Kenmore 153.334530, 153.334430 User Manual

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Page 1

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

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.

For Your Safety

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

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 DE AGUA si 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. 1207 PART NO. 186422-000

www.sears.com

SUPERSEDES 185614-001

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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 hazardous

DANGER

WARNING

CAUTION

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

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.

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

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.

Page 3

SAFETY PRECAUTIONS

Page 4

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 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-ﬁ red 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.

. They

• 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

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)

RECOVERY MINIMUM DIMENSIONS

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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.

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 Teﬂ on 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

PROPANE

TORCH

PHILLIPS SCREWDRIVER

ROLL OF TEFLON

TAPE (USE ONLY ON

WATER CONNECTIONS)

GARDEN HOSE

6 FOOT TAPE

TIN SNIPS

PIPE DOPE

(SQUEEZE TUBE)

USE FOR WATER AND GAS

CONNECTIONS

PIPE WRENCH

3/4” (19 mm) WIRE BRUSH

1/2” (13 mm) WIRE BRUSH

HACKSAW

EMERY CLOTH

ROLL OF LEAD-FREE

SOFT SOLDER

ROLL OF

SOLDER

FLUX

Page 7

TYPICAL INSTALLATION

GET TO KNOW YOUR WATER HEATER - GAS MODELS

A Vent Pipe

B Draft Hood C Anode D Hot Water Outlet E Outlet F Flexible Water Connections G Gas Supply H Manual Gas Shut-off Valve I Ground Joint Union

* INSTALL IN ACCORDANCE WITH LOCAL CODES.

* DRIP LEG AS REQUIRED BY LOCAL CODES.

TO VENT TERMINATION

ON ROOF

J Drip Leg (Sediment Trap) K Inner Door L Outer door M Union N Inlet Water Shut-off Valve O Cold Water Inlet P Inlet Dip Tube Q Temperature-Pressure Relief Valve R Rating Plate

S Flue Bafﬂ e T Thermostat U Drain Valve V Pilot and Main Burner W Flue X Drain Pan Y Piezo Igniter Z Air Intake Screen

(T) THERMOSTAT

* ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS.

(V) PILOT & MAIN BURNER

MAXIMUM 6” AIR GAP

FIGURE 1.

Page 8

INSTALLATION INSTRUCTIONS

Removing the Old Water Heater

MAXIMUM 6” AIR GAP

FIGURE 2.

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 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 5.

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.

2. Turn “OFF” the water supply to the water heater at the water shutoff valve or water meter. Some installations require that the water be turned off to the entire house, see Figures 2 and 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.

FIGURE 3.

FIGURE 4.

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.

Page 9

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 ﬂ ow will not cause damage to the structure. For this reason, it is not advisable to install the water heater in an attic or upper ﬂ oor. 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.

• 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, STORAGE AND UTILITY AREAS, ETC.): Flammable liquids (such as gasoline, solvents, propane [LP or butane, etc.] and other substances such as adhesives, etc.) emit ﬂ ammable 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.

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.

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.

Page 10

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.

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.

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.

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.

Page 11

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

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

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

• Do not cover the instruction manual. Keep it on the side of the water heater or nearby for future reference.

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

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

within 12 inches (30 cm) of the top and one commencing within 12 inches (30 cm) of the bottom of the enclosures.

Combustion Air and Ventilation for Appliances Located in Unconﬁ ned Spaces

UNCONFINED SPACE is space whose volume is not less than

50 cubic feet per 1,000 Btu per hour (4.8 m aggregate input rating of all appliances installed in that space. Rooms communicating directly with the space in which the appliances are installed, through openings not furnished with doors, are considered a part of the unconﬁ ned space.

In unconﬁ ned spaces in buildings, inﬁ ltration may be adequate to provide air for combustion, ventilation and dilution of ﬂ ue gases. However, in buildings of tight construction (for example, weather stripping, heavily insulated, caulked, vapor barrier, etc.), additional air may need to be provided using the methods described in Combustion Air and Ventilation for Appliances Located in Conﬁ ned Spaces.

per kW) of the

Combustion Air and Ventilation for Appliances Located in Conﬁ ned Spaces

CONFINED SPACE is a space whose volume is less than

50 cubic feet per 1,000 Btu per hour (4.8 m aggregate input rating of all appliances installed in that space.

A. ALL AIR FROM INSIDE BUILDINGS:

(See Figure 9 on page 9 and Figure 10 below)

per kW) of the

FIGURE 10.

B. ALL AIR FROM OUTDOORS: (See Figures 9, 11,12 and 13)

The conﬁ ned space shall be provided with two permanent

openings, one commencing within 12 inches (30 cm) of the top and one commencing within 12 inches (30 cm) from the 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.

FIGURE 11.

The conﬁ ned space shall be provided with two permanent

openings communicating directly with an additional room(s) of sufﬁ cient volume so that the combined volume of all spaces meets the criteria for an unconﬁ ned space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each opening shall have a minimum free area of one square inch per 1,000 Btu per hour (22 cm utilization equipment in the conﬁ ned space, but not less than 100 square inches (645 cm

/kW) of the total input rating of all gas

). One opening shall commence

• When directly communicating with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 Btu per hour (5.5 cm

/kW) of total input rating of all equipment

in the enclosure. See Figure 12.

• 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 (5.5 cm total input rating of all equipment in the enclosure. See Figure 12.

/kW) of

Page 12

FIGURE 12.

• When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 BTU per hour (11 cm

/kW) of total input rating of all equipment in the enclosure. See Figure 13.

• When ducts are used, they shall be of the same crosssectional area as the free area of the openings to which they connect. The minimum short side dimension of rectangular air ducts shall not be less than 3 inches (76.2 mm). See Figure 13.

FIGURE 13.

• Louvers and Grilles: In calculating free area, consideration shall be given to the blocking effect of louvers, grilles or screens protecting openings. Screens used shall not be smaller than 1/4 inch (6.4 mm) mesh. If the free 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 speciﬁ ed. If the design and free area is not known, it may be assumed that wood louvers will be 20-25 percent free area and metal louvers and grilles will have 60-75 percent free area. Louvers and grilles shall be ﬁ xed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation.

• Special Conditions Created by Mechanical Exhausting or Fireplaces: operation of exhaust fans, ventilation systems, clothes dryers or ﬁ replaces may create conditions requiring special attention to avoid unsatisfactory operation of installed gas utilization equipment.

FIGURE 13A.

Water Piping

HOTTER WATER CAN SCALD: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, clothes washing, dish washing, cleaning 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 inﬁ rm, or physically/mentally handicapped. If anyone using hot water in your home ﬁ ts 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 addition to using the lowest possible temperature setting that satisﬁ es 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. See Figure 14. Valves for reducing point of use temperature by mixing cold and hot water are also available.

for installation of the valves. Before changing the factory setting on the thermostat, read the Temperature Regulation section in this manual.

Follow manufacturer’s instructions

• Alternatively, a single permanent opening may be used when communicating directly with the outdoors, or with spaces that freely communicate with the outdoors. The opening shall have a minimum free area of 1 square inch per 3,000 BTU per hour (8.3 cm²/kW) of total input rating of all equipment in the enclosure. See Figure 13A.

FIGURE 14.

Page 13

This water heater shall not be connected to any heating systems or component(s) used with a non-potable water heating appliance.

All piping components connected to this unit for space heating applications shall be suitable for use with potable water.

Toxic chemicals, such as those used for boiler treatment shall not be introduced into this system.

Water supply systems may, because of such events as high line pressure, frequent cut-offs or the effects of water hammer among others, have installed devices such as pressure reducing valves, check valves, back ﬂ ow preventers, etc. to control these types of problems. When these devices are not equipped with an internal by-pass, and no other measures are taken, the devices cause the water system to be closed. As water is heated, it expands (thermal expansion) and closed systems do not allow for the expansion of heated water.

to the cold water inlet. It will harm the dip tube and damage the tank.

• Look at the top cover of the water heater. The water outlet is marked “HOT”. Put two or three turns of teﬂ on tape around the threaded end of the threaded-to-sweat coupling and around both ends of the 3/4” NPT threaded nipple. Using ﬂ exible connectors, connect the hot water pipe to the hot water outlet on the water heater.

• Look at the top of the water heater. The cold water inlet is marked “COLD”. Put two or three turns of teﬂ on tape around the threaded end of the threaded-to-sweat coupling and around both ends of the 3/4” NPT threaded nipple. Using ﬂ exible connectors, connect the cold water pipe to the cold water inlet of the water heater.

NOTE: This water heater is super insulated to minimize

heat loss from the tank. Further reduction in heat loss can be accomplished by insulating the hot water lines from the water heater.

INSTALLATION COMPLETED USING INSTALLATION KIT

The water within the water heater tank expands as it is heated and increases the pressure of the water system. If the relieving point of the water heater’s temperature-pressure relief valve is reached, the valve will relieve the excess pressure. The

temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This is an unacceptable

condition and must be corrected. It is recommended that any devices installed which could create a closed system have a by-pass and/or the system have an expansion tank to relieve the pressure built by thermal expansion in the water system. Refer to the Thermal Expansion section under Troubleshooting Guide or contact local plumbing authority or local Sears Service Center on how to control this situation.

NOTE: To protect against untimely corrosion of hot and cold water ﬁ ttings, it is strongly recommended that di-electric unions or couplings be installed on this water heater when connected to copper pipe.

FIGURE 15.

Figure 15 shows the typical attachment of the water piping to the water heater. The water heater is equipped with 3/4” NPT water connections.

NOTE: If using copper tubing, solder tubing to an adapter before attaching the adapter to the cold water inlet connection. Do not solder the cold water supply line directly

Page 14

T & P Valve and Pipe Insulation

Remove insulation for T & P valve and pipe connections from carton.

FIGURE 15A.

Fit pipe insulation over the incoming cold water line and the hot water line. Make sure that the insulation is against the top cover of the heater.

Fit T & P valve insulation over valve. Make sure that the insulation does not interfere with the lever of the T & P valve.

Secure all insulation using tape.

For safe operation of the water heater, the relief valve must not be removed from its designated opening nor plugged.

The temperature-pressure relief valve must be installed directly into the ﬁ tting of the water heater designed for the relief valve. Position the valve downward and provide tubing so that any discharge will exit only within 6 inches (153 mm) above, or at any distance below the structural ﬂ oor, see Figure 16. Be certain 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 (9.14 m), 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 inch air gap is provided. To prevent bodily injury, hazard to life, or property damage, the relief valve must be allowed to discharge water in quantities should circumstances demand. If the discharge pipe is not connected to a drain or other suitable means, the water ﬂ ow may cause property damage.

Temperature-Pressure Relief Valve

This heater is provided with a properly certiﬁ ed combination temperature - pressure relief valve by the manufacturer.

The valve is certiﬁ ed by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 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 certiﬁ ed as indicated in the above paragraph.

The valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater (150 psi = 1,035 kPa) and a discharge capacity not less than the water heater input rate as shown on the model rating plate.

FIGURE 16.

The Discharge Pipe:

• Shall not be smaller in size than the outlet pipe size of the valve, or have any reducing couplings or other restrictions.

• Shall not be plugged or blocked.

• Shall be of material listed for hot water distribution.

• Shall be installed so as to allow complete drainage of both

Page 15

the temperature-pressure relief valve, and the discharge pipe.

• Shall terminate at an adequate drain.

• Shall not have any valve between the relief valve and tank.

The temperature-pressure relief valve must be manually operated at least once a year. Caution should be taken to ensure that (1) no one is in front of or around the outlet of the temperaturepressure relief valve discharge line, and (2) the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot.

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

Venting

VENT DAMPERS - Any vent damper, whether it is operated thermally or otherwise must be removed if its use inhibits proper drafting of the water heater.

Thermally Operated Vent Dampers: Gas-ﬁ red water heaters having thermal efﬁ ciency in excess of 80% may produce a relatively low ﬂ ue gas temperature. Such temperatures may not be high enough to properly open thermally operated vent dampers. This would cause spillage of the ﬂ ue gases and may cause carbon monoxide poisoning.

Vent dampers must bear evidence of certiﬁ cation as complying with the current edition of the American National Standard ANSI Z21.68 (ANSI Z21.66 & 67, respectively, cover electrically and mechanically actuated vent dampers). Before installation of any vent damper, consult your local Sears Service Center or the local gas supplier for further information.

If after manually operating the valve, it fails to completely reset and continues to release water, immediately close the cold water inlet to the water heater, follow the draining instructions, and replace the temperature-pressure relief valve with a new

one.

Filling the Water Heater

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

To ﬁ ll the water heater with water:

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

• Open the cold water supply valve to the water heater.

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

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

To ensure proper venting of this gas-ﬁ red water heater, the correct vent pipe diameter must be utilized. Any additions or deletions of other gas appliances on a common vent with this water heater may adversely affect the operation of the water heater. Consult your gas supplier if any such changes are planned. For replacement heater installations where using preexisting venting, venting must be inspected for obstructions and if deterioration is present, venting must be replaced.

For proper venting in certain installations, a larger diameter vent pipe may be necessary. Consult your local Sears Service Center or gas supplier to aid you in determining the proper venting for your water heater from the vent tables in the current edition of the National Fuel Gas Code ANSI Z223.1/NFPA 54.

Periodically check the venting system for signs of obstruction or deterioration and replace if needed.

The combustion and ventilation air flow must not be obstructed.

Page 16

The water heater with draft hood installed must be connected to a chimney or listed vent pipe system, which terminates to the outdoors. Never operate the water heater unless it is vented to the outdoors and has adequate air supply to avoid risks of improper operation, explosion or asphyxiation.

• For proper draft hood attachment, the draft hood legs may be angled slightly inward.

• Place the draft hood legs in the receiving holes on the top of the water heater. The legs will snap in the holes to give a tight ﬁ t. Secure two legs to top with sheet metal screws.

• Place the vent pipe over the draft hood. With the vent pipe in position, drill a small hole through both the vent pipe and draft hood. Secure them together with a sheet metal screw. See Figure 17.

Obstructed or deteriorated vent systems may present serious health risk or asphyxiation.

Failure to have required clearances between vent piping and combustible material will result in a ﬁ re hazard. Be sure vent pipe is properly connected to prevent escape of dangerous ﬂ ue gases which could cause deadly asphyxiation. Chemical vapor corrosion of the ﬂ ue and vent system may occur if air for combustion contains certain chemical vapors. Spray can propellants, cleaning solvents, refrigerator and air conditioner refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes, bleach and process chemicals are typical

compounds which are potentially corrosive.

FIGURE 17.

The vent pipe from the water heater must be no less than the diameter of the draft hood outlet on the water heater and must slope upward at least 1/4 inch per linear foot (21 mm per meter). See Figure 18.

FIGURE 18.

All vent gases must be completely vented to the outdoors of the

structure (dwelling). Install only the draft hood provided with the new water heater and no other draft hood.

Vent pipes must be secured at each joint with sheet metal screws.

There must be a minimum of 6 inches (153 mm) clearance between single wall vent pipe and any combustible material. Fill and seal any clearance between single wall vent pipe and combustible material with mortar mix, cement, or other noncombustible substance. For other than single wall, follow vent pipe manufacturer’s clearance speciﬁ cations. To insure a tight ﬁ t of the vent pipe in a brick chimney, seal around the vent pipe with mortar mix cement.

Gas Piping

Make sure the gas supplied is the same type listed on the model rating plate. The inlet gas pressure must not exceed 14 inch water column (3.5kPa) for natural and propane gas (L.P.) gas. The minimum inlet gas pressure listed on the rating plate is for the purpose of input adjustment. is subjected to pressures exceeding 1/2 pound per square inch (3.5kPa), the damage to the gas control valve could result in a ﬁ re or explosion from leaking gas.

If the main gas line shutoff serving all gas appliances is used, also turn “OFF” the gas at each appliance. Leave all gas appliances shut “OFF” until the water heater installation is complete.

A gas line of sufﬁ cient size must be run to the water heater. Consult the current edition of National Fuel Gas Code ANSI Z223.1/NFPA 54 and your gas supplier concerning pipe size.

If the gas control valve

Page 17

There must be:

• A readily accessible manual shut off valve in the gas supply line serving the water heater, and

• A drip leg (sediment trap) ahead of the gas control valve to help prevent dirt and foreign materials from entering the gas control valve.

• A ﬂ exible gas connector or a ground joint union between the shut off valve and control valve to permit servicing of the unit.

Be sure to check all the gas piping for leaks before lighting the water heater. Use a soapy water solution, not a match or open ﬂ ame. Rinse off soapy solution and wipe dry.

The minimum inlet gas pressure shown on the rating plate is that which will permit ﬁ ring at the rated input.

The appliance and its gas connection must be leak tested before placing the appliance in operation.

The appliance and its individual shutoff valve shall be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 pound per square inch (3.5kPa). It shall be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 pound per square inch (3.5kPa).

Connecting the gas piping to the gas control valve of the water heater can be accomplished by either of the two methods shown in Figures 19 and 20.

Sediment Traps

Water heaters covered in this manual have been tested and approved for installation at elevations up to 7,700 feet (2,347 m) above sea level. For installation above 7,700 feet (2,347m), the water heater’s Btu input should be reduced at the rate of 4 percent for each 1,000 feet (305 m) above sea level which requires replacement of the burner oriﬁ ce in accordance with the National Fuel Gas Code ANSI Z223.1/NFPA 54. Contact your local gas supplier for further information.

Failure to replace the standard oriﬁ ce with the proper high altitude oriﬁ ce when installed at elevations above 7,700 feet (2,347m) could result in improper and inefﬁ cient operation of the appliance, producing carbon monoxide gas in excess of the safe limits. This could result in serious injury or death. Contact your local gas supplier for any speciﬁ c changes that may be required in your area.

Contaminants in the gas lines may cause improper operation of the gas control valve that may result in ﬁ re or explosion. Before attaching the gas line be sure that all gas pipe is clean on the inside. To trap any dirt or foreign material in the gas supply line, a drip leg (sometimes called a sediment trap) must be incorporated in the piping. The drip leg must be readily accessible. Install in accordance with the Gas Piping section. Refer to the current edition of th

ANSI Z223.1/NFPA 54.

A sediment trap shall be installed as close to the inlet of the water heater as practical at the time of water heater installation. The sediment trap shall be either a tee ﬁ tting with a capped nipple in the bottom outlet or other device recognized as an effective sediment trap. If a tee ﬁ tting is used, it shall be installed in conformance with one of the methods of installation, shown in Figures 19 and 20.

FIGURE 19. GAS PIPING WITH FLEXIBLE CONNECTOR.

e National Fuel Gas Code,

Use pipe joint compound or teﬂ on tape marked as being resistant to the action of petroleum (Propane [L.P.]) gases.

FIGURE 20. GAS PIPING WITH ALL BLACK IRON PIPE TO GAS CONTROL.

Page 18

OPERATING INSTRUCTIONS

Page 19

Temperature Regulation

Due to the nature of the typical gas water heater, the water temperature in certain situations may vary up to 30F° (16.7 C°) higher or lower at the point of use such as, bathtubs, showers, sink, etc.

HOTTER WATER CAN SCALD: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy space heating, 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 inﬁ rm, or physically/mentally handicapped. If anyone using hot water in your home ﬁ ts 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 addition to using the lowest possible temperature setting that satisﬁ es 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 manufacturer’s instructions for installation of the valves. Before changing the factory setting on the thermostat, see Figures 21 and 22.

THE WATER HEATER SHOULD BE LOCATED IN AN AREA WHERE THE GENERAL PUBLIC DOES NOT HAVE ACCESS. IF A SUITABLE AREA IS NOT AVAILABLE, A COVER SHOULD BE INSTALLED OVER THE THERMOSTAT TO PREVENT TAMPERING. Suitable covers are available through the Sears Service Center.

Never allow small children to use a hot water tap, or to draw their own bath water. Never leave a child or handicapped person unattended in a bathtub or shower.

It is recommended that lower water temperatures be used to avoid the risk of scalding. It is further recommended, in all cases, that the water temperature be set for the lowest temperature which satisﬁ es your hot water needs. This will also provide the most energy efﬁ cient operation of the water heater.

NOTE: A water temperature range of 120°F-140°F (49°C-60°C) is recommended by most dishwasher manufacturers.

The thermostat of this water heater has been factory set at its lowest position (OFF). It is adjustable and must be reset to the desired temperature setting. The faceplate of the thermostat is marked with approximate temperature settings. The preferred starting point is approximately 120°F (49°C). Align the knob with the desired water temperature as shown in Figure 21. There is a hot water scald potential if the thermostat is set too high. Some states have a requirement for a lower setting.

Turn the water temperature dial clockwise ( the temperature, or counterclockwise (

) to increase

) to decrease the

temperature.

Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance.

Temperature

Settings

160°F (71°C) About 1/2 second

150°F (66°C) About 1-1/2 seconds

140°F (60°C) Less than 5 seconds

130°F (54°C) About 30 seconds

120°F (49°C) More than 5 minutes

VAC = approx. 80°F (27°C) - - - - - - - - - - - - - - - -

Time to Produce 2nd & 3rd

Degree Burns on Adult Skin

THERMOSTAT DIAL

FIGURE 21.

FIGURE 22.

Page 20

SERVICE AND ADJUSTMENT

Tank (Sediment) Cleaning

Sediment build-up on the tank bottom may create varying amount of noise, and if left in the tank will cause permanent tank failure. In some water areas, you may not be able to drain all sediment deposits by simply draining the tank. In these cases Mag-Erad (part no. 23600) can be used to help remove the sediment deposits. This may be ordered from the Sears Service Center. For ordering, refer to the Parts Order List section.

Vent System Inspection

• Flue gases may escape if vent pipe is not connected.

• Be alert for obstructed, sooted or deteriorated vent system to avoid serious injury or death.

• Do not store corrosive chemicals in vicinity of water heater.

Burner Inspection

Flood damage to a water heater may not be readily visible or immediately detectable. However, over a period of time a ﬂ ooded water heater will create dangerous conditions

can cause DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE. Contact a Sears Service Center to replace a ﬂ ooded water heater. Do not attempt to

replaced!

At least once a year a visual inspection should be made of the main burner and pilot burner. See Figure 23.

You should check for sooting. Soot is not normal and will impair proper combustion.

Soot build-up indicates a problem that requires correction 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 ﬁ re causing death, serious injury, or property damage.

repair the unit! It must be

which

• Chemical corrosion of ﬂ ue and vent system can cause serious injury or death

At least once a year a visual inspection should be made of the venting system. You should look for:

• Obstructions which could cause improper venting. The combustion and ventilation air ﬂ ow must not be obstructed.

• Damage or deterioration which could cause improper venting or leakage of combustion products.

• Rusted ﬂ akes around top of water heater.

Be sure the vent piping is properly connected to prevent escape of dangerous ﬂ ue gasses which could cause deadly asphyxiation.

Obstructions and deteriorated vent systems may present serious health risk or asphyxiation.

Chemical vapor corrosion of the ﬂ ue and vent system may occur if air for combustion contains certain chemical vapors. Spray can propellants, cleaning solvents, refrigerator and air conditioner refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes, bleach and process chemicals are typical compounds which are potentially corrosive.

If when inspecting the vent system you find sooting or deterioration, something is wrong. Call the local gas supplier to correct the problem and clean or replace the ﬂ ue and venting before resuming operation of the water heater.

FIGURE 23.

Burner Cleaning

In the event your burner needs cleaning, following these instructions:

If inspection of the burner shows that cleaning is required, turn the gas control knob counter-clockwise ( depressing slightly.

The burner needs to be removed for cleaning. Call the Sears Service Center to remove and clean the burner and correct the problem that required the burner to be cleaned.

) to the “OFF” position,

Page 21

Housekeeping

Vacuum around base of water heater for dust, dirt, and lint on a regular basis.

AT LEAST ONCE EVERY SIX MONTHS A VISUAL INSPECTION SHOULD BE MADE OF THE AIR INTAKE SCREEN. CLEAN IF LINT ACCUMULATIONS ARE NOTICED.

Temperature-Pressure Relief Valve Operation

The temperature-pressure relief valve must be manually operated at least once a year.

When checking the temperature-pressure relief valve operation, make sure that (1) no one is in front of or around the outlet of the temperature-pressure relief valve discharge line, and (2) that the water discharge will not cause any property damage, as the water may be extremely hot. See Figure 24.

INSTALLED IN SUITABLE AREA: To insure sufﬁ cient ventilation and combustion air supply, proper clearances from the water heater must be maintained. See Facts to Consider About the Location section. Combustible materials such as clothing, cleaning materials, or ﬂ ammable liquids, etc. must not be placed against or adjacent to the water heater because they could catch on ﬁ re.

Anode Rod Inspection

The anode rod is used to protect the tank from corrosion. Most hot water tanks are equipped with an anode rod. The submerged rod deteriorates to protect the tank. Instead of corroding the tank, water ions attack and eat away the anode rod. This does not affect the water’s taste or color. The rod must be maintained to keep the tank in operating condition.

FIGURE 24.

If the temperature-pressure relief valve on the appliance weeps or discharges periodically, this may be due to thermal expansion. You may have a check valve installed in the water line or a water meter with a check valve. Consult the Sears Service Center for further information. Do not plug the temperaturepressure relief valve.

Draining

Anode deterioration depends on water conductivity, not necessarily water condition. A corroded or pitted anode rod indicates high water conductivity and should be checked and/ or replaced more often than an anode rod that appears to be intact. Replacement of a depleted anode rod can extend the life of your water heater. Inspection should be conducted by calling the Sears Service Center for an authorized contractor. At a minimum, the anode(s) should be checked annually after the warranty period.

The water heater should be drained if being shut down during freezing temperatures. Also periodic draining and cleaning of sediment from the tank may be necessary.

1. Turn the gas control knob to the “OFF” position.

Page 22

2. CLOSE the cold water inlet valve to the water heater.

4. Remove the washer and put the new one in place.

3. OPEN a nearby hot water faucet and leave open to allow for draining.

4. Connect a hose to the drain valve and terminate to an adequate drain.

5. OPEN the water heater drain valve to allow for tank draining.

NOTE: If the water heater is going to be shut down and

drained for an extended period, the drain valve should be left open with hose connected allowing water to terminate to an adequate drain.

6. Close the drain valve.

7. Follow instructions in the Filling The Water heater section.

8. Follow the lighting instructions in the Lighting section to restart the water heater.

Drain Valve Washer Replacement

(See Figure 25)

1. Turn “OFF” gas supply to water heater.

2. Follow “Draining” instructions.

3. Turning counter clockwise ( the screw handle.

), remove the hex cap below

5. Screw the handle and cap assembly back into the drain valve and retighten using a wrench. DO NOT OVER TIGHTEN.

6. Follow instructions in the Filling The Water Heater section.

7. Check for leaks.

8. Follow the lighting instructions in the Lighting section to restart the water heater.

FIGURE 25.

Service

Before calling for repair service, read the Start Up Conditions and Operational Conditions found in the Troubleshooting Guide of this manual.

If a condition persists or you are uncertain about the operation of the water heater, let the Sears Service Center check it out.

Contact Sears Service Center at:

1-800-4-MY-HOME

(1-800-469-4663).

Page 23

Start Up Conditions

Thermal Expansion

Water supply system may, because of such events as high line pressure, frequent cut-offs, and the effects of water hammer have installed devices such as pressure reducing valves, check valves, back ﬂ ow preventers, etc., to control these types of problems. When these devices are not equipped with an internal by-pass, and no other measures are taken, the devices cause the water system to be closed. As water is heated, it expands (thermal expansion) and closed systems do not allow for the expansion of heated water.

The water within the water heater tank expands as it is heated and increases the pressure of the water system. If the relieving point of water heater’s temperature-pressure relief valve is reached, the valve will relief the excess pressure. The temperature-

pressure relief valve is not intended for the constant relief of thermal expansion. This is an unacceptable condition and

must be corrected.

It is recommended that any devices installed which could create a closed system have a by-pass and/or the system have an expansion tank or device to relieve the pressure built by thermal expansion. Thermal expansion tanks are available from Sears stores and through the Sears Service Centers. Contact the local plumbing inspector, water supplier and/or the Sears Service Center for assistance in controlling these situations. See Figure 26.

NOTE: Expansion tanks are pre-charged with a 40 psi air charge. If the inlet water pressure is higher than 40 psi, the expansion tank’s air pressure must be adjusted to match that pressure, but must not be higher than 80 psi.

Thermal Expansion Tank Speciﬁ cations

Tank Dimensions Pipe Model Capacity

Number In Gallons Diameter Length On Tank

153.331020 2 8 (203 mm) 12-3/4 (323 mm) 3/4” Male

153.331050 5 11 (279 mm) 14-3/4 (375 mm) 3/4” Male

in Inches Fitting

Expansion Tank Sizing Chart

Inlet* Water Heater Capacity (Gallons) Water Pressure 30 40 50 66 80

Expansion 40psi 2 2 2 5 5 Ta nk 50psi 2 2 2 5 5 Capacity 60psi 2 2 5 5 5 Needed 70psi 2 2 5 5 5 80psi 2 5 5 5 5

*Highest recorded inlet water pressure in a 24 hour period or regulated water pressure.

FIGURE 26.

Strange Sounds

Possible noises due to expansion and contraction of some metal parts during periods of heat-up and cool-down do not represent harmful or dangerous conditions.

Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal. See Condensation section.

Draft Hood Operation

Check draft hood operation by performing a worst case depressurization of the building. With all doors and windows closed, and with all air handling equipment and exhaust fans operating such as furnaces, clothes dryers, range hoods and bathroom fans, a match ﬂ ame should still be drawn into the draft hood of the water heater with its burner ﬁ ring. If the ﬂ ame is not drawn toward the draft hood, shut off water heater and make necessary air supply changes to correct.

Page 24

Condensation

Whenever the water heater is ﬁ lled with cold water, some condensate will form while the burner is on. A water heater may appear to be leaking when in fact the water is condensation. This usually happens when:

the result of four factors which must all be present for the odor to develop:

• a concentration of sulfate in the supply water.

• little or no dissolved oxygen in the water.

• A new water heater is ﬁ lled with cold water for the ﬁ rst time.

• Burning gas produces water vapor In water heaters, particularly high efﬁ ciency models where ﬂ ue temperatures are lower.

• Large amounts of hot water are used in a short time and the reﬁ ll water in the tank is very cold.

Moisture from the products of combustion condense on the cooler tank surfaces and form drops of water which may fall onto the burner or other hot surfaces to produce a “sizzling” or “frying” noise.

Excessive condensation can cause pilot outage due to water running down the ﬂ ue tube onto the main burner and putting out the pilot.

Because of the suddenness and amount of water, condensation water may be diagnosed as a “tank leak”. After the water in the tank warms up (about 1-2 hours), the condition should disappear.

Do not assume the water heater is leaking until there has been enough time for the water in the tank to warm up.

• a sulfate reducing bacteria within the water heater. (This harmless bacteria is non-toxic to humans.)

• an excess of active hydrogen in the tank. This is caused by the corrosion protective action of the anode.

Smelly water may be eliminated or reduced in some water heater models by replacing the anode(s) with one of less active material, and then chlorinating the water heater tank and all hot water lines. Contact Sears Service for further information concerning an Anode Replacement Kit #9001453 and this Chlorination Treatment. Anode replacement and chlorination of the tank are not covered by the water heater’s limited warranty.

If the smelly water persists after the anode replacement and chlorination treatment, it may be necessary to chlorinate or aerate your water supply to eliminate the problem.

Do not remove the anode leaving the tank unprotected. By doing so, all warranty on the water heater tank is voided.

“AIR” In Hot Water Faucets

An undersized water heater will cause more condensation. The water heater must be sized properly to meet the family’s demands for hot water including dishwashers, washing machines and shower heads.

Excessive condensation may be noticed during the winter and early spring months when incoming water temperatures are at their lowest.

Good venting is essential for a gas ﬁ red water heater to operate properly as well as to carry away products of combustion and water vapor.

Smoke / Odor

It is not uncommon to experience a small amount of smoke and odor during the initial start-up. This is due to burning off of oil from metal parts, and will disappear in a short while.

Operational Conditions

Smelly Odor

In each water heater there is installed at least one anode rod

(see parts section) for corrosion protection of the tank. Certain water conditions will cause a reaction between this rod and the water. The most common complaint associated with the anode rod is one of a “rotten egg smell”. This odor is derived from hydrogen sulﬁ de gas dissolved in the water. The smell is

HYDROGEN GAS: Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally two weeks or more). Hydrogen gas is extremely ﬂ ammable and explosive. To prevent the possibility of injury under these conditions, we recommend the hot water faucet, located farthest away, be opened for several minutes before any electrical appliances which are connected to the hot water system are used (such as a dishwasher or washing machine). If hydrogen gas is present, there will probably be an unusual sound similar to air escaping through the pipe as the hot water faucet is opened. There must be no smoking or open ﬂ ame near the faucet at the time it is open.

High Temperature Shut Off System

This water heater is equipped with an automatic gas shutoff system. This system works when high water temperatures are present. Turn “OFF” the entire gas supply to the water heater. The high temperature shutoff is built into the gas control valve. It is non-resettable. If the high temperature shutoff activates, the gas control valve must be replaced. Contact your gas supplier.

Page 25

Operational Conditions (Continued)

Leakage Checkpoints

Read this manual ﬁ rst. Then before checking the water heater make sure the gas supply has been turned “OFF”, and never turn the gas “ON” before the tank is completely full of water.

Never use this water heater unless it is completely ﬁ lled with water. To prevent damage to the tank, the tank must be ﬁ lled with water. Water must ﬂ ow from the hot water faucet before turning “ON” gas to the water heater. See Figure 27.

A. Water at the draft hood is water vapor which has condensed

out of the combustion products. This is caused by a problem in the vent. Contact the gas utility.

B. *Condensation may be seen on pipes in humid weather or

pipe connections may be leaking.

C. *The anode rod ﬁ tting may be leaking.

D. Small amounts of water from temperature-pressure relief valve

may be due to thermal expansion or high water pressure in your area.

E. *The temperature-pressure relief valve may be leaking at the

tank ﬁ tting.

FIGURE 27.

F. Water from a drain valve may be due to the valve being slightly

opened.

G. *The drain valve may be leaking at the tank ﬁ tting.

H. Combustion products contain water vapor which can

condense on the cooler surfaces of the tank. Droplets form and drip onto the burner or run on the ﬂ oor. This is common at the time of start-up after installation and when incoming water is cold.

I. Water in the water heater bottom or on the ﬂ oor may be

from condensation, loose connections, or the relief valve. DO NOT replace the water heater until a full inspection of all possible water sources is made and necessary corrective steps taken.

Leakage from other appliances, water lines, or ground seepage should also be checked.

* To check where threaded portion enters tank, insert cotton

swab between jacket opening and ﬁ tting. If cotton is wet, follow “Draining” instructions in the Periodic Maintenance section and then remove ﬁ tting. Put pipe dope or teﬂ on tape on the threads and replace. Then follow Filling the Water Heater instructions in the Installing the New Water Heater section.

Page 26

SERVICE INSTRUCTIONS FOR GAS CONTROL VALVE ASSEMBLY

A. Tools required:

1. T15 Torx Screwdriver

2. 3/16” slotted screwdriver.

3. Open-end wrenches 7/16”, and 3/4”.

For these instructions, please see Figure 28.

B. Removing Electronic Control Module:

1. Turn the gas control/temperature knob to the “OFF” position.

2. Turn off the gas at the manual shut-off valve on the gas supply line.

3. Disconnect the wire connectors from the piezo igniter, tank sensors, and thermopile mounted on the lower front of the gas control valve assembly.

4. Remove the torx screw located beside the pilot tube on the lower front of the electronic control module with a T15 torx screwdriver.

5. Depress the two plastic locking tabs on the top surface of the electronic control module with a 3/16” slotted screwdriver.

6. Grasp the sides of the electronic control module and pull outward to remove.

C. Removing Gas Valve Assembly:

D. Removing Gas Valve Backplate (If Snap-on Design):

1. Follow steps 1 to 7 in C above to remove the gas valve assembly.

2. Pull forward or break off the two plastic locking tabs using a 3/16” slotted screwdriver.

3. Grasp the sides of the back-plate and slide upward to remove it from the gas valve nipple.

4. Unscrew and remove the gas valve nipple by turning it to the left.

5. Follow steps 1 and 2 in F below to install the new gas valve assembly.

E: Removing Gas Valve Backplate (If Screw-in Design):

1. Follow steps 1 to 7 in C above to remove the gas valve assembly.

2. Unscrew and remove the backplate by turning it to the left until it separates from the backplate nipple.

3. Install new backplate and check for leaks.

F: Installing Gas Valve Assembly:

1. Install the new gas valve (with nipple) onto the tank and tighten securely to ensure no leaks.

2. Reconnect the burner tube, pilot tube, and inlet gas supply line to the gas valve. Tighten securely and check for gas leaks.

1. Follow steps 1 to 6 in B above to remove the electronic control module.

2. Disconnect the inlet gas supply to the gas valve.

3. Loosen the ﬂ are nut that connects the pilot tube to the bottom of the gas control valve assembly with a 7/16” open-end wrench. Pull down on the pilot tube to separate the tube from the gas valve.

4. Loosen the ﬂ ange nut that connects the burner tube to bottom of gas control valve with a 3/4” open-end wrench. Pull down on the burner tube to separate the tube from the gas valve.

5. Remove the torx screw located beside the pilot tube on the lower front of the gas valve assembly with a T15 torx screwdriver.

6. Depress the two plastic locking tabs on lower front surface of gas valve with a 3/16” slotted screwdriver.

7. Grasp the sides of the gas valve and pull outward to remove.

G: Installing Electronic Control Module:

1. Align the two plastic locking tabs on the top surface of the electronic control module with the openings of the gas valve back-plate. Press on the front of the control module until it locks into position.

2. Reinstall the torx screw on the lower front of the electronic control module (beside pilot tube) with a T15 torx screwdriver. Tighten securely.

3. Reconnect the wire connectors from the piezo igniter, tank sensors, and thermopile to the electronic control module.

4. Light the heater following the lighting and operating instructions on the front surface of the heater.

Page 27

GAS VALVE BACKPLATE

GAS VALVE NIPPLE

FIGURE 28.

Page 28

TROUBLESHOOTING GUIDE

These guidelines should be used by a qualiﬁ ed service agent. Call Sears Service at 1-800-4-MY-HOME® (1-800-469-4663)

for assistance. Inform the associate that this is a “Flammable Vapor Ignition Resistant” Product.

Problem LED Status Cause Solution

OFF

1 flash *

2 flashes * Thermopile voltage low.

3 flashes *

4 flashes *

5 flashes *

GAS

VALVE

* Flashes are approximately 1/10 second in duration with approximately three seconds between groups of ﬂ ashes.

6 flashes *

7 flashes *

8 flashes *

6 second solid light

followed by 4 flashes *

6 second solid light

followed by 7 flashes *

6 second solid light

followed by 8 flashes *

6 second solid light with

combinations of 4 + 7

flashes *

6 second solid light with

combinations of 4+ 8

flashes *

6 second solid light with

combinations of 7 + 8

flashes *

6 second solid light with

combinations of 4 + 7 + 8

flashes *

Continuous solid light System shutdown/safety interlock.

Electronic control module off or pilot assembly off.

Electronic control module is powered and pilot lit.

Gas control valve or tank sensor failure.

Gas control valve overheat failure (pilot off or burner off).

Lower tank sensor failure (pilot on and burner off).

Upper tank sensor failure (pilot on and burner off).

Electric control module failure (pilot on or off and burner off). Gas control valve failure (pilot off and burner off). Pilot stays lit only when control knob is depressed in PILOT position. Pilot stays lit only when control knob is depressed in PILOT position.

Pilot stays lit only when control knob is depressed in PILOT position.

Check for power to heater. Check wiring harness for proper connection. Check for line voltage at harness connectors.

Normal operation. No action required.

Inspect thermopile connection to gas control valve. Inspect flame coverage on thermopile. Check inlet gas pressure. Run open circuit thermopile output test and change thermopile if output is low. Replace pilot assembly. Restart gas control valve. If main burner turns on after restart, replace tank sensor. If main burner does not turn on after restart, replace gas control valve. Replace gas control valve assembly and electric control module. Verify tank sensor is connected to electric control module. Verify tank sensor is connected to the heater tank. Run tank sensor calibration check. Replace tank sensor and electric control module. Verify tank sensor is connected to electric control module. Verify tank sensor is connected to the heater tank. Run tank sensor calibration check. Replace tank sensor and electric control module.

Replace electric control module.

Replace gas control valve assembly and electronic control module. Overheat failure. Replace gas control valve assembly and electronic module. Electronic control module failure. Replace module. Gas control valve failure. Replace gas control valve assembly and electronic control module. Overheat failure and electronic control module failure. Replace gas control valve assembly and electronic module. Overheat failure and gas control valve failure. Replace gas control valve assembly and electric module. Electric control module failure and gas control valve failure. Replace gas control valve assembly and electronic module. Overheat failure, electronic control module failure, and gas control valve failure. Replace gas control valve assembly and electronic module. Wait until light goes out to restart gas control valve.

Page 29

TROUBLESHOOTING GUIDE (Continued)

These guidelines should be used by a qualiﬁ ed service agent. Call Sears Service at 1-800-4-MY-HOME® (1-800-469-4663)

for assistance. Inform the associate that this is a “Flammable Vapor Ignition Resistant” Product.

0ROBL EM #AUSE 3OLUTION

Improperly sealed, hot or cold supply connection, relief valve, drain valve, or

WATER LEAKS

LEAKING T&P VALVE

SMELLY ODORS

PILOT WILL NOT LIGHT

BURNER WILL NOT STAY LIT

PILOT OUTAGE

NOT ENOUGH HOT WATER

WATER TOO HOT Thermostat set too high. Refer to TEMPERATURE REGULATION.

WATER HEATER SOUNDS Condensation dripping on burner. Refer to CONDENSATION.

SIZZLING – RUMBLING

SOOTING Improper combustion.

VENT GAS ODORS

thermostat threads. Leakage from other appliances or water lines. Condensation of flue products. Refer to CONDENSATION.

Thermal expansion in closed water system.

Improperly seated valve.

High sulfate or mineral content in water supply. Bacteria in water supply. Chlorinate or aerate water supply. Gas knob dial not positioned correctly. Refer to LIGHTING INSTRUCTIONS. Main gas supply off. Turn on main gas shutoff valve. Igniter tip more than 1/8” from pilot hood. Adjust ignitor tip. Thermopile malfunction. Replace pilot assembly. Thermopile TCO malfunction. Replace pilot assembly. Melted insulation on ignitor wire or shorting of ignitor wire.

High ambient room temperature.

Wire disconnected from piezo igniter. Reconnect wire connector to piezo igniter. Broken electrode or electrical wire. Replace pilot assembly. Piezo Igniter generator fails to operate or malfunctions. Thermopile TCO malfunction. Replace pilot assembly.

High ambient room temperature.

Dirty or clogged Intake Screen. Clean and reinstall Air Intake Screen.

Flame arrestor openings blocked.

Defective Gas Control. Replace Gas Control. Dirty pilot burner. Clean pilot assembly. Dirty or clogged Air Intake Screen. Clean and reinstall Air Intake Screen. Thermopile malfunction. Replace pilot assembly. Thermopile TCO malfunction. Replace pilot assembly. Defective Gas Control. Replace Gas Control. Heater not lit or thermostat not on. Refer to LIGHTING INSTRUCTIONS. Thermostat set too low. Refer to TEMPERATURE REGULATION. Heater undersized. Reduce hot water use. Low gas pressure. Contact your gas supplier. Incoming water is unusually cold. Allow more time for your heater to re-heat. Leaking hot water pipes or fixtures. Have plumber check and repair leaks.

High temperature limit switch activated.

Sediment or calcium in bottom or heater tank.

Lack of supply air. Improperly installed vent piping. Downdraft. Poor Combustion.

Tighten threaded connections.

Inspect other appliances near water heater.

Install thermal expansion tank (DO NOT plug T&P valve). Check relief valve for proper operation (DO NOT plug T&P valve). Drain and flush heater thoroughly, then refill.

Contact Sears Service to determine cause. Contact Sears Service to determine cause.

Replace electronic control module.

Contact Sears Service to determine cause.

Clean sediment from tank. Refer to DRAINING instructions in Maintenance section of manual. No adjustment available. Contact Sears Service to determine cause.

Contact Sears Service to determine cause.

Page 30

PARTS ORDER LIST

HYDROSENSE GAS WATER HEATER

MODEL NO’S

153.334430 40 Gallon

153.334530 50 Gallon

BURNER ASSEMBLY

GAS CONTROL

VALVE ASSEMBLY

Model Numbers

Key No. Part Description 153.334430 153.334530 1 Air Intake Screen 9003983 9003983

2 Anode Rod 9001829 9000734 3 Secondary Anode w/Heat Trap 9004274 9004274 4 Burner Assembly 9006151 9006152 5 Burner Head ** 9003385 9003385 6 Burner Oriﬁ ce ** 9003493 (#33) 9003493 (#33) 7 Burner Tube w/Rubber Boot ** 9006153 9006154 8 Pilot Assembly w/Grommet ** 9006155 9006155 9 Draft Hood 9003526 9003526 10 Drain Valve 9003464 9003464 11 Drain Valve Washer 9001584 9001584 12 Flue Bafﬂ e 9003985 9006150 13 Flue Restrictor 9003524 9003524 14 Gas Valve Assembly Nipple 9006146 9006146 15 Gas Valve Assembly 9006147 9006147 16 Electronic Control Module Assembly 9006148 9006148 17 Gas Control Valve Assembly 9006149 9006149 18 Inlet Tube 9002432 9004014 19 Inlet Tube Gasket * 9003981 9003981 20 Inner Door ** 9003400 9003398 21 Inner Door Gasket 9003401 9003401 22 Mag-Erad * 9005413 9005413 23 Outer Door 9005966 9005966 24 T&P Relief Valve 9000728 9000728 25 Viewport Assembly 9003414 9003414 26 Nipple w/Heat Trap 9003719 9003719 27 Tank Sensor (Upper and Lower) 9006163 9006163 28 Instruction Manual * 186422-000 186422-000

* Not Shown ** Includes Inner Door Gasket

Now that you have purchased your gas water heater, should a need ever exist for repair parts or service, simply contact any Sears Service Center or call 1-800-4-MY-HOME facts when you call or visit.

WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE FOLLOWING INFORMATION:

(1-800-469-4663). Be sure to provide all pertinent

• MODEL NUMBER

• SERIAL NUMBER

• TYPE GAS (NATURAL OR PROPANE (L.P.)

• PART DESCRIPTION

THIS IS A REPAIR PARTS LIST, NOT A PACKING LIST.

Page 31

NOTES

Page 32

For twelve years from date of purchase, if this water heater is installed and operated in a single family home in accordance with the owner’s manual instructions and all local applicable codes, Sears will supply a free water heater for one that develops a leak.

For the second through twelfth year from purchase date, you must pay the labor cost for installation of the water heater.

12 YEAR LIMITED WARRANTY ON WATER HEATER

For three years from date of purchase, if this water heater is installed and operated in a single family home in accordance with the owner’s manual instructions and all local applicable codes, if a part fails due to materials or workmanship, Sears will supply a free replacement part.

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

For the ﬁ rst year from the date of purchase, Sears will, free of charge, supply and install new water heater parts for defective ones or a new water heater for one that develops a leak.

To obtain warranty service, call 1-800-4-MY-HOME States.

For commercial, institutional, industrial or residential use by two or more families, the above limited warranty for tanks that leak is effective for two years from the date of purchase and the above limited parts warranty is effective for one year from the date of purchase.

This warranty gives you speciﬁ c legal rights and you may also have other rights which vary from state to state.

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

3 YEAR LIMITED WARRANTY ON PARTS

1 YEAR EXCLUSIVE KENMORE LABOR WARRANTY

WARRANTY SERVICE

(1-800-469-4663). This warranty applies only while this product is in use in the United

The price of your water heater does not include a free checkup service call. On water heater installations arranged by Sears, Sears warrants the installation.

A charge will be made on service calls due to poor or incomplete installation. These include: a. Adjusting thermostat b. Leaks in pipes or ﬁ ttings c. Condensation

MASTER PROTECTION AGREEMENTS

on products requiring in-home repair, plus convenient repair scheduling.

Congratulations on making a smart purchase. Your new Kenmore® product is designed and manufactured for years of dependable operation. But like all products, it may require preventive maintenance or repair from time to time. That’s when having a Master Protection Agreement can save you money and aggravation.

Purchase a Master Protection Agreement now and protect yourself from unexpected hassle and expense.

The Master Protection Agreement also helps extend the life of your new product. Here’s what’s included in the Agreement:

• Expert Service by our 12,000 professional repair specialist.

• Unlimited service and no charge for parts and labor on all

covered repairs.

• Power surge protection against electrical damage due to power

ﬂ uctuations.

• Rental reimbursement if repair of your covered product takes

longer than promised.

Once you purchase the Agreement, a simple phone call is all that it takes for you to schedule service. You can call anytime day or night, or schedule a service appointment online.

Sears has over 12,000 professional repair specialists, who have access to over 4.5 million quality parts and accessories. That’s the kind of professionalism you can count on to help prolong the life of your new purchase for years to come. Purchase your Master Protection Agreement today!

• “No-lemon” guarantee - replacement of your covered product if

four or more product failures occur within twelve months.

• Product replacement if your covered product can’t be ﬁ xed.

• Annual Preventive Maintenance Check at your request - no extra

charge.

• Fast help by phone - phone support from a Sears technician

Call 24 hours a day, 7 days a week (U.S.A. and Canada)

www.sears.com

The model number of your water heater is found on the model rating plate on the front of the water heater.

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

Some limitations and exclusions apply. For prices and additional information call 1-800-827-6655.

SEARS INSTALLATION SERVICE

For Sears professional Installation of home appliances, garage door openers, water heaters, and other major home items, in the U.S.A., call 1-800-4-MY-HOME

For in-home major brand repair service

1-800-4-MY-HOME

(1-800-469-4663)