Kenmore 153.331492 User Manual

Owner’s Manual

KentnorG

HydroSense

Gas Water Heater

FOR POTABLE WATER HEATING ONLY.

NOT SUITABLE FOR SPACE HEATING.

NOT FOR USE IN MOBILE HOMES.

MODEL NO.

153.331492

153.331592

40 Gallon
50 Gallon

Safety Instructions
Installation
Operation
Care and Maintenance
Troubleshooting
Parts List

ENERGYSTAR

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 foliowed exactiy, a fire

or explosion may resuit causing property
damage, personal injury or death.

Do not store or use gasoline or other

fiammabie vapors and iiquids in the
vicinity of this or any other appiiance.

WHATTO DO iF YOU SMELL GAS:

• Do not try to iight any appliance.

• Do not touch any electrical switch; do

not use any phone in your building.

• immediateiy cali your gas supplier
from a neighbor’s phone. Foliow 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.

• If you cannot reach your gas supplier,

cali the fire department.

- instaliation and service must be
performed by a quaiified instaiier,
service agency or the gas suppiier.

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

PRINTED IN U.S.A. 1208 www.sears.com PART NO. 186422-001

SUPERSEDES 186422-000

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

^WARNING

^CAUTION

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.

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.

DANGER indicates an imminentiy hazardous situation which, if not avoided, wiii
resuit in death or serious injury.

WARNiNG indicates a potentiaiiy hazardous situation which, if not avoided, couid resuit
in death or serious injury.

CAUTiON indicates a potentiaiiy hazardous situation which, if not avoided, couid 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.

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 Aiv/ays 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

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

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

SERVICE INSTRUCTIONS FOR THE GAS CONTROL VALVE/THERMOSTAT

.........................................

28-29

MAINTENANCE OF YOUR WATER HEATER..............................................................................................30-32

Replacement Parts................................................................................................................................................. 30

External Inspection & Cleaning of the Base-Ring Filter.........................................................................................30

Removing the Manifold/Burner Assembly..............................................................................................................30

Removing the Burner from the Manifold/Burner Assembly....................................................................................30

Replacing the Pilot/ Pilot Tube Assembly.........................................................................................................30-31

Cleaning the Combustion Chamber and Flame-arrestor.......................................................................................31

Replacing the Manifold/Burner Assembly.........................................................................................................31-32

Piezoelectric Igniter System................................................................................................................................... 32

Testing the Igniter System......................................................................................................................................32

FVIR System Operational Checklist.......................................................................................................................32

TROUBLESHOOTING GUIDE.......................................................................................................................33-35

Start Up Conditions............................................................................................................................................33-34

Operational Conditions......................................................................................................................................34-35

TROUBLESHOOTING CHART......................................................................................................................36-38

PILOT LIGHT TROUBLESHOOTING FLOWCHART..........................................................................................39

PARTS ORDER LIST..........................................................................................................................................40

PRODUCT WARRANTY

For twelve years from date of purchase, if this water heater is installed and operated in a single family home in accordance with the owner’s

12 YEAR LIMITED WARRANTY ON WATER HEATER

manual instructions and ali iocal appiicable codes, Sears wiii suppiy a free water heater for one that develops a leak.
For the second through twelfth year from purchase date, you must pay the labor cost for installation of the water heater.

For three years from date of purchase, if this water heater is installed and operated in a single family home in accordance with the owner’s manual

3 YEAR LIMITED WARRANTY ON PARTS

instructions and ali iocal applicable codes, if a part faiis due to materials or workmanship. Sears wiii suppiy a free repiacement part.

After one year from purchase date, you must pay the iabor cost for instaliation of the part.

For the first year from the date of purchase. Sears wiii, free of charge, suppiy and instali new water heater parts for defective ones or a

1 YEAR EXCLUSIVE KENMORE LABOR WARRANTY

new water heater for one that develops a leak.

To obtain warranty service, cali 1-800-4-MY-HOME® (1-800-469-4663). This warranty appiies oniy whiie this product is in use in the United

WARRANTY SERVICE

States.
For commercial, institutional, industrial or residential use by two or more families, the above limited warranty for tanks that leak is effective for

two years from the date of purchase and the above iimited parts warranty is effective for one year from the date of purchase.
This warranty gives you specific iegal rights and you may also have other rights which vary from state to state.

Sears, Roebuck and Co., Dept. 817 WA, Hoffman Estates, IL 60179

The price of your water heater does not include a free checkup service caii. 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 1-800-827-6655.

• 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®.

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.

• 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.

READ THE ENTIRE MANUAL

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

153.331492 40 (151) Naturai 40,000 42.0 3(76) OR 4 (102) 20 (508) 58.14 (1477)

153.331592 50 (189) Naturai 40,000 42.0 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 THROUGH
LOCAL SEARS STORE
OR SERVICE CENTER.

WATER HEATER INSTALLATION KIT WITH
FLEXIBLE CONNECTORS FOR 3/4”
(19.05 mm) OR 1/2” (12.7 mm) THREADED OR
COPPER PLUMBING AND FLEXIBLE WATER
HEATER GAS CONNECTOR WITH FITTINGS.

BASIC TOOLS

You may or may not need all these tools, depending on your
type of installation. These tools can be purchased at your local
Sears Store.

Pipe Wrenches (2) 14” (356 mm)
Screwdriver
Tin Snips
6’ (1.82 m) Tape or Folding Ruler
Garden Hose
Drill
Pipe Dope or Teflon Tape

SLOT-HEAD SCREWDRIVER

DRILL

METAL 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 Gas Control Valve/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 Metal 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

' ALL PIPING MATERIALS TO BE

SUPPLIED BY CUSTOMERS.

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.
□ Tempering 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.

©

Open a nearby hot water faucet
and leave it open to allow for
draining. Allow the hot water
to run until water flowing from
the faucet is 100° F or less.
Connect a hose to the drain valve
and terminate to an adequate
drain or outdoors. (Make sure all
connections are tight and that the
water flow is directed away from
people.) Open the drain valve
and allow the tank to drain. (See

Figures 2 and 5.)

Disconnect the vent pipe from the draft hood where it connects
to the water heater. In most installations the vent pipe can
be lifted off after any screw or other attached devices are
removed. Dispose of the draft hood. The new water heater
has a draft hood which must be used for proper operation.

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

the fire department from a neighbor’s home. Do not attempt to

clean the spill until all ignition sources have been extinguished.

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.

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 Base-Ring Filter; also see Cleaning the
Combustion Chamber and 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
area of the water heater, leave the area immediately and call

12

Property Damage Haiard

All water heaters eventually leak
Do not install without adequate drainage.

use on gas water heaters are not necessary with Kenmore
products. The purpose of an insulation blanket is to reduce the
standby heat loss encountered with storage tank heaters. Your

Kenmore water heater meets or exceeds the National Appliance

Energy Conservation Act standards with respect to insulation
and standby loss requirements, making an insulation blanket
unnecessary.

Awarning

IMPORTANT: The water heater should be located in an area
where leakage of the tank or connections will not result in damage
to the area adjacent to the water heater or to lower floors of the
structure. Due to the normal corrosive action of water, the tank will
eventually leak after an extended period of time. Also any external

plumbing leak, including those from improper installation, may

cause early failure of the tank due to corrosion if not repaired. If
the homeowner is uncomfortable with making the repair a qualified
technician should be contacted. A suitable metal drain pan should

be installed under the water heater as shown below, to help protect
the property from damage which may occur from condensate
formation or leaks in the piping connections or tank. The pan must

limit the water level to a maximum depth of 1 -3/4” and be two inches
wider than the heater and piped to an adequate drain. NOTE: The

pan must not restrict combustion air flow. Locate the water heater

near a suitable indoor drain. Outside drains are subject to freezing
temperatures which can obstruct the drain line. The piping should

be at least 3/4” ID and pitched for proper drainage.

Breathing Hazard - Carbon Monoxide Gas

Do not obstruct water heater air
intake with insulating blanket.

Gas and carbon monoxide detectors
are available.

Install water heater in accordance

with the instruction manual.

Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.

AA WARNING

Should you choose to apply an insulation blanket to this
heater, you should follow these instructions (See Figure 1
for identification of components mentioned below). Failure to
follow these instructions can restrict the air flow required for
proper combustion, potentially resulting in fire, asphyxiation,
serious personal injury or death.

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

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

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

FIGURE 9.

Water heater life depends upon water quality, water usage,
water temperature and the environment in which the water

heater is installed. Water heaters are sometimes installed
in locations where leakage may result in property damage,

even with the use of a drain pan piped to a drain. However,

unanticipated damage can be reduced or prevented by a leak

detector or water shut-off device used in conjunction with

a piped drain pan. These devices are available from some
plumbing supply wholesalers and retailers, and detect and react

to leakage in various ways:

• Sensors mounted in the drain pan that trigger an alarm or
turn off the incoming water to the water heater when water

is detected.

• Sensors mounted in the drain pan that turn off the water
supply to the entire home when water is detected in the
drain pan.

• Water supply shut-off devices that activate based on the
water pressure differential between the cold water and hot
water pipes connected to the water heater.

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

Insulation Blankets

Insulation blankets available to the general public for external

________________________

• Do not cover the instruction manual. Keep it on the side of

the water heater or nearby for future reference.

• Do obtain new warning and instruction labels from Sears
for placement on the blanket directly over the existing
labels.

• Do inspect the insulation blanket frequently to make
certain it does not sag, thereby obstructing combustion air
flow.

Clearances and Accessibility

NOTE: Minimum clearances from combustible materials are
stated on the label adjacent to the gas control valve/thermostat
of the water heater. The water heater is certified for installation
on a combustible floor.

• IMPORTANT: If installing over carpeting, the carpeting

must be protected by a metal or wood panel beneath the
water heater. The protective panel must extend beyond the
full width and depth of the water heater by at least three
inches (76.2mm) in any direction; or if in an alcove or closet
installation, the entire floor must be covered by the panel.

• Figure 10 may be used as a reference guide to locate the

specific clearance locations. A minimum of 24 inches of
front clearance should be provided for inspection and
service.

13

________________

FIGURE 10.

Filling the Water Heater

Never use this water heater unless it is completely full of water.
To prevent damage to the tank, the tank must be filled with water.
Water must flow from the hot water faucet before turning “ON” gas
to the water heater. To fill the water heater with water:

• Close the water heater drain valve by turning the handle to
the right (clockwise). The drain valve is on the lower front of
the water heater.

GAS SUPPLY

AWARNING

Open the cold water supply valve to the water heater.

NOTE: The cold water supply valve must be left open
when the water heater is in use.

To ensure complete filling of the tank, allow air to exit by
opening the nearest hot water faucet. Allow water to run until
a constant flow is obtained. This will let air out of the water
heater and the piping.

Check all water piping and connections for leaks. Repair as
needed.

CAUTION

Property Damage Hazard

' Avoid water heater damage.
' Fill tank with water before operating.

codes or, in the absence of local and state codes, the “National
Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edition.

Table 1 on the following page provides a sizing reference for

commonly used gas pipe materials. Consult the “National
Fuel Gas Code” for the recommended gas pipe size of other
materials.

Explosion Hazard

• Use a new CSA approved gas supply line.

• Install a shut-off valve.

• Do not connect a natural gas water heater to an

L.P. gas supply.

• Do not connect an L.P. gas water heater to a

natural gas supply.

• Failure to follow these instructions can result in

death, explosion, or carbon monoxide poisoning.

Gas Requirements

IMPORTANT: Read the rating plate to be sure the water heater
is made for the type of gas you will be using in your home. This
information will be found on the rating plate located near the
gas control valve/thermostat. If the information does not agree
with the type of gas available, do not install or light. Call your
dealer.

NOTE: An odorant is added by the gas supplier to the gas used
by this water heater. This odorant may fade over an extended
period of time. Do not depend upon this odorant as an indication
of leaking gas.

Refer to Figure 11 for the items below.

1. Install a readily accessible manual shut-off valve in the gas
supply line as recommended by the local utility. Know the
location of this valve and how to turn off the gas to this unit.

2. Install a drip leg (if not already incorporated as part of
the water heater) as shown. The drip leg must be no less
than three inches long for the accumulation of dirt, foreign

material, and water droplets.

3. Install a ground joint union between the gas control valve/
thermostat and the manual shut-off valve. This is to allow
easy removal of the gas control valve/ thermostat.

4. Turn the gas supply on and check for leaks. Test all
connections by brushing on an approved noncorrosive
leak-detection solution. Bubbles will show a leak. Correct

any leak found.

Gas Piping

The gas piping must be installed according to all local and state

14