Kenmore 153.332990HA, 153.332980, 153.332970HA, 153.332960, 153.332880 User Manual
...
Owners
Manual
FOR POTABLEWATER
HEATING ONLY
NOT SUITABLEFOR
SPACEHEATING
NOT FOR USE IN
MOBILE HOMES
THE ECONOMIZER TM6
MODEL NUMBERS:
153.332861 40 Gal.L.R
153.332870HA 40 Gal. High Altitude L.E
153.332880 50 Gal.L.R
153.332890HA 50 Gal. High Altitude L.E
153.332960 40 Gal.
153.332970HA 40 Gal. High Altitude
153.332980 50 Gal.
153.332990HA 50 Gal. High Altitude
POWER VENT
GAS WATER HEATER
• Safety Instructions
• Installation
• Operation
For Your Safety
AN ODORANT IS ADDED TO THE GAS USED BY THIS
WATER HEATER
WARNING: If the information in these instructions are not followed exactly, a
fire or explosionmay result, causingproperty damage, personalinjury or death.
- Do not store or use gasoline or other flammable vapors and liquids in the
vicinity of this or anyother 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
gassuppliers instructions.
• If you cannot reach your gassupplier,call the fire department
-Installation and service must be performed by a qualified installer, service
agencyor the gassupplier.
• Care and Maintenance
• Troubleshooting
• Parts List
Caution:
Read and Follow
All Safety Rules and
Operating Instructions
Before First Use of
This Product,
Save this Manual for Future Reference.
Improper installation, adjustment, alteration, service or maintenance can I
cause DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE. Refer I
to this manual for assistance or consult the local Sears Service Center or gas
ut ty for further nformat on.
AWARNING
Flammable vapors may be drawn by air currents from other areas of the
structure to this appliance.
AWARNING
READ THE GENERAL SAFETY SECTION BEGINNING ON INSIDE
COVER AND THEN THIS ENTIRE MANUAL BEFORE INSTALLING OR
OPERATING THIS WATER HEATER.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
Printed in the U.S.A. 0304 www.sears.com Part No. 184820_0OO
AWARNING I
Safety Precautions
AWARNING J
Improper installation, adjustment, alteration, service
or maintenance can cause DEATH, SERIOUS BODILY
INJURY,OR PROPERTY DAMAGE. Referto this manu- J
al for assistance or consult your local Sears Service
Center for further information.
_;LWARNING
WATER HEATERS EQUIPPED FOR ONE TYPE GAS
ONLY: This water heater is equipped for one type gas
only. Check the model rating plate near the gas control
valve for the correct gas. DO NOT USE THIS WATER
HEATER WITH ANY GAS OTHER THAN THE ONE
SHOWN ON THE MODEL RATING PLATE. Failure to
use the correct gas can cause problems which can result in
DEATH, SERIOUS BODILY INJURY, OR PROPERTY
DAMAGE. If you have any questions or doubts consult
your gassupplier or local utility.
AWARNING
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQ-
UIDS (VAPORS) ARE LIKELY TO BE PRESENT OR
STORED (GARAGES, STORAGE, AND UTILITY AREAS,
ETC): Flammable liquids (such as gasoline, solvents,
propane (LP) or butane, etc.), all of which emit flammable
vapors, may be improperly stored or used in such areas.
The gas water heater ignitor or main burner can ignite
such vapors. The resulting flashback and fire can cause
death or serious burns to anyone in the area, as well as
property damage.
If installation in such areas is your only option, then the
installation must be accomplished in a way that the ignitor
and main burner flame are elevated from the floor at least
18 inches. While this may reduce the chances of
flammable vapors from a floor spill being ignited, gasoline
and other flammable substances should never be stored or
used in the same room or area containing a gas water
heater or other open flame or spark producing appliance.
NOTE: Flammable vapors may be drawn by air currents
from other areas of the structure to the appliance.
_WARNING
If this water heater will be used in beauty shops, barber
shops, cleaning establishments, or self-service laundries
with dry cleaning equipment, it is imperative that the
water heater or water heaters be installed so that combus-
tion and ventilation air be taken from outside these areas.
Refer to the "Facts to Consider About the Location" sec-
tion of this manual and also the current edition of the
National Fuel Gas Code, ANSI Z223.1, also referred to as
NFPA 54 for specificsprovided concerning air required.
AWARNING
A fire can start if combustible materials suchas clothing,
cleaningmaterials, or flammable liquidsare placedagainst
or nextto the water heater.
AWARNING
At the time of manufacture this water heater was provided
with a combination temperature-pressure relief valve certi-
fied by a nationally recognized testing laboratory that
maintains periodic inspection of production of listed equip-
ment or materials, as meeting the requirements for Relief
Valves and Automatic Gas Shutoff Devices for Hot Water
Supply Systems, and the current edition of ANSI Z21.22,
CSA 4.4 and the code requirements of ASME. If replaced,
the valve must meet the requirements of local codes, but
not less than a combination temperature and pressure
relief valve certified as meeting the requirements for Relief
Valves and Automatic Gas Shutoff Devices for Hot Water
Supply Systems ANSI Z21.22 • CSA 4.4 by a nationally rec-
ognized testing laboratory that maintains periodic inspec-
tion of production of listed equipment or materials.
The valve must be marked with a maximum set pressure
not to exceed the marked hydrostatic working pressure of
the water heater (I 50 Ibs./sq. in.) and a discharge capacity
not lessthan the water heater input rate as shown on the
model rating plate. (Electric heaters, watts divided by
1000 x 3412 equal BTU/Hr. rate.)
Your localjurisdictional authority, while mandating the use of
a temperature-pressure relief valve complying with ANSI
Z21.22, CSA 4.4 and ASME, may require a valve model dif-
ferent from the one furnished with the water heater.
Compliance with such local requirements must be satis-
fied bythe installer or end user of the water heater with a
locally prescribed temperature-pressure relief valve
installed in the designated opening in the water heater in
place of the factory furnished valve.
For safe operation of the water heater, the relief valve must
not be removed from it's designated opening or plugged.
The temperature-pressure relief valve must be installed
directly into the fitting of the water heater designated for
the relief valve. Position the valve downward and provide
tubing so that any discharge will exit only within 6 inches
above, or at any distance below the structural floor. Be cer-
tain that no contact is made with any live electrical part.
The discharge opening must not be blocked or reduced in
size under any circumstances. Excessive length, over 30
feet, or use of more than four elbows can cause restriction
and reduce the discharge capacity of the valve.
No valve or other obstruction is to be placed between
the relief valve and the tank. Do not connect tubing
directly to discharge drain unless a 6" air gap is provided.
To prevent bodily injury, hazard to life, or property dam-
age, the relief valve must be allowed to discharge water
in quantities should circumstances demand. If the dis-
charge pipe is not connected to a drain or other suitable
means, the water flow may cause property damage.
The Discharge Pipe:
_Must not be smaller in size than the outlet pipe size of
the valve, or have any reducing couplings or other
restrictions.
_Must not be plugged or blocked.
_Must be of material listed for hot water distribution.
_Must be installed so as to allow complete drainage of
both the temperature-pressure relief valve, and the
discharge pipe.
--Must terminate at an adequate drain.
_Must not have any valve between the relief valve and
tank.
2
Safety Precautions (cont'd)
AWARNING
A gas water heater cannot operate properly without the
correct amount of air for combustion. Do not install in a
confined area such a closet, unless you provide air as
shown in the "Facts to Consider About the Location" sec-
tion. Never obstruct the flow of ventilation air. If you have
any doubts or questions at all, call your gas company.
Failure to provide the proper amount of combustion air
can result in a fire or explosion and can cause DEATH
SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.
AWARNING
HOTTER WATER CAN SCALD: Water heaters are
intended to produce hot water. Water heated to a tem-
perature which will satisfy clothes washing, dish washing,
and other sanitizing needs can scald and permanently
injure you upon contact. Some people are more likely to
be permanently injured by hot water than others. These
include the elderly, children, the infirm, or physically/men.
tally handicapped. If anyone using hot water in your home
fits into one of these groups or if there is a local code or
state law requiring a certain temperature water at the hot
water tap, then you must take special precautions. In addi-
tion to using the lowest possible temperature setting that
satisfies your hot water needs, a means such as a mixing
valve, should be used at the hot water taps used by these
people or at the water heater. Mixing valves are available
at plumbing supply or hardware stores. Follow manufac-
turers instructions for installation of the valves. Before
changing the factory setting on the thermostat, read the
"Temperature Regulation" section in this manual.
AWARNING
This water heater must not be installed directly on car-
peting. Carpeting must be protected by a metal or wood
panel beneath the appliance extending beyond the full
width and depth of the appliance by at least 3 inches
(76.2mm) in any direction, or if the appliance is installed
in an alcove or closet, the entire floor must be covered b
the panel. Failure to heed this warning may result in
fire hazard.
AWARNING
The power vent water heater requires its own (separate)
venting system. It cannot be connected to an existing vent
pipe or chimney. It must be terminated to the outdoors.
Failure to properly install the venting system can result in
asphyxiation, a fire or explosion and can cause DEATH, SE-
RIOUS BODILY INJURY, OR PROPERTY DAMAGE.
AWARNING
No vent damper installation is compatible with this power
vented water heater design. No vent damper, whether it is
operated thermally or otherwise is to be installed on this
power vented water heater. Alteration of any part of the fac-
tory-furnished vent assembly could result in improper oper-
ation due to restriction of flue gases, spillage of flue gases
and may cause carbon monoxide poisoning.
AWARNING
Soot build-up indicates a problem that requires correc-
tion before further use. Turn "off" gas to water heater
and leave "off" until repairs are made, because failure to
correct the cause of the sooting can result in a fire or
explosion causing DEATH, SERIOUS BODILY INJURY,
OR PROPERTY DAMAGE.
_,WARNING
BEFORE OPERATING [PROPANE (L.P.) GAS WATER
HEATERS]: Propane (LR) gas is heavier than air. Should
there be a leak in the system, the gas will settle near the
ground. Basements, crawl spaces, skirted areas under
mobile homes (even when ventilated), closets and areas
below ground level will serve as pockets for the accumula-
tion of this gas. Before attempting to operate the water
heater or turning on a nearby electrical light switch, be
absolutely sure there is no accumulated gas in the area.
Search for odor of gas by sniffing at ground level in the
vicinity of the appliance. If odor is detected, follow steps
indicated at "For Your Safety" on the cover page of this
manual then leave the premises.
AWARNING
•The appliance and its individual shutoff valve must be dis-
connected from the gas supply piping system during any
pressure testing of the gas system at test pressures in
excess of I/2 pound per square inch (3.5kPa).
•The appliance must be isolated from the gas supply pip-
ing system by closing its individual manual shutoff valve
during any pressure testing of the gas supply piping sys-
tem at test pressures equal or less than I/2 pound per
square inch (3.5kPa).
AWARNING
Chemical vapor corrosion of the flue and vent system
may occur if air for combustion contains certain chemical
vapors. Spray can propellants, cleaning solvents, refrigera-
tor and air conditioner refrigerants, swimming pool
chemicals, calcium and sodium chloride, waxes, bleach,
and process chemicals are typical compounds which are
potentially corrosive.
Obstructed or deteriorated vent systemsmay present
serioushealth risk or asphyxiation.
AWARNING a
Safety Precautions continued on page 4.
3
Safety Precautions (cont'd)
&WARNING
Minimum clearances between the water heater and com-
bustible construction are 0" at the sides and rear, 5" at the
front, and 0"from the vent pipe. Clearance from the top of
the jacket is 12". Provide 24 inches front clearance for ser-
vicing and adequate clearance between the jacket top &
ceiling for servicing the flue area. (See Figure I). Refer to
the label on the water heater adjacent to the gas control
valve for all clearances.
AWARNING
Flood damage to a water heater may not be readily visible
or immediately detectible. However, over a period of time
a flooded water heater will create dangerous conditions
which can cause DEATH, SERIOUS BODILY INJURY, OR
PROPERTY DAMAGE. Call a Sears Service Technician or
contractor to replace a flooded water heater. Do not
attempt to repair the unit! It must be replaced!
_,WARNING
HYDROGEN GAS: Hydrogengascan beproducedina hot
water systemthat has not been usedfor a long period of
time (generally two weeks or more). Hydrogen gas is
extremely flammable and explosive.To preventthe possi-
bility of injury under these conditions,we recommend the
hot water faucet be opened for several minutes at the
kitchen sink before any electrical appliances which are
connected to the hot water system are used (such as a
dishwasheror washing machine). If hydrogen gasis pre-
sent, there will probablybean unusualsoundsimilar to air
escaping through the pipe as the hot water faucet is
opened. There must be no smoking or open flame near
the faucet at the time it isopen.
_,WARNING J
such termination must not be within 4 feet of any items
Vent as gas meters, gas valves or other gas regulating
equipment.
CAUTION
WATER HEATERS EVENTUALLY LEAK: Installation of
the water heater must be accomplished in such a manner
that if the tank or any connections should leak, the flow of
water will not cause damage to the structure. For this
reason, it is not advisable to install the water heater in an
attic or upper floor. When such locations cannot be avoid-
ed, a suitable drain pan should be installed under the
water heater. Such a drain pan must be not greater than
1½ inches deep, have a minimum length and width of at
least 2 inches greater than the water heater dimensions
and must be piped to an adequate drain. The pan must
not restrict combustion air flow.
_,WARNING
INSULATING JACKETS: When installinganexternalwater
heater insulationjacketona gaswater heater:
• DO NOT coverthetemperature-pressurerelief valve.
• DO NOT put insulationoveranypartofthe top ofthe gas
water heater.
• DO NOT put insulationoverthe gascontrol valveor gas
control valve/burner cover,or any accessareas to the
burner.
• DO NOT let insulationaroundthe gaswater heater to get
within 8 inchesofthefloor (air must getto the burner).
• DO NOT remove operating instructions,andsafetyrelat-
ed warning labels and materials affixed to the water
heater.
• DO obtain new warning andinstructionlabelsfrom Sears
for placement on the jacket directly over the existing
labels.
Failureto heed this will result in the possibilityof a fire or
explosion.
4
Table of Contents
ec_L__oa,cty Precautions ............................................................................................................................................2-4
Table of Contents ................................................................................................................................................5
Customer
Responsibilities .......................................................................................................................6
>d:cmgPn%atic°}aoe :::::::::::::::::::::::::::::::::::::::
Materials Needed ..................................................................................................................................................................... 27
Basic 2bols............................................................................................................................................................................... 27
Installation Instructions ........................................................................................................................8-27
Removing the Old Water Heater. ............................................................................................................................................ .8
Facts m Consider About the Location .................................................................................................................................. 9,10
Combustion Air and Ventilation ........................................................................................................................................ 10,11
Venting Clearances ........................................................................................................................................................ 10,11
Combustion Air and Ventilation for Appliances in Unconfined Spaces ................................................................................... 12
Combustion Air and Ventilation for Appliances in Confined Spaces....................................................................................... 12
Water Piping ........................................................................................................................................................................... 13
"l_mpemture-Pressure Relief Valve........................................................................................................................................... 14
Filling the Water Hearer .......................................................................................................................................................... 15
Wiring ............................................................................................................................................................................... 15,16
Venring. ............................................................................................................................................................................. 17-23
Gas Piping ......................................................................................................................................................................... 2324
Installation Checklist .............................................................................................................................................................. 25
_gpertat!n.g....!ns.t.ruc.t!_n.s..:Z_:ZZ:::::ZZ_::::::::ZZ::::::::_ZZ::::::::Z::::::::::::::::::::::::::::::Z::_:x:
_I_mpemture Regulation ......................................................................................................................................................... 229
Ser_vi_ceiand.lAd ) =============================:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::..:!!:33a
Venting SystemInspection......................................................................................................................................................30
Burner Inspection...................................................................................................................................................................30
Burner Cleaning .....................................................................................................................................................................30
Aim& Rod Inspection............................................................................................................................................................30
"lhnperature-Pressure Relief Valve Operation ......................................................................................................................... .31
Draining ................................................................................................................................................................................ .31
Drain Valve Washer Replacement .......................................................................................................................................... .31
Housekeeping ........................................................................................................................................................................ .31
Service ................................................................................................................................................................................... .31
Troubleshooting Guide ........................................................................................................................32-38
Start Up Conditions ............................................................................................................................................................ 32,33
Thermal Expansion ................................................................................................................................................................ .32
Strange Stun& ...................................................................................................................................................................... .32
Condensation ....................................................................................................................................................................... .33
Smoke/Odor .......................................................................................................................................................................... .33
Operational Conditions ....................................................................................................................................................... 33,34
Smelly Water .......................................................................................................................................................................... .33
"Air" in Hot Water Faucets ................................................................................................................................................... .33
Venting Manual Reset Switch ............................................................................................................................................... .34
High "Ihnperature Limit Switch ........................................................................................................................................... .34
Not Enough or No Hot Water .............................................................................................................................................. .34
Water Is _Ibo Hot ................................................................................................................................................................... .34
Leakage Checkpoints ............................................................................................................................................................... .35
Thermostat and Gas Supply Check .......................................................................................................................................... .36
Systems Check ..................................................................................................................................................................... 37,38
Parts Order Lisa.............................................................................................................................................40-43
Customer Responsibilities
•-rl l
_r
lnanK xou for purchasing a Searswater heater. Properly
installedand maintained, it should giveyouyears of trouble freeser-
vice. If you should decidethat you want the new water heater profes-
sionally installed by Searscall the local SearsServiceCenter or any
Searsstore.They will arrangefor prompt, quality installationby Sears
authorizedcontractors.
Abbreviations Found In This Instruction Manual
CSA - Canadian Standards Association
ANSI - American National Standards Institute
NFPA - National Fire Protection Association
AWARNING
This gas-fired water heater is design certified by CSA
INTERNATIONAL under American National
Standard/CSA Standard for Gas Water Heaters ANS
Z21.10.1 ° CSA 4.1 (current edition). The installation
must conform with this manual, Local Codes and
with the current edition of the National Fuel Gas
Code, ANSI Z223.1.
This publication is available from your local govern-
ment or public library, gas company, or by writing
NFPA, I Batterymarch Park, Quincy, MA 02269.
• Read the "Safety Precautions" section, pages 2 and 3 of this
manual first and then the entire manual carefully. If you don't
follow the sai?ty rules, the water heater will not operate prop-
erly. It could cause DEATH, SERIOUS BODILY INJURY
AND/OR PROPERTY DAMAGE.
This manual contains instructions for the installation, opera-
tion, and maintenance of the gas-fired water heater. It also
contains warnings through out the manual that you must read
and be aware o£ All warnings and all instructions are essential
to the proper operation of the water heater and your safety.
Since we cannot put everythingon the first few pages, READ
THE ENTIRE MANUAL BEFORE ATTEMPTING TO
INSTALL OR OPERATE THE WATER HEATER.
• The installation must confbrm with the instructions in this
manual; gas company rules; and Local Codes, or in the
absence of Local Codes, with the current edition of the
National Fuel Gas code, ANSI Z223.1, also referred to as
NFPA 54. This publication is available from your local gov-
ernment or public library or gas company or by writing
NFPA, 1 Batterymarch Park, Quincy, MA 02269.
• If after reading this manual you have any questions or do not
understand any portion of the instructions, call the Sears
Service Center.
• Carefully plan the place where you are going to put the water
heater. Correct combustion, vent action, and vent pipe instal-
lation are very important in preventing death from possible
carbon monoxide poisoning and fires.
Examine the location to ensure the water heater complies with
the "Locating the New Water Heater" 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 proce-
dures. Instructions may be obtained from your local dealer,
wholesaler, public utilities or California Office of the State
Architect, 400 P Street, Sacramento, CA 95814.
• Complies with SCAQMD rule #1121 and districts having
equivalent NOx requirements.
Product Specifications
TANK
MODEL NUMBER
153.332861
153.332870HA
153.332880
153.332890HA
153.332960
153.332970HA
153.332980
153.332990HA
CAPACITY
IN GAIA.ONS
40
40
50
50
40
40
50
50
* Limited usageof 2" vent pipe - see "Venting" on pages 17-23.
TYPE
OF
GAS
PROPANE
PROPANE
PROPANE
PROPANE
NKFURAL
NKFURAL
NKFURAL
NKFURAL
B.ZU.
RATE
40,000
40,000
40,000
40,000
40,000
40,000
40,000
40,000
RECOVERY
RATE GALS.
PER HOUR
@ 90°F RISE
42.0
42.0
41.5
41.5
42.0
42.0
41.5
41.5
MINIMUM
VENT
PIPE*
3"
3"
3"
3"
3"
3"
3"
3"
DIMENSIONS IN INCHES
HEIGHT TO
DIAMETER
18"
18"
20"
20"
18"
18"
20"
20"
JACKET TOP
59/"
59/"
60"
60"
59/"
59/"
60"
60"
6
Materials and Basic Tools Needed
Materials Needed
"Ib simplify the installation Sears has available the installation
parts shown below. You may or may not need all of these materi-
als, depending on your type of installation.
WATER HEATER STAND 24"x24"x I 8"
FOR USE WITH WATER HEATERS
INSTALLED IN RESIDENTIAL
GARAGES HAVING A DIAMETER 24"
OR LESS AND A RATED CAPACITY 75
GALLONS OR LESS
EXPANSION TANKS FOR
THERMAL EXPANSION
CONDITIONS AVAILABLE IN
2 GALLON AND 5 GALLON
CAPACITY THROUGH
LOCAL SEARS STORE OR
SERVICE CENTERS
WATER HEATER INSTALLATION
KIT WITH FLEXIBLE
CONNECTORS FOR 3/4" OR I/2"
THREADED OR COPPER
PLUMBING AND FLEXIBLE GAS
CONNECTOR WITH FITTINGS
DRAIN PANS ARE AVAILABLE IN 20",
22", 24" AND 28" DIAMETERS. SELECT A
DRAIN PAN THAT IS AT LEAST 2"
LARGER THAN THE DIAMETER OF THE
WATER HEATER.
Basic Tools
You may or may not need all of these tools, depending on your
type of installation. These tools can be purchased at your local
Sears store.
• Pipe Wrenches (2) 14"
• Screwdriver
• Tin Snips
• 6 Foot Tape or Folding Rule
• Garden Hose
• Drill
• Pipe dope or Teflon Tape
GARDEN HOSE 6 FOOT TAPE
SLOT-HEAD SCREWDRIVER
PHILLIPS SCREWDRIVER
PIPE
WRENCH
TIN SNIPS
tP
ROLL OF TEFLON TAPE
(USE ONLY ON WATER
CONNECTIONS)
PIPE DOPE (SQUEEZE TUBE)
(USE FOR WATER AND
GAS CONNECTIONS)
DRILL
ADDITIONAL TOOLS NEEDED
WHEN SWEAT SOLDERING
• Tubing Cutters or Hacksaw
• Propane Torch
• Soft_ Solder
• Solder Flux
• EmeryCIoth
• Wire Brushes
HACKSAW
3/4" WIRE BRUSH
1/2" WIRE BRUSH
ROLL OF LEAD FREE
SOFT SOLDER
ROLL OF EMERY
CLOTH SOLDER FLUX TUBING
7
PROPANE
TORCH
CUTTER
Installation Instructions
Removing the Old Water Heater
Q_Iilrn gas supply to water
If the main gas line shutoff serving all gasappliances is I
used,alsoshut "off" the gas at each appliance.Leave all
gasappliancesshut "off" untilthe water heater installation
iscomplete.
"OFF" the the heater.
_WARNING
"OFF" the the
Turn water to water
heater. Some installations require that
the water be turned off to the entire
house.
©
Disconnect the vent pipe from the draft hood where
they connect 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 the draft hood which
must be used for proper operation.
Q a.
® ©
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 con-
nect to the water heater. This willavoid
cutting off the pipes too short.
Additional cuts can be made later if nec-
essary. Disconnect the temperature-pres-
sure 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.
Check again to make sure the gas supply
is "OFF" to the water heater. Then dis-
connect the gas supply connection from
the gas control valve.
a to water
Attach hose the heater drain
valve and put the other end in a floor
drain or outdoors. Open the water heater
drain valve. Open a nearby hot water
faucet which will relieve pressure in the
water heater and speed draining.
AWARNING I
The water passingout ofthe drainvalvemay be extremely I
hot. To avoid beingscalded,make sure all connectionsare
tight and that the water flow is directed away from any
person.
Qb.
If you have galvanized pipe to the water
heater, loosen the two galvanized pipes
with a pipe wrench at the union in each
line. Also disconnect the piping remain-
ing to the water heater. These pieces
should be saved since they may be need-
ed when reconnecting the new water
heater. Disconnect the temperature-pres-
sure relief valve drain llne. 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.
_, CAUTION J
Mineral buildupor sediment may haveaccumulatedin the
old water heater.Thiscausesthe water heater to be much J
heavierthan normal and this residue,if spilledout, could
causestaining.
Installation Instructions (cont'd)
Facts to Consider About the
Location
You should carefully choose an indoor location for the new water
heater, because the placement is a very important consideration
for the safety of the occupants in the building and for the most
economical use of the appliance. This water heater is not for
use in mobile homes or outdoor installation.
Whether replacing an old water heater or putting the water
heater in a new location, the following critical points must be
observed.
1. The location selected should be indoors as close as practical
to the vent termination point, and as centralized with the
water piping system aspossible. The water heater, as all water
heaters, will eventually leak. Do not install without adequate
drainage provisions where water flow will cause damage.
2. ALL MODELS - If vented through an outside wall or
through the roof, the 3" vent piping cannot exceed a total of
115 feet (50 feet if optional 2" vent piping is used), including
vertical and horizontal runs with one 90° elbow. If more
elbows are required, the venting distance must be reduced 5
feet for every 90° elbow. See pages 19, 20 and 23 for vent
charts.
3. Vent piping cannot slope downward and horizontal runs
require a minimum V_"rise per five feet. All horizontal runs
require adequate support at 3½ foot intervals and vertical
runs supported at 5 foot intervals.
4. The water heater requires its own (separate) venting system.
It cannot be connected to an existing vent pipe or chimney.
It must terminate to the outdoors. Whenever possible termi-
nate the vent on the leaward side of the building if vented
through an outside wall. NOTE: Condensation may be cre-
ated, at times, as the combustion gases exit the vent cap
and discoloration of surfaces in proximity to the vent cap
may occur.
_,WARNING
The power vent water heater requires its own (separate) vent-
ingsystem. It cannot beconnected to an existing vent pipe or
chimney. It must be terminated to the outdoors. Failure to
properly install the venting system can result in asphyxiation,
a fire or explosion and can cause DEATH, SERIOUS BODILY
INJURY, OR PROPERTY DAMAGE.
5. The water heater comes equipped with a 7 foot power cord
which can be used to connect to a 110/120 volt power
source if (1) local codes allow, and (2) there is a three prong
receptacle available.
CAUTION
WATER HEATERS EVENTUALLY LEAK: Installation of the
water heater must be accomplished in such a manner that if
the tank or any connections should leak, the flow of water will
not cause damage to the structure. For this reason, it is not
advisableto install the water heater in an attic or upper floor.
When such locations cannot be avoided, a suitable drain pan
should be installed under the water heater. Such a drain pan
must be not greater than 1'/2 inches deep, have a minimum
length and width of at least 2 inches greater than the water
heater dimensions and must be piped to an adequate drain.
The pan must not restrict combustion air flow.
6. The location selection must provide adequate clearances for
servicing and proper operation of the water heater.
_WARNING
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQ-
UIDS (VAPORS) ARE LIKELY TO BE PRESENT OR STORED
(GARAGES, STORAGE, AND UTILITY AREAS, ETC):
Flammable liquids(such as gasoline, solvents, propane (LP) or
butane, etc.), all of which emit flammable vapors, may be
improperly stored or used in such areas. The gaswater heater
ignitor or main burner can ignite such vapors. The resulting
flashback and fire can cause death or serious burns to anyone
in the area, aswell as property damage.
If installation in such areas is your only option, then the instal-
lation must be accomplished in a way that the ignitor and main
burner flame are elevated from the floor at least 18 inches.
While this may reduce the chancesof flammable vapors from
a floor spill being ignited, gasoline and other flammable sub-
stances should never be stored or used in the same room or
area containing a gas water heater or other open flame or
spark producing appliance.
Also, the water heater must be located andlor protected so it
isnot subject to physicaldamage by a moving vehicle.
NOTE: Flammable vapors may be drawn by air currents from
other areas of the structure to the appliance.
&WARNING
Propellants of aerosol sprays and volatile compounds,
(cleaners, chlorine based chemicals, refrigerants, etc.) in
addition to being highly flammable in many cases, will also
change to corrosive hydrochloric acid when exposed to the
combustion products of the water heater. The results can
be hazardous, and also cause product failure.
&WARNING I
Do not use an extension cord. If there is not a suitable recep-
tacle and/or local codes prohibit use of a power cord, field
w r ng must be prov ded.
9
Installation Instructions (cont'd)
Facts to Consider About the
Location (cont'd)
AWARNING
Thiswater heatermust not be installeddirectlyoncarpeting.
Carpeting must be protected by a metal or wood panel
beneaththe applianceextendingbeyondthe full width and
depth of the appliancebyat least3 inches(76.2mm) in an)
direction,or if the applianceisinstalledinan alcoveorcloset
the entire floormust becoveredbythepanel.Failureto hee¢
thiswarningmay resultina fire hazard.
&WARNING
Minimum clearances between the water heater and com-
bustible construction are 0" at the sides and rear, 5" at the
front, and 0" from the vent pipe. Clearance from the top of
the jacket is 12". Provide 24 inches front clearance for servic-
ing and adequate clearance between the jacket top & ceiling
for servicing the flue area. (See Figure I). Refer to the label
on the water heater adjacent to the gas control valve for all
clearances.
12" MAX
Combustion Air and Ventilation
When determining the installation location for a power vent
water heater, snow accumulation and drifting should be consid-
ered in areas where applicable.
VENTING CLEARANCES
• 0" clearance for 3" (and optional 2") PVC, ABS or CPVC
Schedule 40 vent piping from combustible surfaces.
• 12"minimum from the ground, 9" ceilingoverhangs. Figure 2.
• The Power Vent outlet terminal shall terminate at least 36"
above any forced air inlet located within 10 feet. Figure 3a.
• The Power Vent outlet terminal shall terminate at least 4 feet
below, 4 feet horizontally from or 1 foot above any door, win-
dow or gravity air inlet into the building. Figure 3a.
• 18" minimum in all directions from any obstruction that may
interf?re. Figure 3b.
• 18" minimum from other natural draft (gravity) direct vent,
power vent or power direct vent appliance inlet and/or outlet
vent(s) when directly aboveor 135° to either side of center line.
Figure3c
a 24" minimum from any appliance inlet and/or outlet vents when
directlybelowor 45° to either side of center line. Figure 3c.
V N[(A[((}N
AIR
)_ NIN 3_
TOPVIEW -[_" MIN.
OF CL{}SET .')_ ViEW
WTI OUT DOOR OF (lOSE[
_2" MAX. WI]H D{){>}i
Figure I ]
AIR [>LCI
_, WARNING
A gaswater heater cannot operate properly without the cor-
rect amount of air for combustion. Do not install in a con-
fined area such a closet, unless you provide air as shown in
the "Facts to Consider About the Location" section. Never
obstruct the flow of ventilation air. If you have any doubts or
questions at all, call your gascompany. Failure to provide the
proper amount of combustion air can result in a fire or explo-
sion and can cause DEATH, SERIOUS BODILY INJURY, OR
PROPERTY DAMAGE.
_,WARNING
If this water heater will be used in beauty shops, barber
shops, cleaning establishments, or self-service laundries
with dry cleaning equipment, it is imperative that the
water heater or water heaters be installed so that combus-
tion and ventilation air be taken from outside these areas.
Refer to the "Facts to Consider About the Location" sec-
tion of this manual and also the current edition of the
National Fuel Gas Code, ANSI Z223.1, also referred to as
NFPA 54 for specificsprovided concerning air required.
• The location selection must provide clearances for servicing
and proper operation of the water heater. Figure 4.
• Vent termination must not be within 4 feet of any items such
asgas meters, gas valvesor other gas regulating equipment.
• The venting system must be installed in a manner which
allows inspection of the installation of the venting pipes and
joints as well as periodic inspection after installation as
required by ANSI Standards.
&WARNING J
Vent termination must not be within 4 feet of any items such as
gas meters, gas valves or other gas regulating equipment.
Failureto haverequired clearancesbetweenwater
combustiblematerialwillresultin afire hazard.
Figure 2 1
& WARNING heaterand
10
Installation Instructions (cont'd)
Venting Through Roof- Clearances
• 0' clearancefor Y' (or opt'onal 2") PVC, ABS,or CPVC Schedule
40 piping fromcombustiblesurfaces.
POWER VENT J
TERMINAL 12"rain.
Figure 3a I
VENT TERMINAL
f
J_lS" MIN. _ OBSTRUCTIONS THAT
Figure 3b I
POWER VENTTERMINAL _js -- ".
•LESSTHAN
120"
FORCED AIR
INLET
18"TO WALL OR OTHER
MAY INTERFEREWFTH
VENTING.
VENT TERMINAL
CORNER OF BUILDING
• "The location selection must provide clearances for servicing and
proper operation of the water heater• Figure 4.
• "The Power Vent outlet terminal shall terminate at least 18" above the
roof surface. Figure 5.
• The venting system must be installed in a manner which allows
inspection of the installation of the venting pipes and joints as
well as periodic inspection aiier installation as required by ANSI
Standards.
45° VENT CAP 90°STREETELL
N
-- _ , / DIRECT VENT, POWER VENT
_ _/ OR POWER D,RECT VENT
24" _J_!-- APPDANCEINLETAND/OR
Figure 3c]
MUST MAINTAIN
ADEQUATE SERVICE
AVAILABLE FOR VENT
Figure 4 ]
.... " PIPEINSTALLATION.
Figure 5 ]
11
Installation Instructions (cont'd)
Combustion Air and Ventilation
for Appliances Located in
Unconfined Spaces
Unconfined Space is a spacewhose volume is not less than 50 cubic
feet per 1,000 Btu per hour of the aggregateinput rating of all appli-
ances installedin that space. Rooms communicating directly witll the
space in which tile appliancesare installed, through openings not fur-
nishedwith doors, are considereda part ofthe unconfined space.
In unconfined spaces in buildings, infiltration may be adequate to
provide air for combustion, ventilation and dilution of flue gases.
However, in buildings of tight construction (for example, weather
stripping, heavilyinsulated, caulked,vaporbarrier,etc.), additional air
may need to be provided using the methods describedin Combustion
Air and Ventilation forAppliancesLocated in Confined Spaces.
Combustion Air and Ventilation
for Appliances Located in
Confined Spaces
Confined Space is a space whose volume is less than 50 cubic feet per
1,000 Btu per hour of the aggregate input rating of all appliances
installed in that space.
a. ALL AIR FROM INSIDE BUILDINGS:
(See Page 10 Figure 1, and Figure 6 below)
"Ille confined space shall be provided with two permanent openings
communicating directly with an additional room(s) of sufficient
volume so that the combined volume of all spaces meets the criteria
lbr an unconfined space. "Ille total input of all gas utilization equip-
ment installed in the combined space shall be considered in making
this determination. Each opening shall have a mininmm flee area of
one square inch per 1,000 BTU per hour of the total input rating of
all gas utilization equipment in the confined space, but not less than
100 square inches. One opening shall commence within 12 inches
of the top and one commencing within 12 inches of the bottom of
the endosurc.
VENT THROUGH
1. When directly communicating with the outdoors, each opening
shall have a minimum free area of 1 square inch per 4,000 BTU
per hour of total input rating of all equipment in the enclosure.
(See Figm'e 7.)
2. When communicating with the outdoors through vertical ducts,
each opening shall have a minimum free area of 1 square inch
per 4,000 BTU per hour of total input rating of all equipment
in the enclosure. (See Figure 8.)
I Figure 8 ]
3. When communicating with the outdoors through horizontal
ducts, each openingshall have a minimum free area of 1 square
inch per 2,000 BTU per hour of total input rating of all equip-
ment in the enclosure. (SeeFigure 9.)
Figure 6 ]
b. ALL AIR FROM OUTDOORS: (see Figures 7-9)
The confined space shall be provided with two permanent openings,
one commencing within 12 inches of the top and one commencing
within 12 inches from tile bottom of the enclosure. The openings
shall communicate directly, or by ducts, with the outdoors or spaces
(crawl or attic) that freely communicate with the outdoors.
VENTILATION LOUVERS_
(each end of attic)
Figure 7 ]
VENTILATION LOUVERS
VENT THROUGH
2 ROOF
VENT TO
OUTDOORS
Figure 9]
4. When ducts are used, they shall be of the same cross-sectional area
as the flee area of the openings to which they connect. The mini-
mum short side dimension of rectangular air ducts shall not be
less than 3 inches. (See Figure 9.)
5. Louvers and Grilles: In calculating flee area, consideration shall be
given to the blocking effect of louvers, grilles or screens protect-
ing openings. Screens used shall not be smaller than ¼ inch mesh.
If the flee area through a design of louver or grille is known, it
should be used in calculating the size opening required to provide
the free area specified. If the design and flee area is not known, it
may be assumed that wood louvers will be 20-25 percent flee area
and metal louvers and grilles will have 60-75 percent free area.
Louvers and grilles shall be fixed in the open position or inter-
locked with the equipment so that they are opened automatically
during equipment operation.
6. Special Conditions Created by Mechanical Exhausting or
Fireplaces: Operation of exhaust fans, ventilation systems, clothes
dryers or fireplaces may create conditions requiring special atten-
tion to avoid unsatisfactory operation of installed gas utilization
equipment.
12
Installation Instructions (cont'd)
Water Piping
*A WARNING
HOTTER WATER CAN SCALD: Water heaters are intended to
_roduce hot water. Water heated to a temperature which will
satisfyclothes washing,dishwashing,andother sanitizingneeds
can scaldand permanently injure you upon contact. Some pet-
fie are more likelyto be permanently injured by hot water than
others. These include the elderly, children, the infirm, or physb
cally/mentally handicapped. If anyone using hot water in your
home fits into one of these groupsor if there isa local codeor
state lawrequiring a certain temperature water at the hot water
tap, then you must take specialprecautions.Inaddition to using
the lowest possibletemperature setting that satisfiesyour hot
water needs, a means suchasa mixing valve, shouldbe used at
the hot water taps usedby these people or at the water heater.
Mixing valves are available at plumbing supply or hardware
stores. Follow manufacturers instructions for installation of the
valves. Before changingthe factory setting on the thermostat
read the "Temperature Regulation"section inthis manual.
HOT WATER
OUTLET
TEMPERED
WATER
OUTL ET t
*MIXING WATER
VALVE OUTLET
This water heater shall not be connected to any heating sys-
tems or component(s) now or previously used with a non=
potable water heating appliance.
FROM HOT
ON WATER
HEATER
AWARNING
COLD WATER
TO COLDWATER
'INLET ON WATER
HEATER
Lookatthetopcoverofrhewaterhearer.Thehotwateroutletismarkedhot.
Puttwoorthreeturnsofteflonrapearoundrilethreadedendofthethreaded-
to-sweatcouplingandaroundbothendsofthe_" threadednipple.Usingtlexi-
hieconnectors,connectthehotwaterpipetothehotwateroudetollthewater
heater.
Lookat thetopcoverofthewaterheater.Thecoldwaterinletismarkedcold.
Puttwoorthreeturnsofteflonrapearoundthethreadedendofrilethreaded-
to-sweatcouplingandaroundbothendsofthe_" threadednipple.Usingflexi-
bleconnectors,connectthecoldwaterpipetothecoldwaterinletoftbewater
hearer.
NOTE:Thiswaterheaterisinsulatedtominimizeheat lossfromthe tank.
Furtherreductionin heat losscan beaccomplishedby insulatingthe hot
waterlinesfromthewaterheater.
INSTALLATION COMPLETED
COLD INLET
NIPPLE
TEMPERATURE-
PRESSURE
RELIEF VALVE
SWEAT COUPLING
THREADED TO
SWEAT COUPLING
HOT OUTLET
TO HOUSE
3/4"THREADED j
NIPPLE
PIPE
(Do not cap or
plug)
PROVIDE A 6"
AIR GAP
BETWEEN THE
END OF THE
DISCHARGE
PIPE AND DRAIN
THREADED TO VALVE ._"
SHUTOFF WATER LINE
AWARNING
Toxicchemicalssuchas usedfor treatment of boilersor
non-potablewater heatingappliancesshall never be intro-
ducedinto a potablewater heatingsystem.
lfa waterheaterisinstalledin aclosedwatersupplysystem;suchasonehavinga
bach-flowpreventer,checkvalve,watermeterwithacheckvalve,etc..,in thecold
watersupply;meansshallheprovidedtocontrolthermalexpansion.Contactthe
localutilityorlocalSearsServiceCenteron howtocontrolthissitoarion.
NOTE:Toprotectagainstuntimelycorrosionofhot andcoldwaterfittings,
it isstronglyrecommendedthatdielectricunionsorcouplingsbeinstalledon
thiswaterheaterwhenconnectedtocopperpipe.
Theillustrationshowstheattachmentofthewaterpipingtothewaterheater.The
waterheaterisequ'ppedw'th/_ 'nchwaterconnect'ons.
NOTE:Ifusingcoppertubing,soldertubingto an adapterbeforeattaching
the adapterto thecoldwaterinletconnection.Donot solderthecoldwater
supplylinedirectlyto thecoldwaterinletorit willharmthediptube.
T&P Valve and Pipe Insulation
Removeinsulationfor T&P Valveand pipeconnectionsfromcarton.
Fitpipeinsulationover the incomingcold
water line and the hot water line. Make
sure that the insulationis against the top
coverof the heater.
FitT&PValveinsulationovervalve.Make
suredlartheinsulationdoesnotinterfbre
withtheleverof'theT&I valve.
Secureallinsulationusingtape.
13
)
Installation Instructions (cont'd)
Temperature-Pressure Relief Valve
AWARNING
At the time of manufacture thiswater heater wasprovided
with a combinationtemperature-pressuresrelief valvecerti-
fied bya nationallyrecognized testinglaboratorythat main-
tains periodicinspectionof productionof listedequipment
or materials, as meeting the requirements for ReliefValves
and Automatic Gas ShutoffDevicesfor Hot Water Supply
Systems,andthe current edition of ANSI Z21.22, CSA 4.4
Standardsandthe code requirements of ASME. If replaced,
the valve must meet the requirements of localcodes,but
not lessthan a combinationtemperature and pressurerelief
valvecertifiedasmeeting the requirements forReliefValves
and Automatic Gas ShutoffDevicesfor Hot Water Supply
Systems,ANSI Z21.22 • CSA 4.4 Standardsbya nationally
recognized testing laboratory that maintains periodic
inspectionof productionoflistedequipmentormaterials.
The valve must be marked with a maximum set pressure
not to exceed the marked hydrostaticworking pressureof
the water heater (150 Ibs./sq.in.) and a dischargecapacity
not lessthan the water heater input rate as shownon the
model rating plate. (Electric heaters- watts dividedby 1000
x 3412equalBTU/Hr. rate.)
Your localjurisdictionalauthority, while mandatingthe use
of a temperature-pressurerelief valvecomplyingwith ANSI
Z21.22 •CSA 4.4 StandardsandASME, may require a valve
model different from the one furnished with the water
heater.
Compliancewith suchlocalrequirements must be satisfied
bythe installeror end user of the water heater with a locally
_rescribedtemperature-pressurerelief valveinstalledinthe
designatedopeninginthe water heater in placeof the facto-
ry furnishedvalve.
For safeoperationofthe water heater,the relief valvemust
not beremoved from it'sdesignatedopeningor plugged.
The temperature-pressure relief valve must be installed
directly into the fitting of the water heater designatedfor
the relief valve. Positionthe valve downward and provide
tubing so that any dischargewill exit only within 6 inches
above,or at any distancebelowthe structuralfloor. Becer-
tain that no contact is made with any live electrical part.
The dischargeopeningmust not be blockedor reduced in
sizeunderanycircumstances.Excessivelength,over30 feet,
or useof more than four elbowscan causerestriction and
reduce the dischargecapacityof the valve.
No valveor other obstructionisto be placedbetween the
relief valveandthe tank. Do not connecttubing directlyto
dischargedrain unlessa 6"air gap is provided.Toprevent
bodilyinjury,hazard to life, or property damage, the relief
valve must be allowed to dischargewater in quantities
shouldcircumstancesdemand.If the dischargepipe is not
connected to a drain or other suitablemeans, the water
flowmaycausepropertydamage.
The DischargePipe:
• Must not be smallerinsizethan the outlet pipesizeof the
valve,or haveanyreducing couplingsor other restrictions.
• Must notbe pluggedor blocked.
• Must be ofmateriallistedforhot water distribution.
• Must be installedsoasto allowcomplete drainageof both
the temperature-pressurerelief valve, and the discharge
pipe.
• Mustterminate at anadequatedrain.
• Must nothaveanyvalvebetweenthe relief valveandtank.
_'LWARNING
The temperature-pressure relief valve must be manually
operated at least oncea year.Caution shouldbe taken to
ensurethat (I) no one isinfront of or aroundthe outlet of
the temperature-pressure relief valve dischargeline, and
(2) the water manuallydischargedwill not causeany bodi-
ly injury or property damage becausethe water may be
extremely hot.
If after manually operating the valve, it failsto completely
reset and continuesto release water, immediately close
the cold water inlet to the water heater,followthe drain-
ing instructions, and replace the temperature-prossuro
relief valvewith a new one.
TEMPERATURE-PRESSURE
R_LIEF VALVE
DISCHARGE PIPE
I I_ (Do not cap or
I1\
II \ PROVIDEA6"AIR
I I \ GAPBETWEEN
I I t THE END OF THE
I I • DISCHARGE PIPE
__ AND DRAIN
RELIEFVALVEOPENING
"THISWATERHEATERISAPPROVEDWITHA COMBINATIONTEMPERATURE-
PRESSURERELIEFVALVE. FORSAFEOPERATIONOF THEWATERHEATER,
THE RELIEFVALVE(S) MUST NOT BE REMOVED FROM ITS DESIGNATED
POINTOF INSTALLATIONORPLUGGED."
YOUR LOCALJURISDICTIONALAUTHORITY,WHILEMANDATINGTHE USE
OF A TEMPERATURE-PRESSURERELIEFVALVE COMPLYING WITH ANSI
Z21.22 AND ASME,MAY REQUIREA VALVEMODEL DIFFERENTFROM THE
ONEFURNISHEDWITHTHEWATERHEATER.
COMPLIANCEWITH SUCH LOCALREQUIREMENTSMUST BE SATISFIEDBY
THE INSTALLEROR END USEROFTHEWATERHEATERWITH A LOCALLY
PRESCRIBEDTEMPERATURE-PRESSURERELIEFVALVEINSTALLEDIN THE
DESIGNATEDOPENINGIN THEWATERHEATER.
SEEMANUAL HEADING- "TEMPERATURE-PRESSURERELIEFVALVES" FOR
INSTALLATIONAND MAINTENANCEOF RELIEFVALVE, DISCHARGELINE
AND OTHERSAFETYPRECAUTIONS.
14
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