Kenmore 153.331472 User Manual
Owner’s Manual
KentnorG
POWER MISER™ 12
GAS WATER HEATER
FOR POTABLE WATER HEATING ONLY.
NOT SUITABLE FOR SPACE HEATING.
NOT FOR USE IN MOBILE HOMES.
MODEL NO.
153.331472
153.331572
40 Gallon
50 Gallon
Safety Instructions
Installation
Operation
Care and Maintenance
Troubleshooting
Parts List
ENEROYSTAR
This water heater complies with ANSI Z21.10.1current edition regarding the accidental or
unintended ignition of flammable vapors, such
as those emitted by gasoline.
AWARNING
Read and understand instruction
manual and safety messages
before installing, operating or
servicing this water heater.
Failure to follow instructions and
safety messages could result in
death or serious injury.
Instruction manual must remain
with water heater.
For Your Safety
AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER.
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
— Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
— 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.
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
www.sears.com
• If you cannot reach your gas supplier,
call the fire department.
— Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
PART NO. 315425-000
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 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 aiert symboi. it is used to aiert you to potentiai personai injury hazards.
A
Obey aii safety messages that foiiow this symboi to avoid possibie injury or death.
.DANGER
^W ARNING
^C AUTION
CAUTION
Aii safety messages wiii generaiiy teii you about the type of hazard, what can happen if you do not foiiow the safety message and
how to avoid the risk of injury.
DANGER indicates an imminentiy hazardous situation which, if not avoided, couid
resuit in death or injury.
WARNiNG indicates a potentiaiiy hazardous situation which, if not avoided, couid resuit
in death or injury.
CAUTiON indicates a potentiaiiy hazardous situation which, if not avoided, may resuit
in minor or moderate injury.
CAUTiON used without the safety aiert symboi indicates a potentiaiiy hazardous
situation which, if not avoided, couid resuit 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
• Qualified Technician: A qualified technician must have ability equivalent to a licensed tradesman in the fields of plumbing, air supply,
venting, and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the
installation of gas fired water heaters. The qualified technician must also be familiar with the design features and use of flammable vapor
ignition resistant water heaters, and have a thorough understanding of this instruction manual.
• Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing, air supply, venting
and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of
gas fired water heaters. The service agency must also have a thorough understanding of this instruction manual, and be able to perform
repairs strictly in accordance with the service guidelines provided by the manufacturer.
• 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.
© Sears, Roebuck and Co.
SAFETY PRECAUTIONS
AWARNING
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
A
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity of this
or any other appliance. Storage of 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.
Read and follow water heater warnings and instructions.
AWARNING
Read and understand instruction
manual and safety messages
before installing, operating or
servicing this v^ater heater.
Failure to follow instructions and
safety messages could result in
death or serious injury.
Instruction manual must remain
with water heater.
AWARNING
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.
ADANGER
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
temperaturesetting.
AWARNING
Fire or Explosion Harzard
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 Natural or LP 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.
Read instruction manual before
installing, using or servicing
water heater.
è
if
AWARNING
Explosion Hazard
' Overheated water can cause
watertank explosion.
' Properly sized temperature
and pressure relief valve must
be installed in opening
provided.
AWARNING
Breathing Hazard - Carbon Monoxide Gas
• Install vent system in accordance with
codes.
• Do not operate v/ate** heater if flood
damaged,
• High altitude orifice must be installed for
operation above 7.700 feet (2,347m).
• Do not operate if soot is present.
■ Do not obstruct water heater air intake
with insuiating jacket
• Do not place chemical vapcr emtting
products nea' water heater
• Gas and carbon monox.de detectors
are available
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
CAUTION
Improper Installation and use may result
In property damage.
• Do not operate water heater if flood damaged.
• Inspect and replace anode.
• Install in location with drainage.
• Fill tank with water before operation.
• Be alert for thermal expansion.
Refer to instruction manual for installation and service.
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE............................................................................................................................................ 2
SAFETY PRECAUTIONS..........................................................................................................................................................................2-3
PRODUCT WARRANTY.............................................................................................................................................................................. 6
CUSTOMER RESPONSIBILITIES..............................................................................................................................................................7
PRODUCT SPECIFICATIONS ...................................................................................................................................................................7
MATERIALS AND BASIC TOOLS NEEDED.............................................................................................................................................8
TYPICAL INSTALLATION............................................................................................................................................................................9
IMPORTANT INFORMATION ABOUT THIS WATER HEATER........................................................................................................... 10
Installation Checklist.........................................................................................................................................................................10
INSTALLATION INSTRUCTIONS....................................................................................................................................................... 11-14
Removing the Old Water Heater.....................................................................................................................................................11
Location Requirements.....................................................................................................................................................................12
Site Location.......................................................................................................................................................................................12
Insulation Blankets............................................................................................................................................................................13
Clearances and Accessibility.....................................................................................................................................................13-14
Filling the Water Heater....................................................................................................................................................................14
GAS SUPPLY.........................................................................................................................................................................................14-15
Gas Requirements............................................................................................................................................................................. 14
Gas Piping........................................................................................................................................................................................... 14
Gas Pressure.......................................................................................................................................................................................15
Gas Pressure Testing........................................................................................................................................................................15
LP Gas Only........................................................................................................................................................................................ 15
COMBUSTION AIR SUPPLY & VENTILATION.................................................................................................................................16-19
Unconfined Space..............................................................................................................................................................................16
Confined Space.................................................................................................................................................................................. 16
All Air from Inside the Building..................................................................................................................................................16-17
All Air from Outdoors........................................................................................................................................................................ 17
Louvers and Grilles......................................................................................................................................................................17-18
Vent Pipe System...............................................................................................................................................................................18
Draft Hood Installation......................................................................................................................................................................18
Vent Pipe Size.....................................................................................................................................................................................18
Vent Connectors...........................................................................................................................................................................18-19
Chimney Connection.........................................................................................................................................................................19
Vertical Exhaust Gas Vent................................................................................................................................................................19
WATER SYSTEM PIPING....................................................................................................................................................................20-21
Piping Installation..............................................................................................................................................................................20
Closed System/Thermal Expansion...............................................................................................................................................21
Temperature and Pressure Relief Valve........................................................................................................................................21
T&P Relief Valve and Pipe Insulation.............................................................................................................................................21
OPERATING YOUR WATER HEATER.............................................................................................................................................. 22-24
Lighting Instructions.........................................................................................................................................................................22
Checking the Draft.............................................................................................................................................................................23
Burner Flames....................................................................................................................................................................................23
Emergency Shut Down.....................................................................................................................................................................23
Water Temperature Regulation..................................................................................................................................................23-24
SERVICE AND ADJUSTMENT............................................................................................................................................................25-27
Tank (Sediment) Cleaning................................................................................................................................................................ 25
Vent System Inspection....................................................................................................................................................................25
Burner Inspection.............................................................................................................................................................................. 25
Burner Cleaning................................................................................................................................................................................. 25
Housekeeping.....................................................................................................................................................................................26
Anode Rod Inspection.......................................................................................................................................................................26
Temperature-Pressure Relief Valve Operation.............................................................................................................................26
Draining and Flushing.................................................................................................................................................................26-27
Service..................................................................................................................................................................................................27
MAINTENANCE OF YOUR WATER HEATER..................................................................................................................................28-31
Replacement Parts.............................................................................................................................................................................28
External Inspection & Cleaning of the Base-Ring Filter.............................................................................................................28
Removing the Manifold/Burner Assembly....................................................................................................................................28
Removing the Burner from the Manifold/Burner Assembly......................................................................................................28
Replacing the Thermocouple.....................................................................................................................................................28-29
Replacing the Pilot/ Pilot Tube Assembly.....................................................................................................................................29
Cleaning the Combustion Chamber and Flame-arrestor........................................................................................................... 29
Replacing the Manifold/Burner Assembly.................................................................................................................................... 30
Piezoelectric Igniter System............................................................................................................................................................30
Testing the Igniter System...............................................................................................................................................................31
Removing and Replacing the Gas Control Valve/Thermostat..................................................................................................31
FVIR System Operational Checklist...............................................................................................................................................31
TROUBLESHOOTING GUIDE............................................................................................................................................................. 32-34
Start Up Conditions......................................................................................................................................................................32-33
Operational Conditions............................................................................................................................................................... 33-34
TROUBLESHOOTING CHART............................................................................................................................................................35-36
PILOT LIGHT TROUBLESHOOTING FLOWCHART.............................................................................................................................37
PARTS ORDER LIST................................................................................................................................................................................. 38
PRODUCT WARRANTY
12 - Y E A R LIM ITED W ARRANTY O N W A TE R HEATER
For twelve 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 the twelfth 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 KENM O RE LABOR WARRA N TY
For the first year from the date of purchase. Sears will, free of charge, supply and install new water heater parts for defective
ones or a new water heater for one that develops a leak.
WARRANTY SERVICE
To obtain warranty service, call 1-800-4-MY-FIOME® (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 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. Flere’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.
• $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 1-800-827-6655.
• Coverage in Canada varies on some items. For full details,
call Sears Canada at 1-800-361-6665.
• 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
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®.
us as a “talking owner’s manual.”
• Power surge protection against electrical damage due to
power fluctuations.
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 Manuai:
• 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
Important Information About This Water Heater:
This gas water heater was manufactured to voluntary safety
standards to reduce the likelihood of a flammable vapor ignition
incident. New technology used in meeting these standards makes this
product more sensitive to installation errors or improper installation
environments. Please review the Installation Checklist found at the
end of the installation instructions section and make any required
installation upgrades or changes.
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,
BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER
HEATER.
READ THE ENTIRE MANUAL
• 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:
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.
• 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 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.
•
A WARNING
Excessive Weight Hazard
Use two or more people to move and install the water heater.
Failure to do so can result in injury (including back 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.
PRODUCT SPECIFICATIONS
MODEL
NUMBER
153.331472 40 (151) Naturai 40,000 40.9 3(76) OR 4 (102) 20 (508) 58.14 (1477)
153.331572 50 (189) Naturai 40,000 40.9 3(76) OR 4 (102) 22 (559) 57.28 (1455)
TANK CAPACITY
iN GALS (LTRS)
TYPE
OF
GAS
INPUT
RATE
(Btu/hr)
RECOVERY
RATE GALS.
PER HOUR
@ 90°F RISE
MINIMUM
VENT PIPE
DIA. INCHES
(mm)
DIAMETER
INCHES
(mm)
DIMENSIONS
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 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
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
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 AVAILABLE 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
Ò
PROPANE
TORCH
PHILLIPS SCREWDRIVER
ROLL OF TEFLON
TAPE (USE ONLY ON
WATER CONNECTIONS)
GARDEN HOSE
6 FOOT TAPE
TIN SNIPS
L.0PC
c
PIPE DOPE
(SQUEEZE TUBE)
USE FOR WATER AND GAS
CONNECTIONS
PIPE WRENCH
CH=
HACKSAW
3/4” (19 mm) WIRE BRUSH
ROLL OF LEAD-FREE
1/2” (13 mm) WIRE BRUSH SOFT SOLDER
ROLL OF
EMERY CLOTH
SOLDER
FLUX
TYPICAL INSTALLATION
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A Vent Pipe J Inner Door S Thermostat
B Draft Hood K Outer Door T Drain Valve
c Anode (Not Shown) L Union u Pilot and Main Burner
D Hot Water Outlet M Inlet Water Shut-off Valve V Flue
E Insulation N Cold Water Inlet w Drain Pan
F Gas Supply Piping O Inlet Dip Tube X Piezo Igniter
G Manual Gas Shut-off Valve P Temperature-Pressure Relief Valve Y Base-Ring Filter
H Ground Joint Union
I Drip Leg (Sediment Trap) R Flue Baffle
* INSTALL IN ACCORDANCE
WITH LOCAL CODES.
Rating Plate
Q
^DRIP LEG AS REQUIRED
BY LOCAL CODES.
TO VENT
TERMINATION ON
ROOF
INSTALL THERMAL EXPANSION
TANK OR DEVICE IF WATER
HEATER IS INSTALLED IN A
CLOSED WATER SYSTEM
(S) GAS CONTROL VALVE/
THERMOSTAT: WHITE-RODGERS
GAS CONTROL KNOB
WATER TEMPERATURE DIAL
(ADJUSTING DIAL)
"ON”
POSITION
(U) MANIFOLD/BURNER ASSEMBLY
MAIN BURNER
IGNITER RODf^*;-^^
MANIFOLD DOOR
THERMOCOUPLE
I'XXil
--------
^
PILOT TUBE
J V
MÉ IGNITER WIRE
MANIFOLD TUBE
^ ALL PIPING MATERIALS TO BE
SUPPLIED BY CUSTOMERS.
DISCHARGE PIPE
(DO NOT CAP OR PLUG.)
6” MAXIMUM
AIR GAP
FLOOR DRAIN
FIGURE 1.
9
IMPORTANT INFORMATION ABOUT THIS WATER HEATER
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
Water Heater Location
Water heater location is important and can affect system
performance. Please check the following:
□ Installation area free of corrosive elements and flammable
materials.
□ Centrally located with the water piping system (For new
installations). Located as close to the 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.
□ Sufficient room to service the water heater. See Clearances
and Accessibility section of this manual.
□ Water heater not located near an air moving device.
□ Is the installed environment dirty (excessive amounts of
lint, dirt, dust, etc.)? If so, the base-ring filter located on
the bottom of the water heater will need to be cleaned
periodically. Refer to the “Maintenance of your Water
Heater” section of this manual for information on cleaning
the base-ring filter.
Combustion Air Suppiy and Ventiiation
Check for sufficient combustion air supply. Insufficient air for
the combustion of gas will result in the flame becoming “lazy”,
thereby allowing heat to build up in the combustion chamber.
This excessive heat will cause a thermal switch on the door
assembly to trip. Is the water heater installed in a closet or other
small, enclosed space? If so:
□ Are there openings for make-up air to enter and exit the
room/area?
□ Are the openings of sufficient size? Remember, if there
are other gas-fired or air-consuming appliances in the
same room, you need more make-up air. Refer to the
“Installation Instructions” and “Combustion Air Supply and
Ventilation” sections for specific requirements.
□ Make sure that fresh air is not taken from areas that contain
negative pressure producing devices such as exhaust fans,
dryers, fireplaces, etc.
□ Is there a furnace/air handler in the same room space as
the water heater? If so, has a return air duct system been
attached that exits the room? If so, check for leaks on the
air duct system. If no air duct system is present, correct
immediately by contacting a local Heating, Ventilation, Air
Conditioning & Refrigeration (HVAC-R) authorized service
provider.
□ Use a fresh air supply that is free of corrosive elements and
flammable vapors.
□ Fresh air openings must be sized correctly with consideration
given to the blocking effect of louvers and grilles.
□ Ductwork must be the same cross-sectional area as the
openings.
Vent Pipe System
Check for proper drafting at the water heater draft hood. Refer
to the “Checking the Draft” section of this manual for the test
procedure. If the procedure shows insufficient draft is present,
please check the following:
□ Draft hood properly installed.
□ Vent connectors securely fastened with screws and
supported properly to maintain six inch clearance.
□ Vent connector made of approved material and sized
correctly.
□ Vent pipe system installed according to all local and state
codes or, in the absence of local and state codes, the
“National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current
edition.
□ Flue baffle properly positioned in the flue tube.
□ Check the vent system for restrictions/obstructions and
check the vent termination height. Refer to the “Combustion
Air Supply and Ventilation” section of this water heater
manual for specific requirements.
□ Recheck for sufficient combustion air supply.
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 devices installed.
□ Mixing valve (when applicable) installed per manufacturer’s
instructions (See “Water Temperature Regulation” section).
Gas Suppiy and Piping
□ Gas type is the same as that listed on the water heater rating
plate.
□ Gas line equipped with shut-off valve, union, and drip leg.
□ Use pipe joint compound or teflon tape marked as being
resistant to the action of petroleum [Propane (L.P.)] gases.
□ Adequate pipe size and approved pipe material.
□ An approved noncorrosive leak detection solution used
to check all connections and fittings for possible gas leaks.
Correct any leak found.
10
INSTALLATION INSTRUCTIONS
Removing the Old Water Heater
FIGURE 2.
©
Turn “OFF” the gas supply to the
water heater.
©
©
Attach a hose to the water heater
drain valve and put the other end
in a floor drain or outdoors. (See
Figures 2 and 5.) 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.
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.
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.
©
©
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.
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.
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.
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.
11
Location Requirements
A WARNING
Carbon Monoxide Poisoning Hazard
Do not install in a mobile home.
Doing so can result in carbon monoxide poisoning and death.
The FVIR System is designed to reduce the risk of flammable
vapor-related fires. The patented system protects your family by
trapping the burning vapors within the water heater combustion
chamber through the special flame-arrestor. The burning vapors
literally “burn themselves out” without escaping back into the
room. In the event of a flammable vapor incident, the FVIR
System disables the water heater by shutting off the gas supply
to the water heater’s burner and pilot, preventing re-ignition
of any remaining flammable vapors in the area. This will not
prevent a possible fire/explosion if the igniter is depressed
and flammable vapors have accumulated in the combustion
chamber with the pilot light off. If you suspect a flammable
vapor incident has occurred, do not use this appliance. Do not
attempt to light this appliance, or depress the igniter button
if you suspect flammable vapors have accumulated inside or
outside the appliance. Immediately call a qualified technician to
inspect the appliance. Water heaters subjected to a flammable
vapors incident will show a discoloration on the flame-arrestor
and require replacement of the entire water heater.
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
A
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other
appliance. Storage of 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.
Read and follow water heater warnings and instructions.
area of the water heater, leave the area immediately and call
the fire department from a neighbor’s home. Do not attempt to
clean the spill until all ignition sources have been extinguished.
A WARNING
Fire or Explosion Hazard
Read instruction manuai before instaiiing, using or
servicing water heater.
Improper use may resuit in fire or expiosion.
Maintain required ciearances to combustibies.
Keep combustibles such as boxes,
away from the water heater area.
Site Location
• Select a location near the center of the water piping system.
The water heater must be installed indoors and in a vertical
position on a level surface. DO NOT install in bathrooms,
bedrooms, or any occupied room normally kept closed.
• Locate the water heater as close to the chimney or gas
vent as practical. Consider the vent system piping and
combustion air supply requirements when selecting the
water heater location. The venting system must be able
to run from the water heater to termination with minimal
length and elbows.
• Locate the water heater near the existing gas piping. If
installing a new gas line, locate the water heater to minimize
the pipe length and elbows.
• The water heater should be located in an area not subject
to freezing temperatures. Water heaters located in
unconditioned spaces (i.e., attics, basements, etc.) may
require insulation of the water piping and drain piping
to protect against freezing. The drain and controls must
be easily accessible for operation and service. Maintain
proper clearances as specified on the rating plate.
• Do not locate the water heater near an air-moving device.
The operation of air-moving devices such as exhaust fans,
ventilation systems, clothes dryers, fireplaces, etc., can
affect the proper operation of the water heater. Special
attention must be given to conditions these devices may
create. Flow reversal of flue gases may cause an increase
of carbon monoxide inside of the dwelling (Figure 8).
• If the water heater is located in an area that is subjected to
lint and dirt, it may be necessary to periodically clean the
base-ring filter and flame-arrestor (see External Inspection
& Cleaning of the Flame-arrestor).
• This water heater is not for use in manufactured (mobile)
homes or outdoor installation.
NOTE: This water heater must be installed according to all local
and state codes or, in the absence of local and state codes, the
“National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edition.
magazines, clothes, etc.
Do not use or store flammable products such as gasoline,
solvents, or adhesives in the same room or area near the
water heater. If such flammables must be used, all gas burning
appliances in the vicinity must be shut off and their pilot lights
extinguished. Open the doors and windows for ventilation while
flammable substances are in use.
If flammable liquids or vapors have spilled or leaked in the
FIGURE 8
12
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