Use & Care Guide
Model No.
153.576300 30 Gallon Short
153.576310 30 Gallon
153.576320 30 Gallon (L.P.)
153.576400 40 Gallon Short
153.576410 40 Gallon
153.576420 40 Gallon (L.P.)
153.576500 50 Gallon
153.576510 50 Gallon (L.P.)
I<enmore
For potable water heating only.
Not suitable for space heating.
Not for use in mobile homes.
LOW LEAD
CONTENT
L-oa of
INSTALLER:Affix these instructions to or near
the water heater.
OWNER: Retain these instructions for future
reference.
FOR YOUR SAFETY: An odorant is added to
the gas used by this water heater.
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 U OPERAR ESTE CALENTADOR DE AGUA
Sl NO ENTIENDE LAS INSTRUCCIONES. No hacer caso de esta
advertencia podria originar lesiones graves o mortales.
P/N 100263524 (0315)
Sears Brands Management Corporation,
Hoffman Estates, IL 60179 U.S.A.
www.kenmore.com
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.
m lnstallation and service must be
performed by a qualified installer,
service agency or the gas supplier.
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.
n
,_ This is the safety alert symbol, it is used to alert you to potential personal injury hazards. I
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 listof substances known tothe State
of California to cause cancer, birthdefects, or other reproductive harm, and requires businesses towarn 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 inthe act.
This product is certified to comply with a maximum weighted average of 0.25% lead content as required in some areas.
• 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.
Obey all safety messages that follow this symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous situation which, if not avoided, will result
in death or injury.
WARNING indicates a potentially hazardous situation which, if notavoided, could result
in death or injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, could result
in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous
situation which, if not avoided, could result in property damage.
IMPORTANT DEFINITIONS
I
Read and follow water heater warnings and instructions.
© Sears Brands Management Corporation
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 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 Hazard
• Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
• Avoid all ignition sources if you smell 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 instruction manual for installation and service.
Breathing Hazard - Carbon Monoxide Gas
• Install vent system in accordance with
codes,
• Do not operate water heater if flood
damaged.
• High altitude orifice must be installed for
operation above 10,100 feet (3,048m).
• Do not operate if soot is present.
• Do not obstruct water heater air intake
with insulating jacket.
• Do not place chemical vapor emitting
products near water heater.
• Gas and carbon monoxide detectors
are available.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
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 ...................................................................................................................................................... 13-14
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
OPERATINGYOURWATERHEATER...................................................................................................23-26
LightingInstructions...........................................................................................................................................23-24
CheckingtheDraft..................................................................................................................................................25
BurnerFlames........................................................................................................................................................25
EmergencyShutDown...........................................................................................................................................25
WaterTemperatureRegulation..........................................................................................................................25-26
OperatingtheTemperatureControlSystem...........................................................................................................26
SERVICEANDADJUSTMENT...............................................................................................................27-29
VentSystemInspection..........................................................................................................................................27
BurnerInspection....................................................................................................................................................27
BurnerCleaning......................................................................................................................................................27
Housekeeping.........................................................................................................................................................28
AnodeRodInspection............................................................................................................................................28
Temperature-PressureReliefValveOperation.......................................................................................................28
DrainingandFlushing........................................................................................................................................28-29
Service....................................................................................................................................................................29
MAINTENANCEOFYOURWATERHEATER........................................................................................30-33
ReplacementParts.................................................................................................................................................30
ExternalInspection&Cleaningof theBase-RingFilter.........................................................................................30
RemovingtheManifold/BurnerAssembly...............................................................................................................30
RemovingtheBurnerfromtheManifold/BurnerAssembly....................................................................................30
ReplacingtheThermopile..................................................................................................................................30-31
ReplacingthePilot/PilotTubeAssembly...............................................................................................................31
CleaningtheCombustionChamberandFlame-arrestor........................................................................................31
ReplacingtheManifold/BurnerAssembly...............................................................................................................32
PiezoelectricIgniterSystem...................................................................................................................................32
TestingtheIgniterSystem......................................................................................................................................32
RemovingandReplacingtheGasControlValve/Thermostat................................................................................33
FVlRSystemOperationalChecklist.......................................................................................................................33
TROUBLESHOOTINGGUIDE................................................................................................................34-36
StartUpConditions............................................................................................................................................34-35
OperationalConditions......................................................................................................................................35-36
TROUBLESHOOTINGCHART...............................................................................................................37-38
STATUSLIGHTANDDIAGNOSTICTROUBLESHOOTINGCHART.....................................................39-40
PILOTLIGHTTROUBLESHOOTINGFLOWCHART...................................................................................41
PARTSORDERLIST..............................................................................................................................42-43
NOTES....................................................................................................................................................44-47
KENMORE LIMITED WARRANTY
WITH PROOF OF SALE, the following warranty coverage applies
when this water heater is correctly connected, installed, operated
and maintained according to all supplied instructions. In all cases,
replacement units, tanks or parts are warranted only for the unexpired
portion of the warranty period from the original date of sale.
FOR ONE YEAR from the date of sale this water heater is warranted
against defects in material or workmanship. A defective water heater
will receive free repair or replacement at option of seller.
FOR SIX YEARS from the date of sale this water heater is warranted
against leaks in the tank. If a tank leak occurs within the first year, a
new water heater of equal capacity and quality will be supplied and
installed at no charge. If a tank leak occurs after the first year, a new
water heater of equal capacity and quality will be supplied but not
installed at no charge. You are responsible for the labor cost of water
heater installation after the first year from the date of sale.
FOR SIX YEARS from the date of sale all water heater parts are
warranted against defects in material or workmanship. If a part is
defective within the first year, a new part will be supplied and installed
at no charge. If a part is defective after the first year, a new part will
be supplied but not installed at no charge. You are responsible for the
labor cost of part installation after the first year from the date of sale.
For warranty coverage details to obtain free repair or replacement,
visit the web page: www.kenmore.com/warranty
This warranty applies for only two years on the tank and one year on
all parts if this water heater is ever used in a residence of more than
one family or in a commercial, institutional or industrial installation.
This warranty covers ONLY defects in material and workmanship,
and will NOT pay for:
1. Expendable items that can wear out from normal use, including
but not limited to filters, belts, bags or screw-in base light bulbs.
2. A service technician to clean or maintain this appliance, or to
instruct the user in correct appliance installation, operation and
maintenance.
3. Service calls to correct appliance installation not performed by
Sears authorized service agents, or to repair problems with house
fuses, circuit breakers, house wiring, and plumbing or gas supply
systems resulting from such installation.
4,
Damage to or failure of this appliance resulting from installation
not performed by Sears authorized service agents, including
installation that was not in accord with electrical, gas or plumbing
codes.
5. Damage to or failure of this appliance, including discoloration
or surface rust, if it is not correctly operated and maintained
according to all supplied instructions.
6. Damage to or failure of this appliance, including discoloration or
surface rust, resulting from accident, alteration, abuse, misuse or
use for other than its intended purpose.
7. Damage to or failure of this appliance, including discoloration or
surface rust, caused by the use of detergents, cleaners, chemicals
or utensils other than those recommended in all instructions
supplied with the product.
8. Damage to or failure of parts or systems resulting from
unauthorized modifications made to this appliance.
9. Service to an appliance if the model and serial plate is missing,
altered, or cannot easily be determined to have the appropriate
certification logo.
Disclaimer of implied warranties; limitation of remedies
Customer's sole and exclusive remedy under this limited warranty
shall be product repair or replacement as provided herein. Implied
warranties, including warranties of merchantability or fitness for a
particular purpose, are limited to one year on the water heater, and
six years on the tank and parts, or the shortest period allowed by law.
Seller shall not be liable for incidental or consequential damages.
Some states do not allow the exclusion or limitation of incidental
or consequential damages, or limitation on the duration of implied
warranties of merchantability or fitness, so these exclusions or
limitations may not apply to you.
This warranty applies only while this appliance is used 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 Brands Management Corporation,
Hoffman Estates, IL 60179
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 not just for repairing defects, but to help keep
products operating properly under normal use. 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 sup-
port 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.
25% 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 1-844-553-6667..
ThankYouforpurchasingaKenmorewaterheater.Properlyinstalled
andmaintained,itshouldgiveyouyearsoftroublefreeservice.If
youshoulddecidethatyouwantthenewwaterheaterprofessionally
installedbySearscall1-844-553-6667.Theywillarrangeforprompt,
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
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 product is certifield to comply with a maximum weighted average
of 0.25% lead content as required in some areas.
For California installation, this water heater must be braced,
anchored, or strapped to avoid falling or moving during an
earthquake. Correct installation procedure 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.
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: 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.
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 CodeANSl 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.
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.
• 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.
Keep combustibles such as boxes, magazines, clothes, etc.,
away from water heater area.
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
153.576300 30 (114) Natural 35,500 36.34 3 (76) or 4 (102) 20 (508) 46.38 (1178)
153.576310 30 (114) Natural 35,500 36.34 3 (76) or4(102) 18 (457) 58.00 (1473)
153.576320 30 (114) Propane 35,500 36.34 3 (76) or4(102) 18 (457) 58.00 (1473)
(L.P.)
153.576400 40 (151) Natural 40,000 40.94 3 (76) or4(102) 22 (559) 47.75 (1213)
153.576410 40 (151) Natural 35,500 36.34 3(76)or4(102) 20 (508) 58.14 (1477)
153.576420 40 (151) Propane 36,000 36.85 3(76)or4(102) 20 (508) 58.14 (1477)
(L.P.)
153.576500 50 (189) Natural 40,000 40.94 3 (76)or4(102) 21 (533) 57.28 (1455)
153.576510 50 (189) Propane 37,000 37.87 3 (76)or4(102) 21 (533) 57.28 (1455)
(L.P.)
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 THROUGH
LOCAL SEARS STORE
OR SERVICE CENTER.
WATER HEATER INSTALLATION KIT
WITH FLEXIBLE CONNECTORS FOR 3/4"
(19.05 ram) COPPER PLUMBING AND FLEXIBLE
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
METAL DRAIN PANS
AVAILABLE IN 20"
DIAMETER FOR WATER
HEATERS HAVING A
DIAMETER 18" OR LESS
AND IN 24" DIAMETER FOR
WATER HEATERS HAVING A
DIAMETER OF 22" OR LESS.
ADDITIONAL TOOLS NEEDED
WHEN SWEAT SOLDERING
• Tubing Cutters or Hacksaw
• Propane Torch
• Soft Solder
• Solder Flux
• Emery Cloth
• Wire Brushes
TUBING CUTTER
\
1
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
B Draft Hood
C Anode (Not Shown)
D Hot Water Outlet
E Insulation
F Gas Supply Piping
G Manual Gas Shut-off Valve
H Ground Joint Union
I Sediment Trap
* INSTALL IN ACCORDANCE
WITH LOCAL CODES.
* SEDIMENT TRAP AS REQUIRED
BY LOCAL CODES.
TO VENT
TERMINATION ON
ROOF
J Inner Door
K Outer Door
L Union
M Inlet Water Shut-off Valve
N Cold Water Inlet
O Inlet Dip Tube
P Temperature-Pressure Relief Valve
Q Rating Plate
R Flue Baffle
INSTALL THERMAL EXPANSION
TANK IF WATER HEATER IS
INSTALLED IN A
CLOSED WATER SYSTEM
(S) GAS CONTROL VALVE/
THERMOSTAT
S Gas Control Valve/Thermostat
T Drain Valve
U Manifold/Burner Assembly
V Flue
W Metal Drain Pan
X Piezo Igniter
Y Base-Ring Filter
M
B
N
Temperatures shown are approximates and may vary.
(U) MANIFOLD/BURNER ASSEMBLY
\\ p
F
G
DISCHARGE PIPE
H\
(DO NOT CAP OR PLUG.)
i 6"MAXIMUM
AIR GAP
MAIN BURNER
MANIFOLD DOOR 1
//
/PILOT TUBE
f
IGNITER WIRE
MANIFOLD
TUBE
* ALL PIPING MATERIALS TO BE
SUPPLIED BY CUSTOMERS.
FIGURE 1.
10
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 1-844-553-6667.
Installation Checklist
Water Heater Location
Water heater location is important and can affect system
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. Is the 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.
[] Fresh airopenings 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 sediment
trap.
[] 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.
If such a solution is not available, use a mixture of dish
washing soap and water (one part soap to 15 parts water)
or children's soap bubble solution. Bubbles forming indicate
a leak. Correct any leak found.
11
Removing the Old Water Heater (_
®
Q
MANUAL GAS
SHUT-OFFVALVE--......=
GROUND-------_
JOINT
UNION
CHECK WITH
LOCAL UTILITY
FOR MINIMUM HEIGHT
©
Turn "OFF" the gas supply to
the water heater.
3"MINIMUM
SUITABLE "_ f
DRAIN
FIGURE 2.
DISCHARGE PIPE
(DO NOT CAP
OR PLUG)
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. 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.
FIGURE 5.
Disconnect the vent pipe from the draft hood where it connects
to the water heater. In most installations the vent pipe can
be lifted off after any screw or other attached devices are
removed. Dispose of the draft hood. The new water heater
has a draft hood which must be used for proper operation.
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.
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.
©
®
Open a nearby hot water faucet
until the water is no longer hot.
When the water has cooled,
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.
Ir I,7_ I [€-]:1;tl
FIGURE 3.
FIGURE 4.
• Burn hazard
• Hotwater 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.
• Keep hands clear of drain
valve discharge.
FIGURE 7.
12
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 a vertical
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
13
Property Damage Hazard
• All water heaters eventually leak.
• Do not installwithout adequate drainage.
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 the water 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.
NOiAP OR PLUG)
" " I /ARGAP
AT LEAST 2" GREATER THAN THE _x /
DIAMETER OF THE WATER HEATER. PIPED TO AN
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 metal 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 metal 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 metal drain pan that trigger an
alarm or turn off the incoming water to the water heater
when water is detected.
• Sensors mounted in the metal 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.
An_l IATF nRAIN
Insulation Blankets
Insulation blankets available to the general public for external
use on gas water heaters are not necessary with Kenmore
products. The purpose of an insulation blanket is to reduce the
standby heat 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.
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.
I
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
,_IL 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 wilt 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 surfaces 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.
14
-_ II _VENT
,_ BACK SIDES
TOP --
VIEW l
FIGURE 10.
S°ESlll"IH
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 hotwater faucet. Allow water to run until
a constant flow is obtained. This will let air out of the water
heater and the piping.
Check allwater 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 inthe 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
Check with local
minimum height
15
Manual Gas
Shut-off Valve'-....._
Joint
Ground
Union
utility for
Drip Leg
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 the maximum
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 operating
pressure does not exceed 13" water column (3.237kPa).
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.
• If the gas lines are to be tested at apressure 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 will 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 Gas CapacityTable
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.
Nominal Iron Pipe Length of Pipe, Feet
Size, in. l(k 20 31) 40 30 60 70 8Q 90 ]0Q 125 ]5(Z
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 latest edition ofthe "National Fuel Gas Code", ANSi Z223.1.
Total pipe length, 80 feet = 3/4" IPS required.
16
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 as sulfur,
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
17
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
I
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 1 sq. in, per 4000 BTUH Figure 14
Vertical Ducts 1sq. in, per 4000 BTUH Figure 15
Horizontal Ducts 1sq. 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.
18
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)
_,P"-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, in the 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 walt 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,
19
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 in the 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. I(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
(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. IMPORTANT: 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
TYPE B DOUBLE
WALLVENTPIPE
**MAINTAIN
CLEARANCE
SUPPORT
*MAINTAIN
CLEARANCE
t
3 FT. MINtMU! WITHIN 10 FT, HORIZONTALLY
2 FT. MINIMUM ABOVE ANY OBJECT
WITHIN 10FT. HORIZONTALLY
DO NOT EXTEND
OF CHIMNEY
CONNECTOR
MAINTAIN
CLEARANCE*
SUPPORT
STRAP
t
3FT-MINIMUM I
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
separation, and maintain clearances to combustible materials
VERTICAL GAS VENT SYSTEM WITH
TYPE B DOUBLE WALL VENT PIPE.
FIGURE 20.
_LISTED VENT CAP
_MAINTAIN
SPECIFIED
CLEARANCE
MAINTAIN MANUFACTURER'S
SPECIFIED MINIMUM CLEARANCE
SUPPORT
STRAP
*MAINTAIN
CLEARANCE
±
T
t
VENT
CONNECTOR
SLOPE
I_IN. PBR 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 Fuel Gas 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 ins_uctions provided
with each chimney support assembly. Minimum airspace clearance to
combustible materialsshould be maintained as marked on the chimney
sections.
2O
CONNECTOR
UNUSED CHIMNEY
_P---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 should 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.
3,
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.
4,
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."
5,
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.
6,
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."
7,
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
Hot Water
l"minimum_Hq-r_
Metal t _r
Drain Pan
1 314" depth maximum
thermal xpansion tank
'_ L_Pressure reducin_ ply
Cold Water
Inlet Valve valve with bypass
3erature and
Pressure Relief Valve
Discharge Pipe
'---Do Not Cap or Plug
Drain line 3/4"
_/.ID minimum
........ 0
u___[ IMassachussetts:
_= I Install a vacuum relief I
6" Maximum
"_ i--Air Gap
V _ lin cold water line per I
_Xgloor Drain Isect_°n19 MGL 142. I
Water
to Fixtures
FIGURE 22.
Mixed
To Fixtures
Hot Water
Outlet
Mixing Valve
(Set To 120°F)
Follow The Mixing Valve
Manufacturer's Instructions
Inlet
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.
• It is 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.
21
Closed System/Thermal Expansion
Property Damage Hazard
• All water 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 wilt increase. As the volume of
water increases, 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.
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. In cold climates, it is
recommended that the discharge line be terminated at an
adequate drain inside 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.
1"minimum
Metal 1
Drain Pan--_
Explosion Hazard
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.
• Do not plug, block, or cap the
discharge line.
• Failure to follow this warning
can result in excessive tank
pressure, serious injury or
death.
\Temperature and Pressure Relief (T&P)
Valve (Optional Top T&P Relief
Valve Not shown)
'--Discharge Pipe
,_ Do Not Cap or Plug
Drain line 3/4"
r_ -_ IDminimum
Drain._,'v"
FIGURE 24.
22
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 34.) 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 type of 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
Lighting the Pilot:
Read and follow the lighting instructions on the water heater's
label.
1. Turn the Control Knob to Pilot. Press the Knob in fully and
hold it in.
2. (The knob will travel in about ¼ inch if it is set to Pilot
correctly.)
3. Click the Igniter button continuously for up to 90 seconds
or until the Status Light begins to blink for 90 seconds. If
the Status Light does not begin to blink after 90 seconds,
STOP. Wait 10 minutes before attempting to relight the
Pilot. Repeat these steps 2-3 times if necessary.
The circuitry on this gas valve requires that your wait 10
minutes between lighting attempts. If the Status Light
blinks, release the Control Knob and set temperature to
desired setting ("Hot" is approx 120°F).
If the Status Light Does Not Blink:
1. Wait 10 minutes before another lighting attempt.
2. If the Status Light did not blink, repeat the lighting
procedure following the lighting instructions on the water
heater's label. Remove the outer door. The Control Knob
must be set to Pilot and held in continuously while clicking
the igniter button (about once per second for up to 90
seconds. To observe the Pilot, remove the outer door and
look through the view port (sight glass).
3. Continue clicking the Igniter button (for up to 90 seconds)
until Pilot lights.
4. Once the Pilot is lit, continue to hold the Control Knob in
until the Status Light begins to blink.
5. Release Control Knob and set Knob to desired
temperature setting ("Hot" is approx 120°F).
6. Replace outer door.
If the Pilot Does Not Light:
1. Wait 10 minutes before another lighting attempt. If the
pilot does not light, the Igniter may not be sparking or the
unit may not be getting gas (or on a new installation, there
may still be air in the gas line). Each time the Igniter
button is clicked, you should be able to see the spark by
looking through the sight glass (you may have to darken
the room lights to see the spark). You do not have to push
the Control Knob in to check the Igniter button. Simply
Explosion Hazard
Replace view port if glass is missing
or damaged.
Failure to do so can result in death,
explosion or fire.
look through the sight glass while clicking the Igniter
button and look for a spark. If you can't see a spark when
the Igniter button is clicked, check the wiring connections
from the Igniter button and make sure they are tight..
2. If you see the Igniter spark, try relighting the pilot by
following the instructions on the water heater's label.
Insure that the gas supply is tuned on. There may be
air in the gas line, and several lighting attempts may be
needed to completely fill the line with gas and successfully
light the pilot.
If the Pilot Lights but the Status Light Does Not Blink:
1. If the pilot lights, continue to hold the Control Knob in until
the Status Light blinks. If the pilot is lit and remains lit for
90 seconds and the Status Light still does not blink, the
thermopile connections may be loose, the thermal switch
may need to be reset or the thermopile may be defective.
Remove outer door.2,
3.
Press reset button on thermal switch referencing Figure
34.
4. If switch clicks, it may have tripped. Check area for
flammable vapors before trying to light Pilot. Do not light
the Pilot if flammable vapors are present. Check flame
arrestor for signs of discoloration (which could be caused
by flammable vapors). If the flame arrestor is discolored,
do not attempt to relight the Pilot. Have the water heater
inspected by a qualified service technician.
5. Check wiring connections from the thermopile and the
thermal switch to the gas valve (see Figure 33). Ensure
that all wiring connections are tight.
6. Replace outer door.
7. Wait 10 minutes and try to light Pilot according to the
instructions on the water heater's label.
8. While clicking the Igniter button continuously, the Control
Knob must be set to Pilot and held in until the Status Light
blinks. Once the Status light blinks, release the control
knob and set knob to desired temperature setting ("HOT"
is approx 120°F).
For additional help visit www.Lightmywaterheater.com.
23
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-eIectric
spark gas ignition system. Do not open the inner door
of the appliance and try to light the pilot by hand.
B. BEFORE LIGHTING smell all around the appliance
area for gas. Be sure to smell next to the floor 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.
• 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 supptier's instructions.
• If you cannot reach your gas supplier, call the fire
department.
C.Use only your hand to push in or turn the gas control
knob. Never use tools. Ifthe knob will not push in or turn
by hand, do not try to repair it, call a qualified service
technician. Force or attempted repair may result in a fire
or explosion.
D. Do not use this appliance if any part has been
underwater. 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!
E. 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.
ias Control/Temperature Knob FIGURE 'A'
GASCONTROL_ Low
i O Light _oT,_
FIGURE 'B'
120°F c
Mark_
LO_
"PILOT" POSITION
FIGURE 'C'
_THERMOPtLE
CONTROl_KNOB
6.
STOP! It is imperative that you read all safety warnings
before lighting the pilot.
2.
Turn the gas control/temperature knob counterclock-
wise") to the "OFF" setting.
3.
Wait ten (10) minutes to clear out any gas. If you then
smell gas, STOP! Follow" B" in the safety information
above on this label. If you do not smell gas, go to the
next step.
4.
Turn the gas controI/temperature knob clockwise L*to
"PILOT". See Figure 'B'.
5.
Press the gas control/temperature knob all the way in
and hold it in. The knob should travel in about 1/4 inch
if it is set to "PILOT" correctly.
While holdinq the qas control/temperature knob in, click
the iqniter button continuously (about once a second) for
up to 90 seconds or until Status Liqht beqins to blink.
When the status light starts blinking, release the gas
control/temperature knob. Set the gas control/
temperature knob to the desired setting. See Figure 'C'.
If the status light does not start blinking within 90
seconds, repeat steps 2 through 5 up to THREE (3)
times, waiting 10 minutes between lighting attempts.
The circuitry in this advanced qas valve requires that
you wait 10 minutes between Iiqhtinq attempts.
If the status light turns a solid color, release the gas
control/temperature knob and repeat steps 2 through 5
(waiting 10 minutes before attempting to relight the
pilot).
If the status light does not start blinking after three
lighting attempts, turn the gas control/temperature knob
to "OFF" and call a qualified service technician or your
gas supplier.
1. Turn the gas control/temperature knob counterclockwise _pto the "OFF" setting. Thestatus lightwill stop blinking
and stay on for a short time after thewater heater isturned off. See Figure'A'.
24
Checking the Draft Water Temperature Regulation
Burn Hazard
Do not touch vent.
Doing so can result in burns.
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 25). 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
"" /J"L/
MATOH_
FIGURE 25.
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 26. 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.
IF! I=7_,I :4-'II
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 taw 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 27. Using the lowest
hot water temperature that meets your needs wilt 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: A water temperature range of 120°F-140°F (49°C-60°C)
is recommended by most dishwasher manufacturers.
The thermostat is adjusted to the pilot position when it is shipped
from the factory. Water temperature can be regulated by moving
the temperature dial to the preferred setting. The preferred
starting point is 120°F at the "HOT" setting. Align the knob with
the desired water temperature as shown in Figure 19A. There is
a hot water scald potential if the thermostat is set too high.
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.
FIGURE 26.
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.
NOTE: Temperatures shown on the gas control valve/
thermostat are approximates. The actual temperature of the
heated water may vary.
Should overheating occur or the gas supply fail to shut off, turn
off the manual gas control valve to the appliance.
25
iiGas Control/Temperature Knob 160°F
138°F
147°F
Status
_, _-_;i _Light
!_J Ill 120°F
____," Mark V_
Temperatures shown are approximates and may vary.
IMPORTANT: Adjusting the thermostat past the 120°F bar on
the temperature dial wilt increase the risk of scald injury, Hot
water can produce first degree burns within:
110
116
116
122
131
140
149
154
(U.S.GovemmentMemorandum,C.RS.C., PeterL Armstrong,Sept. 15,1978)
(normal shower temp.)
(pain threshold)
35 minutes
1 minute
5 seconds
2 seconds
1 second
instantaneous
45 minutes
5 minutes
25 seconds
5 seconds
2 seconds
1 second
FIGURE 27.
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.
Water Temperature Adjustment
The water temperature setting can be adjusted from 55°F to
155°F. Turn the Gas Control/Temperature Knob to the desired
setting/temperature.
NOTE: Some models are certified for 180°F outlet
temperatures. See the Data Plate on the front of the water
heater for the maximum outlet temperature.
NOTE: The temperatures indicated are approximates. The
actual temperature of the heated water may vary.
Operating Modes and Settings
• Standard Mode - The controller adjusts the water heater to
maintain the temperature set by the user.
• The Vacation Setting (VAC) sets the controller at
approximately 55°F. This setting is recommended when
the water heater is not in use for a long period of time. This
effectively turns the controller temperature setting down to
a temperature that prevents the water in the water heater
from freezing while still conserving energy.
Status Light Code
Normal Flashes:
• 0 Flashes Indicates Control Off/Pilot Out.
• 1 Flash Indicates Normal Operation.
• A continuous Light indicates the gas control
valve/thermostat is shutting down.
Diagnostic Flashes: If the water heater is not working look
for the following diagnostic flashes after lighting the pilot.
For more details see the "Status Light and Diagnostic Code
Troubleshooting Chart."
2 Flashes
4 Flashes
5 Flashes
7 Flashes
8 Flashes
Indicates Thermopite Voltage Low
Indicates Overheat Failure
Indicates Sensor Failure
Indicates Electronic Control Failure
See "Status Light and Diagnostic Code
Troubleshooting Chart."
Operating the Temperature Control System
List of status codes are shown
at top of gas control valve/thermostat.
C
PILOT
FIGURE 28.
26
Vent System Inspection
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.
Carbon Monoxide and Fire Hazard
• Flue gases may escape if vent pipe
is not connected.
• Be alert for obstructed, sooted or
deteriorated vent system to avoid
serious injury or death.
• Do not store corrosive chemicals
in vicinity of water heater.
• Chemical corrosion of flue and vent
system can cause serious injury or
death
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
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.
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
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
water heater.
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.
Burner Inspection
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! It must be replaced!
Ifinspection of the burner shows that cleaning is required, turn the
gas control knob counterclockwise ( _ ) to the "OFF" position.
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.
27
Housekeeping
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.
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. The anode
rod should be inspected after a maximum of three years and
annually thereafter until the condition of the anode rod dictates
its replacement. NOTE: artificially softened water requires the
anode rod to be inspected annually.
Temperature-Pressure Relief Valve Operation
The temperature-pressure relief valve must be manually
operated at least once a year.
V: ,7:1 d
• Burn hazard
• Hot water discharge.
• Keep clear of relief valve
discharge outlet.
AT LEASTANNUALLY, A VISUAL INSPECTION SHOULD BE
MA DE OF THE BA SE-RING FILTER AND FLA ME ARRES TER.
CLEAN IF LINT ACCUMULATIONS ARE NOTICED.
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.
Exposed Pitted Exposed
Support Anode Support
Wire Rod Wire
FIGURE 30.
Anode deterioration depends on water conductivity, not
necessarily water condition. A corroded or pitted anode rod
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 31.
TEMPERATURE-PRESSURE
RELIEFVALVE
DISCHARGE PIPE
FIGURE 31.
If after manually operating the valve, it fails to completely reset
and continues to release water, immediately close the manual
gas shut-off valve and the cold water inlet valve and call the
Sears Service Center.
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
• Hotwaterdischarge burn hazard.
• Keep clear of relief valve discharge
unit.
Temperature limiting valves are
available.
Read instruction manual for safe
tem perature setting.
It is recommended that the tank be drained and flushed
every 6 months to remove sediment which may build up during
28
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. Open a nearby hot water faucet until the water is no longer
hot.
3. Close the cold water inlet valve.
4. Connect a hose to the drain valve and terminate it to an
adequate drain or external to the building.
5. Open the water heater drain valve and allow all of 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 in this manual.
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:
1-844-553-6667.
29
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 1-844-553-6667. 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 itto 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: Ifunable to inspect or clean the base-ring filter, follow
the "Cleaning the Combustion Chamber and Flame-arrestor"
instructions.
4. After the base-ring filter has been cleaned, follow the
Lighting Instructions to return the water heater to service.
Removing the Manifold/Burner Assembly
1,
Turn the gas control/temperature knob to the "OFF" position.
2.
Before performing any maintenance, it is important to 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).
3,
With the unit shut-off allow sufficient time for the water heater to
cool before performing any maintenance.
J
._. _ : [_] whree
!gniter I; _ _ i'.I..(R.ight
Leaa n T_ _# ,'_' bide)
Wire L[ /_ _ _k_/
_JPilot / Red Wire
Igniter-_i Tube _ (Left Side)
Wire ',,i Mdeifold Tube
FIGURE 32.
4,
Remove the outer door.
5.
Disconnect the pilot tube (7/16" wrench), the igniter
wire from the igniter lead wire, and manifold tube (3/4"
wrench) at the gas control valve/thermostat. (Figure 33).
NOTE: L.R Gas systems use reverse (left-hand) threads on
the manifold tube.
GAS CONTROLVALVE/THERMOSTAT
GAS CONTROL/
TEMPERATURE
PIEZOIGNITER BUTTON
PILOT TUBE _ -MANIFOLD TUBE
VIEWPORT
OUTER DOOR] -MANIFOLD DOOR
NOT SHOWN ]
MANIFOLD SCREW (2) --
/
MANIFOLD COMPONENT BLOCK
THERMOPILE AND
.SWITCH WIRE
CONNECTIONS
i
- THERMAL SWITCH
FIGURE 33.
6. Use needle nose pliers to disconnect the white (-) thermopile
wire from the gas control valve/thermostat (Figure 32). Then
disconnect both red thermal switch wires from the thermal
switch on the old manifold door. (Figure 33).
7. Grasp the manifold tube and push down slightly to free the
manifold tube and pilot tube.
8. Remove the screws (1/4" nut driver) securing the manifold
door to the combustion chamber. Carefully remove the
manifold door assembly from the combustion chamber. BE
SURE NOT TO DAMAGE ANY 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.
IMPORTANT: DO NOT remove the orifice.
2. Check the burner to see if it is dirty or clogged. The burner
may be cleaned with soap and hot water (Figure 34).
(BOTTOM VIEW)
SCREW_
BURNER
(BOTTOM VIEW)
FIGURE 34.
Replacing the Pilot/Thermopile Assembly
1. Follow the "Removing the Burner/Manifold Assembly"
instructions on the following pages to remove the manifold
door assembly.
2. Natural Gas/LP Models - Remove the burner to access the
pitot/thermopite assembly. Remove and keep the screws
securing the burner to the manifold (Figure 35).
3. Remove the screw securing the pilot/thermopile assembly to
the pilot bracket and keep for reuse later.
4. Lift the retainer clip straight up from the back of the
manifold component block (using a flat-blade screwdriver),
then remove the manifold component block from the
manifold door (Figure 35). IMPORTANT: Be careful not to
bend or alter the position of the pilot tube, it will be used
3O
as a bending template for the new pilot assembly. Note
the placement/order of the wires in the manifold component
block.
PILOT / THERMOPILE
CONNECTORS
_ _ i _ BURNER AND OTHER
IGNITER _ii_ i \ "X_'.pS_, FOR CLARITY.
! _ i \ _Q\\ FITTINGS NOT SHOW
_¢// ASSEMBLY SCREW
REDW,RESTO
BMLAoNIFOLDCOMPONEb T _/.._ ; I THERMAL SWITCH (2)
MANIFOLD DOOR _
FIGURE 35.
8,
Lift the pitot/thermopite assembly (including the igniter wire)
from the manifold assembly.
6.
NOTE: Read this step carefully before proceeding. Use the
old pilot/pilot tube assembly as a guide, bend the new pilot
tube to match the old one. Make only the bends closest to
the pilot before going to the next step.
8. Using the pilot/thermopite assembly screw removed earlier
reattach the new pitot/thermopite assembly. Reattach the
burner to the manifold using the screws removed earlier.
NOTE: make sure the burner scoop is oriented to the pilot
side of the manifold tube (Figure 34).
9. Reinstall the manifold component block in the manifold door
(Figure 37).
10. Carefully bend the new pilot tube to match the bend of the
manifold tube. NOTE: When bending DO NOT crimp or
crease the pilot tube.
11. Before you proceed to the next step, install the new brass
ferrule nut in the gas control valve/thermostat's pilot tube
opening. HAND TIGHT ONLY.
12. Follow the "Replacing the Burner/Manifold Assembly"
instructions to replace the manifold door.
Cleaning the Combustion Chamber and
Flame-arrestor
1,
Follow procedure outlined in "Removing the Manifold/
Burner Assembly."
2.
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.
DOOR GASKET
FLAMEARRESTOR
COMBUSTION CHAMBER
IGNITER
CONNECTOR
ASSEMBLY
CONNECTORS
(RED WIRES)
FOR CLARITY, PILOT
TUBE NOT SHOWN .
FIGURE 36.
7,
Route the new pilot tube, new igniter wire and new
thermopite wire through the opening in the manifold door
(Figure 37).
RED (+) THERMAL SWITCH WIRE
_" CONNECTS TO THE GAS CONTROL
VALVE\THERMOSTAT.
(-)
CONNECTS TO THE GAS
MANIFOLD
COMPONENT
BLOCK _
\
__ WHITE THERMOPILE WIRE
, CONNECTI_T_, , MANIFOLD DOOR
CONTROL VALVE\TH ERMOSTAT.
RED THERMAL SWITCH WIRE
BASE-RING
FILTER
FIGURE 38.
3,
Reassemble by following the procedure under "Replacing
the Manifold/Burner Assembly."
@
IGNITER WIRE PASSES
THROUGH CENTER OF
MANIFOLD COMPONENT
BLOCK(SMALLESTHOLE)
_ hJ H PASS THROUGH TOP
, "-_-__J COMPONENT BLOCK
PILOT TUBE PASSES _-
THROUGH BOTTOM HOLE
OF MANIFOLD COMPONENT
BLOCK (LARGEST HOLE)
HOLE OF THE MANIFOLD
FIGURE 37.
31
Replacing the Manifold/Burner Assembly 10
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 manifold component block if missing
or removed.
Follow the lighting instructions on the front of the water
heater. With the main burner lit, check for leaks at
the manifold and pilot connections by brushing on an
approved noncorrosive leak detection solution, or a
mixture of hand dish washing soap and water (one part
soap to 15 parts water) or childrens soap bubble solution.
Bubbles forming indicate a leak. Correct any leak found.
Verify proper operation and then replace the outer door.
FLAMEARRESTOR BRACKET
TIP
FIGURE 39.
• Replace door gasket if damaged.
• Failure to follow these instructions can result
in death, explosion, or fire.
1. Check the door gasket for damage or imbedded debris
prior to installation.
2. Inspect the view port for damage and replace as required.
3. 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).
4. Inspect the door gasket and make sure there is no
fiberglass insulation between the gasket and the
combustion chamber.
5. Tighten the two screws which secure the burner/
manifold assembly to the combustion chamber.
There should be no space between the gasket part
of the manifold door and combustion chamber.
IMPORTANT: Do not operate the water heater if the door
gasket does not create a seal between the manifold door
and the combustion chamber.
6. Reconnect the manifold tube (3/4" wrench) and pilot tube
(7/16" wrench) to the gas control valve/thermostat. Do
not cross-thread or apply any thread sealant to the fittings.
IMPORTANT: If you were supplied with a new ferrule nut in
a parts kit, follow these steps:
1.) Install the ferrule nut into the gas valve at the pilot tube
location, hand tight only. 2.) Insert the pilot tube into the
ferrule nut until the tube bottoms out, then tighten the nut
with a 7/16" wrench until the crimp connection seals to the
pilot tube. Continue to tighten until the nut is tight in the gas
valve.
NOTE: L.R Gas systems use reverse (left-hand) threads on
the manifold tube.
7. Connect the white (-) thermopile wire to the gas control
valve/thermostat. Then connect the red thermal switch
wires to the thermal switch on the on the manifold door.
(Figure 37).
8. Reconnect the igniter wire (Figure 32).
9. Turn on the gas supply to the water heater at the manual gas
shut-off valve (Figure 11).
CLOSE-UP INSIDE VIEW OF
THE COMBUSTION CHAMBER.
MANIFOLD TUBE
TIP
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. (See Figure 42).
)lie
Pilot/
3lie
Bracket
Electrode
Igniter Button
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.
32
Removing and Replacing the Gas Control Valve/Thermostat
IMPORTANT: The gas control valve/thermostat is a standard
valve with wire leads that connect to a thermal switch.
Removing the Gas Control Valve/Thermostat:
1. Turn the gas control/temperature knob to the "OFF"
position See the "Lighting Instructions" on the front of the
water heater or in this manual.
2. Turn off the gas at the manual shut-off valve on the gas
supply pipe (Figure 11).
3. Drain the water heater. Refer to the section of "Draining and
Flushing" and follow the procedure.
4. Disconnect the igniter wire from the igniter lead wire. Use
needle nose pliers to disconnect the red (+) and white (-)
thermopile wires. Disconnect pilot tube (7/16" wrench) and
manifold tube (3/4" wrench) at the gas control valve/thermostat
(Figure 32). NOTE: L.P.Gas systems use reverse (left-hand)
threads on the manifold tube.
5. Refer to "Gas Piping" (Figure 11)and disconnect the ground
joint union in the gas piping. Disconnect the remaining pipe
from the gas control valve/thermostat.
6. To remove the gas control valve/thermostat, thread a
section of 4" gas pipe into the inlet and use it to turn the
gas control valve/thermostat (counterclockwise.) Do not
use pipe wrench or equivalent to grip body. Damage may
result, causing leaks. Do not insert any sharp objects into
the inlet or outlet connections. Damage to the gas control
valve/thermostat may result.
Gas Control Valve/Thermostat:
To replace the gas control valve/thermostat, reassemble in
reverse order. When replacing the gas control valve/thermostat,
thread a section of 4" gas pipe into the inlet and use it to turn
the gas control valve/thermostat (clockwise.) DO NOT OVER
TIGHTEN, damage may result.
• Be sure to use approved Teflon@ tape or pipe joint
compound on the gas piping connections and fitting on the
back of the gas control valve that screws into tank.
• Be sure to remove the pilot ferrule nut from the new gas
control valve/thermostat.
• Turn the gas supply on and check for leaks. Test the water
heater by brushing on an approved noncorrosive leak
detection solution or a mixture of hand dish washing soap
and water (one part soap to 15 parts water) or chitdrens
soap bubble solution. Bubbles forming indicate a leak.
Correct any leak found.
• Check the operation of the burner by following the
"Lighting Instructions" on the front of the water heater or
in this manual. With the burner tit, check the gas control
valve thermostat supply line, manifold tube and pilot tube
connections for leaks. Use an approved noncorrosive leak
detection solution or a mixture of hand dish washing soap
and water (one part soap to 15 parts water) or chitdrens
soap bubble solution. Bubbles forming indicate a leak.
Correct any leak found.
• Be sure tank is completely filled with water before lighting
and activating the water heater. Follow the "Lighting
Instructions" on the front of the water heater or in this
manual.
• If additional information is required, Contact Sears at 1-844-
553-6667.
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. Manifold component block properly installed.
5. No leaks at pilot and manifold connection.
6. Manifold door screws securely tightened.
7. Depress the button on the thermal switch.
33
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
_LD_ COLD WATER PRESSURE
INLET FITTING REDUCING
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.
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. See
Figure 42.
Table 5: Thermal Ex
Tank
Model Capacity
Number In Gallons
153.331020 2
153.331050 5
)ansion Tank Specifications
Dimensions
in Inches
Diameter Len£1th
8 (203 mm) 12-3/4 (323 mm)
11 (279 mm) 14-3/4 (375 mm)
On Tank
3/4" Male
3/4" Male
Pipe
Fitting
Table 6: Expansion Tank Sizing Chart
Inlet*
Water
Pressure
Expansion
Tank
Capacity
Needed
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 2 2 5 5
2 2 2 5 5
2 2 5 5 5
2 2 5 5 5
2 5 5 5 5
(2)
I I
WATER HEATER
COLD WATER
INLET FITTING
HOT COLD
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
(1) BY-PASS
VALVE WITH
/I' t
WATER SHUT-OFF
FIGURE 42.
Strange Sounds
Possible noises due to expansion and contraction of some
metal parts during periods of heat-up and cool-down do not
represent harmful or dangerous conditions.
Condensation causes sizzling and popping within the burner
area during heating and cooling periods and should be
considered normal. See "Condensation" section.
Draft Hood Operation
Check draft hood operation by performing a worst case
depressurization of the building. With all doors and windows
closed, and with all air handling equipment and exhaust fans
operating such as furnaces, clothes dryers, range hoods and
bathroom fans, a match 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.
34
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.
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.
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
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.
"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
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 thermopite is used to determine if a pilot flame is present, and
wilt 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 insufficient combustion air or
improper venting. 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. Ifyou suspect
a flammable vapor incident has occurred, do not use this
35
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 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. The gas control valve\
thermostat includes a temperature limiting ECO (Energy Cut
Off) system that will shut off the water heater if the water
temperature exceeds 189°F (87°C) for 155°F models or 199°F
(93°C) for 180°F models. See the data plate for your model.
Should the water temperature get too high, the Diagnostic
Status Light will flash a code (4 flashes) indicating an over-
temperature condition and the main burner wilt be shut off.
If a high-temperature condition occurs, turn the main gas
supply OFF and have the water heater repaired by a qualified
service technician. Contact Sears at 1-844-553-6667 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.
H,
Combustion products contain water vapor which can
condense on the cooler surfaces of the tank. Droplets form
and drip onto the burner or run on the floor. This is common
at the time of start-up after installation and when incoming
water is cold.
6" MAXIMUM
AIR GAP
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 in the "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.
FIGURE 43.
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.
36
PROBLEM CORRECTIVE ACTION
BURNER WILL NOT IGNITE
1. Pilot not tit
2. Thermostat set too tow
3. Main burner line clogged
4. Non-functioning thermostat
POSSIBLE CAUSE(S)
1. Light pilot
2. Turn temp. dial to desired temperature
3. Clean, locate source and correct
4. Check status light codes and reference
the "Status Light and Diagnostic Code
5. Base-Ring Filter blocked with tint/dust
Troubleshooting Chart"
5. Clean filter, See "External Cleaning &
6. Heater installed in a confined area
7. FVIR Flame Arrestor blocked with lint/
dust.
Inspection of the Base-Ring Filter" section.
6. Provide fresh air ventilation
7. Clean filter, See "Cleaning the Combustion
Chamber and Flame-Arrestor" section.
SMELLY WATER 1. Sulfides in the water 1. Replace the anode with a special anode (See
Smelly Odor section)
BURNER FLAME YELLOW-
LAZY
PILOT WILL NOT LIGHT OR
REMAIN LIT
1. Insufficient combustion air
2. Low gas pressure
3. Water heater flue or vent system
blocked
4. Main burner line clogged
5. Base-Ring Filter blocked with tint/dust
6. Heater installed in a confined area
7. FVIR Flame Arrestor blocked with lint/
dust.
8. Obstruction in main burner orifice
1. Non-functioning igniter
2. The thermal switch tripped
3. Wire lead connection at thermal switch
loose
1. Provide ventilation to water heater
2. Check with gas utility company
3. Clean, locate source and correct
4. Clean, locate source and correct
5. Clean filter, See "External Cleaning &
Inspection of the Base-Ring Filter" section.
6. Proper fresh air ventilation
7. Clean filter, See "Cleaning the Combustion
Chamber and Flame-Arrestor" section.
8. Clean or replace orifice
1. Replace igniter pilot assembly
2. See Pilot LightTroubleshooting Flowchart section
3. Remove and reconnect the wire leads at
thermal switch, confirm connections are tight
and not loose
4. Thermopite connection loose
5. Air in gas line
6. Low gas pressure
7. No gas
8. Dirt in gas lines
9. Cold drafts
10. Thermostat temperature limit
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
was
10. Replace thermostat
exceeded, status light will blink 4
flashes
11.
Pilot line or orifice clogged
12.
Non-functioning thermopite
13.
Air for combustion obstructed
11. Clean, locate source and correct
12. Replace thermopite
13. See maintenance section for inspection and
cleaning of flame arrester
14.
FVIR Flame Arrestor blocked with lint/
dust
15.
Flammable vapors incident, FVIR
function actuated
16.
Base-Ring Filter blocked with lint/dust
14. Clean filter, See "Cleaning the Combustion
Chamber and Flame-Arrestor" section.
15. Replace water heater, eliminate flammable
vapors source. Contact Sears Service.
16. Clean filter, See "External Cleaning &
Inspection of the Base-Ring Filter" section.
HIGH OPERATION COSTS
INSUFFICIENT HOT WATER
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. 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
37
PROBLEM
SLOW HOT WATER
RECOVERY
POSSIBLE CAUSE(S)
1,
insufficient combustion air
2.
Water heater flue or vent system
1. Provide ventilation to water heater. Check flue
way, flue baffle, and burner
2. Clean flue, locate source and correct
CORRECTIVE ACTION
blocked
3.
Low gas pressure
4.
Improper calibration
5.
Base-Ring Filter blocked with lint/dust
3. Check with gas utility company
4. Replace thermostat
5. Clean filter, See "External Cleaning &
Inspection of the Base-Ring Filter" section.
6.
FVIR Flame Arrestor blocked with lint/ 6.
dust.
Clean filter, See "Cleaning the Combustion
Chamber and Flame-Arrestor" section.
DRIP FROM RELIEF VALVE 1. Excessive waterpressure 1. Use a pressure reducing valve and relief
2. Heater stacking valve
3. Closed water system 2. Lower the thermostat setting
3. See "Closed System/Thermal Expansion"
THERMOSTAT FAILS TO Thermostat not functioning properly 1. Replace thermostat
SHUT-OFF Improper calibration 2. Replace thermostat
COMBUSTION ODORS Insufficient combustion air 1.
1,
2.
1.
Provide ventilation to water heater. Check flue
way, flue baffle, and burner
2.
Water heater flue or vent system
2,
Clean, locate source and correct
blocked
Heater installed in a confined area
3.
4.
Base-Ring Filter blocked with lint/dust
3. Provide fresh air ventilation
4. Clean filter, See "External Cleaning &
Inspection of the Base-Ring Filter" section.
FVIR Flame Arrestor blocked with lint/
FORMATION (SOOTING)
5.
dust.
1. Insufficient combustion airSMOKING AND CARBON
2. Low gas pressure
3. Water heater flue or vent system
blocked
4. Thermostat not functioning properly
5. Heater installed in a confined area
6. Burner flame yellow-lazy
7. Base-Ring Filter blocked with lint/dust
8. FVIR Flame Arrestor blocked with lint/ 8.
dust.
5. Clean filter, See "Cleaning the Combustion
Chamber and Flame-Arrestor" section.
1. Provide ventilation to water heater. Check flue
way, flue baffle, burner
2. Check with gas utility company
3. Clean, locate source and correct
4. Replace thermostat
5. Provide fresh air ventilation
6. See "Burner Flame Yellow-Lazy"
7. Clean filter, See "External Cleaning &
Inspection of the Base-Ring Filter" section.
Clean filter, See "Cleaning the Combustion
Chamber and Flame-Arrestor" section.
CONDENSATION 1. Temperature setting too low 1. Increase the temperature setting. Refer to the
"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
38
LED STATUS
0 FLASHES (LED NOT LIT)
Pilot light is not lit or Thermopite
PROBLEM
has not yet reached normal
operating temperature.
STATUS LIGHT ON (SOLID)
Pilot light was recently extinguished
and the Thermopile is cooling
down.
1 FLASH (EVERY 3 SECONDS) Normal operation.
2 FLASHES Pilot is tit but the Thermopite is
not producing the required output
voltage.
CORRECTIVE ACTION
Turn Gas Control Valve/Thermostat knob to OFF.
Wait 10 minutes, then attempt to relight Pilot by
following the lighting instructions on the water
heater's label. Until the Thermopite reaches its
normal operating temperature, the Status Light wilt
not blink, even if the Pilot is tit. It may take up to 90
seconds of continuous Pilot operation before the
Thermopite reaches normal operating temperature
and the Status Light starts to blink.
If the Status Light does not blink after three lighting
attempts, check to make sure unit is getting gas.
Remove the outer door. Press reset button. Replace
outer door. Turn Gas Control Valve/Thermostat
knob to OFF. Wait 10 minutes, then attempt to light
Pilot by following the lighting instructions on the
water heater's label. Look through the sight glass
for the Pilot flame. If Pilot is not visible, the spark
igniter or gas supply to the Pilot should be checked.
If the Pilot is visible and the Status Light does not
blink after 90 seconds of continuous Pilot operation,
the Pilot flame may not be heating the Thermopile
sufficiently (weak Pilot) or the Thermopite may be
defective, or wiring connectors may be loose.
Replace outer door and verify proper operation after
servicing
NOTE: If the water heater has been operating
but has stopped and will not re-light, check the
flame-arrestor for signs of high temperature (blue
or black) discoloration indicating a flammable
vapor incident. 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 wilt require replacement of the entire
water heater. NOTE: Check the gas control valve/
thermostat and thermal switch for any loose wiring
connections, correct immediately.
Turn Gas Control Valve/Thermostat knob to OFF.
Wait 10 minutes for the Thermopite to cool, then
attempt to relight Pilot by following the lighting
instructions on the water heater's label. NOTE: This
gas control valve/thermostat has built-in circuitry
that requires waiting 10 minutes between lighting
attempts. Until the Thermopile reaches its normal
operating temperature, the Status Light wilt not
blink, even if the Pilot is tit. It may take up to 90
seconds of continuous Pilot operation before the
Thermopite reaches normal operating temperature
and the Status Light starts to blink.
No corrective action necessary.
Turn Gas Control Valve/Thermostat knob to OFF.
The Thermopite is probably defective, but loose
wiring connections or a weak Pilot flame can also
cause this symptom.
39
LED STATUS PROBLEM CORRECTIVE ACTION
4 FLASHES The Gas Control Valve's
temperature sensor has detected
that the water temperature was too
high. Once this condition occurs,
Relight pliot and verify 4 flashes. If 4 flashes are
observed turn Gas Control Valve/Thermostat knob
to OFF. Turn Main Gas Supply OFF. Replace the
Gas Control Valve/Thermostat.
the Main Burner and the Pilot Light
wilt be shut off. Since the Pilot light
will be off, should this condition
occur, this Flash Code will only
be displayed immediately after
the Pilot has been relit. Turn Gas
Control Valve/Thermostat knob to
OFF.
5 FLASHES The temperature sensor Turn Gas Control Valve/Thermostat knob to OFF.
(thermistor) is defective. Replace the Gas Control Valve/Thermostat.
7 FLASHES Gas Control Valve failure. Turn Gas Control Valve/Thermostat knob to OFF.
Turn Main Gas Supply OFF. Replace the Gas
Control Valve/Thermostat.
8 FLASHES
This condition only appears if the
gas control/temperature knob has
been turned off and the thermopite
continued to produce electric
power. This condition can occur
if the thermopile does not cool
down as quickly as expected when
the unit is shut off. This condition
can also occur if the gas control/
temperature knob has been turned
off and the pilot continues to
operate because the pilot valve is
stuck in the open position.
Make sure that the gas control valve/thermostat
knob is set to OFF. Wait one minute. Remove
the outer door. Look through the sight glass for
a pilot flame. If a pilot flame is observed with the
gas control valve/thermostat knob set to the OFF
position, the pilot valve is stuck open. Turn the main
gas supply OFF. Replace the gas control valve/
thermostat. For instructions, see "Removing and
Replacing the Gas Control Valve/Thermostat."
If the pilot flame is not observed when the gas
control valve/thermostat knob is set to the OFF
position, wait 10 minutes for the thermopite to cool,
then attempt to relight the pilot by following the
lighting instructions on the water heater's label. If
this condition returns, replace the gas control valve/
thermostat. See "Removing and Replacing the Gas
Control Valve/Thermostat" for instructions.
4O
Section A: Pilot light will not light (new installation).
Is the manual gas shut-off valve, / klTurn the manual gas shut-off valve to I
located in the supply line to the I_ NO _ the on position and follow the lighting
water heater, in the on position? 1 " l instructions on the front of the water heater.
YES
÷
Have you bled all the air / . IWhile repeatedly depressing the igniter
from the pilot tube and ImNOml_lbutton, push in and hold the gas control/
I gas supply line? l --Itemperature knob until the pilot is lit and
. n maintains a stable flame (status light will
YES blink). It may take up to 90 seconds of
spark?IStheNoigniterproducing a pYES _
pilot operation before status light blinks.
Once status light blinks, release the gas
control/temperature knob.!
",!,"
Follow the "Testing the Igniter ISet to I
[System sect on n th s manua. I thermostat desired temperature.
Section B: Pilot light repeatedly goes out.
Section C: Pilot light wilt not remain lit.
lCheck for insufficient combustionair. I
I
Are the combustion air supply and ventilation openings
of sufficient size? See "Combustion Air Supply and
IVentilation" section in this manual for requirements.
Complete this section after completing Section B.
Y_S
YES
÷
Does the return air duct for the furnace/ / 1
air handler/air conditioner draw its air from
the same location as the water heater? NO
See the "Location Requirements" section
and the Combust on A r Supp y sect on.
YES
Contact a Heating and Air
Conditioning service technician
to relocate the return air duct.
The water heater's pilot can be
extinguished when the heating
or cooling system is turned on
if the return air duct is in the
same location.
h,. Correct size of
i NOip, openings to allow
Is there proper I
drafting at the 1
drafthood? See I'NO1
"Checking the Draft" l |
section in this manual.| i
surf cent a r.
I
i ,/---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.
Check the Base-Ring Filter and I Refer to the "Maintenance of
Flame Arrestor for blockage due i L.I your Water Heater" section of this
to lint or dust. Are both the Air Im NPl1 manual for information on cleaning
I Filter and Flame Arrestor clean? / Ithe flame arrestor and burner.
YES
Does the flame
arrestor show signs
of discoloration?
YES YES NO
Shut-off the gas supply to the water heater at the I
manual gas shut-off valve, and contact Sears Service
at 1-844-553-6667.
NO . . .
Reassemble the heater, press the thermal
switch, and attempt to return the heater to
service. Does the pilot remain lit?
I
,[
I Set to desired temperature. I
Does the diagnostic status light on the I
i Igas control valve/thermostat give
.o
ego to section C. I Assemby nstructons n the manua. I
La two flash error code?
Refer to the "Replacing the Pilot I
If you are still having difficulty keeping the pilot I
lit, Contact Sears at 1-844-553-6667 to request I
service.
1
1
NOTE: If you are still experiencing difficulties
after following the steps in sections A, B, and C,
please contact Sears Service at 1-800-MY-HOME
(1-800-4694663).
THERMAL SWITCH LOCATION
I
I
I
!
I Reassemble and restore to service. I
FIGURE 44.
41
KENMORE 6 YEAR GAS WATER HEATER
153.576300 30 Gallon Short (Natural)
153.576310 30 Gallon Tall (Natural)
153.576400 40 Gallon Short (Natural)
153.576410 40-35.5 Gallon Tall (Natural)
153.576500 50 Gallon Tall (Natural)
Key No. Part Description
1 Anode Rod
2 Base-Ring Filter
3 Burner Head
4 Burner Orifice
5 Draft Hood
6 Drain Valve
7 Gas Control Valve/Thermostat
8 Inlet Tube w/Nipple
9 Inner Door Gasket *
10 Instruction Manual *
11 Manifold Door Assembly Con-
tains: Manifold Tube, Gasket, Door, Pilot
Tube, Thermopile, Manifold Component
Block, Thermal Switch, Burner Head,
Burner Orifice and PilotAssembly.
12 Nipple w/Heat Trap
13 Outer Door
14 Pilot Assembly w/Tubing and
Fittings
15 T & P Relief Valve
16 Thermopile
17 Manifold Component Block w/Clip
• Not Shown.
153.576300 153.576310 153.576400 153.576410 153.576500
9003944 9003944 9003944 9003944 9003944
9006616 9006616 9006616 9006616 9006660
9006136 9006136 9006136 9006136 9006136
9006699 9006699 9006699 9006699 9006699
9006647 9006647 9006647 9006647 9006647
9008958 9008958 9008958 9008958 9008958
9008987 9008987 9008987 9008987 9008987
9006809 9003473 9006692 9003473 9006653
9006141 9006141 9006141 9006141 9006141
100263524 100263524 100263524 100263524 100263524
9008965 9008967 9008963 9008980 9008971
9003719 9003719 9003719 9003719 9000415
9006648 9006648 9006648 9006648 9006648
9007876 9007876 9007876 9007876 9007876
9000071 9000071 9000071 9000071 9000071
9007872 9007872 9007872 9007872 9007872
9006449 9006449 9006449 9006449 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 1-844-553-6667. Be sure to provide
all pertinent facts when you call or visit.
Model Numbers
• MODEL NUMBER
• SERIAL NUMBER
• TYPE GAS - NATURAL OR PROPANE (L.R)
• PART DESCRIPTION
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE
FOLLOWING INFORMATION:
THIS IS A REPAIR PARTS LIST, NOT A PACKING LIST.
42
KENMORE 6 YEAR GAS WATER HEATER
........... i
153.576320
153.576420
153.576510
Key No. Part Description
1 Anode Rod
2 Base-Ring Filter
3 Burner Head
4 Burner Orifice
5 Draft Hood
6 Drain Valve
7 Gas Control Valve/Thermostat
8 Inlet Tube w/Gasket
9 Inner Door Gasket *
10 Instruction Manual *
11 Manifold Door Assembly Con-
tains: Manifold Tube, Gasket, Door, Pilot
Tube, Thermopile, Manifold Component
Block, Thermal Switch, Bumer Head,
Bumer Onfice and PilotAssembly.
12 Nipple w/Heat Trap
13 Outer Door
14 Pilot Assembly w/Tubing and
Fittings
15 T & P Relief Valve
16 Thermopile
17 Manifold Component Block w/Clip
• Not Shown.
30 Gallon Tall (LP)
40 Gallon Tall (LP)
50 Gallon Tall (LP)
153.576320
9003944
9006616
9006651
186056-052
9006647
9008958
9007890
9003473
9006141
100263524
9007877
9000415 9000415 9000415
9006648 9006648 9006648
9007877 9007877 9007877
9000071 9000071 9000071
9007872 9007872 9007872
9006449 9006449 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 1-844-553-6667. Be sure to provide
all pertinent facts when you call or visit.
i
Model Numbers
153.576420
9003944
9006616
9006603
9006700
9006647
9008958
9007890
9003473
9006141
100263524
9009066
153.576510
9003944
9006660
9006603
9006700
9006647
9008958
9007890
9006653
9006141
100263524
9007911
• MODEL NUMBER
• SERIAL NUMBER
• TYPE GAS - NATURAL OR PROPANE (L.R)
• PART DESCRIPTION
WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE
FOLLOWING INFORMATION:
THIS IS A REPAIR PARTS LIST, NOT A PACKING LIST.
43
I(enmore
For Sears Home Services in-home repair
of all I<enmore major appliances.
For the replacement parts, accessories and
Use & Care Guides that you need to do-it-yourself.
For professional installation of major home appliances
and items like air conditioners and water heaters.
1-844-553-6667
www.kenmore.com
In Canada 1-800-469-4663
www.sears.ca
Call anytime for the location of your nearest
Sears Parts & Repair Service Center
1-800-488-1222 (U.S.A.) 1-800-469-4663 (Canada)
To purchase a protection agreement on a serviceable product:
1-800-827-6655 (U.S.A.) 1-800-361-6665 (Canada)
Para pedir servicio de reparaci6n
a domicilio, y ordenar piezas:
1-888-SU-HOGAR ®
(1-888-784-6427)
www.kenmore.com
Au Canada pour service en fran_:ais:
1-800-LE-FOYER MC
(1-800-533-6937)
www.sea rs.ca
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