Kenmore 153.334530, 153.334430 User Manual

Owner’s Manual

HydroSense

Gas Water Heater

FOR POTABLE WATER HEATING ONLY.

NOT SUITABLE FOR SPACE HEATING.

NOT FOR USE IN MOBILE HOMES.

MODEL NO.

153.334430	40 Gallon
153.334530	50 Gallon

• Safety Instructions

• Installation

• Operation

• Care and Maintenance

• Troubleshooting

• Parts List

For Your Safety

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

C3 Technology® Gas Water Heaters meet the new ANSI Z21.10.1 standard that deals with the accidental or unintended ignition of fl ammable vapors, such as those emitted by gasoline.

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 CALENTADORDEAGUAsinoentiendelainformaciónenlasetiquetas 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. 1207	1	PART NO. 186422-000
	www.sears.com
		SUPERSEDES 185614-001

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.

				DANGERindicatesanimminentlyhazardous
		DANGER
				situation which, if not avoided, could result
				in death or injury.
				WARNING indicates a potentially hazardous
		WARNING
				situation which, if not avoided, could result
				in death or injury.
				CAUTION indicates a potentially hazardous
		CAUTION
				situation which, if not avoided, may result
				in minor or moderate injury.
				CAUTION used without the safety alert
	CAUTION			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.

IMPORTANT DEFINITIONS

•Gas Supplier: The natural gas or propane utility or service who supplies gas for utilization by the gas burning appliances within this application. The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the natural gas meter or propane storage tank of a building. Many gas suppliers also offer service and inspection of appliances within the building.

© Sears, Roebuck and Co.

2

SAFETY PRECAUTIONS

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TABLE OF CONTENTS

SAFE INSTALLATION, USE AND SERVICE .....................................................................................................................................	2
SAFETY PRECAUTIONS...................................................................................................................................................................	3
TABLE OF CONTENTS......................................................................................................................................................................	4
CUSTOMER RESPONSIBILITIES.....................................................................................................................................................	5
PRODUCT SPECIFICATIONS ...........................................................................................................................................................	5
MATERIALS AND BASIC TOOLS NEEDED ......................................................................................................................................	6
Material Needed...........................................................................................................................................................................	6
Basic Tools...................................................................................................................................................................................	6
TYPICAL INSTALLATION...................................................................................................................................................................	7
INSTALLATION INSTRUCTIONS .................................................................................................................................................	8-17
Removing the Old Water Heater..................................................................................................................................................	8
Facts to Consider About the Location.....................................................................................................................................	9-10
Insulation Blankets.....................................................................................................................................................................	10
Combustion Air and Ventilation for
Appliances Located in Unconfi ned Spaces.................................................................................................................................	11
Combustion Air and Ventilation for
Appliances Located in Confi ned Spaces ...............................................................................................................................	11-12
Water Piping..........................................................................................................................................................................	12-13
Temperature Pressure Relief Valve ...........................................................................................................................................	14
Filling the Water Heater .............................................................................................................................................................	15
Venting..................................................................................................................................................................................	15-16
Gas Piping ............................................................................................................................................................................	16-17
Sediment Trap............................................................................................................................................................................	17
OPERATING INSTRUCTIONS....................................................................................................................................................	18-19
Lighting & Operating Label ........................................................................................................................................................	18
Temperature Regulation.............................................................................................................................................................	19
SERVICE AND ADJUSTMENT ...................................................................................................................................................	20-22
Tank (Sediment) Cleaning..........................................................................................................................................................	20
Venting System Inspection.........................................................................................................................................................	20
Burner Inspection.......................................................................................................................................................................	20
Burner Cleaning.........................................................................................................................................................................	20
Housekeeping............................................................................................................................................................................	21
Anode Rod Inspection................................................................................................................................................................	21
Temperature-Pressure Relief Valve Operation ..........................................................................................................................	21
Draining.................................................................................................................................................................................	21-22
Drain Valve Washer Replacement .............................................................................................................................................	22
Service.......................................................................................................................................................................................	22
Start Up Conditions...............................................................................................................................................................	23-24
Thermal Expansion .............................................................................................................................................................	23
Strange Sounds...................................................................................................................................................................	23
Draft Hood Operation ..........................................................................................................................................................	23
Condensation ......................................................................................................................................................................	24
Smoke/Odor ........................................................................................................................................................................	24
Operational Conditions .........................................................................................................................................................	24-25
Smelly Odor.........................................................................................................................................................................	24
Air in Hot Water Faucets......................................................................................................................................................	24
High Temperature Shut-Off System.....................................................................................................................................	24
Leakage Checkpoints ..........................................................................................................................................................	25
SERVICE INSTRUCTIONS FOR GAS CONTROL VALVE ASSEMBLY .....................................................................................	26-27
TROUBLESHOOTING GUIDE....................................................................................................................................................	28-29
PARTS ORDER LIST .......................................................................................................................................................................	30
NOTES .............................................................................................................................................................................................	31
WARRANTY .....................................................................................................................................................................................	32

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CUSTOMER RESPONSIBILITIES

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

Abbreviations Found In This Instruction 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 fi rst 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 fi rst 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 fi res. See fi gure 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 Offi ce of the State Architect, 400 P Street, Sacramento, CA 95814.

•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.

PRODUCT SPECIFICATIONS

				RECOVERY	MINIMUM			DIMENSIONS
	TANK	TYPE	INPUT	RATE GALS.	VENT PIPE		DIAMETER	IN INCHES (mm)
	CAPACITY	OF	RATE	PER HOUR	INCHES		INCHES	HEIGHT TO
MODEL NUMBER	IN GALS (LTRS)	GAS	(Btu/hr)	@ 90°F RISE	(mm)		(mm)	JACKET TOP
153.334430	40 (151)	NATURAL	40,000	45.8	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)

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MATERIALS AND BASIC TOOLS NEEDED

Materials Needed

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

EXPANSION TANKS FOR THERMAL EXPANSION CONDITIONS AVAILABLE IN 2 GALLONS

(7.6 LITERS) AND

5 GALLONS (18.9 LITERS) CAPACITY HROUGH LOCAL SEARS STORE OR SERVICE CENTER.

WATER HEATER INSTALLATION KIT WITH FLEXIBLE CONNECTORS FOR 3/4”

(19.05 mm) OR 1/2” (12.7 mm) THREADED OR COPPER PLUMBING AND FLEXIBLE WATER HEATER GAS CONNECTOR WITH FITTINGS.

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.

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

PHILLIPS SCREWDRIVER

ROLL OF TEFLON

TAPE (USE ONLY ON

WATER CONNECTIONS)

DRILL

TIN SNIPS

PIPE DOPE

(SQUEEZE TUBE)

USE FOR WATER AND GAS

CONNECTIONS

GARDEN HOSE

6 FOOT TAPE

PIPE WRENCH

Additional Tools Needed

When Sweat Soldering

•Tubing Cutters or Hacksaw

•Propane Tank

•Soft Solder

•Solder Flux

•Emery Cloth

•Wire Brushes

	PROPANE
TUBING CUTTER	TORCH

	ROLL OF
HACKSAW	EMERY CLOTH

3/4” (19 mm) WIRE BRUSH
	ROLL OF LEAD-FREE	SOLDER
1/2” (13 mm) WIRE BRUSH	SOFT SOLDER	FLUX

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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	Q	Temperature-Pressure Relief Valve	Z	Air Intake Screen
I	Ground Joint Union	R	Rating Plate

* INSTALL IN ACCORDANCE WITH LOCAL CODES.

(T) THERMOSTAT

*DRIP LEG AS REQUIRED BY LOCAL CODES.

TO VENT TERMINATION ON ROOF

(V) PILOT & MAIN BURNER

MAXIMUM 6”

AIR GAP

* ALL PIPING MATERIALS TO BE	FIGURE 1.
SUPPLIED BY CUSTOMERS.

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INSTALLATION INSTRUCTIONS

Removing the Old Water Heater

	1. Turn “OFF” the gas supply to the
	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.	FIGURE 3.
	2. Turn “OFF” the water supply to
	the water heater at the water shut-
	off valve or water meter. Some
	installations require that the water
	be turned off to the entire house,
	see Figures 2 and 4.
		FIGURE 4.

3.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.

4. Attach a hose to the water heater
drain valve and put the other end in
a fl oor 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 fl ow is
directed away from any person, see	FIGURE 5.
Figures 2 and 5.

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.

6.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.

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.

FIGURE 7.

8

Facts to Consider About the Location

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.

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 fl ow.

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.

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

INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS (VAPORS) ARE LIKELY TO BE PRESENT OR STORED (GARAGES, STORAGEAND UTILITYAREAS, ETC.): Flammable liquids (such as gasoline, 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 fl ashback and fi re can cause death or serious burns to anyone in the area. Even though this water heater is a fl ammable vapors ignition resistant water heater and is designed to reduce the chances of fl ammable vapors being ignited, gasoline and other fl ammable substances should never be stored or used in the same vicinity or area containing a gas water heater or other open fl ame 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.

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 fl oor must be covered by the panel. Failure to heed this warning may result in a fi re hazard.

9

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.

FIGURE 8.

A gas water heater cannot operate properly without the correct amount of air for combustion, see Figure 9. Do not install in a confi ned area such as a closet, unless you provide air as shown in the Locating The New Water Heater section. Never obstruct the fl ow 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 fi re or explosion and cause death, serious bodily injury, or property damage.

FIGURE 9.

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 highly fl ammable 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

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.

WARNING

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

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