth
Wire Brushes
TUBING CUTTER
HACKSAW
3/4" (q9 mm)WIRE BRUSH
ROLL OF LEAD-FREE
1/2" (13 ram) WIRE BRUSH
SOFTSOLDER
PROPANE
TORCH
ROLLOF
EMERY CLOTH
B
SOLDER
FLUX
11
Get To Know Your Water Heater - Gas Models
18-------
17j
16
3
/
/5
21
21
/
26
22
4
Blower
Dilution Air
Inlets
Combustion
Air Inlets
25
q
\
"4
22
117
Item 9 detail
Front View
Figure 1
30 .----.........._
27
Figure 2
®
28
12
Rear View
Figure 3
Item 19 detail
Power Cord
Figure 4
1 Vent Termination Elbow with Rodent Screen
2 *Vent Pipe
3 T&P Valve
4 Cold-Water Inlet Nipple/Diptube
5 Gas Control Valve/Thermostat (Honeywell)
6 **Control Harness
7 Drain Valve
8 Outer Gas Door
9 Manifold Door Assembly (behind outer door) (see Figure 2)
10 *Floor Drain
11 *Metal Drain Pan
12 Flammable Vapor Sensor (under cover)
13 *Sediment Trap/Dirt Leg
14 *Ground Joint Union (gas connection)
15 *Main Manual Gas Shut-off Valve
16 *Gas Supply
17 Baffle Assembly
18 Rating Plate
19 Blower with Power Cord
20 Rubber Coupling
21 *Inlet Water Shut-off Valve
22 *Union (water connection)
23 Hot-Water Outlet Nipple
24 Anode (under cap)
25 Air Inlet Snorkel
26 *Thermal Expansion Tank (required for all closed systems)
27 Flame Sensor Rod (see Figure 2)
28 Hot-Surface Igniter (see Figure 2)
29 Manifold Door (see Figure 2)
30 Burner
31 Blower High Limit Switch
32 Blower Air Pressure Switch
33 2" Rubber Coupling
Notes:
* Items not supplied with the water heater
** CAUTION: HARNESS HAS 120 VAC IN OPERATION.
13
This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a
flammable vapor ignition incident. The new technology used in meeting these standards makes this
product more sensitive to installation errors. Please review the following checklist and make any required
installation upgrades or changes.
Questions? Contact Sears at 1-800-4-MY-HOME (1-800-469-4663).
Installation Checklist
NOTE: Use and complete this checklist before
lighting the heater. Correct any conditions that do
not meet these instructions.
Water Heater Location
[] Centrally located with the water piping system.
Located as close to gas piping and vent pipe
system as possible.
[] Located indoors and in a vertical position.
Protected from freezing temperatures.
[] Proper clearances from combustible surfaces
maintained and not installed directly on a
carpeted floor.
[] Provisions made to protect the area from water
damage. Metal drain pan installed and piped to
an adequate drain.
[] Installation area free of corrosive elements and
flammable material.
[] Sufficient room to service the water heater.
Gas Supply and Piping
[] Gas supply is the same type as listed on the
water heater data plate.
[] Gas line equipped with shut-off valve, union
and dirt leg
[] Approved pipe joint compound used.
[] Adequate pipe size and of approved material.
[] Chloride-free soap and water solution or other
approved means used to check all connections
and fittings for possible gas leaks.
Water System Piping
[] Temperature and Pressure relief valve properly
installed with a discharge line run to an open
drain and protected from freezing.
[] All piping properly installed and free of leaks.
[] Heater completely filled with water.
[] Closed system pressure build-up precautions
installed.
Vent Pipe System
[] Vent pipe and fittings of approved material.
[] Acceptable size, length and number of elbows
on exhaust vent system.
[] Installed in accordance with prevailing
provisions of local codes, or in the absence of
such, the latest edition of "National Fuel Gas
Code" ANSI Z223.1 (NFPA 54).
[] Horizontal piping slopes at an upward pitch of
1/8 in. (3mm) rise per 4 ft. (1.2m) away from
the water heater.
[] Not obstructed in any way.
Vent Termination
Horizontal
[] 12 in. (300mm) min. above grade/snow level.
[] Away from corners, other vents, windows etc.
Vertical
[] Exhaust vent termination 18 in. (457mm) min.
above roof/snow level.
Electrical Connections
[] Unit connected to a dedicated 120V electrical
supply.
[] Proper polarity.
[] Water heater properly grounded.
[] Installed in accordance with prevailing
provisions of local codes, or in the absence of
such, the latest edition of "National Electrical
Code" (NFPA 70)".
After all actions on checklist are checked/
completed, read the Lighting Instructions and
proceed with lighting the heater.
14
Removing the Old Water Heater
®
@ ®
®
MANUAL GAS
SHUT-OFF
UNION
JOINT
CHECK WITH
LOCAL UTILITY
FOR MINIMUM HEIGHT
J 3" MINIMUM
DIRT LEG
DRAIN LINE MUST PASS THROUGH FLOOR _
AND TERMINATE EXTERNAL TO BUILDING
,,
(DO NOT CAP
OR PLUG)
Figure 5
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 5 and 6.
Figure 6
2. Open a nearby hot water faucet until the water
is no longer hot. When the water has cooled,
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 5 and 7.
Figure 7
,
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.
,
Attach a hose to the water heater drain valve
and put the other end in a floor drain or
outdoors. (See Figures 5 and 8.) Open the water
heater drain valve. The water passing out of
the drain valve may be extremely hot. To avoid
being scalded, make sure all connections are
tight and that the water flow is directed away
from any person.
Figure 8
,
Disconnect the vent pipe from the draft hood or
blower 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 blower coupling which must
be used for proper operation.
,
If you have copper piping to the water heater,
the two copper water pipes can be cut with a
hacksaw or tubing cutter approximately four
inches away from where they connect to the
water heater. See Figure 9. This will avoid
cutting off pipes too short. Additional cuts can
be made later if necessary. Disconnect the
temperature-pressure relief valve discharge
pipe. 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.
15
Figure9
Ifyouhavegalvanizedpipestothewaterheater,
loosenthetwogalvanizedpipeswithapipe
wrenchattheunionineachline.Alsodisconnect
thepipingremainingtothewaterheater.See
Figure10.Thesepiecesshouldbesavedsince
theymaybeneededwhenreconnectingthenew
waterheater.Mineralbuilduporsedimentmay
haveaccumulatedintheoldwaterheater.This
causesthewaterheatertobemuchheavier
thannormalandthisresidue,ifspilledout,could
causestaining.
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:
1. Select a location indoors as close as practical
to the vent termination or location to which
the water heater vent piping is going to be
connected, and as centralized with the water
piping system as possible.
2. Selected location must provide adequate
clearances for servicing and proper operation
of the water heater.
3. Ensure the area has a continuous supply of air
for combustion, dilution and ventilation.
4. Avoid locations that could cause the water
heater to freeze from outside air.
5. Selected location must provide access to a
properly grounded electrical branch circuit. A
dedicated circuit is preferred. Do not use a GFI
outlet.
6. Avoid locations that expose the water heater to
direct sunlight.
7. Keep combustibles such as boxes, magazines,
clothes, etc., away from the water heater area.
8. The water heater must be located and/or
protected so it is not subject to physical
damage by a moving vehicle.
IMPORTANT: Do not use an extension cord to
connect the water heater to an electrical outlet.
IMPORTANT: This heater has special venting
requirements when installed in areas where the
ambient temperatures exceed 110°F (43°C) (see
"Hi( h Ambient Tem )erature Installations"
Property Damage Hazard
• All water heaters eventually leak.
• Do not install without adequate drainage,
Installation of the water heater must be
accomplished in such a manner that if the tank
or any connections should leak, the flow of water
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. In all cases, a metal drain
16
pan should be installed under the water heater.
Such a metal drain pan must have a clearance of
at least 1" (25mm) greater than any point on the
water heater's outer jacket and must be piped to
an adequate drain. The pan must have a maximum
depth of 1.75" (45mm).
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 metal drain pan piped to a drain. However,
unanticipated damage can be reduced or prevented
by a leak detector or water shut-off device used in
conjunction with a piped metal drain pan. These
devices are available from some plumbing supply
wholesalers and retailers, and detect and react to
leakage in various ways:
• Sensors mounted in the metal drain pan that
trigger an alarm or turn off the incoming water to
the water heater when leakage is detected.
• Sensors mounted in the metal drain pan that
turn off the water supply to the entire building
when water is detected in the metal 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.
• Devices that will turn off the gas supply to a gas
water heater while at the same time shutting off
its water supply.
producing appliance. Examples of such locations
are garages, storage and utility areas.
Fire or Explosion Hazard
• Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
• Avoid all ignition sources if you smell gas.
• Do not expose water heater control to excessive gas
pressure.
• Use only gas shown on rating plate.
• Maintain required clearances to combustibles.
• Keep ignition sources away from faucets after extended
period of non-use,
installing, using or servicing
l_ Read instruction manual before
,_Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance. Storage or
use of gasoline or other flammable vapors or liquids in the
vicinity of this or any other appliance can result in serious injury
or death.
water heater.
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
Storage Of Flammable Liquids
Flammable liquids (such as gasoline, solvents,
propane (LP or butane, etc.) and other substances
(such as adhesives, paints, etc.) emit flammable
vapors which can be ignited by a gas water
heater's hot surface igniter (HSI) or main burner.
The resulting flashback and fire can cause death or
serious burns to anyone in the area.
This water heater is equipped with a FV
(Flammable Vapor) sensor for detecting the
presence of flammable vapors. When the sensor
detects those vapors, the unit will shut down and
not operate. Should this happen, please refer
to the "Troubleshooting Guidelines" section of
this manual. Even though this water heater is a
flammable vapors ignition resistant (FVlR) 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
Fire Hazard
For continued protection against
risk of fire:
• Do not install water heater on
carpeted floor.
• Do not operate water heater if
flood damaged.
Clearances To Combustibles
Minimum clearances between water heater and
combustibles are 0" at the sides and rear, 5.5"
(140mm) from the front and 12" (300mm) from top
(standard clearance.) If clearances stated on the
heater differ from standard clearances, install water
heater according to clearances stated on the heater
(see Figure 11).
NOTE: Do not block air intakes at the rear of the
water heater.
17
Floors With Carpeting
This water heater must not be installed directly on
carpeting. Carpeting must be protected by a metal
or wood panel beneath the appliance extending
beyond the full width and depth of the appliance
by at least 3" (76mm) in every 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.
Breathing Hazard -Carbon Monoxide Gas
• Install water heater in accordance with the
instruction manual and NFPA54.
• To avoid injury, combustion and ventilation air
must be taken from outdoors.
• Do not place chemical vapor emitting products
near water heater.
Clearance For Servicing
Adequate clearance of 24" (610mm) for servicing
this appliance should be considered before
installation, such as changing the anodes, etc.
A minimum clearance of 5.5" (140mm) must be
allowed for access to replaceable parts such as
thermostats, drain valve and relief valve.
When installing the heater, consideration must
be given to proper location. Location selected
should be as close to the wall as practicable and
as centralized with the water piping system as
possible.
TOP VIEW
OF CLOSET
WITHOUT DOOR
0" MIN. _
0" MIN.' _'-
* DO NOT BLOCK THE AIR INTAKES AT THE BACK OF THE WATER HEATER.
5.5" (14cm)
MIN. TO
INSIDE OF
DOOR"
Figure 11
IMPORTANT: This gas water heater cannot operate
properly without the correct amount of air for
combustion, dilution and ventilation. Do not install
in a confined area such as a closet unless you
provide air as shown below and described in the
"Air Requirements" section (see Figure 12). Never
obstruct the flow of air required for combustion,
dilution and ventilation. 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.
TOP VIEW OF
CLOSET WITH
DOOR
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
12" MAX. /
(305mm)
.... A VENTILATION
-IUUSq In _ I AIR
(645 sq. cm) _1 OPENING O
eacn
FRONT VIEW
OF DOOR
-- 12" MAX.
I RECTAIIGULAR ( 3" MIN.
(305mm)
AiRDUCT (76mm)
AIR DUCT
Figure 12
If this water heater will be used in beauty shops,
barber shops, cleaning establishments, or self-
service laundries with dry cleaning equipment, it is
imperative that the water heater or water heaters be
installed so that combustion and ventilation air be
taken from outside these areas.
Propellants of aerosol sprays and volatile
compounds, (cleaners, chlorine based chemicals,
refrigerants, etc.)in addition to being highly
flammable in many cases, will also react to form
corrosive hydrochloric acid when exposed to the
combustion products of the water heater. The
results can be hazardous, and also cause product
failure.
18
Insulation Blankets
Insulation blankets are available to the general
public for external use on gas water heaters but are
not necessary with these products The purpose
of an insulation blanket is to reduce standby
heat loss encountered with storage tank heaters
Your water heater meets or exceeds the current
standards with respect to insulation and standby
loss requirements making an insulation blanket
unnecessary
Should you choose to apply an insulation blanket
to this heater you should follow these instructions
(For identification of components mentioned below
see Figures 14) Failure to follow these instructions
can restrict the air flow required for proper
combustion, dilution and ventilation potentially
resulting in fire asphyxiation serious personal
injury or death
• Do not apply insulation to the top of the water
heater as this will interfere with safe operation
of the blower assembly
• Do not cover the outer door thermostat or T&P
relief valve FV sensor or Air Intake Snorkel
• Do not cover the Use & Care Guide Keep it on
the side of the water heater or nearby for future
reference
• Do obtain new warning and instruction labels
from the manufacturer 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
Breathing Hazard - Carbon Monoxide Gas
• Do not obstruct water heater air intake(s) with
insulating jacket.
• Gas and carbcn monoxide detectors are available.
• install water heater in accordance with the
instruction manual and NFPA54.
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
19
Gas Piping
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.
Fire and Explosion Hazard
• Do not use water heater with
any gas other than the gas
shown on the rating plate.
• Excessive pressure to gas
control valve can cause serious
injury or death.
• Turn off gas lines during
installation.
• Contact qualified installer or
service agency.
Explosion Hazard
Havea qualifiedtechnicianmake surethat the L.P.
gasoperating pressuredoes notexceed13" water
column (3.237kilopascals).
Failureto do so can resultin death, explosion,or
fire.
Make sure the gas supplied is the same type listed
on the model rating plate. The inlet gas pressure
must not exceed 14 inch w.c. (3.5kPa) for natural
gas and propane gas. The minimum inlet gas
pressure shown on the rating plate is that which will
permit firing at rated input.
There must be:
• A readily accessible manual shut-off valve in the
gas supply line serving the water heater, and
• A sediment trap (dirt leg) ahead of gas control
valve/thermostat to help prevent dirt and foreign
materials from entering the gas control valve/
thermostat.
• Aflexible gas connector or a ground joint union
between the shut-off valve and gas control
valve/thermostat to permit servicing of the unit.
Connecting gas piping to the gas control valve/
thermostat of water heater can be accomplished by
either of two methods shown in Figures 13 and 14.
GROUND JOINT FLEX PIPE
UNION "_ I ./
(OPTIONA_
3" MIN. _ I I SEDIMENT TRAP GAS
(76mm} _ I I (DIRT LEG) CONTROL
T _ VALVE
CAP
Figure 13
GROUND JOIN1
UNION
(OPTIONAL)
All gas piping must comply with local codes and
ordinances or with the National Fuel Gas Code
(ANSI Z223.1/NFPA-54). Copper or brass tubing
and fittings (except tin lined copper tubing) should
not be used.
If the gas control valve/thermostat is subjected to
pressures exceeding 1/2 psi (3.5kPa), the damage
to the gas control valve/thermostat could result in a
fire or explosion from leaking gas. 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.
CAP
Figure 14
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. Repair and
retest as required. When finished, rinse off soapy
solution and wipe dry.
2O
Fire and Explosion Hazard
• Use joint compound or tape
compatible with natural gas
and propane.
• Leak test before operating
heater.
• Disconnect gas piping and
shut-off valve before pressure
testing system.
Use pipe joint compound or Teflon tape marked as
being resistant to the action of gases.
The appliance and its gas connection must be leak
tested before placing the appliance in operation.
The appliance and its individual shut-off valve
should be disconnected from the gas supply piping
system during any pressure testing of that system
at test pressures in excess of 1/2 psi (3.5kPa).
It should 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 psi (3.5kPa).
Sediment Traps/Dirt Leg
Fire and Explosion Hazard
• Contaminants in gas lines can
cause fire or explosion.
• Clean all gas piping before
installation.
• Install sediment trap (dirt leg)
in accordance with NFPA54.
A sediment trap should be installed as close to the
inlet of the water heater as practical at the time of
water heater installation. The sediment trap should
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
should be installed in conformance with one of the
methods of installation shown in Figures 13 and 14.
Contaminants in the gas lines may cause improper
operation of the gas control valve/thermostat 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 sediment trap (sometimes called
a dirt leg) must be incorporated in the piping. The
sediment trap must be readily accessible. Install in
accordance with the "Gas Piping" section. Refer to
the current edition of the National Fuel Gas Code
(ANSI Z223.1/NFPA 5 4).
High Altitude Installation
Breathing Hazard -Carbon Monoxide Gas
• For operation above 10,100 ft.
(3,048 metres) a high altitude
orifice must be installed.
• Contact a qualified installer or
service agency.
Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.
This heater is approved for operation up to 10,100
feet (3,079 m) without alteration.
Failure to replace standard orifice with a high
altitude orifice when installed above 10,100 feet
(3,079 m) could result in improper and inefficient
operation of the appliance, producing carbon
monoxide gas in excess of safe limits, which could
result in serious injury or death. Contact your gas
supplier for any specific changes which may be
required in your area.
21
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