Kenmore 153339530, 153339492, 153339270 Owner’s Manual

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Owner's Manual

POWER MISERTM 9

GAS WATER HEATER

FOR POTABLE WATER HEATING ONLY.

NOT SUITABLE FOR SPACE HEATING.

NOT FOR USE IN MOBILE HOMES.

MODEL NO.

153.339270

153.339492

153.339530

40 Gallon Short 40 Gallon Tall 50 Gallon Tall

• Safety Instructions

• Installation

• Operation

• Care and Maintenance

• Troubleshooting

• Parts List

This water heater complies with ANSI Z21.10.1-

current edition regarding the accidental or unintended ignition of flammable vapors, such as those emitted by gasoline.

Read and understand instruction manual and safety messages

before installing, operating or servicing this water heater.

Failure to follow instructions and safety messages could result in

death or serious injury. Instruction manual must remain

with water heater.

For Your Safety

AN ODORANT ISADDED TO THE GAS USED BY THIS WATER HEATER.

WARNING: If the information in these

instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

m Do not store or use gasoline or other

flammable vapors and liquids in the

vicinity of this or any other appliance.

-- WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do

not use any phone in your building.

• Immediately call your gas supplier

from a neighbor's phone. Follow the

gas supplier's instructions.

• If you cannot reach your gas supplier,

call the fire department.

Si no puede leer o entender el ingles y necesita el manual de instrucciones en espaSol, puede solicitarlo al 1-800-821-2017. NO

TRATE DE INSTALAR UOPERAR ESTE CALENTADOR DE AGUA Sl NO ENTIENDE LAS INSTRUCCIONES. No hacer caso de esta

advertencia podria originar lesiones graves o mortales.

m lnstallation and service must be

performed by a qualified installer,

service agency or the gas supplier.

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

PRINTED IN THE U.S.A 1208 www.sears.com PART NO. 315424-000

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.

,_ I This is the safety alert symbol, it is used to alert you to potential personal injury hazards.

Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates an imminently hazardous situation which, if not avoided, could result in death or injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, could result inproperty 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

• Qualified Technician: A qualified technician must have ability equivalent to a licensed tradesman in the fields of plumbing, air supply,

venting, and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters The qualified technician must also be familiar with the design features and use of flammable vapor ignition resistant water heaters, and have a thorough understanding of this instruction manual

• Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing, air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of

gas fired water heaters The service agency must also have a thorough understanding of this instruction manual, and be able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer

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

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death

Do not store or use gasoline or other

flammable vapors and liquids in the vicinity of this

or any other appliance. Storage of or use of

gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance can result in serious injury or death.

Read and follow water heater warnings and instructions.

Read and understand instruction manual and safety messages

before installing, operating or

servicing this water heater.

Failure to follow instructions and

safety messages could result in

death or serious injury. Instruction manual must remain

with water heater.

Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury

or death.

Children, the elderly, and the physically or mentally disabled

are at highest riskforscald injury. Feel water before bathing or

showering. Temperature limiting valves are

available.

Read instruction manual for safe temperature setting

Fire Hazard

For continued protection against riskof fire:

• Do not install water heater on carpeted floor.

• Do not operate water heater if

flood damaged.

Explosion Hazard

• Overheated water can cause watertank explosion.

• Properly sized temperature and pressure relief valve must

be installed in opening provided.

Fire or Explosion Harzard

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

• Avoid all ignition sources if you smell Natural or LP gas.

• Do not expose water heater control to excessive gas pressure.

• Use only gas shown on rating plate.

• Maintain required clearances to combustibles.

• Keep ignition sources away from faucets after extended period of non-use.

installing, using or servicing

Read instruction manual before

water heater.

Improper installation and use may result

in property damage.

• Do not operate water heater if flood damaged.

• Inspect and replace anode.

• Install in location with drainage.

• Fill tank with water before operation.

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

Breathing Hazard - Carbon Monoxide Gas

• Instaii vent system in accordance with cedes.

- Do not operate water heater if flood damaged.

• High altitude orifice must be installed for opera, on above 7.700 feet (2.347m).

, Do not operate if s_t is present.

• Do not obstru_ water hea_er air intake with insulating jacket.

, Do not place chemical vapor emi_Jng

produc_s near water heater.

, Gas and carbon monoxide detectors

are available

Breathing carbon monoxide car cause brain damage or

death Always read and understand instruction manual_

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

SAFETY PRECAUTIONS ........................................................................................................................... 2-3

PRODUCT WARRANTY ................................................................................................................................ 6

CUSTOMER RESPONSIBILITIES ................................................................................................................. 7

PRODUCT SPECIFICATIONS ...................................................................................................................... 8

MATERIALS AND BASIC TOOLS NEEDED .................................................................................................. 9

TYPICAL INSTALLATION ............................................................................................................................ 10

IMPORTANT INFORMATION ABOUT THIS WATER HEATER .................................................................... 11

Installation Checklist ................................................................................................................................................ 11

INSTALLATION INSTRUCTIONS ........................................................................................................... 12-15

Removing the Old Water Heater ............................................................................................................................. 12

Location Requirements ........................................................................................................................................... 13

Site Location ........................................................................................................................................................... 13

Insulation Blankets .................................................................................................................................................. 14

Clearances and Accessibility ............................................................................................................................. 14-15

Filling the Water Heater .......................................................................................................................................... 15

GAS SUPPLY .......................................................................................................................................... 15-16

Gas Requirements .................................................................................................................................................. 15

Gas Piping .............................................................................................................................................................. 15

Gas Pressure .......................................................................................................................................................... 16

Gas Pressure Testing .............................................................................................................................................. 16

LP Gas Only ............................................................................................................................................................ 16

COMBUSTION AIR SUPPLY & VENTILATION ...................................................................................... 17-20

Unconfined Space ................................................................................................................................................... 17

Confined Space ...................................................................................................................................................... 17

All Air from Inside the Building ........................................................................................................................... 17-18

All Air from Outdoors ............................................................................................................................................... 18

Louvers and Grilles ............................................................................................................................................ 18-19

Vent Pipe System ................................................................................................................................................... 19

Draft Hood Installation ............................................................................................................................................ 19

Vent Pipe Size ........................................................................................................................................................ 19

Vent Connectors ................................................................................................................................................ 19-20

Chimney Connection ............................................................................................................................................... 20

Vertical Exhaust Gas Vent ...................................................................................................................................... 20

WATER SYSTEM PIPING ....................................................................................................................... 21-22

Piping Installation .................................................................................................................................................... 21

Closed System/Thermal Expansion ........................................................................................................................ 22

Temperature and Pressure Relief Valve ................................................................................................................. 22

T&P Relief Valve and Pipe Insulation ........................................................................................................................ 22

OPERATINGYOURWATERHEATER...................................................................................................23-25

LightingInstructions................................................................................................................................................23

CheckingtheDraft..................................................................................................................................................24

BurnerFlames........................................................................................................................................................24

EmergencyShutDown...........................................................................................................................................24

WaterTemperatureRegulation..........................................................................................................................24-25

SERVICEANDADJUSTMENT...............................................................................................................26-28

Tank(Sediment)Cleaning......................................................................................................................................26

VentSystemInspection..........................................................................................................................................26

BurnerInspection....................................................................................................................................................26

BurnerCleaning......................................................................................................................................................26

Housekeeping.........................................................................................................................................................27

AnodeRodInspection............................................................................................................................................27

Temperature-PressureReliefValveOperation.......................................................................................................27

DrainingandFlushing........................................................................................................................................27-28

Service....................................................................................................................................................................28

MAINTENANCEOFYOURWATERHEATER........................................................................................29-32

ReplacementParts.................................................................................................................................................29

ExternalInspection& CleaningoftheBase-RingFilter.........................................................................................29

RemovingtheManifold/BurnerAssembly...............................................................................................................29

RemovingtheBurnerfromtheManifold/BurnerAssembly....................................................................................29

ReplacingtheThermocouple.............................................................................................................................29-30

ReplacingthePilot/PilotTubeAssembly...............................................................................................................30

CleaningtheCombustionChamberandFlame-arrestor........................................................................................30

ReplacingtheManifold/BurnerAssembly...............................................................................................................31

PiezoelectricIgniterSystem...................................................................................................................................31

TestingtheIgniterSystem......................................................................................................................................32

RemovingandReplacingtheGasControlValve/Thermostat................................................................................32

FVlRSystemOperationalChecklist.......................................................................................................................32

TROUBLESHOOTINGGUIDE................................................................................................................33-35

StartUpConditions............................................................................................................................................33-34

OperationalConditions......................................................................................................................................34-35

TROUBLESHOOTINGCHART...............................................................................................................36-37

PILOTLIGHTTROUBLESHOOTINGFLOWCHART...................................................................................38

PARTSORDERLIST...................................................................................................................................39

9 - YEAR LIMITED WARRANTY ON WATER HEATER

For nine years from the 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 plumbing codes, Sears will:

1. Supply free water heater parts for those that are defective in material or workmanship.

2. Supply a free water heater for one that develops a leak.

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

For commercial, institutional, industrial or residential use by two or more families, the above limited warranty is only for two years. During the second year you must pay the labor cost for parts or water heater installation.

1 - YEAR EXCLUSIVE KENMORE LABOR WARRANTY

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

WARRANTY SERVICE

To obtain warranty service, call 1-800-4-MY-HOME ® (1-800-469-4663).

This warranty applies only while this product is in use in the United States. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

SEARS, ROEBUCK AND CO., Dept.817WA, Hoffman Estates, IL 60179

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

warrants the installation. A charge will be made on service calls due to poor or incomplete installation. These include:

a. Adjusting thermostat b. Condensation c. Leaks in pipes or fittings

Master Protection Agreements

Congratulations on making a smart purchase. Your new Kenmore ® product is designed and manufactured for years

of dependable operation. But like all products, it may require preventive maintenance or repair from time to time. That's when

having a Master Protection Agreement can save you money and aggravation.

The Master Protection Agreement also helps extend the life of your new product. Here's what the Agreement* includes:

• Parts and labor needed to help keep products operating properly under normal use, not just defects. Our coverage

goes well beyond the product warranty. No deductibles, no

functional failure excluded from coverage-- real protection.

• Expert service by a force of more than 10,000 authorized Sears service technicians, which means someone you can trust will be working on your product.

• Unlimited service calls and nationwide service, as often as you want us, whenever you want us.

• "No-lemon" guarantee - replacement of your covered product if four or more product failures occur within twelve months.

• Product replacement if your covered product can't be fixed.

• Annual Preventive Maintenance Check at your request - no extra charge.

• Fast help by phone - we call it Rapid Resolution - phone support from a Sears representative on all products. Think of

us as a "talking owner's manual."

• Power surge protection against electrical damage due to power fluctuations.

• $250 Food Loss Protection annually for any food spoilage that is the result of mechanical failure of any covered

refrigerator or freezer.

• Rental reimbursement if repair of your covered product takes longer than promised.

• 10% discount off the regular price of any non-covered repair service and related installed parts.

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

or schedule a service appointment online. The Master Protection Agreement is a risk free purchase. If you

cancel for any reason during the product warranty period, we will provide a full refund. Or, a prorated refund anytime after the

product warranty period expires. Purchase your Master Protection Agreement today!

Some limitations and exclusions apply. For prices and additional information in the U.S.A. call 1-800-827-6655.

* Coverage in Canada varies on some items. For full details,

call Sears Canada at 1-800-361-6665.

Sears Installation Service

For Sears professional installation of home appliances, garage door openers, water heaters, and other major home items, in the U.S.A.

or Canada call 1-800-4-MY-HOME ®.

ThankYouforpurchasingaKenmorewaterheater.Properlyinstalled andmaintained,itshouldgiveyouyearsoftroublefreeservice.If

youshoulddecidethatyouwantthenewwaterheaterprofessionally

installedbySearscall1-800-4-MY-HOME®.Theywillarrangefor prompt,qualityinstallationbySearsauthorizedcontractors.

Abbreviations Found In This Instruction Manual:

• CSA- Canadian Standards Association

• ANSI- American National Standards Institute

• N FPA- National Fire Protection Association

• ASME - American Society of Mechanical Engineers

• GAMA- Gas Appliance Manufacturers Association

Massachusetts Code requires this water heater to be installed in

accordance with Massachusetts 248-CMR 2.00: State Plumbing

Code and 248-CMR 5.00.

Complies with 40 Ng/J NOx requirements of Texas and most California AQM Districts.

Excessive Weight Hazard

Use two or more people to move and install the water heater.

Failure to do so can result in injury (including back injury).

Important Information About This Water Heater:

This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition

incident. New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation

environments. Please review the Installation Checklist found at the end of the installation instructions section and make any required

installation upgrades or changes.

This manual contains instructions for the installation, operation, and maintenance of the gas-fired water heater, tt also contains

warnings through out the manual that you must read and be aware of. All warnings and all instructions are essential to the proper operation of the water heater and your safety. Since we cannot put everything on the first few pages, READ THE ENTIRE MANUAL

BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER.

The installation must conform with these instructions and the local code authority having jurisdiction. In the absence of local

codes, installations shall comply with the following:

In the United States: The National Fuel Gas CodeANSI Z223.1/

NFPA 54. This publication is available from the Canadian StandardsAssociation, 8501 East Pleasant Valley Rd, Cleveland Ohio 44131, or The National Fire Protection Association, 1

Batterymarch Park, Quincy, MA 02269.

IMPORTANT: Do not remove any permanent instructions, labels, or

the data label from either the outside of the water heater or on the

inside of water heater panels.

• Remove exterior packaging and place installation components aside.

• Inspect all parts for damage prior to installation and start-up.

• Completely read all instructions before attempting to assemble and install this product.

• After installation, dispose of/recycle all packaging materials.

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

Carefully plan the place where you are going to put the water heater. Correct combustion, vent action, and vent pipe installation are

very important in preventing death from possible carbon monoxide

poisoning and fires. See Figure 1.

• Examine the location to ensure the water heater complies with

the Installation Instructions section in this manual.

For California installation, this water heater must be braced,

anchored, or strapped to avoid falling or moving during an earthquake. See instructions for correct installation procedures.

Instructions may be obtained from California's Office of the State Architect, 1102 Q Street, Suite 5100, Sacramento, CA

95811. Instructions can also be downloaded to your computer

at www.dsa.dgs.ca.gov/Pubs.

MODEL TANK CAPACITY TYPE INPUT RECOVERY MINIMUM DIAMETER DIMENSIONS

NUMBER IN GALS (LTRS) OF RATE

GAS (Btu/hr) PER HOUR DIA. INCHES (mm) HEIGHT TO

153.339270 40 (151) Natural 40,000 40.9 3 (76) OR 4 (102) 22 (559) 47.75 (1213)

153.339492 40 (151) Natural 40,000 40.9 3 (76) OR 4 (102) 20 (508) 58.14 (1477)

153.339530 50 (189) Natural 40,000 40.9 3 (76) OR 4 (102) 22 (559) 57.28 (1455)

RATE GALS. VENT PIPE INCHES INCHES (mm)

@ 90°F RISE (mm) JACKET TOP

MATERIALS NEEDED

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

EXPANSION TANKS FOR THERMAL EXPANSION CONDITIONS AVAILABLE

IN 2 GALLONS (7.6 LITERS) AND 5 GALLONS (18.9 LITERS)

CAPACITY HROUGH LOCAL SEARS STORE

OR SERVICE CENTER.

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

(19.05 ram) 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 Teflon Tape

SLOT-HEAD SCREWDRIVER

DRILL

DRAIN PANS AVAILABLE IN 20" (508 ram) 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

HACKSAW

3/4" (19 mm) WIRE BRUSH

1/2" (13 mm)WIRE BRUSH

EMERY CLOTH

ROLL OF LEAD-FREE

SOFT SOLDER

ROLL OF

SOLDER

FLUX

GET TO KNOW YOUR WATER HEATER - GAS MODELS

A Vent Pipe J Inner Door S Thermostat B Draft Hood K Outer Door T Drain Valve

C Anode (Not Shown) L Union U Pilot and Main Burner D Hot Water Outlet M Inlet Water Shut-off Valve V Flue

E Insulation N Cold Water Inlet W Drain Pan

F Gas Supply Piping O Inlet Dip Tube X Piezo Igniter

G Manual Gas Shut-off Valve P Temperature-Pressure Relief Valve Y Base-Ring Filter

H Ground Joint Union Q Rating Plate

I Drip Leg (Sediment Trap) R Flue Baffle

* INSTALL INACCORDANCE

WITH LOCAL CODES.

* DRIP LEG AS REQUIRED

BY LOCAL CODES.

TO VENT

TERMINATION ON

ROOF

INSTALL THERMAL EXPANSION

TANK OR DEVICE IF WATER HEATER IS INSTALLED IN A

CLOSED WATER SYSTEM

_\ p

VACUUM RELIEF

VALVE

*INSTALL PER

LOCAL CODES

NOT CAP OR PLUG.)

(S) GAS CONTROL VALVE/

THERMOSTAT: WHITE-RODGERS

GAS CONTROL KNOB

WATER TEMPERATURE DIAL

(ADJUSTING DIAL)

"OFF .... PILOT ON"

POSITION POSITION POSITION

TOP VIEW

(U) MANIFOLD/BURNER ASSEMBLY

MAIN BURNER

_i_.... THERMOCOUPLE

__ ",, pILOTTUBE

_x_o/__ :7_'_ IG N ITE R WIRE

IGNITER RO

,f- MANIFOLD TUBE

MANIFOLD DOOR _

PIPE

* ALL PIPING MATERIALS TO BE

SUPPLIED BY CUSTOMERS.

" 6" MAXIMUM

AIR GAP

FIGURE 1.

This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. The new technology used in meeting these standards makes this product more sensitive to installation errors. Please review the following checklist and make any required installation upgrades or changes.

Questions? Contact Sears at 1-800-4-MY-HOME (1-800-469-4663).

Installation Checklist

Water Heater Location

Water heater location is important and performance. Please check the following:

[]

Installation area free of corrosive elements and flammable materials.

[] Centrally located with the water piping system (For new

installations). Located as close to the gas piping and vent pipe system as possible.

[] Located indoors and in a vertical position. Protected from

freezing temperatures.

[] Proper clearances from combustible surfaces

maintained and not installed directly on a carpeted floor.

[] Provisions made to protect the area from water damage.

Metal drain pan installed and piped to an adequate drain.

[] Sufficient room to service the water heater. See Clearances

and Accessibility section of this manual.

[] Water heater not located near an air moving device. [] Is the installed environment dirty (excessive amounts of

lint, dirt, dust, etc.)? If so, the base-ring filter located on the bottom of the water heater will need to be cleaned

periodically. Refer to the "Maintenance of your Water Heater" section of this manual for information on cleaning

the base-ring filter.

Combustion Air Supply and Ventilation

Check for sufficient combustion air supply. Insufficient air for the combustion of gas wilt result in the flame becoming "lazy",

thereby allowing heat to build up in the combustion chamber. This excessive heat wilt cause a thermal switch on the door

assembly to trip. Isthe water heater installed in a closet or other small, enclosed space? If so:

[]

Are there openings for make-up air to enter and exit the room/area?

[]

Are the openings of sufficient size? Remember, if there are other gas-fired or air-consuming appliances in the

same room, you need more make-up air. Refer to the "Installation Instructions" and "Combustion Air Supply and Ventilation" sections for specific requirements.

[]

Make sure that fresh air is not taken from areas that contain negative pressure producing devices such as exhaust fans,

dryers, fireplaces, etc.

[]

Is there a furnace/air handler in the same room space as the water heater? If so, has a return air duct system been attached that exits the room? If so, check for leaks on the

air duct system. If no air duct system is present, correct immediately by contacting a local Heating, Ventilation, Air- Conditioning & Refrigeration (HVAC-R) authorized service

provider.

[]

Use a fresh air supply that is free of corrosive elements and flammable vapors.

can affect system

[]

Fresh air openings must be sized correctly with consideration given to the blocking effect of louvers and grilles.

[]

Ductwork must be the same cross-sectional area as the openings.

Vent Pipe System

Check for proper drafting at the water heater draft hood. Refer to the "Checking the Draft" section of this manual for the test

procedure. If the procedure shows insufficient draft is present, please check the following:

[]

Draft hood properly installed.

[]

Vent connectors securely fastened with screws and supported properly to maintain six inch clearance.

[]

Vent connector made of approved material and sized correctly.

[]

Vent pipe system installed according to all local and state codes or, in the absence of local and state codes, the

"National Fuel Gas Code", ANSI Z223.1(NFPA 54)-current edition.

[] Flue baffle properly positioned in the flue tube. [] Check the vent system for restrictions/obstructions and

check the vent termination height. Refer to the "Combustion Air Supply and Ventilation" section of this water heater manual for specific requirements.

[] Recheck for sufficient combustion air supply.

Water System Piping

[] Temperature and pressure relief valve properly installed with

a discharge line run to an open drain and protected from freezing.

[] All piping properly installed and free of leaks. [] Heater completely filled with water.

[] Closed system pressure build-up devices installed. [] Mixing valve (when applicable) installed per manufacturer's

instructions (See "Water Temperature Regulation" section).

Gas Supply and Piping

[] Gas type is the same as that listed on the water heater rating

plate.

[] Gas line equipped with shut-off valve, union, and drip leg. [] Use pipe joint compound or teflon tape marked as being

resistant to the action of petroleum [Propane (L.R)] gases.

[]

Adequate pipe size and approved pipe material.

[]

An approved noncorrosive leak detection solution used to check all connections and fittings for possible gas leaks. Correct any leak found.

Removing the Old Water Heater (_

MANUAL GAS SHUT-OFF VALVE--_

GROUN D-------_ JOINT

UNION

CHECK WITH LOCAL UTILITY

FOR MINIMUM HEIGHT

Turn "OFF" the gas supply to the water heater.

3" MINIMUM

DRIP

FIGURE 2.

DISCHARGE PIPE

NOT CAP ('5.)(DO

OR PLUG)

DRAIN VALVE

COVERED BY OUTER DOOR

6" MAXIMUM AIR GAP

Attach a hose to the water heater drain valve and put the other end

in a floor drain or outdoors. (See Figures 2 and 5.) Open the water heater drain valve. Open a nearby

hot water faucet which will relieve

pressure in the water heater and speed draining. The water passing out of the drain valve may be extremely

hot. To avoid being scalded, make sure all connections are tight and that

the water flow is directed away from any person.

Disconnect the vent pipe from the draft hood where it connects to the water heater. In most installations the vent pipe can

be lifted off after any screw or other attached devices are

removed. Dispose of the draft hood. The new water heater

has a draft hood which must be used for proper operation.

If you have copper piping to the water heater, the two copper water pipes can be cut with a hacksaw approximately four

inches away from where they connect to the water heater.

See Figure 6. This will avoid cutting off pipes too short. Additional cuts can be made later if necessary. Disconnect the temperature-pressure relief valve drain line. When the water

heater is drained, disconnect the hose from the drain valve.

Close the drain valve. The water heater is now completely disconnected and ready to be removed.

FIGURE 5.

If the main gas line shutoff valve serving all gas appliances is used, also shut "OFF" the gas at each

appliance. Leave all gas appliances shut "OFF" until the water heater

installation is completed. See Figures 2 and 3.

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.

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

FIGURE 3.

FIGURE 4.

• Burn hazard

• Hotwater discharge.

• Keep hands clear of drain valve discharge.

FIGURE 6.

If you have galvanized pipes to the water heater, loosen the two galvanized pipes with a pipe wrench at the union in each line. Also disconnect the piping remaining to the water

heater. See Figure 7. These pieces should be saved since they may be needed when reconnecting the new water heater.

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

the drain valve. Close the drain valve. The water heater

is now completely disconnected and ready to be removed.

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

heavier than normal and this residue, if spilled out, could

cause staining.

FIGURE 7.

Location Requirements

area of the water heater, leave the area immediately and call the fire department from a neighbor's home. Do not attempt to clean the spill until all ignition sources have been extinguished.

I Carbon Monoxide Poisoning Hazard

Do not install in a mobile home. Doing so can result in carbon monoxide poisoning and death.

The FVIR System is designed to reduce the risk of flammable vapor-related fires. The patented system protects your family by trapping the burning vapors within the water heater combustion chamber through the special flame-arrestor. The burning vapors literally "burn themselves out" without escaping back into the room. In the event of a flammable vapor incident, the FVIR System disables the water heater by shutting off the gas supply to the water heater's burner and pilot, preventing re-ignition of any remaining flammable vapors in the area. This will not prevent a possible fire/explosion if the igniter is depressed and flammable vapors have accumulated in the combustion chamber with the pilot light off. If you suspect a flammable vapor incident has occurred, do not use this appliance. Do not attempt to light this appliance, or depress the igniter button if you suspect flammable vapors have accumulated inside or outside the appliance. Immediately call a qualified technician to inspect the appliance. Water heaters subjected to a flammable vapors incident will show a discoloration on the flame-arrestor and require replacement of the entire water heater.

Rarnrnable Vapors

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death

_Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other

appliance. Storage of or use of gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance can result in serious injury or death.

Read and follow water heater warnings and instructions.

Fire or Explosion Hazard

• Read instruction manual before installing, using or servicing water heater.

• Improper use may result in fire or explosion.

• Maintain required clearances to combustibles.

Keep combustibles such as boxes, magazines, clothes, etc. away from the water heater area.

Site Location

• Select a location near the center of the water piping system. The water heater must be installed indoors and in avertical

position on a level surface. DO NOT install in bathrooms, bedrooms, or any occupied room normally kept closed.

• Locate the water heater as close to the chimney or gas vent as practical. Consider the vent system piping and combustion air supply requirements when selecting the water heater location. The venting system must be able

to run from the water heater to termination with minimal length and elbows.

• Locate the water heater near the existing gas piping. If installing a new gas line, locate the water heater to minimize the pipe length and elbows.

• The water heater should be located in an area not subject to freezing temperatures. Water heaters located in unconditioned spaces (i.e., attics, basements, etc.) may require insulation of the water piping and drain piping to protect against freezing. The drain and controls must be easily accessible for operation and service. Maintain proper clearances as specified on the rating plate.

• Do not locate the water heater near an air-moving device. The operation of air-moving devices such as exhaust fans,

ventilation systems, clothes dryers, fireplaces, etc., can affect the proper operation of the water heater. Special

attention must be given to conditions these devices may create. Flow reversal of flue gases may cause an increase

of carbon monoxide inside of the dwelling (Figure 8).

• If the water heater is located in an area that is subjected to lint and dirt, it may be necessary to periodically clean the base-ring filter and flame-arrestor (see External Inspection & Cleaning of the Flame-arrestor).

• This water heater is not for use in manufactured (mobile) homes or outdoor installation.

NOTE: This water heater must be installed according to all local and state codes or, in the absence of local and state codes, the

"National Fuel Gas Code", ANSI Z223.1(NFPA 54)-current edition.

Do not use or store flammable products such as gasoline, solvents, or adhesives in the same room or area near the water heater. If such flammables must be used, all gas burning appliances in the vicinity must be shut off and their pilot lights extinguished. Open the doors and windows for ventilation while

flammable substances are in use. If flammable liquids or vapors have spilled or leaked in the

REVERSE FLOW

L OF GASES

FIGURE 8

Property Damage Hazard

• AJlwater heaters eventuafly leak

• Do notinstall without adequate drainage.

use on gas water heaters are not necessary with Kenmore products. The purpose of an insulation blanket isto reduce the standby heat toss encountered with storage tank heaters. Your

Kenmore water heater meets or exceeds the National Appliance Energy Conservation Act standards with respect to insulation and standby loss requirements, making an insulation blanket

unnecessary.

IMPORTANT: The water heater should be located in an area where leakage of the tank or connections will not result in damage

to the area adjacent to the water heater or to lower floors of the structure. Due to the normal corrosive action of water, the tank wilt eventually leak after an extended period of time. Also any external plumbing leak, including those from improper installation, may cause early failure of the tank due to corrosion if not repaired. If the homeowner is uncomfortable with making the repair a qualified technician should be contacted. A suitable metal drain pan should be installed under the water heater as shown below, to help protect the property from damage which may occur from condensate formation or leaks in the piping connections or tank. The pan must limit thewater level to a maximum depth of 1-3/4" and be two inches wider than the heater and piped to an adequate drain. NOTE: The pan must not restrict combustion air flow. Locate the water heater near a suitable indoor drain. Outside drains are subject to freezing temperatures which can obstruct the drain line. The piping should be at least 3/4" ID and pitched for proper drainage.

METAL DRAIN PAN

I AT LEAST 2" GREATER THAN THE_

DIAMETER OF THE WATER HEATER.

PIPED TO AN

ADEQUATE DRAIN

FIGURE 9.

Water heater life depends upon water quality, water usage, water temperature and the environment in which the water

heater is installed. Water heaters are sometimes installed in locations where leakage may result in property damage,

even with the use of a 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 water

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 wilt turn off the gas supply to a gas water heater while at the same time shutting off its water supply.

Insulation Blankets

Insulation blankets available to the general public for external

Breathing Hazard - Carbon Monoxide Gas

• Do not obstruct water heater air intakewith insulating blanket.

° Gas and carbon monoxide detectors

are available.

• Install water heater in accordance

with the instruction manual.

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

'_' WARNING

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

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

serious personal injury or death.

• 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 floor to prevent blockage of combustion air flow to the

burner. Do not cover the instruction manual. Keep it on the side of

the water heater or nearby for future reference. Do obtain new warning and instruction labels from Sears

for placement on the blanket directly over the existing labels.

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

Clearances and Accessibility

NOTE: Minimum clearances from combustible materials are stated on the label adjacent to the gas control valve/thermostat

of the water heater. The water heater is certified for installation on a combustible floor.

• IMPORTANT: If installing over carpeting, the carpeting must be protected by a metal or wood panel beneath the

water heater. The protective panel must extend beyond the full width and depth of the water heater by at least three inches (76.2mm) in any direction; or if in an alcove or closet installation, the entire floor must be covered by the panel.

• Figure 10 may be used as a reference guide to locate the specific clearance locations. A minimum of 24 inches of

front clearance should be provided for inspection and service.

-_ II _VENT

,_ BACK SIDES

TOP -- VIEW l

S°ESlll"IH

FIGURE 10.

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 filled with water. Water must flow from the hot water faucet before turning "ON" gas

to the water heater. To fill 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.

Explosion Hazard

Use a new CSA approved gas supply line. Install a shut-off valve.

Do not connect a natural gas water heater to an

L.P. gas supply.

Do not connect an L.P. gas water heater to a

natural gas supply.

Failure to follow these instructions can result in death, explosion, or carbon monoxide poisoning.

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 filling of the tank, allow air to exit by opening the nearest hot water faucet. Allow water to run until

a constant flow is obtained. This will let air out of the water heater and the piping.

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

Property Damage Hazard

• Avoid water heater damage.

• Fill tank with water before operating.

codes or, in the absence of local and state codes, the "National Fuel Gas Code", ANSI Z223.1(NFPA 54)-current edition.

Tables 1 and 2 on the following page provide a sizing reference for commonly used gas pipe materials. Consult the "National Fuel Gas Code" for the recommended gas pipe size of other

materials. NOTE: Use pipe joint compound or teflon tape marked as being

resistant to the action of petroleum [Propane (L.P.)] gases. (See Figure 11.)

1. Install a readily accessible manual shut-off valve in the gas supply line as recommended by the local utility. Know the location of this valve and how to turn off the gas to this unit.

2. Install a drip leg (if not already incorporated as part of the water heater) as shown. The drip leg must be no less than three inches tong for the accumulation of dirt, foreign material, and water droplets.

3. Install a ground joint union between the gas control valve/ thermostat and the manual shut-off valve. This is to allow

easy removal of the gas control valve/thermostat.

4. Turn the gas supply on and check for leaks. Test all connections by brushing on an approved noncorrosive

leak-detection solution. Bubbles will show a leak. Correct any leak found.

Gas Requirements

IMPORTANT: Read the rating plate to be sure the water heater is made for the type of gas you wilt be using in your home. This information wilt be found on the rating plate located near the gas control valve/thermostat. If the information does not agree with the type of gas available, do not install or light. Call your

dealer. NOTE: An odorant is added by the gas supplier to the gas used

by this water heater. This odorant may fade over an extended period of time. Do not depend upon this odorant as an indication

of leaking gas.

Gas Piping

The gas piping must be installed according to all local and state

MANUAL GAS

SHUT-OFF VALVE-_

GROUND_ JOINT

UNION

CHECK WITH LOCAL UTILITY

FOR MINIMUM HEIGHT

3" MINIMUM

r DRIP LEG j

_E _E

SUITABLE

U DRAIN

FIGURE 11.

Gas Pressure

Explosion Hazard

• Gas leaks can not always be detected by smell.

• Gas suppliers recommend that you use a gas

detector approved by UL or CSA.

• For more information, contact your gas supplier.

• If a gas leak is detected, follow the "What to do if you

smell gas" instructions on the cover of this manual.

IMPORTANT:The gas supply pressure must not exceed themaximum supply pressure as stated on the water heater's rating plate. The

minimum supply pressure is for the purpose of input adjustment.

Gas Pressure Testing

the fuel is not spilled in the area of the water heater installation, or any source of ignition. If the fuel is spilled while purging the piping system of air follow the "WHAT TO DO IF YOU SMELL

GAS" instructions on the cover of this manual.

LP Gas Only

Explosion Hazard

Have a qualified person make sure L.P.gas pressure does not exceed 13" water column.

Examples of a qualified person include: licensed plumbers, authorized gas company personnel, and authorized service personnel.

Failure to do so can result in death, explosion, or

fire.

IMPORTANT: This water heater and its gas connection must be leak tested before placing the appliance in operation.

• If the code requires the gas lines to be tested at a pressure exceeding 14" W.C., the water heater and its manual shut-off valve must be disconnected from the gas supply piping system and the line capped.

• Ifthe gas lines are to be tested at a pressure tess than 14" W.C., the water heater must be isolated from the gas supply piping system by closing its manual shut-off valve.

NOTE: Air may be present in the gas lines and could prevent the pilot from lighting on initial start-up. The gas lines should be purged of air by a qualified technician after installation of the gas piping system. While purging the gas piping system of air, ensure that

Table1 NaturalGas PipeCapacityTable(Cu.Ft./Hr.)

Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity of 0.60 (natural gas).

Nominal mron Pipe Length of Pipe, Feet

1/2 132 92 73 63 56 50 46 43 40 38 34 31 28 26 3/4 278 190 152 130 115 105 96 90 84 79 72 64 59 55

I 520 350 285 245 215 195 180 170 160 150 130 120 110 100

1-1/4 1050 730 590 500 440 400 370 350 320 305 275 250 225 210

1-112 1600 1100 890 760 670 610 560 530 490 460 410 380 350 320

After the length of pipe has been determined, select the pipe size which wiB provide the minimum cubic feet per hour required for the gas input rating of the water heater. By formula:

Cu. Ft. Per Hr. Required=

The gas input of the water heater is marked on the water heater data plate. The heating value of the gas (BTU/FT _) may be determined by consulting the local natural gas utility.

Gas Input of Water Heater

Heating Value of Gas (BTU/FT 3)

Liquefied petroleum gas is over 50% heavier than air and in the occurrence of a leak in the system, the gas will settle at floor level. Basements, crawl spaces, closets and areas below ground level will serve as pockets for the accumulation of gas.

Before lighting an L.R gas water heater, smell all around the appliance at floor level. If you smell gas, follow the instructions as given in the warning on the front page.

When your L.R tank runs out of fuel, turn off the gas at ait gas appliances including pilot lights. After the tank is refilled,

all appliances must be re-lit according to their manufacturer's instructions.

Table2 LP GasCapacityTable

Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 inches water column pressure). Based on a pressure drop of 0.5 inch water column.

Nomina[ Iron Pipe Length of Pipe, Feet

Size, in. 1(1 20 30 40 5£) 60 7Q 80 9_) ] O0 125 _50

1/2 275 189 152 129 114 103 96 89 83 78 69 63 3/4 576 393 315 267 237 217 196 185 173 162 146 132

1 1071 732 590 504 448 409 378 346 322 307 275 252

1=114 2205 1496 1212 1039 913 834 771 724 677 630 567 511

Example: Input BTU requirement of the water heater 100,000 BTUH.

Additional tables are available in the latestedition ofthe "National FuelGas Code", ANSI Z223,1,

Total pipe length, 80 feet = 3/4" IPS required.

Carbon Monoxide Warning

TABLE 3

120,000 750 25 x 30 135,000 844 28 x 30

Follow all the local and state codes or,in the absence of local and state codes, the "National Fuel Gas Code",

ANSI Z223.1 (NFPA 54)- current edition to properly install vent system.

Failure to do so can result in death, explosion, or carbon monoxide poisoning.

IMPORTANT: Air for combustion and ventilation must not come from a corrosive atmosphere. Any failure due to corrosive

elements in the atmosphere is excluded from warranty coverage.

The following types of installation (not limited to the following) wilt require outdoor air for combustion due to chemical exposure and may reduce but not eliminate the presence of corrosive

chemicals in the air:

• beauty shops

• photo processing labs

• buildings with indoor pools

• water heaters installed in laundry, hobby, or craft rooms

• water heaters installed near chemical storage areas Combustion air must befree of acid-forming chemicals such assulfur,

fluorine, and chlorine. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, air fresheners, paint, and vamish removers, refrigerants, and many other commercial and household products. When bumed, vapors from these products form highly corrosive acid compounds. These products should not

be stored or used near the water heater or air inlet. Combustion and ventilation air requirements are determined by

the location of the water heater. The water heater may be located in either an open (unconfined) area or in a confined area or small enclosure such as a closet or small room. Confined spaces are areas with tess than 50 cubic feet for each 1,000 BTUH of the total input for all gas-using appliances.

IMPORTANT:

The area must be open and be able to provide the proper air requirements to the water heater. Areas that are being used for storage or contain large objects may not be

suitable for water heater installation. Water heaters installed in open spaces in buildings with

unusually tight construction may still require outdoor air to function properly. In this situation, outside air openings should be sized the same as for a confined space.

• Modern home construction usually requires supplying outside air into the water heater area.

Confined Space

For the correct and proper operation of this water heater, ample air must be supplied for the combustion, ventilation, and dilution of flue gases. Small enclosures and confined areas must have two permanent openings so that sufficient fresh air can be drawn from outside of the enclosure. One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure as shown in Figure 12.

The size of each opening (free area) is determined by the total BTUH input of all gas utilization equipment (i.e., water heaters, furnaces, clothes dryers, etc.) and the method by which the air

is provided. The BTUH input can be found on the water heater rating plate. Additional air can be provided by two methods:

1. All air from inside the building.

2. All air from outdoors.

12" MAXIMUM

Unconfined Space

A water heater in an unconfined space uses indoor air for combustion and requires at least 50 cubic feet for each 1,000 BTUH of the total input for ait gas appliances. The table below shows a few examples of the minimum square footage (area) required for various BTUH inputs.

TABLE 3

Minimum Square

BTUH Input Feet with

8' Ceiling

30,000 188 9 x 21 45,000 281 14 x 20

60,000 375 15 x 25 75,000 469 15 x 31

90,000 563 20 x 28

105,000 657 20 x 33

Typical Room

with 8' Ceiling

CLOSET

PERMANENT

OPENINGS TO

THE OUTSIDE OR

ADDITIONAL

ROOMS WITHIN

THE BUILDING

12" MAXIMUM /

___ OR

-- -- OTHER

CONFINED

SPACE

=:_

FIGURE 12.

All Air from Inside the Building

When additional air is to be provided to the confined area from additional room(s) within the building, the total volume of the room(s) must be of sufficient size to properly provide the necessary amount of fresh air to the water heater and other

gas utilization equipment in the area. If you are unsure that the structure meets this requirement, contact your local gas utility company or other qualified agency for a safety inspection. Each of the two openings shall have a minimum free area of 1 square inch per 1,000 BTUH of the total input rating of all gas utilization equipment in the confined area, but not less than 100 square inches (Figure 13).

CONFINED

SPACE

PERMANENT

OPENINGS

INCH/1000

BTUH

(MINIMUM

_ 1 SQUARE

100 SQ. IN.)

FIGURE 13.

TABLE 4

Minimum Free Area of Permanent Openings for Ventilation and Combustion Air Supply - All Air from Outdoors Only.

Based on total BTUH input rating for all utilizing equipment

within the confined space.

Minimum Free Area Reference

Opening Source Per Opening (sq. in.) Drawing

*Direct to outdoors 1sq. in, per 4000 BTUH Figure 14

Vertical Ducts 1sq. in, per 4000 BTUH Figure 15

Horizontal Ducts 1 sq. in, per 2000 BTUH Figure 16

Single Opening 1sq. in, per 3000 BTUH Figure 17

Example: A water heater with an input rating of 50,000 BTUH using horizontal ducts would require each opening to have a minimum free

area of 25 square inches.

Minimum free area = 50,000 BTUH x 1 sq. in. ! 2000 BTUH = 25 sq. in.

* These openings connect directly with the outdoors through a

ventilated attic, a ventilated crawl space, or through an outside walt.

Consult the local codes of your area for specific ventilation and combustion air requirements.

GABLE VENT

j TO OUTDOORS

All Air from Outdoors

Outdoor fresh air can be provided to a confined area either directly or by the use of vertical and horizontal ducts. The

fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors. Attic or crawl

spaces cannot be closed and must be properly ventilated to the outside.

Ductwork must be of the same cross-sectional area as the free area of the opening to which they connect. The minimum dimension of rectangular air ducts cannot be less than three

inches. The size of each of the two openings is determined by the

method in which the air is to be provided. Refer to Table 4 to calculate the minimum free area for each opening. Figures 14, 15, 16 and 17 are typical examples of each method.

Louvers and Grilles

In calculating free area for ventilation and combustion air supply openings, consideration must be given to the blocking effect

of protection louvers, grilles, and screens. These devices can reduce airflow, which in turn may require larger openings to achieve the required minimum free area. Screens must not be smaller than 114" mesh. If the free area through a particular design of louver or grille is known, it should be used in

calculating the specified free area of the opening. If the design and free area are not known, it can be assumed that most wood louvers will allow 20 - 25% of free area while metal louvers and

grilles will allow 60 - 75% of free area. Louvers and grilles must be locked open or interconnected with

the equipment so that they are opened automatically during equipment operation.

Keep louvers and grilles clean and free of debris or other obstructions.

F INSTALL ABOVE

INSULATION

CONFINED OUTLET

SPACE AIR TO

ALTERNATE FROM

AIR INLET CRAWL SPACE

I SQ. INCH PER _ OPEN _K_

4000 BTUH FOUNDATION -_

ALL AIR FROM OUTDOORS: INLET AIR FROM VENTILATED

CRAWL SPACE/OUTLET AIR TO VENTILATED ATTIC

_,TTIC 1 SQ.

INCH PER

4000 BTUH

VENT

FIGURE 14.

GABLE VENT TO OUTDOORS

[_ _INSTALL ABOVE

_J INSULATION

OUTLET AIR

ATTIC

1 SQ. INCH PER 4000 BTUH

INLET AIR DUCT 1 SQ. INCH PER 4000 BTUH

12" MAXIMUM

ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC

FIGURE 15.

2000 BTUH

CONFINED

SPACE

1 SQ. INCH PER 2000 BTUH

ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS

FIGURE 16.

ALTERNATIVE

OPENING

LOCATION

CONFINED

SPACE

1SQ. INCH

PER3OOOBTUH

using the manufacturer's instructions and local codes, rules, or regulations.

IMPORTANT: If you tack the necessary skills required to properly install this venting system, you should not proceed, but

get help from a qualified technician.

Draft Hood Installation

L SCREWS (FOUR PROVIDED)

_tP'--'DRAFT HOOD

SLOTJ _ _JACKETTOP p" LSLOT

INSTALL THE DRAFT HOOD WITH THE FOUR SCREWS PROVIDED.

FIGURE 18.

Align the legs of the draft hood with the slots provided. Insert the legs and secure the draft hood to the water heater's top with the four screws provided as shown in Figure 18. Do not

alter the draft hood in any way. If you are replacing an existing

water heater, be sure to use the draft hood supplied with this water heater.

Vent Pipe Size

It is important that you follow the guidelines in these instructions

for sizing a vent pipe system. If a transition to a larger vent size

is required, the vent transition connection must be made at the

draft hood outlet.

ALL AIR FROM OUTDOORS - USING A SINGLE PERMANENT OPENING

FIGURE 17.

Vent Pipe System

This water heater uses a non-direct, single-pipe vent system to remove exhaust gases created by the burning of fossil fuels.

Air for combustion is taken from the immediate water heater location or is ducted in from the outside (see "Combustion Air

Supply and Ventilation"). This water heater must be properly vented for the removal of

exhaust gases to the outside atmosphere. Correct installation of the vent pipe system is mandatory for the proper and efficient

operation of this water heater and is an important factor in the life of the unit.

The vent pipe must be installed according to all local and state codes or, inthe absence of local and state codes, the "National

Fuel Gas Code", ANSI Z223.1(NFPA 54)-current edition. The vent pipe installation must not be obstructed so as to prevent the removal of exhaust gases to the outside atmosphere.

IMPORTANT: The use of vent dampers is not recommended by the manufacturer of this water heater. Although some vent dampers are certified by CSA International, this certification applies to the vent damper device only and does not mean they

are certified for use on this water heater. U.L. recognized fuel gas and carbon monoxide (CO) detectors

are recommended in all applications and should be installed

Vent Connectors

1. Type B, Double wall, U.L. Listed Vent Pipe.

2. Single walt Vent Pipe.

Maintain the manufacturer's specified minimum clearance from combustible materials when using type B double wall vent pipe.

Vent connectors made of type B, double walt vent pipe material

may pass through walls or partitions constructed of combustible material if the minimum listed clearance is maintained.

Maintain a six inch minimum clearance from all combustible materials when using single walt vent pipe. IMPORTANT: Single walt vent pipe cannot be used for water

heaters located in attics and may not pass through attic spaces, crawl spaces or any confined or inaccessible location. A single

wall metal vent connector cannot pass through any interior walt.

When installing a vent connector, please note the following

(See Figures 19-21):

• Install the vent connector avoiding unnecessary bends, which create resistance to the flow of vent gases.

• Install without dips or sags with an upward slope of at least

1/4-inch per foot.

• Joints must be fastened by sheet metal screws or other

approved means. It must be supported to maintain clearances and prevent separation of joints and damage.

• The length of the vent connector cannot exceed 75% of the vertical vent height.

• The vent connector must be accessible for cleaning, inspection, and replacement.

• Vent connectors cannot pass through any ceiling, floor, firewall, or fire partition.

• It is recommended (but not mandatory) that a minimum 12 inches of vertical vent pipe be installed on the draft hood prior to any elbow inthe vent system.

IMPORTANT: Existing vent systems must be inspected for obstructions, corrosion, and proper installation.

Chimney Connection

IMPORTANT: Before connecting a vent to a chimney, make sure the chimney passageway is clear and free of obstructions. The chimney must be cleaned if previously used for venting solid fuel appliances or fireplaces. Also consult local and state codes for proper chimney sizing and application or, in the absence

of local and state codes, the "National Fuel Gas Code", ANSI Z223.1 (NFPA 54)-current edition.

• The connector must be installed above the extreme bottom of the chimney to prevent potentially blocking the flue

gases.

• The connector must be firmly attached and sealed to prevent it from falling out.

• To aid in removing the connector, a thimble or slip joint may be used.

• The connector must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney (Figure 19).

LISTED LINED CHIMNEY

separation, and maintain clearances to combustible materials (Figures 20 and 21).

IMPORTANT: This gas vent must be terminated in a vertical position to facilitate the removal of the burnt gases.

An unused chimney flue or masonry enclosure may be used as a passageway for the installation of a gas vent (Figure 21).

Common (combined) venting is allowable with vertical type B vent systems and lined masonry chimneys as tong as proper

draft for the water heater is established under all conditions of operation. CAUTION: DO NOT common vent this water heater with any power vented appliance.

Figures 19-21 are examples of vent pipe system installations and may or may not be typical for your specific application. Consult the "National Fuel Gas Code", NFPA 54, ANSI Z223.1- current edition and the guidelines set forth by prevailing local

codes.

_' 2 FT. MINIMUM ABOVE ANY OBJECT

3 FT. MINtMU! WITHIN 10 FT. HORIZONTALLY

SUPPORT

*MAINTAIN

CLEARANCE

TYPE B DOUBLE WALLVENTPIPE

**MAINTAIN

CLEARANCE

2 FT. MINIMUM ABOVE ANY OBJECT WITHIN 10FT. HORIZONTALLY

DO NOT EXTEND

OF CHIMNEY

CONNECTOR

MAINTAIN CLEARANCE*

3FT. MINIMUM

SUPPORT STRAP

CHIMNEY TERMINATION VENT SYSTEM

FIGURE 19.

Do not terminate the vent connector in a chimney that has not been certified for this purpose. Some local codes may prohibit the termination of vent connectors in a masonry chimney.

Vertical Exhaust Gas Vent

Vertical exhaust gas vents must be installed with U.L. listed type B vent pipe according to the vent manufacturer's instructions and the terms of its listing.

It must be connected to the water heater's draft hood by a listed vent connector or by directly originating at the draft hood opening.

Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer's

instructions. Gas vents must be supported to prevent damage, joint

VERTICAL GAS VENT SYSTEM WITH TYPE B DOUBLE WALL VENT PIPE.

FIGURE 20.

-,i-_LISTED VENT CAP

*MAINTAIN

CLEARANCE

SUPPORT STRAP

5 FT. MINIMUM

_MAINTAIN

SPECIFIED CLEARANCE

VENT

CONNECTOR

SLOPE

I_IN. PER FT.

MINIMUM

VENTING THROUGH A CHIMNEY WITH

TYPE B DOUBLE WALL VENT PIPE.

FIGURE 21.

, Maintain vent pipe clearance requirements to local, state and/or the "National FuelGas Code",ANSI Z223.1(NFPA 54)-current edition.

** NFPA 211, Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Buming Appliances states that these chimneys are intended to be installed in accordance with the installation instructions provided with each chimney support assembly. Minimum airspace clearance to combustible materials should be maintained as marked on the chimney

sections.

CONNECTOR

UNUSED CHIMNEY

-.,F--_FLUE OR MASONRY

ENCLOSURE

Piping Installation

Piping, fittings, and valves should be installed according to the installation drawing (Figure 22). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation.

The water supply pressure should not exceed 80 psi. If this occurs, a pressure reducing valve with a bypass may need to be installed in the cold water inlet line. This should be placed on the supply to the entire house in order to maintain equal hot and cold water pressures.

IMPORTANT: Heat cannot be applied to the water fittings on the heater as they may contain nonmetallic parts. If solder

connections are used, solder the pipe to the adapter before attaching the adapter to the hot and cold water fittings.

IMPORTANT: Always use a good grade of joint compound and be certain that all fittings are drawn up tight.

1. Install the water piping and fittings as shown in Figure 22.

Connect the cold water supply (3/4" NPT) to the cold water inlet fitting. Connect the hot water supply (3/4" NPT) to the hot water outlet fitting.

IMPORTANT: Some models may contain energy saving heat traps to prevent the circulation of hot water within the pipes. Do not remove the inserts within the heat traps.

2. The installation of unions in both the hot and cold water

supply lines is recommended for ease of removing the water heater for service or replacement.

The manufacturer of this water heater recommends installing a mixing valve or an anti-scald device in the

domestic hot water line as shown in Figure 23. These valves reduce the point-of-use temperature of the water by mixing cold and hot water and are readily available

for use.

If installing the water heater in a closed water system, install an expansion tank in the cold water line as specified

under "Closed System/Thermal Expansion."

Install a shut-off valve in the cold water inlet line. It should be located close to the water heater and be easily

accessible. Know the location of this valve and how to shut off the water to the heater.

A temperature and pressure relief valve must be installed in the opening marked "Temperature and Pressure

(T & P) Relief Valve" on the water heater. A discharge line must be added to the opening of the T&P Relief Valve.

Follow the instructions under "Temperature and Pressure Relief Valve."

After piping has been properly connected to the water heater, remove the aerator at the nearest hot water faucet. Open the hot water faucet and allow the tank to completely fill with water. To purge the lines of any excess air, keep the hot water faucet open for 3 minutes after a constant

flow of water is obtained. Close the faucet and check all connections for leaks.

IN A CLOSED SYSTEM USE A

_THERMAL EXPANSION TANK

1" MINIMUM--_-

METAL

DRAIN PAN

HOT WATER OUTLET

RELIEF VALVE (OPTIONAL TOP T&P RELIEF VALVE NOT SHOWN)

(DO NOT CAP OR PLUG)

DRAIN LINE A VACUUM RELIEF IN COLD 3/4" ID WATER LINE PER SECTION

MINIMUM 19 MGL 142.

_ AIR GAP

DRAIN _

COLD WATER INLET

COLD WATERINLET VALVE

MASSACHUSETTS: INSTALL

6" MAXIMUM

(T&P)

FIGURE 22.

TO FIXTURES

COLD

WATER

INLET

HOT

OUTLET

UNTEMPERED HOT WATER

MIXING VALVE (SET TO 120°F)

FOLLOW THE MIXING

VALVE MANUFACTURER'S

INSTRUCTIONS

FIGURE 23.

Please note the following:

• The system should be installed only with piping that is suitable for potable (drinkable) water such as copper, CPVC, or polybutytene. This water heater must not be installed using iron piping or PVC water piping.

• Use only pumps, valves, or fittings that are compatible with potable water.

• Itis recommend that only full flow ball or gate valves are used in water piping installations. The use of valves that may cause

excessive restriction to water flow is not recommended.

• Use only 95/5 tin-antimony or other equivalent solder. Any lead based solder must not be used.

• Piping that has been treated with chromates, boiler seal, or other chemicals must not be used.

• Chemicals that may contaminate the potable water supply must not be added to the piping system.

Closed System/Thermal Expansion

Property Damage Hazard

• AHwater heaters eventually leak

• Do not install without adequate drainage,

As water is heated, it expands (thermal expansion). In a closed system, the volume of water will grow. As the volume of water grows, there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent temperature- pressure relief valve operation: water discharged from the valve due to excessive pressure build up. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This condition is not covered under the limited warranty.

A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of 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. (For additional information, see the Troubleshooting Guide later

in this manual.)

Temperature and Pressure Relief Valve

For protection against excessive pressures and temperatures, a temperature and pressure relief valve must be installed in the opening marked "T & P RELIEF VALVE." (See Figure 24). This valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of listed equipment or materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22. The function of the temperature and pressure relief valve is to discharge water in large quantities in the event of excessive temperature or pressure developing in the water heater. The valve's relief pressure must not exceed the working pressure of the water heater as stated on the rating plate.

IMPORTANT: Only a new temperature and pressure relief valve should be used with your water heater. Do not use an old or existing valve as it may be damaged or not adequate for the working pressure of the new water heater. Do not place any

valve between the relief valve and the tank. The Temperature & Pressure Relief Valve:

• Must not be in contact with any electrical part.

• Must be connected to an adequate discharge line.

• Must not be rated higher than the working pressure shown on the rating plate of the water heater.

The Discharge Line:

• Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line.

• Must not be capped, blocked, plugged or contain any valve between the relief valve and the end of the discharge line.

• Must terminate a maximum of six inches above a floor drain or external to the building.

• Must be capable ofwithstanding 250°F (121°C)without distortion.

• Must be installed to allow complete drainage of both the valve and discharge line.

T&P Relief Valve and Pipe Insulation

Explosion Harzard

Temperature-pressure relief valve must comply with ANSI

Z21.22-CSA 4.4 and ASME code.

• Properly sized temperature- pressure relief valve must be installed in opening provided.

• Can result in overheating and excessive tank pressure.

• Can cause serious injury or death.

_TEMPERATURE AND PRESSURE (T&P)

_ELIEF VALVE (OPTIONAL TOP T&P

i EL'%C"C T'

__- (DO NOT CAP OR PLUG)

1. Locate the T&P Relief Valve on the water heater.

2. Locate the slit running the length of the insulation. 3 Spread this slit open and slip it up under the T&P Relief

Valve. See Figure 25. Apply gentle pressure to the insulation to ensure it is fully seated on the T&P Relief Valve. Once

sealed secure the insulation with a section of tape. IMPORTANT: The insulation or tape should not block or

cover the T&P Relief Valve drain opening. Also the insulation or tape should not block or hinder access to the T&P Relief

Valve manual relief lever.

4. Next locate the hot water (outlet) & cold water (inlet) pipes to the water heater.

5. Select one of the sections of pipe insulation and locate the slit that runs the length of the insulation.

6. Spread the slit open at the base of the insulation and slip it over the cold water (inlet) pipe. Apply gentle pressure along the length of the insulation to ensure it is fully seated around the cold water pipe. Also ensure that the base of insulation is flush with the water heater. Once seated, secure the insulation with a section of tape.

7. Repeat steps 5 through 6 for the hot water (outlet) pipe.

T&P RELIEF VALVE INSULATION

MANUAL RELIEF LEVER

,,,MIN,MUM------_ _/

METAL____J__--_LJ'- _ MA×,MUM

ORA,NPAN,' A,R AP

DRAIN /

FIGURE 24.

RELIEF VALVE

DRAIN LINE

FIGURE 25.

Lighting Instructions

Read and understand these directions thoroughly before attempting to light or re-light the pilot. Make sure the view port is not missing or damaged. (See Figure 32.) Make sure the tank is completely filled with water before lighting the pilot. Check the rating plate near the gas control valve/thermostat for the correct gas. Do not use this water heater with any gas other than the one listed on the rating plate. If you have any questions or doubts, consult your gas supplier or gas utility company.

BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES

A. This appliance has a pilot which is lit by a piezo-

electric spark gas ignition system. Do not open the inner door of the appliance and try--['olight

the pilot by hand.

B.BEFORE LIGHTING smell allaround the appliance

area for gas. Be sure to smell next to the floor D. because some gas is heavier than air and will

settle on the floor.

WHAT TO DO IF YOU SMELL GAS

*Do not try to light any appliance. E. *Do not touch any electric switch; do not use any

phone in your building.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

olf you cannot reach your gas supplier, call the fire

department.

Explosion Hazard

Replace view port if glass is missing or damaged.

Failure to do so can result in death,

explosion or fire.

C. Use only your hand to push in or turn the gas control

knob. Never use tools. If the knob will not push in or turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may

result in a fire or explosion. Do not use this appliance if any part has been under water. Immediately contact a qualified installer or service agency to replace a flooded water heater.

Do not attempt to repair the unit! It must be replaced! DO NOT USE THIS APPLIANCE IF THERE HAS

BEEN AN IGNITION OF VAPORS. Immediately call a qualified service technician to inspect the appliance. Water heaters subjected to a flammable vapors ignition will show a

discoloration on the air intake grid and require replacement of the entire water heater.

FIGURE 'B' FIGURE 'C'

GASCONTROL

1. _ STOP! Read the safety information 9. Once the pilot has been found, push the gas knob _ above on this label.

2. Set the thermostat to lowest setting(PILOT LIGHTING). button rapidly (4) to (5) times. If the pilot will not

Turn thermostat dial fully clockwise d" until it stops, light, repeat step (3) through (9).

3. Push the gas control knob down slightly and turn 10. ConlJnuetoholdlf_egasconlrol knobdown forabout

clockwise d" to "OFF". SEE FIGURE 'A'. one (1) minute after the pilot is lit. Release the gas

NOTE: Knob cannot be tumed from "PILOT" to "OFF" remain,lit. If it goes out repeat step,(3)_rough _:9).It unless knob is pushed down slightly. Do not force, may taKe several minutes Torair to clear tl_e lines

4. Remove the outer burner door located below the gas control.

5. Wait ten (10) minutes to clear out any gas. If you then smell gas STOP! Follow "B" in the

safety infonnation above on this label. If

you don't smell gas, o to next step.

6. This unit is equipped with a push button pilot ignitor, call your service technician or gas supplier. which is used to light the pilot. Locate the ignitor 11. Once the pilot flame is established replace the

on the gas control, outer burner door.

7. Turn gas control knob counterclockwise to "PILOT". SEE FIGURE 'B'. 12. At arm's length away, turn gas control knob

8. The pilot is located on the left side of the burner. It 13. Set thermostat to desired setting.

can be located bylooking through the glass view port

while pressing the piezo ignitorbutton several times. 4_, scald injury. Consult the instruction

Lookfor a spark at the pilot location, Figure "D". manual before changing temperature.

"PILOT" POSITION "ON" POSITION THERMOCOUPLE

TOP KNOB FIGURE "D"

all the way down. Immediately press the pilot ignitor

control knob and itwill pop back up. Pilot should

before the pilot will light.

• If knob does not pop up when released, stop and immediately call your service technician or gas

supplier.

• If the pilot will not stay lit after several tries, tum the gas control knob clockwise C to 'OFF' and

SEE FIGURE 'A'

counterclockwise "_ to 'ON'. SEE FIGURE 'C'.

,_L_ Hotter water increases the riskof

MAINBURNER

1.Set the thermostat to lowest setting 2. Push gas control knob down slightly and turn clock- ( P I L O T L I G HT I N G ). wise C_ to 'OFF'. Do not force. SEE FIGURE 'A'.

Checking the Draft Water Temperature Regulation

IF:1,7_'I ::4

• Burn hazard

• Hot water discharge.

• Keep clear of relief valve discharge outlet.

After successfully lighting the water heater, allow the unit to operate for 15 minutes and check the draft hood relief opening for proper draft (Figure 26). Make sure all other appliances in the area are operating and all doors are closed when performing the draft test. Pass a match flame around the relief opening of the draft hood. A steady flame drawn into the opening indicates proper draft.

DRAFT HOOD

MATCH_

FIGURE 26.

If the flame flutters or is blown out, combustion products are escaping from the relief opening. If this occurs, do not operate the water heater until proper adjustments or repairs are made to the vent pipe system and/or air supply requirements.

Burner Flames

Inspect the burner flames through the viewport and compare them to the drawing in Figure 27. A properly operating burner should produce a soft blue flame. Blue tips with yellow inner cones are satisfactory. The tips of the flame may have a slight

yellow tint. The flame should not be all yellow or have a sharp blue-orange color. Contaminated air may cause an orange

colored flame. Contact a qualified technician if the flame is not satisfactory.

Er:I,7_,I d .I

Water temperature over 125°F (52°C) can cause servere burns instantly

resulting in severe injury or death. Children, the elderly, and the

physically or mentally disabled are at highest risk for scald injury.

Feel water before bathing or

showering. Temperature limiting valves are

available.

Read instruction manual for safe

temperature setting.

Due to the nature of the typical gas water heater, the water temperature in certain situations may vary up to 30°F (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 wilt

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 infirm, or physically/mentally handicapped. If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisfies your hot water needs, a means such as a mixing valve should be used at the hot water taps used by these people or at the water heater. Mixing valves are available at plumbing supply or hardware stores. See Figure 23. Follow

manufacturer's instructions for installation of the valves. Before changing the factory setting on the thermostat, see Figure 28.

Using the lowest hot water temperature that meets your needs will also provide the most energy efficient operation of the water

heater.

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.

NOTE: Awater 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. It is adjustable and must be reset to the desired temperature setting to reduce the risk of scald injury. The • mark is indicative of approximately 120°F (49°C) and is the preferred starting point. See Figure 28 on the next page. Some states have a requirement for a lower setting.

FIGURE 27.

Emergency Shut Down

IMPORTANT: Should overheating occur or the gas supply fails to shut off, turn off the water heater's manual gas control valve and call a qualified technician.

Turn the water temperature dial clockwise ( f'_ ) to decrease the temperature, or counterclockwise ( f'_ ) to increase the temperature.

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

INDEX BAR_

(OFF-PILOT-ON)

VERY HOT= approx. 160°F (71°C)

C = approx. 150°F (66°C)

B = approx. 140°F (60°C)

A = approx. 130°F (54°C)

• = approx. 120°F (49°C)

LOW = approx. 80°F (27°C)

About 1/2 second About 1-1/2 seconds Less than 5 seconds About 30 seconds More than 5 minutes

FIGURE 28.

NOTE: During tow demand periods when hot water is not being used, a lower thermostat setting wilt reduce energy

losses and may satisfy your normal hot water needs. If hot water use is expected to be more than normal, a higher

thermostat setting may be required to meet the increased

demand. When leaving your home for extended periods (vacations, etc.) turn the temperature dial to its lowest

setting. This wilt maintain the water at tow temperatures with minimum energy losses and prevent the tank from freezing

during cold weather.

Tank (Sediment) Cleaning Burner Inspection

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

Ca_on Monoxide and Fire Hazard

, Fiue gases may escape if vent pipe

is not connected

, Be alert for obstructed, sooted or

deteriorated vent system to avoid

sedous inju_ or death.

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

• Chemical corrosion of flue and vent

system can cause serious injury or death

Breathing carbon monoxide can cause brain damage or death. A(ways read and understand instruction manual

Flood damage to a water heater may not be readily visible or immediately detectable. However, over a period of time a flooded water heater will create dangerous conditions which can cause DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.

Contact a Sears Service Center to replace a flooded water heater. Do not attempt to repair the unit! tt must be replaced!

At least once a year, a visual inspection should be made of the main burner and pilot burner. See Figure 29.

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 fire causing death, serious injury, or property damage.

FIGURE 29.

Burner Cleaning

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 flow must not be obstructed.

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

• Rusted flakes around top of water heater.

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

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

Chemical vapor corrosion of the flue 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 flue and venting before resuming operation of the water heater.

Fire or Explosion Hazard

Failure to properly reseal the combustion chamber will disable the flammable vapor ignition resistance feature

of this water heater, which could result in death or serious injury. Contact your local Sears Service Center

for assistance.

installing, using or servicing

Read instruction manual before

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

If inspection of the burner shows that cleaning is required, turn the gas control knob clockwise (t'_ ) to the "OFF" position, depressing

slightly.

NOTE: The knob cannot be turned from "PILOT" to "OFF" unless knob is depressed slightly. DO NOT FORCE.

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.

water heater.

Housekeeping

Temperature-Pressure Relief Valve Operation

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

Fire and Explosion Hazard

Do not obstruct combustion air openings at the bottom of the

water heater. Do not use or store flammable

vapor products such as gasoline, solvents or adhesives in the

same room or area near water heater or other appliance.

At least annually, check the

base-ring filter and flame arrester

for any dust, lint, or debris that

may have accumulated. Clean as necessary. Can cause serious injury or death.

AT LEAST ANNUALLY, A VISUAL INSPECTION SHOULD BE MADE OF THE BASE-RING FILTER AND FLAME ARRESTER. CLEAN IF LINT ACCUMULATIONS ARE NOTICED.

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

V! 1,7,_I [r] =4"•

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 30.

TEMPERATURE-PRESSURE

* Burn hazard

• Hot water discharge.

• Keep clear of relief valve discharge outlet.

INSTALLED IN SUITABLEAREA: Toensure sufficient ventilation and combustion air supply, proper clearances from the water

heater must be maintained. See "Installation Instructions." Combustible materials such as clothing, cleaning materials, or

flammable liquids, etc. must not be placed against or adjacent to the water heater because they could catch on fire.

Anode Rod Inspection

Property Damage Hazard

• Avoid water heater damage.

• Inspection and replacement of anode rod required.

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.

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.

DISCHARGE PIPE

FIGURE 30.

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.

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

temperature-pressure relief valve.

Draining and Flushing

Hotwater discharge burn hazard.

Keep clear of relief valve discharge unit.

Temperature limiting valves are available.

Read instruction manual for safe temperature setting.

It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during

operation. The water heater should be drained if being shut

down during freezing temperatures. To drain the tank, perform the following steps:

1. Turn off the gas to the water heater at the manual gas shut- off valve.

2. Close the cold water inlet valve.

3. Open a nearby hot water faucet.

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

NOTE: The drain hose should be rated for at least 200°F. If the drain hose does not have this rating, open the cold water inlet

valve and a nearby hot faucet until the water is no longer hot.

5. Open the water heater drain valve and allow all the water to drain from the tank. Flush the tank with water as needed

to remove sediment.

6. Close the drain valve, refill the tank, and restart the heater as directed under the "Operating Your Water Heater" section.

If the water heater is going to be shut down for an extended

period, the drain valve should be left open. IMPORTANT: Condensation may occur when refilling the tank

and should not be confused with a tank leak.

Service

Before calling for repair service, please read the Troubleshooting Guide in 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).

Replacement Parts

IMPORTANT: The following maintenance procedures are for

the FVIR System components and should be performed by a qualified technician.

Replacement parts may be ordered from Sears Parts and Service Centers or by calling 1-800-4-MY-HOME (1-800-469-4663). When ordering replacement parts, always have the following information ready:

1. model, serial, and product number

2. type of gas

3. item number

4. parts description See the Parts Order List section for a list of available repair parts.

External Inspection & Cleaning of the Base-Ring Filter

1. At least annually, check the base-ring filter (Figure 38) for

any dust or debris that may have accumulated on the filter screen. NOTE: If the water heater is located in an area that

is subjected to tint and dirt, it may be necessary to check the base-ring filter more frequently.

2. Follow the Lighting Instructions to turn off the water heater

and allow it to coot for 10 minutes before attempting to clean the base-ring filter.

3. Use a vacuum cleaner with a hose attachment to remove

any dust or debris that may have accumulated on the filter. NOTE: If unable to inspect or clean the base-ring filter, follow

the "Cleaning the Combustion Chamber and Flame-arrestor" instructions.

After the base-ring filter has been cleaned, follow the Lighting Instructions to return the water heater to service.

GAS CONTROL VALVE/ THERMOSTAT

IGNITER

MANIFOLD

TUBE PILOT

THERMOCOUPLE TUBE

P_D EZO

VIEW PORT SWITCH

I / "Y r

MANIFOLD_ \ TWO PIECE

SCREWS (2) WIRE CONNECTOR

/ /\ I

BUTTON

THERMAL

MANIFOLD

OOR

FIGURE 32.

6. Disconnect the thermocouple (right-hand thread), pilot tube, the igniter wire from the igniter button, the two connectors attached to the thermal switch, and manifold tube at the gas control valve/thermostat. (Figures 31 & 32.) NOTE: L.R Gas systems use reverse (left-hand) threads on the manifold tube.

7. Grasp the manifold tube and push down slightly to free the manifold, pilot tube, and thermocoupte.

8. Carefully remove the manifold/burner assembly from the burner compartment. NOTE: Be sure not to damage internal parts.

Removing the Burner from the Manifold/ Burner Assembly

Natural Gas (Low Nox) & L.P. Gas Burner

1. Take off the burner by removing the two (2) screws located underneath the burner.

Check the burner to see if it is dirty or clogged. The burner may be cleaned with soap and hot water (Figure 33).

(BOTTOM VIEW)

Removing the Manifold/Burner Assembly

1. Turn off the gas supply to the water heater at the manual gas shut-off valve. This valve is typically located beside the water heater (Figure 11). Note the position of the shut-off valve in the open/on position then proceed to turn it off.

2. On the lower front of the water heater, locate the gas control valve/thermostat (see Figure 32). Before performing any maintenance, it is important to turn the temperature dial on the gas control valve/thermostat to its lowest setting.

3. On top of the gas control valve/thermostat, turn the gas control knob to the "OFF" position.

WHITE RODGERS GAS VALVE

_"_!. '_i

8g_ TM

THERMOCOUPLE_

MANIFOLD TUBE

FIGURE 31.

Remove the outer door.

Remove the two screws securing the manifold door assembly to the combustion chamber (Figure 32).

SCREW_

BURNER

(BOTTOM VIEW)

FIGURE 33.

Replacing the Thermocouple

Remove the manifold/burner assembly as directed previously.

Lift the retainer clip straight up from the back of the two piece wire connector (using a flat-blade screwdriver), then remove the two piece wire connector from the manifold door (Figure 34.)

3. Remove the burner. See "Removing the Burner from the Manifold/Burner Assembly."

4. Pull the thermocoupte from the pilot assembly (Figure 35).

IMPORTANT: Be careful not to bend or alter the position of the pilot assembly components.

5. Insert the thermocouple tip into the holes provided in the pilot bracket until it clicks into place. NOTE: The base of the thermocouple must be flush with the base of the pilot bracket.

6. Position the new thermocoupte through the bottom opening 7. of the two piece wire connector (Figure 34). Be sure igniter wire is positioned through the small opening of the two

piece wire connector. 8.

7. Re-attach the burner. Note the orientation of the burner (Figure 33.) 9.

8. See "Replacing the Manifold/Burner Assembly."

FERROLE,UTil

_ _GNITER WIRE

_J_ _ _ P LOT PILOT BRACKET

',!, I i OTHER FITTINGS

,,,,,__.-_ _-_ ....... _o_

Route the new pilot tube, thermocoupte, and igniter wire through the manifold/burner door opening. (Figure 34)

Re-attach the pilot assembly to the pilot bracket and secure using the screw removed earlier.

Position the new pilot tube through the largest opening of the two piece wire connector. NOTE: The largest opening should be located at the top position. The igniter wire should be located in the middle opening and thermocouple in the bottom opening. (Figure 37)

tLL _N

I "/ i 3] RETAINER

-2 " I _

(_ t_TwlWROEPc_EoC_ % ..... D ..........

} [ OT1UEE \MANIFOLD/BURNER

FIGURE 34.

FIGURE 35.

Replacing the Pilot/Pilot Tube Assembly

Remove the manifold/burner assembly. See "Removing the Manifold/Burner Assembly."

2. Lift the retainer clip straight up from the back of the two piece wire connector (using a flat-blade screwdriver), then remove the two piece wire connector from the manifold door (Figure 34.)

IMPORTANT: Be careful not to bend or alter the position of the pilot tube. It will be used as a bending template for the new pilot assembly.

3. Take off the burner by removing the two (2) screws located underneath the burner. See Figure 33.

4. Remove and keep the screw securing the pilot assembly to the pilot bracket. (Figure 36)

5. Remove and keep the old pilot/pilot tube assembly.

Using the old pilot/pilot tube assembly as a guide, bend the new pilot tube and new thermocouple to match the old ones. NOTE: Make only the bends closest to the pilot before going to the next step. (Figure 36)

PILOT TUBE

.IGNITER WIRE

THERMOCOUPLE

TWO PIECE WIRE CONNECTOR

FIGURE 37,

10.

Reposition the two piece wire connector in the manifold door opening and secure it with the retainer clip.

11.

Carefully bend the new pilot tube and thermocoupte to match the bend of the manifold tube. NOTE: When bending, DO NOT crimp or crease the pilot tube or thermocouple. (Figure 34)

12. Before you proceed to the next step, install the new brass ferrule nut in the gas control valve/thermostat's pilot tube opening. HAND TIGHTEN ONLY.

13. See "Replacing the Manifold/Burner Assembly."

Cleaning the Combustion Chamber and Flame-arrestor

Follow procedure outlined in "Removing the Manifold/ Burner Assembly."

Use a vacuum cleaner/shop vac to remove all loose debris in the combustion chamber (Figure 38). Use compressed

air to clear any dust or debris that may have accumulated in the flame-arrestor.

COMBUSTION CHAMBER

DOOR GASKET

FLAME ARRESTOR

PILOTTUBE

IGNITER WIRE

SCREW

OTHER FITTINGS NOT SHOWN

FOR CLARITY

THERMOCOUPLE FIRST BEND(S)

FIGURE 36.

BASE-RINC

FIGURE 38.

Reassemble by following the procedure under "Replacing the Manifold/Burner Assembly."

Replacing the Manifold/Burner Assembly

Explosion Hazard

Tighten both manifold door screws securely. Remove any fiberglass between gasket

and combustion chamber.

Replace viewport if glass is missing or damaged.

Replace two piece wire connector if missing or removed.

• Replace door gasket if damaged.

• Failure to follow these instructions can result

in death, explosion, or fire.

control valve/thermostat. Finally, start the thermocouple nut and turn it all the way in by hand. An additional quarter turn with a 3/8" open-end wrench will then be sufficient to seat the lockwasher. When you are finished, connect the two wire leads that go to the thermal switch.

Reconnect the igniter wire.

Turn gas supply on and refer to the Lighting Instructions.

With the burner tit, check the gas control valve/thermostat supply line, two piece wire connector, manifold tube, and pilot tube connections for leaks. Check for leaks by

brushing on an approved noncorrosive leak detection solution. Bubbles forming indicate a leak. Correct any leak

found. IMPORTANT: All leaks must be fixed immediately.

10. Replace the outer door.

FLAMEARRESTOR BRACKET

Check the door gasket for damage or imbedded debris prior to installation.

Inspect the view port for damage and replace as required.

Insert the manifold/burner assembly into the burner compartment, making sure that the tip of the manifold tube engages in the slot of the bracket inside the combustion

chamber (Figures 39 & 40).

Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion chamber.

Replace the two screws, which secure the manifold/ burner assembly door to the combustion chamber and

tighten securely. Once the manifold/burner assembly door is tightened, visually inspect the door gasket between the manifold/burner assembly door and the combustion

chamber for spaces or gaps that would prevent a seal. IMPORTANT: Do not operate the water heater if the door gasket does not create a seal between the manifold door

and the combustion chamber.

During the following procedure, do not cross-thread or apply any thread sealant to any of the fittings listed below. First, reconnect the manifold tubing to the gas control valve/ thermostat. NOTE: L.R gas systems use reverse (left-hand)

threads on the manifold tube. NOTE: If a ferrule nut needs to be installed for the pilot

tube, locate the one provided with your parts kit. Install it in the gas control valve/thermostat at the pilot location, hand

tight only. Next, insert the pilot tube into the ferrule nut until it bottoms

out. NOTE: Hold the tube in this position. Tighten the ferrule nut with a wrench until the crimp connection seals to the pilot tube. Continue to tighten until the nut is tight in the gas

TiP

FIGURE 39.

CLOSE-UP INSIDE VIEW OF THE COMBUSTION CHAMBER.

_ _SLOT

TIP

MANIFOLD TUBE

BRACKET

FIGURE 40.

Piezoelectric Igniter System

The piezoelectric igniter system consists of the igniter button, electrode, and wire. The pilot is ignited by an electric spark

generated when the igniter button is pressed. The spark gap of 0.125 inch is set when the electrode is installed at the factory. (Figure 41). Use only factory authorized piezoelectric igniter parts for replacement.

___L IGNITER

THERMOCOUPLE

/2PILOTI

BUTTON

ECTRODE

SNAP-ON CONNECTOR

* NOTE: SPARK GAP DISTANCE MEASURED FROM ELECTRODE TIP TO PILOT.

BRACKET J ELECTRODE

FIGURE 41.

Testing the Igniter System

Turn off the gas to the water heater at the manual gas shut-off valve. Watch the electrode tip while activating the igniter. A

visible spark should jump from the electrode. To avoid shock, do not touch the burner or any metal part on the pilot or pilot assembly. If no spark is visible, check the wire connections and make sure the electrode is not broken. Replace the igniter if defective. Dirt and rust on the pilot or electrode tip can

prevent the igniter spark. Wipe clean with a damp cloth and dry completely. Rust can be removed from the electrode tip and metal surfaces by lightly sanding with an emery cloth or fine grit sandpaper.

Removing and Replacing the Gas Control Valve/Thermostat

IMPORTANT: This water heater has a resettable thermal switch installed. Do not attempt to disable or modify this

feature in any way. Use only factory authorized replacement parts.

Removing the Gas Valve:

1. Turn off the gas supply to the water heater at the manual gas shut-off valve. This valve is typically located beside the water heater. Note the position of the shut-off valve in the open/on position then proceed to turn it off (Figure 11).

2. On the lower front of the water heater, locate the gas control

valve/thermostat (see Figure 32). Before performing any maintenance, it is important to turn the temperature dial on the gas control valve/thermostat to its lowest setting.

3. On top of the gas control valve/thermostat turn the gas

control knob to the "OFF" position. See Lighting Instructions on the water heater.

4. Drain the water heater. Refer to the section of "Draining

and Flushing" section and follow the procedure.

Disconnect the igniter wire from the igniter. NOTE: There are two types of igniters. If you have the square igniter, slide the igniter bracket backwards away from the gas valve to remove it. Ifyou have the round igniter, first remove the igniter from the bracket bydepressing front and rear holding tabs and lift. Next, remove the igniter bracket from the gas valve. Disconnect the thermocouple (right-hand threads), pilot tube, and manifold tube at the gas control valve/thermostat (Figure 31). NOTE: L.P. gas systems use reverse (left-hand) threads on the

manifold tube.

Refer to "Gas Piping" section (Figure 11) and disconnect the ground joint union in the gas piping. Disconnect the remaining pipe from the gas control valve/thermostat.

To remove the gas control valve/thermostat, thread a correctly sized pipe into the inlet and use it to turn the gas control valve/thermostat (counterclockwise.) Do not use a pipe wrench or equivalent to grip body. Damage may result, causing leaks.

Do not insert any sharp objects into the inletor outlet connections. Damage to the gas control valve/thermostat may result.

Replacing the Gas Valve:

1. To replace the gas control valve/thermostat, reassemble

in reverse order. When replacing the gas control valve/ thermostat, thread a correctly sized pipe into the inlet and use it to turn the gas valve (clockwise.) DO NOT OVER TIGHTEN or damage may result. NOTE: Use an approved

TEFLON® tape or pipe compound only on the threaded section of the gas control valve/thermostat that screws into

the tank.

2. Reconnect the gas piping to the gas control valve/ thermostat. NOTE: Use an approved Teflon tape or pipe compound on the gas piping connections.

3. Attach the igniter and bracket to the new gas control valve/ thermostat, clipping it at the back edge of thermostat and snapping it into place. NOTE: Do not use the (pilot) ferrule nut supplied with the new gas control valve/thermostat, unless the existing nut is not usable. Reconnect the pilot tube, manifold tube, igniter wire, and thermal switch wires. NOTE: L.R gas systems use reverse (left-hand) threads on

the manifold tube.

4. Fill the tank completely with water. NOTE: To purge the lines of any excess air, keep the hot water faucet open for

3 minutes after a constant flow of water is obtained.

5. Turn on the gas supply and test the gas supply connections by brushing on an approved noncorrosive leak detection

solution. Bubbles forming indicate a leak. Correct any leak found.

6. Check the operation of the burner by following the lighting instructions on the front of the water heater. With the

burner tit, check the gas control valve/thermostat supply line, manifold tube and pilot tube connections for leaks.

7. Verify proper operation and then replace the outer door.

8. If additional information is required, contact Residential Technical Assistance by referencing the number on the water

heater.

TEFLON® is a registered trademark of E.I. Du Pont De Nemours and Company.

FVIR System Operational Checklist

1. Manifold gasket properly sealed.

2. Viewport not damaged or cracked.

3. Flame-arrestor free of debris and undamaged.

4. Two piece wire connector properly installed.

5. No leaks at pilot and manifold connection.

6. Manifold door screws securely tightened.

7. Depress the button on the thermal switch.

Start Up Conditions

Thermal Expansion

Property Damage Hazard

• Avoid water heater damage.

• install thermal expansion tank or device if necessary.

• Contact qualified installer or service agency.

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.

WATER HEATER (3)

HOT

INLET FITTING REDUCING

../ COLD WATER PRESSURE

VALVE WITH

BY-PASS

As water is heated, it expands (thermal expansion). In a closed system, the volume of water wilt grow. As the volume of water grows, there wilt be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent temperature-pressure relief valve operation: water discharged from the valve due to excessive pressure build up. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This condition is not covered under the limited warranty.

TABLE 5 Thermal Expansion Tank Specifications

Model

Number

153.331020

153.331050

Tank Dimensions Pipe

Capacity in Inches Fitting FIGURE 42.

In Gallons Diameter Len£1th On Tank

2 8 (203 mm) 12-3/4 (323 mm) 3/4" Male 5 11 (279 mm) 14-3/4 (375 mm) 3/4" Male Strange Sounds

I I

WATER HEATER

COLD WATER

INLET FITTING

HOT

COLD

(2)

PRESSURE GAUGE INLET COLD

RECOMMENDED INSTALLATION

(VERTICAL MOUNTING)

EXPANSION /

PRESSURE GAUGE-- INLET COLD

ALTERNATE RECOMMENDED INSTALLATION

(HORIZONTAL MOUNTING)

WATER SHUT-OFF

FLOOR, CEILING JOIST, ETC.

(3)

PRESSURE REDUCING

VALVE WITH

(1) BY-PASS

.,I t

WATER SHUT-OFF

TABLE 6

Expansion Tank Sizing Chart

Inlet*

Water

Pressure

Expansion 2 2 2 5 5

Tank 2 2 2 5 5

Capacity 2 2 5 5 5

Needed 2 2 5 5 5

40psi

50psi 60psi 70psi

80psi

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

Water Heater Capacity (Gallons)

30 40 50 66 82

2 5 5 5 5

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 flame should still be drawn into the draft hood of the water heater with its burner firing. If the flame is not

drawn toward the draft hood, shut off water heater and make necessary air supply changes to correct.

Condensation

Whenever the water heater is filled with cold water, some condensate will form while the burner is on. Awater heater may

appear to be leaking when in fact the water is condensation. This usually happens when:

• A new water heater is filled with cold water for the first time.

• Burning gas produces water vapor In water heaters, particularly high efficiency models where flue temperatures

are lower.

• Large amounts of hot water are used in a short time and the refill 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.

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 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 tess active material, and then chlorinating the water heater tank and all

hot water lines. Contact Sears Service for further information concerning this chlorination treatment and an anode replacement

kit #9001453. (For short heaters, use anode replacement kit #9006299.) 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.

Excessive condensation can cause pilot outage due to water running down the flue 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.

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 fired 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 wilt disappear in a short while.

"AIR" In Hot Water Faucets

Explosion Hazard

• Flammable hydrogen gases may be present.

• Keep all ignition sources away from faucet when

turning on hot water.

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 flammable 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 flame near the faucet at the time it is open.

Safety Shut-off and Thermal Switch

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 sulfide gas dissolved in the water. The smell is the

This water heater is designed to automatically shut-off in the event of the following:

1. The pilot flame is extinguished for any reason.

2. The water temperature exceeds 195°F (91°C).

3. Excessive build up of dust on the base ring filter or flame arrestor. See Maintenance of your Water Heater Section.

4. The ignition of flammable vapors.

A thermocouple is used to determine if a pilot flame is present, and will shut off the gas supply to the main burner and the pilot

if the flame is absent. This unit is also equipped with a thermal switch, designed to shut off the gas supply in the event the water heater has been exposed to flammable vapors (e.g., spilled gasoline), poor combustion caused by a blocked vent or insufficient combustion air. If the thermal switch opens:

1. Check the flame-arrestor for signs of high temperature (blue or black discoloration). See Figure 38.

2. If there are signs of high temperature or that the thermal switch has opened, inspect your installation for problems with venting, combustion air supply, or a possible flammable vapor event. (See "Pilot Light Troubleshooting Flowchart" section.) Correct any issues prior to resetting the thermal switch. If you suspect

a flammable vapor incident has occurred, do not use this appliance. Immediately call a qualified technician to inspect the appliance. Water heaters subjected to a flammable vapors ignition will require replacement of the entire water heater.

Read and understand instruction manual and safety messages

before installing, operating or

servicing this water heater.

Failure to follow instructions and

safety messages could result in

death or serious injury.

Instruction Manual must remain

with water heater.

Read this manual first. 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.

3. Reset the thermal switch by depressing the small button in the center of the thermal switch. Follow the Lighting Instructions

found on the front of your water heater. A high temperature limit switch or ECO (Energy Cut Off) in the tank is used to shut off the unit if the water temperature exceeds 195°F (91°C). The ECO is a single-use switch, which, if activated, requires complete replacement of the entire gas control valve/

thermostat. Ifthe ECO should activate, the water heater cannot be used until the gas control valve/thermostat is replaced by a qualified technician. Contact Sears at 1-800-4-MY-HOME (1-800-469-4663) to request service.

Leakage Checkpoints

Never use this water heater unless it is completely filled with water. To prevent damage to the tank, the tank must be filled

with water. Water must flow from the hot water faucet before turning "ON" gas to the water heater.

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 a qualified technician.

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

pipe connections may be leaking.

C. *The anode rod fitting 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 fitting.

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 fitting.

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 floor. This is common at the time of start-up after installation and when incoming

water is cold.

6" MAXIMUM T AIR GAP ._L

f DRAIN VALVE LOCATED BEHIND OUTER DOOR.

FIGURE 43.

Water in the water heater bottom or on the floor 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 fitting. If cotton is wet, follow draining instructions inthe "Draining and Flushing" section and then remove fitting. Put pipe dope or teflon tape on the threads and replace. When you are finished, follow the steps in "Filling

the Water Heater" in the Installation Instructions earlier in this manual.

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

BURNER WILL NOT IGNITE

SMELLY WATER

BURNER FLAME YELLOW- LAZY

PILOT WILL NOT LIGHT OR REMAIN LIT

HIGH OPERATION COSTS

INSUFFICIENT HOT WATER

SLOW HOT WATER

RECOVERY

DRIP FROM RELIEF VALVE

1. Pilot not tit

2. Thermostat set too low

3. No gas

4. Dirt in the gas lines

5. Pilot line clogged

6. Main burner line clogged

7. Non-functioning thermocouple

8. Non-functioning thermostat

9. Heater installed in a confined area

1. Sulfides in the water 1.

1. Insufficient secondary air

2. Low gas pressure

3. Water heater flue or vent system blocked

4. Main burner line clogged

5. Heater installed in a confined area

6. Obstruction in main burner orifice

1. Non-functioning igniter

2. The thermal switch tripped

3. Wire lead connection at thermal switch loose

4. Thermocouple connection loose

5. Air in gas line

6. Low gas pressure

7. No gas

8. Dirt in gas lines

9. Cold drafts

10. Thermostat ECO switch open

11. Pilot line or orifice clogged

12. Non-functioning thermocouple

13. Air for combustion obstructed

14. Flammable vapors incident, FVIR function actuated

15. Base-ring filter obstructed

1. Thermostat set too high

2. Sediment or time in tank

3. Water heater too small for job

4. Wrong piping connections

5. Leaking faucets

6. Gas leaks

7. Wasted hot water

8. Long runs of exposed piping

9. Hot water piping in exposed wall

1. Thermostat set too tow

2. Sediment or time in tank

3. Water heater too small

4. Wrong piping connections

5. Leaking faucets

6. Wasted hot water

7. Long runs of exposed piping

8. Hot water piping in outside wall

9. Low gas pressure

1. Insufficient secondary air

2. Water heater flue or vent

system

blocked

3. Low gas pressure

4. Improper calibration

5. Thermostat set too tow

6. Water heater too small

7. Wrong piping connections

8. Wasted hot water

1. Excessive water pressure

2. Heater stacking

3. Closed water system

1. Light pilot

2. Turn temp. dial to desired temperature

3. Check with gas utility company

4. Notify utility-install trap in gas line

5. Clean, locate source and correct

6. Clean, locate source and correct

7. Replace thermocouple

8. Replace thermostat

9. Provide fresh air ventilation Replace the anode with a special anode

Provide ventilation to water heater

Check with gas utility company

3. Clean, locate source and correct

4. Clean, locate source and correct

5. Proper fresh air ventilation

6. Clean or replace orifice

1. Replace igniter pilot assembly

2. See Pilot Light Troubleshooting Flowchart section

3. Remove and reconnect the wire leads at thermal switch, confirm connections are tight

and not loose

4. Finger tighten; then 1/4 turn with wrench

5. Bleed the air from the gas line

6. Check with gas utility company

7. Check with gas utility company

8. Notify utility-install dirt trap in gas line

9. Locate source and correct

10. Replace thermostat

11. Clean, locate source and correct

12. Replace thermocouple

13. See maintenance section for inspection and cleaning of flame arrester

14. Replace water heater, eliminate flammable vapors source. Contact Sears Service.

15. Inspect and clean base-ring filter. See "External Cleaning & Inspection of the Base-Ring Filter."

1. Set temperature dial to lower setting

2. Drain/flush-provide water treatment if needed

3. Install adequate heater

4. Correct piping-dip tube must be in cold inlet

5. Repair faucets

6. Check with utility-repair at once

7. Advise customer

8. Insulate piping

9. Insulate piping

1. Turn temperature dial to desired setting

2. Drain/flush-provide water treatment if needed

3. Install adequate heater

4. Correct piping-dip tube must be in cold inlet 5 Repair faucets

6. Advise customer

7. Insulate piping

8. Insulate piping

9. Check with gas utility company

1. Provide ventilation to water heater. Check flue way, flue baffle, and burner

2. Clean flue, locate source and correct

3. Check with gas utility company

4. Replace thermostat

5. Turn temperature dial to desired setting

6. Install adequate heater

7. Correct piping-dip tube must be in cold inlet

8. Advise customer

1. Use a pressure reducing valve and relief valve

2. Lower the thermostat setting

3. See "Closed System/Thermal Expansion"

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

THERMOSTAT FAILS TO Thermostat not functioning properly 1. Replace thermostat

SHUT-OFF Improper calibration 2. Replace thermostat COMBUSTION ODORS Insufficient secondary air 1. Provide ventilation to water heater. Check flue

1. way, flue baffle, and burner

Water heater flue or vent system 2. Clean, locate source and correct blocked

Heater installed in a confined area 3. Provide fresh air ventilation

SMOKING AND CARBON FORMATION (SOOTING)

Insufficient secondary air

Low gas pressure

Water heater flue or vent system

1. Provide ventilation to water heater. Check flue way, flue baffle, burner

2. Check with gas utility company

3. Clean, locate source and correct

blocked

Thermostat not functioning properly

Heater installed in a confined area

Burner flame yellow-lazy

CONDENSATION Temperature setting too low 1. Increase the temperature setting. Refer to the

4. Replace thermostat

5. Provide fresh air ventilation

6. See "Burner Flame Yellow-Lazy"

"Condensation" sub-section of this manual's Troubleshooting Guide.

BURNER FLAME FLOATS 1. Orifice too large 1. Replace with correct orifice

AND LIFTS OFF PORTS 2. High gas pressure 2. Check with gas utility company

3. Water heater flue or vent system 3. Clean flue and burner-locate source and correct blocked

4. Cold drafts 4. Locate source and correct

BURNER FLAME TOO HIGH 1. Orifice too large 1. Replace with correct orifice FLAME BURNS AT ORIFICE 1. Thermostat not functioning properly 1. Replace thermostat

2. Low gas pressure 2. Check with gas utility company

PILOT FLAME 1. Pilot line or orifice clogged 1. Clean, locate source and correct

TOO SMALL 2. Low gas pressure 2. Check with gas utility company

Does pilot light go out when i./ ,.in• ICheck Draft. (See "Checking the button s re eased? r NO '_Draft" section of this manual.)

YES

Has the thermal switch |NO Are the wires from the gas

tripped? r

YES

Check for insufficient combust on a r.

Is the base-ring filter clean (i.e., free

of nt, dust, or debts)?

yr=s

Are there openings for make-up air to enter the room?

YES

Are the openings of sufficient size? / • ICorrect size of openings to

See "Combustion Air Supply and Ventilation" r NO _allow sufficient air.

section in this manual for requirements.

YES

NO m_lthe "Combustion Air Supply and Ventilation"

_1 control valve/thermostat firmly

--I connected to the switch?

Are the wir amaged

I and/or frayed.

Replace the gas control va ve/thermostat.

NO _ Inspection & Cleaning of the Base-Ring Filter" section of this manual.

I_llnstall correct size make-up air openings per

--Isection in this manual.

YEes_e_

._IILI Inspect and clean the base-ring filter. Refer to the "External

Im mPIconnectlon/oose, pNOm_

• ISecure connections

mNO m_lland attempt a relight.

N_ i. lls the thermocouple

U . ?

ITighten the connection I 1

yl=s Does the thermocouple pass the test?

YES

Test the thermocouple using the following procedure: Disconnect the thermocouple from the

gas control valve/thermostat. Using a multimeter with alligator clip leads, attach the red lead to the body (copper part) of the thermocouple.

Attach the black lead to the end (silver part) of the thermocouple that connects to the gas control valve/thermostat. Follow the instruction to light

the pilot and watch the voltage readings on the multimeter. After 45 seconds the meter should

read 12 millivolts DC or more.

I_ NO_lReplace the thermocouple n

=NO,,,{handler in the same room

| Is there a furnace/air as

the water heater?

YES

Does the return air duct for the furnace/air handier draw / i,.I Contact a local Heating, Ventilation, Air its air from a separate location than the water heater?

See the "Location Requirements" and "Combustion Air _NO _ Conditioning & Refrigeration authorized Supp y and Vent at on sect ons n th s manua. / "1 service provider.

YES

I Is there proper drafting at the /

_ldraft hood? See "Checking the rNO

--IDraft" section in this manual.

YES

Is the flame-arrestor free from

debris due to excessive lint, dirt, dust or o ?

YES

Check the water heater for a Flammable Vapor (FV) event. Note: it may be necessary to remove the manifold door assembly to visually inspect the water

heater. Reference the "Maintenance of your Water Heater" section of this manua for remove nstructons.

Is the igniter wire insulation burnt or _NO m_l_ls the pilot tube _NO m_,lDoes the flame

shows gns of d sco orat on? / "1 damaged? | --larrest°r show signs

Y S I°r

i _ / Iof discoloration and/

mNO _ manual for information on cleaning the flame-arrestor. I

Check the vent system for restrictions/obstructions and check the vent termination height. Refer to the "Installation Instructions" section of this

manual for specific requirements.

,.I Refer to the "Maintenance of Your Water Heater" section of this I

debris.

Shut-off the gas supply to the water I |

• heater at the manual gas shut-off ylvalve, then contact Sears Service at

l-800-4-MY-HOME (1-800-469-4663).

YtS

FIGURE 44.

POWER MISER TM 9 GAS WATER HEATER

153.339270

153.339492

153.339530

Key No.

1 2

3 4 5 6 7 8 9

10 11 12

13 14 15 16

17 18 19

* Not Shown.

40 Gallon Short (Natural) 40 Gallon Tall (Natural) 50 Gallon Tall (Natural)

Part Description

Anode Rod

Base-Ring Filter Burner Head

Burner Orifice Draft Hood

Drain Valve Gas Control Valve Inlet Tube w/Gasket Inner Door Gasket

Instruction Manual * Mag-Erad *

Manifold Door Assembly - Contains:

Manifold Tube, Gasket, Door, Pilot Tube, Thermocouple, Two-Piece Wire Connector w/Clip, Thermal Switch and PilotAssembly.

Nipple w/Heat Trap Outer Door

Piezo Igniter w/Clip

Pilot Assembly w/Tubing and Fittings

r &P Relief Valve

Temperature Adjustment Knob Thermocouple Two-Piece Wire Connector w/Clip

153.339270

9003721 9006660

9006136 9006698 9006647 9000058

F145-1554

9006803 9006141

315424-000

23600

9006619

9003719 9006649 9006143 9006666

9000728

F145-1280

9000056 9006449

153.339492

9003721 9006616

9006136 9006698 9006647 9000058

F145-1554

9006798 9006141

315424-000

23600

9006620

9003719 9006649 9006143 9006666

9000728

F145-1280

9000056 9006449

153.339530

9001829 9006660

9006136 9006698 9006647 9000058

F145-1554

9006804 9006141

315424-000

23600

9006621

9003719 9006649 9006143 9006666

9000728

F145-1280

9000056 9006449

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 ® (1-800-469-4663). Be sure to provide all pertinent facts when you call or visit.

WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE THIS IS A REPAIR PARTS LIST, NOT A PACKING LIST.

FOLLOWING INFORMATION:

• MODEL NUMBER

• SERIAL NUMBER

• TYPE GAS - NATURAL OR PROPANE (L.R)

• PART DESCRIPTION

Your Home

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1-800-827-6655 (U.S.A.) 1-800-361-6665 (Canada)

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`::_:;:_i:ii_ii_ii_ii_ii_ii_ii_ii_iiii_!!_!_!i_i_i_i_i_ii_ii_ii_i_ii_....... (1-888-784-6427) www.sears.ca .....................................................

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Kenmore 153339530, 153339492, 153339270 Owner’s Manual

Specifications and Main Features

Frequently Asked Questions

User Manual