Kenmore 153.33443 User Manual

Owner’s Manual

Kenmore

HydroSense

Gas Water Heater

FOR POTABLE WATER HEATING ONLY.

NOT SUITABLE FOR SPACE HEATING.

NOT FOR USE IN MOBILE HOMES.

MODEL NO.

153.334430

153.334630

40 Gallon 50 Gallon

• Safety Instructions

• Installation

• Operation

• Care and Maintenance

• Troubleshooting

• Parts List

03 Technology® Gas Water Heaters meet the new ANSI Z21.10.1 standard that deals with the accidental or unintended ignition of flammable vapors, such as those emitted by gasoline.

AWARNING

Read and understand instruction manual and safety messages before installing, operating or servicing this water heater.

Failure to follow instructions and safety messages could result In death or serious injury.

Instruction manual must remain with water heater.

For Your Safety

AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER.

WARNING: if the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

-WHATTODOIFYOUSMELLGAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in yourbuilding.

• Immediately call your gas supplier

from a neighbor’s phone. Follow the gas supplier’s instructions.

ADVERTENCIA

Si no puede leer o entender el inglés y necesita el manual instructivo y/o etiquetas en español puede obtenerlos llamando al 1-800-821-2017. NO TRATE DE INSTALAR O OPERAR ESTE CALENTADOR DEAGUAsi no entiende la información en las etiquetas o en el manual instructivo. No hacer caso de esta advertencia podría resultar en la MUERTE O GRAVES LESIONES CORPORALES.

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

PRINTED IN U.S.A. 0806

www.sears.com

• If you cannot reach your gas supplier, call the fire department.

- Installation and service must be performed by a qualified installer, service agency or the gas supplier.

PART NO. 185614-000

SAFE INSTALLATION, USE AND SERVICE

Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.

Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use or service this water heater.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates an imminently

A DANGER A WARNING

A CAUTION

hazardous situation which, if not avoided, could 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, may result in minor or moderate injury.

CAUTION used without the safety alert

CAUTION

Ail 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.

Gas Supplier: The natural gas or propane utility or service who supplies gas for utilization by the gas burning

symbol indicates a potentially hazardous situation which, if not avoided, could resuit in property damage.

IMPORTANT DEFINITIONS

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.

^WARNING

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.

AWARNlNG

Fire Hazard

For continued protection against risk of fire:

•Do not install water heater on carpeted floor.

•Do not operate water heater if

flood damaged.

▲DANGER

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 riskfor scald injury.

Feel water before bathing or showering.

Temperature limiting valves are available.

Read instruction manual for safe

temperature setting.

A WARNING

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 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

V extended period of non-use.

Read instruction manual before

installing, using or servicing

water heater.

W I

Awarning

Explosion Hazard

■ Overheated water can cause water tank explosion.

^ Properly sized temperature

and pressure relief valve must be installed in opening provided.

Awarning

Breathing Hazard - Carbon Monoxide Gas

■ Install vent system in accordance with codes.

■ Do not operate water heater it flood damaged.

■ High altitude orifice must be installed for operation above 7,700 feet (2,347 m).

■ Do not operate if soot buildup.

■ Do not obstruct water heater air intake

with insulating jacket

■ Do not place chemical vapor emitting 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

CAUTION

Improper installation and use may result

in property damage.

• Do not operate water heater if flood damaged.

• Inspect and replace anode.

• Install in location with drainage,

• Fill tank with water before operation.

• Be alert for thermal expansion Refer to instruction manual for installation and service.

SAFE INSTALLATION, USE AND SERVICE ..............................................................................................................................................................................2

SAFETY PRECAUTIONS .............................................................................................................................................................................................................3

TABLE OF CONTENTS ................................................................................................................................................................................................................4

CUSTOMER RESPONSIBILITIES

PRODUCT SPECIFICATIONS......................................................................................................................................................................................................5

MATERIALS AND BASIC TOOLS NEEDED................................................................................................................................................................................6

Material Needed.....................................................................................................................................................................................................................6

Basic Tools............................................................................................................................................................................................................................ 6

TYPICAL INSTALLATION ............................................................................................................................................................................................................7

INSTALLATION INSTRUCTIONS

Removing the Old Water Heater...........................................................................................................................................................................................8

Facts to Consider About the Location..............................................................................................................................................................................9-10

Insulation Jackets................................................................................................................................................................................................................10

Combustion Air and Ventilation Appliances

in Unconfined Spaces

Combustion Air and Ventilation Appliances

in Confined Spaces........................................................................................................................................................................................................ 11-12

Wafer Piping....................................................................................................................................................................................................................12-13

Temperature Pressure Relief Valve............................................................................................................................................................................... 13-14

Filling the Water Heater.......................................................................................................................................................................................................14

Venting

...

..................................................................................................................................................................................................... 14-15

Gas Piping...................................................................................................................................................................................................................... 15-16

Sediment Trap................................................................................................................................................................................................................16-17

OPERATING INSTRUCTIONS .............................................................................................................................................................................................18-19

Lighting & Operating Label..................................................................................................................................................................................................18

Temperature Regulation

SERVICE AND ADJUSTMENT..............................................................................................................................................................................................20-22

Tank (Sediment) Cleaning...................................................................................................................................................................................................20

Venting System Inspection.................................................................................................................................................................................................. 20

Burner Inspection.................................................................................................................................................................................................................20

Burner Cleaning ..................................................................................................................................................................................................................20

Housekeeping ............................................................................................................................................................................................. 20-21

Anode Rod Inspection.........................................................................................................................................................................................................21

Temperature-Pressure Relief Valve Operation...................................................................................................................................................................21

Draining...........................................................................................................................................................................................................................21-22

Drain Valve Washer Replacement......................................................................................................................................................................................22

Service

Start Up Conditions.........................................................................................................................................................................................................23-24

Thermal Expansion......................................................................................................................................................................................................23

Strange Sounds...........................................................................................................................................................................................................23

Draft Hood Operation.............................................................................................................................................................................................23-24

Condensation...............................................................................................................................................................................................................24

Smoke/Odor................................................................................................................................................................................................... 24

Operational Conditions...................................................................................................................................................................................................24-25

Smelly Odor..................................................................................................................................................................................................................24

Air in Hot Water Faucets..............................................................................................................................................................................................25

High Temperature Shut-Off System............................................................................................................................................................................24

Leakage Checkpoints

SERVICE INSTRUCTIONS FOR GAS CONTROL VALVE ASSEMBLY..............................................................................................................................26-27

TROUBLESHOOTING GUIDE...............................................................................................................................................................................................28-29

PARTS ORDER LIST..................................................................................................................................................................................................................30

NOTES........................................................................................................................................................................................................................................31

WARRANTY.................................................................................................................................................................................................................................32

................................................................................................................................................................................. 5

..........

.................................................................................................................................................................. 8-16

......................................................................................................................................................................................... 10

........................................................................................................................................................................................ 19

.................................................................................................................................................................................... 25

CUSTOMER RESPONSIBILITIES

Thank You for purchasing a Kenmore water heater. Properly

installed and maintained, it should give you years of trouble free service. If you should decide that you want the new water heater professionally installed by Sears call 1-800-4-MY-HOIVIE®. They will arrange for prompt, quality installation by Sears authorized contractors.

Abbreviations Found In This Instruction Manual:

CSA - Canadian Standards Association ANSI - American National Standards Institute NFPA - National Fire Protection Association ASME - American Society of Mechanical Engineers GAMA - Gas Appliance Manufacturers Association

This gas-fired water heater is design certified by CSA

INTERNATIONAL under American National Standard/CSA Standard for Gas Water Heaters ANSI Z21.10.1 • CSA 4.1 (current edition).

Read the “Safety Precautions” section, page 3 of this manual first and then the entire manual carefully. If you don't follow the safety rules, the water heater will not operate properly. It could cause DEATH, SERIOUS BODILY INJURY AND/OR

PROPERTY DAMAGE.

This manual contains instructions for the installation, operation, and maintenance of the gas-fired water heater. It also contains warnings through out the manual that you must read and be aware of. All warnings and all instructions are essential to the proper operation of the water heater and your safety. Since we cannot put everything on the first few pages, READ THE

ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER.

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:

The National Fuel Gas Code ANSI Z223.1/NFPA 54. This publication is available from the Canadian Standards Association, 8501 East Pleasant Valley Rd, Cleveland Ohio 44131, or The National Fire Protection Association,

1 Batterymarch Park, Quincy, MA 02269.

If after reading this manual you have any questions or do not understand any portion of the instructions, call the Sears

Service Center.

Carefully plan the place where you are going to put the water

heater. Correct combustion, vent action, and vent pipe

installation are very important in preventing death from possible carbon monoxide poisoning and fires. See figure 1.

Examine the location to ensure the water heater complies with the Facts to Consider About the Location 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 your local dealer, wholesaler, public utilities or California Office of the State Architect, 400 P Street, Sacramento, CA 95814.

Massachusetts Oode 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 SCAQMD rule #1121 and districts having equivalent NOx requirements.

PRODUCT SPECIFICATIONS

RECOVERY

TANK

CAPACITY

MODEL NUMBER

153.334430 40(151) NATURAL 40,000 46.9 3” (76) or 4" (102) 20 1/2” (521) 55 1/2" (1,410)

153.334530 50(189) NATURAL 40,000 45.8 3" (76) or 4" (102) 22” (558) 56 1/2" (1,435)

IN GALS (LTRS)

TYPE

GAS

INPUT

RATE

(Btu/hrj

RATE GALS.

PER HOUR

@90°F RISE

MINIMUM

VENT PIPE

INCHES

(mm)

DIAMETER

INCHES

(mm)

DIMENSIONS

IN INCHES (mm)

HEIGHT TO

JACKET TOP

MATERIALS AND BASIC TOOl-S NEEDED

Materials Needed

To simplify the installation Sears has available the installation parts shown below. You may or may not need all of these materials, depending on your type of installation.

EXPANSION TANKS FOR THERMAL EXPANSION CONDITIONS AVAILABLE

m 2 GALLONS

(7.6 LITERS) AND 5 GALLONS {18,9 LITERS) CAPACITY HROUGH LOCAL SEARS STORE OR SERVICE CENTER.

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

Basic Tools

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

Pipe Wrenches (2) 14” (356 mm) Screwdriver Tin Snips 8’ (1.82 m) Tape or Folding Ruler

Garden Hose

Drill

Pipe Dope or Teflon Tape

SLOT-HEAD SCREWDRIVER

DRILL

DRAIN PANS AVAILABLE IN 20” (508 mm) DIAMETER FOR WATER HEATERS HAVING A DIAMETER 18” (457 mm) OR LESS, 24” {610mm) DIAMETER FOR WATER HEATERS HAVING A DIAMETER 22” {559 mm) OR LESS AND AVAILABLE IN 28” (711 mm) DIAMETER FOR WATER HEATERS HAVING A DIAMETER 26” (660 mm) OR LESS.

Additional Tools Needed When Sweat Soldering

• Tubing Cutters or Hacksaw

• Propane Tank

• Soft Solder

• Solder Flux

• Emery Cloth

• Wire Brushes

TUBING CUTTER

PHILLIPS SCREWDRIVER

ROLL OF TEFLON

TAPE (USE ONLY ON

WATER CONNECTIONS)

GARDEN HOSE

€ FOOT TAPE

TIN SNIPS

P.fii

PIPE DOPE

{SQUEEZE TUBE)

USE FOR WATER AND GAS

CONNECTIONS

PIPE WRENCH

03CI

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

TYPICAL INSTALLATION

GET TO KNOW YOUR WATER HEATER - GAS MODELS

A Vent Pipe J Drip Leg (Sediment Trap) S Flue Baffle

B Draft Hood K Inner Door T Thermostat c Anode L Outer door u Drain Valve

D Hot Water Outlet M Union V Pilot and Main Burner

E Outlet N Inlet Water Shut-off Valve w Flue

F Flexible Water Connections O Cold Water Inlet X Drain Pan G Gas Supply P Inlet Dip Tube Y Piezo Igniter

H Manual Gas Shut-off Valve

I Ground Joint Union R Rating Piate

* INSTALL IN ACCORDANCE

WITH LOCAL CODES.

*DRIP LEG AS REQUIRED

BY LOCAL CODES.

TO VENT TERMINATION

ON ROOF

INSTALL THERMAL EXPANSION

TANK OR DEVICE IF WATER

HEATER IS INSTALLED IN A

CLOSED WATER SYSTEM

Temperature-Pressure Relief Valve z Air intake Screen

“ALL PIPING MATERIALS TO BE

SUPPLIED BY CUSTOMERS.

FIGURE 1.

INSTALLATION INSTRUCTIONS

Removing the Old Water Heater

Attach a hose to the water 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. 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, see

Figures 2 and 5.

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.

water heater.

If the main gas line shut-off 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.

water heater at the water shut-off valve or water meter. Some

installations require that the water be turned off to the entire house, see Figures 2 and 4.

Check again to make sure the gas supply is “OFF” to the water heater. Then disconnect the gas supply connection from the gas control valve.

If you have galvanized pipes to the water heater, loosen the

two galvanized pipes with a pipe wrench at the union in each

line. Also disconnect the piping remaining to the water heater,

see Figure 7. These pieces should be saved since they may

be needed when reconnecting the new water heater.

Disconnect the temperature-pressure relief valve drain line. When the water heater is drained, disconnect the hose from the drain valve. Close the drain valve. The water heater is

now completely disconnected and ready to be removed.

Mineral buildup or sediment may have accumulated in the old water heater. This causes the water heater to be much

heavier than normal and this residue, if spilled out, could cause staining.

FIGURE 7.

Facts to Consider About

the Location

Devices that will turn off the gas supply to a gas water heater

while at the same time shutting off its water supply.

Carefully choose an indoor location for the new water heater, because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance. This water heater is not for

use in manufactured (mobile) homes or outdoor installation.

Whether replacing an old water heater or putting the water heater

in a new location, the following critical points must be observed:

• Select a location indoors as close as practical to the gas vent or chimney to which the water heater vent is going to be connected, and as centralized with the water piping system as possible.

” Selected location must provide adequate clearances for

servicing and proper operation of the water heater.

CAUTION

Property Damage Hazard

All water heaters eventually leak Do notinstall without adequate drainage.

Installation of the water heater must be accomplished in such a

manner that if the tank or any connections should leak, the flow 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 avoided, a suitable drain pan should be installed under the water heater. Drain pans are available at your local Sears or hardware store. Such a drain pan must have a minimum length and width of at least 2 inches (51 mm) greater that the water heater dimensions and must be piped to an adequate drain. The pan must not restrict combustion air flow.

Awarning

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 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

V extended period of non-use.

Read instruction manual before

installing, using or servicing

INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS (VAPORS) ARE LIKELY TO BE PRESENT OR STORED (GARAGES, STORAGE AND UTILITY AREAS. ETC.):

Flammable liquids (such as gasoiine, solvents, propane [LP or butane, etc.] and other substances such as adhesives, etc.) emit flammable vapors which can be ignited by a gas water heater's pilot light or main burner. The resulting flashback and fire can cause death or serious burns to anyone in the area. Even though this water heater is a flammable vapors ignition resistant water heater and is designed to reduce the chances of flammable vapors being ignited, gasoline and other flammable substances should never be stored or used in the same vicinity or area containing a gas water heater or other open fiame or spark producing appliance.

Also, the water heater must be located and/or protected so it is not subject to physical damage by a moving vehicle.

water heater.

Water heater life depends upon water quality, water pressure and the environment in which the water heater is installed. Water

heaters are sometimes installed in locations where leakage may

result in property damage, even with the use of a drain pan piped to a drain. However, unanticipated damage can be reduced or prevented by a leak detector or water shut-off device used in conjunction with a piped drain pan. These devices are available from some plumbing supply wholesalers and retailers, and detect and react to leakage in various ways:

• Sensors mounted in the drain pan that trigger an alarm or

turn off the incoming water to the water heater when leakage

is detected.

‘ Sensors mounted in the drain pan that turn off the water supply

to the entire home when water is detected in the drain pan.

‘ Water supply shut-off devices that activate based on the water

pressure differential between the cold water and hot water pipes connected to the water heater.

Awarning

Fire Hazard

For continued protection against risk of fire:

•Do not install water heater on carpeted floor.

•Do not operate water heater if flood damaged.

This water heater must not be installed directly on carpeting. Carpeting must be protected by 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 by the panel. Failure to heed this warning may result in a fire hazard.

A WARNING

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

Minimum clearances between the water heater and combustible construction are 0 inch at the sides and rear, 4 inches (102 mm) at the front, and 6 inches (153 mm) from the vent pipe, see Figure 8. Clearance from the top of the jacket is 12 inches (305 mm) on most models. Note that a lesser dimension may be allowed on some models, refer to the label attached adjacent to the gas control valve on the water heater.

combustibles.

TOP VIEW

OF CLOSET

WITHOUT DOOR

I I 0" MIN.

: 0" MIN.

TOP VIEW

OF CLOSET

WITH DOOR

0" MIN.

4" MIN.

(104 mmj

j. 12 " MAX. [30 cm)

T I ™STi'l

VENTILATION

AIR

OPENING^

12" MAX.

FRONT VIEW T

OF DOOR

If this water heater will be used in beauty shops, barber shops, cleaning establishments, or self-service laundries with dry cleaning equipment, it is imperative that the water heater or water heaters be installed so that combustion and ventilation air be

taken directly from outdoors (direct vent).

Propellants of aerosol sprays and volatile compounds, (cleaners,

chlorine based chemicals, refrigerants, etc.) in addition to being

highiy 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.

insulation Blankets

(30 cm)

FIGURE 9.

_____________________

№CTANQULAR

AIR DUCT

3" MIN.

(7®,2 mm)

FIGURE 8.

AWARNING

Breathing Hazard - Carbon Monoxide Gas

Install water heater in accordance

with the instruction manual and

NFPA 54.

To avoid injury, combustion and ventilation air must be taken from outdoors.

Do not place chemical vapor

emitting products near water

heater.

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

A gas water heater cannot operate properly without the correct amount of air for combustion, see Figure 9. Do not install in a confined area such as a closet, unless you provide air as shown in the Locating The New Water Heater section. Never obstruct the flow of ventilation air. If you have any doubts or questions at all, call your gas supplier. Failure to provide the proper amount of combustion air can result in a fire or explosion and cause death, serious bodily injury, or property damage.

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 loss encountered with storage tank heaters. Your

Kenmore water heater meets or exceeds the National Appliance

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

unnecessary.

Awarning

Breathing Hazard - Carbon Monoxide Gas

Do not obstruct water heater air intake with insulating blanket.

Gas and carbon monoxide detectors are available

Install water heater in accordance

with the instruction manual.

Breathing carbon monoxide can cause brain damage or

death. Always read and understand instruction manual.

Jim WARNING

Should you choose to apply an insulation blanket to this heater, you should follow these instructions (See Figure 1 for

identification of components mentioned below). Failure to follow these instructions can restrict the air flow required for proper combustion, potentially resulting in fire, asphyxiation, serious personal injury or death.

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