153331882
Use & Care Guide
Model No.
153.331830 40 Gallon Short
153.331840 40 Gallon
153.331851 40 Gallon (L.P.)
153.331861 50 Gallon Short
153.331882 50 Gallon
I<enmore
For potable water heating only.
Not suitable for space heating.
Not for use in mobile homes.
LOW LEAD
CONTENT
L-oa or
INSTALLER: Affix these instructions to or near
the water heater.
OWNER: Retain these instructions for future
reference.
FOR YOUR SAFETY: An odorant is added to
the gas used by this water heater.
Si no puede leer o entender el ingles y necesita el manual de
instrucciones en espaSol, puede solicitarlo al 1-800-821-2017. NO
TRATE DE INSTALAR U OPERAR ESTE CALENTADOR DE AGUA
Sl NO ENTIENDE LAS INSTRUCCIONES. No hacer caso de esta
advertencia podria originar lesiones graves o mortales.
P/N 320390-002 (0712)
Sears Brands Management Corporation,
Hoffman Estates, IL 60179 U.S.A.
www. kenmore.com
www.seclrs.com
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
m Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance,
-- WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do
not use any phone in your building.
• Immediately call your gas supplier
from a neighbor's phone. Follow the
gas supplier's instructions.
• If you cannot reach your gas supplier,
call the fire department.
m lnstallation and service must be
performed by a qualified installer,
service agency or the gas supplier.
Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of
a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning
of each safety message is understood by you and others who install, use or service this water heater.
n
,_ I This is the safety alert symbol, it is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
I
DANGER indicates an imminently hazardous situation which, if not avoided, will result
in death or injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result
in death or injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, could result
in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous
situation which, if not avoided, could result in property damage.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and
how to avoid the risk of injury.
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.
This product is certified to comply with a maximum weighted average of 0.25% lead content as required in some areas.
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
Read and follow water heater warnings and instructions.
© Sears Brands Management Corporation
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
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 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.
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 riskforscald injury.
Feel water before bathing or
showering.
Temperature limiting valves are
available.
Read instruction manual for safe
temperature setting
Fire Hazard
For continued protection against
riskof fire:
• Do not install water heater on
carpeted floor.
• Do not operate water heater if
flood damaged.
Explosion Hazard
• Overheated water can cause
watertank explosion.
• Properly sized temperature
and pressure relief valve must
be installed in opening
provided.
Fire or Explosion Hazard
• Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
• Avoid all ignition sources if you smell 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.
installing, using or servicing
Read instruction manual before
water heater.
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.
Breathing; Hazard - Carbon Monoxide Gas
• Install vent system in accordance win
codes
• Do not operate water heater if flood
damaged
• High altitude orifice must be installed for
operaaen abe_e 10,100 feet (3,048m)_
• Do not o_rate if soot is present,
• Do not obstru_ water hea_er air intake
with insulating iacket
. Do not place chemical vapor emi_Jng
products near water heater,
, Gas and carbon monoxide detectors
are available
Breathing carbon monoxide can cause brain damage or
death Always read and understand instruction manual_
SAFE INSTALLATION, USE AND SERVICE ................................................................................................. 2
SAFETY PRECAUTIONS ........................................................................................................................... 2-3
PRODUCT WARRANTY ................................................................................................................................ 6
CUSTOMER RESPONSIBILITIES ................................................................................................................. 7
PRODUCT SPECIFICATIONS ...................................................................................................................... 8
MATERIALS AND BASIC TOOLS NEEDED .................................................................................................. 9
TYPICAL INSTALLATION ............................................................................................................................ 10
IMPORTANT INFORMATION ABOUT THIS WATER HEATER .................................................................... 11
Installation Checklist ................................................................................................................................................ 11
INSTALLATION INSTRUCTIONS ........................................................................................................... 12-15
Removing the Old Water Heater ............................................................................................................................. 12
Location Requirements ........................................................................................................................................... 13
Site Location ...................................................................................................................................................... 13-14
Insulation Blankets .................................................................................................................................................. 14
Clearances and Accessibility ............................................................................................................................. 14-15
Filling the Water Heater .......................................................................................................................................... 15
GAS SUPPLY .......................................................................................................................................... 15-16
Gas Requirements .................................................................................................................................................. 15
Gas Piping .............................................................................................................................................................. 15
Gas Pressure .......................................................................................................................................................... 16
Gas Pressure Testing .............................................................................................................................................. 16
LP Gas Only ............................................................................................................................................................ 16
COMBUSTION AIR SUPPLY & VENTILATION ...................................................................................... 17-20
Unconfined Space ................................................................................................................................................... 17
Confined Space ...................................................................................................................................................... 17
All Air from Inside the Building ........................................................................................................................... 17-18
All Air from Outdoors ............................................................................................................................................... 18
Louvers and Grilles ............................................................................................................................................ 18-19
Vent Pipe System ................................................................................................................................................... 19
Draft Hood Installation ............................................................................................................................................ 19
Vent Pipe Size ........................................................................................................................................................ 19
Vent Connectors ................................................................................................................................................ 19-20
Chimney Connection ............................................................................................................................................... 20
Vertical Exhaust Gas Vent ...................................................................................................................................... 20
WATER SYSTEM PIPING ....................................................................................................................... 21-22
Piping Installation .................................................................................................................................................... 21
Closed System/Thermal Expansion ........................................................................................................................ 22
Temperature and Pressure Relief Valve ................................................................................................................. 22
T&P Relief Valve and Pipe Insulation ........................................................................................................................ 22
OPERATINGYOURWATERHEATER...................................................................................................23-26
LightingInstructions...........................................................................................................................................23-24
CheckingtheDraft..................................................................................................................................................25
BurnerFlames........................................................................................................................................................25
EmergencyShutDown...........................................................................................................................................25
WaterTemperatureRegulation..........................................................................................................................25-26
OperatingtheTemperatureControlSystem...........................................................................................................26
SERVICEANDADJUSTMENT...............................................................................................................27-29
VentSystemInspection..........................................................................................................................................27
BurnerInspection....................................................................................................................................................27
BurnerCleaning......................................................................................................................................................27
Housekeeping.........................................................................................................................................................28
AnodeRodInspection............................................................................................................................................28
Temperature-PressureReliefValveOperation.......................................................................................................28
DrainingandFlushing........................................................................................................................................28-29
Service....................................................................................................................................................................29
MAINTENANCEOFYOURWATERHEATER........................................................................................30-33
ReplacementParts.................................................................................................................................................30
ExternalInspection&CleaningoftheBase-RingFilter.........................................................................................30
RemovingtheManifold/BurnerAssembly...............................................................................................................30
RemovingtheBurnerfromtheManifold/BurnerAssembly....................................................................................30
ReplacingtheThermopile..................................................................................................................................30-31
ReplacingthePilot/PilotTubeAssembly...............................................................................................................31
CleaningtheCombustionChamberandFlame-arrestor........................................................................................31
ReplacingtheManifold/BurnerAssembly...............................................................................................................32
PiezoelectricIgniterSystem...................................................................................................................................32
TestingtheIgniterSystem......................................................................................................................................32
RemovingandReplacingtheGasControlValve/Thermostat................................................................................33
FVlRSystemOperationalChecklist.......................................................................................................................33
TROUBLESHOOTINGGUIDE................................................................................................................34-36
StartUpConditions............................................................................................................................................34-35
OperationalConditions......................................................................................................................................35-36
TROUBLESHOOTINGCHART...............................................................................................................37-38
STATUSLIGHTANDDIAGNOSTICTROUBLESHOOTINGCHART.....................................................39-40
PILOTLIGHTTROUBLESHOOTINGFLOWCHART...................................................................................41
PARTSORDERLIST..............................................................................................................................42-43
9 - YEAR LIMITED WARRANTY ON WATER HEATER
For nine years from the date ofpurchase, if this water heater is installed and operated in a single-family home in accordance with the
owner's manual instructions andall local applicable plumbing codes, Sears will:
2" Supply free water heater parts for those that are defective in material or workmanship.
• Supply a free water heater for one that develops a tank leak. See notes below also.
For the second through ninthyear from the purchase date, you must pay the labor cost for installation of parts or water heater.
For commercial, institutional, industrialor residential use by two or more families, the above limited warranty isonly for two years. During
the second year you must pay the labor cost for parts or water heater installation.
Ifgovernmental regulations prohibit Sears from furnishing a comparable model replacement water heater under this warranty, Sears will
furnish a new water heater of comparable output as permitted by such governmental regulations; however, the Owner will be charged
for the additional cost associated with the changes made to comply with such governmental regulations•
Replacements furnished under this warranty do not carry a new warranty and are only covered by the unexpired portion of the original
warranty•
1 - YEAR EXCLUSIVE KENMORE LABOR WARRANTY
For the first year from the date of purchase, Sears will, free of charge, supply and install new water heater parts for defective ones or a
new water heater for one that develops a leak.
WARRANTY SERVICE
To obtain warranty service, call 1-800-4-MY-HOME ®(1-800-469-4663)•
This warranty applies only while this product is in use in the United States•
This warranty gives you specific lega/rights, and you may also have other rights which vary from state to state•
SEARS BRANDS MANAGEMENT CORPORATION, Hoffman Estates, IL 60179
The price of your water heater does not include a free checkup service call. On water heater installations arranged by Sears, Sears
warrants the installation.
A charge will be made on service calls due to poor or incomplete installation. These include:
a. Adjusting thermostat b. Condensation c. Leaks in pipes or fittings
Master Protection Agreements
Congratulations on making a smart purchase. Your new Kenmore ®
product is designed and manufactured for years of dependable
operation. But like all products, it may require preventive
maintenance or repair from time to time. That's when having a
Master Protection Agreement can save you money and aggravation.
The Master Protection Agreement also helps extend the life of your
new product. Here's what the Agreement* includes:
• Parts and labor needed to help keep products operating
properly under normal use, not just defects. Our coverage
goes well beyond the product warranty. No deductibles, no
functional failure excluded from coverage-- real protection.
• Expert service by a force of more than 10,000 authorized
Sears service technicians, which means someone you can
trust will be working on your product.
• Unlimited service calls and nationwide service, as often as
you want us, whenever you want us.
• "No-lemon" guarantee - replacement of your covered product
if four or more product failures occur within twelve months.
• Product replacement if your covered product can't be fixed.
• Annual Preventive Maintenance Check at your request - no
extra charge.
• Fast help by phone - we call it Rapid Resolution - phone
support from a Sears representative on all products. Think of
us as a "talking owner's manual."
• Power surge protection against electrical damage due to
power fluctuations.
• $250 Food Loss Protection annually for any food spoilage
that is the result of mechanical failure of any covered
refrigerator or freezer.
• Rental reimbursement if repair of your covered product takes
longer than promised.
• 10% discount off the regular price of any non-covered repair
service and related installed parts.
Once you purchase the Agreement, a simple phone call is all that it
takes for you to schedule service. You can call anytime day or night,
or schedule a service appointment online.
The Master Protection Agreement is a risk free purchase. If you
cancel for any reason during the product warranty period, we
will provide a full refund. Or, a prorated refund anytime after the
product warranty period expires. Purchase your Master Protection
Agreement today!
Some limitations and exclusions apply. For prices and
additional information in the U.S.A. call 1-800-827-6655.
* 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 ®.
ThankYouforpurchasingaKenmorewaterheater.Properlyinstalled
andmaintained,itshouldgiveyouyearsoftroublefreeservice.If
youshoulddecidethatyouwantthenewwaterheaterprofessionally
installedbySearscall1-800-4-MY-HOME®.Theywillarrangefor
prompt,qualityinstallationbySearsauthorizedcontractors.
Abbreviations Found In This Instruction Manual:
• CSA- Canadian Standards Association
• ANSI- American National Standards Institute
• N FPA- National Fire Protection Association
• ASME - American Society of Mechanical Engineers
• GAMA- Gas Appliance Manufacturers Association
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.
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 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, tt also contains
warnings through out the manual that you must read and be aware
of. All warnings and all instructions are essential to the proper
operation of the water heater and your safety. Since we cannot put
everything on the first few pages, READ THE ENTIRE MANUAL
BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER
HEATER.
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 CodeANSI Z223.1/
NFPA 54. This publication is available from the Canadian
StandardsAssociation, 8501 East Pleasant Valley Rd, Cleveland
Ohio 44131, or The National Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02269.
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.
• 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.
MODEL TANK CAPACITY TYPE INPUT RECOVERY MINIMUM DIAMETER DIMENSIONS
NUMBER IN GALS (LTRS) OF RATE
GAS (Btu/hr) PER HOUR DIA. INCHES (mm) HEIGHT TO
153.331830 40 (151) Natural 40,000 40.94 3 (76)or4(102) 20 (508) 47.75 (1213)
153.331840 40 (151) Natural 40,000 40.94 3(76)or4(102) 18 (457) 58.14 (1477)
153.331851 40 (151) Propane 36,000 36.85 3(76)or4(102) 18 (457) 58.14 (1477)
(L.P.)
153.331861 50 (189) Natural 45,000 45.45 4 (102) 24 (610) 49.5 (1257)
153.331882 50 (189) Natural 40,000 40.94 3 (76)or4(102) 20 (508) 57.28 (1455)
RATE GALS. VENT PIPE INCHES INCHES (mm)
@ 90°F RISE (mm) JACKET TOP
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 ram) COPPER PLUMBING AND FLEXIBLE
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"
DIAMETER FOR WATER
HEATERS HAVING A
DIAMETER 18" OR LESS
AND IN 24" DIAMETER FOR
WATER HEATERS HAVING A
DIAMETER OF 22" OR LESS.
ADDITIONAL TOOLS NEEDED
WHEN SWEAT SOLDERING
• Tubing Cutters or Hacksaw
• Propane Torch
• Soft Solder
• Solder Flux
• Emery Cloth
• Wire Brushes
TUBING CUTTER
\
1
PROPANE
TORCH
PHILLIPS SCREWDRIVER
ROLL OF TEFLON
TAPE (USE ONLY ON
WATER CONNECTIONS)
GARDEN HOSE
6 FOOT TAPE
TIN SNIPS
PIPE DOPE
(SQUEEZE TUBE)
USE FOR WATER AND GAS
CONNECTIONS
PIPE WRENCH
HACKSAW
3/4" (19 mm) WIRE BRUSH
1/2" (13 mm)WIRE BRUSH
EMERY CLOTH
ROLL OF LEAD-FREE
SOFT SOLDER
ROLL OF
SOLDER
FLUX
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A Vent Pipe
B Draft Hood
C Anode (Not Shown)
D Hot Water Outlet
E Insulation
F Gas Supply Piping
G Manual Gas Shut-off Valve
H Ground Joint Union
I Drip Leg (Sediment Trap)
* INSTALL INACCORDANCE
WITH LOCAL CODES.
* DRIP LEG AS REQUIRED
BY LOCAL CODES.
TO VENT
TERMINATION ON
ROOF
J Inner Door
K Outer Door
L Union
M Inlet Water Shut-off Valve
N Cold Water Inlet
O Inlet Dip Tube
P Temperature-Pressure Relief Valve
Q Rating Plate
R Flue Baffle
INSTALL THERMAL EXPANSION
TANK IF WATER HEATER IS
INSTALLED IN A
CLOSED WATER SYSTEM
(S) GAS CONTROL VALVE/
THERMOSTAT
Control/Temperature Knob
S Gas Control Valve/Thermostat
T Drain Valve
U Manifold/Burner Assembly
V Flue
W Metal Drain Pan
X Piezo Igniter
Y Base-Ring Filter
120°F
Status Mark
Light 1
D
F
G
H\
B
DISCHARGE PIPE
(DO NOT CAP OR PLUG.)
i 6"MAXIMUM
AIR GAP
gniter
Temperatures shown are approximates and may vary.
(U) MANIFOLD/BURNER ASSEMBLY
MAIN BURNER
MANIFOLD DOOR J
_PILOT TUBE
f
//
IGNITER WIRE
MANIFOLD
TUBE
* ALL PIPING MATERIALS TO BE
SUPPLIED BY CUSTOMERS.
FIGURE 1.
10
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 Supply and Ventilation
Check for sufficient combustion air supply. Insufficient air for
the combustion of gas wilt result in the flame becoming "lazy",
thereby allowing heat to build up in the combustion chamber.
This excessive heat wilt 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 airopenings 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 Supply 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.R)] 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.
If such a solution is not available, use a mixture of dish
washing soap and water (one part soap to 15 parts water)
or children's soap bubble solution. Bubbles forming indicate
a leak. Correct any leak found.
11
Removing the Old Water Heater C)
@
O
MANUAL GAS
SHUT-OFFVALVE--_
GROU ND-------_
JOINT
UNION
CHECK WITH
LOCAL UTILITY
FOR MINIMUM HEIGHT
©
Turn "OFF" the gas supply to
the water heater.
3"MINIMUM
SUITABLE
DRAIN
FIGURE 2.
DISCHARGE PIPE
(DO NOT CAP
OR PLUG)
6" MAXIMUM
AIR GAP
®
®
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. The water
passing out of the drain valve
may be extremely hot. To avoid
being scalded, make sure all
connections are tight and that the
water flow is directed away from
any person.
FIGURE 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.
Open a nearby hot water faucet
until the water is no longer hot.
When the water has cooled, turn
"OFF" the water supply tothe water
heater at the water shut off valve
orwater 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.
FIGURE 3.
FIGURE 4.
• Burn hazard
• Hotwater discharge.
FIGURE 6.
If you have galvanized pipes to the water heater, loosen
the two galvanized pipes with a pipe wrench at the union in
each line. Also disconnect the piping remaining to the water
heater. See Figure 7. These pieces should be saved since
they may be needed when reconnecting the new water heater.
Disconnect the temperature-pressure relief valve drain line.
When the water heater is drained, disconnect the hose from
the drain valve. Close the drain valve. The water heater
is now completely disconnected and ready to be removed.
Mineral buildup or sediment may have accumulated in the
old water heater. This causes the water heater to be much
heavier than normal and this residue, if spilled out, could
cause staining.
• Keep hands clear of drain
valve discharge.
FIGURE 7.
12
Location Requirements
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.
I 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.
Rarnrnable Vapors
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
_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.
Fire or Explosion Hazard
• Read instruction manual before installing, using or
servicing water heater.
• Improper use may result in fire or explosion.
• Maintain required clearances to combustibles.
Keep combustibles such as boxes, magazines, clothes, etc.
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.
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
REVERSE FLOW
L OF GASES
FIGURE 8
13
Property Damage Hazard
• All water heaters eventually leak.
• Do not installwithout adequate drainage.
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 wilt
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.
DISCHARGE PIPE
:)O NOT CAP OR PLUG)
Insulation Blankets
Insulation blankets available to the general public for external
use on gas water heaters are not necessary with Kenmore
products. The purpose of an insulation blanket is to reduce the
standby heat toss 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.
Breathing Hazard - Carbon Monoxide Gas
•=;':';:°;:-oo
.',?d_:::.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
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 obstruct water heater air
intakewith insulating blanket.
• Gas and carbon monoxide detectors
are available.
• Install water heater in accordance
with the instruction manual.
I
,_k, WARNING
METAL
DRAIN
PAN
X. 6" MAXIMUM
I_AT LEAST 2" GREATER THAN THE
DIAMETER OF THE WATER HEATER. PIPED TO AN
AIR GAP
ADEQUATE DRAIN
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 metal drain pan piped to a drain. However,
unanticipated damage can be reduced or prevented by a leak
detector or water shut-off device used in conjunction with a
piped metal drain pan. These devices are available from some
plumbing supply wholesalers and retailers, and detect and react
to leakage in various ways:
• Sensors mounted in the metal drain pan that trigger an
alarm or turn off the incoming water to the water heater
when water is detected.
• Sensors mounted in the metal 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 wilt turn off the gas supply to a gas water
heater while at the same time shutting off its water supply.
• Do not apply insulation to the top of the water heater, as
this wilt interfere with safe operation of the draft hood.
• Do not cover the outer door, thermostat or temperature &
pressure relief valve.
• Do not allow insulation to come within 2" (50.8 mm) of
the floor to prevent blockage of combustion air flow to the
burner.
• Do not cover the instruction manual. Keep it on the side of
the water heater or nearby for future reference.
• Do obtain new warning and instruction labels from Sears
for placement on the blanket directly over the existing
labels.
• Do inspect the insulation blanket frequently to make
certain it does not sag, thereby obstructing combustion air
flow.
Clearances and Accessibility
NOTE: Minimum clearances from combustible surfaces 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.
14
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