Kenmore 154330090, 154330080, 154330050, 154330040 Owner’s Manual

Owner's Manual
305 and 505 Models
Direct Vent Tankless Water Heaters
FOR OUTDOOR APPLICATIONS ONLY
MODEL NO.
154.330040 Natural Gas 305 Series
154.330050 Propane Gas 305 Series
154.330080 Natural Gas 505 Series
154.330090 Propane Gas 505 Series
Safety Instructions
Installation
Care and Maintenance
Troubleshooting
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.
INSTALLER:
AFFIX THESE INSTRUCTIONS TO OR ADJACENT TO THE WATER HEATER.
OWNER:
RETAIN THESE INSTRUCTIONS AND WARRANTY FOR FUTURE REFERENCE.
RETAIN THE ORIGINAL RECEIPT AS PROOF
OF PURCHASE.
For Your Safety
AN ODORANT ISADDED TO THE GAS USED BY THIS WATER HEATER.
WARNING: If the information in these
instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
m Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
-- WHAT TO DO IF YOU SMELL GAS:
Do not try to light any appliance.
Do not touch any electrical switch; do
not use any phone in your building.
Immediately call your gas supplier
from a neighbor's phone. Follow the
gas supplier's instructions.
If you cannot reach your gas supplier,
call the fire department.
m lnstallation and service must be
performed by a qualified installer,
service agency or the gas supplier.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A
PRINTED IN THE U.S.A 0409 www.sears.com
PART NO. 316052-001
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
,_ I This is the safety alert symbol, it is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
I
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, 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 inproperty damage.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and how to avoid the risk of injury.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances. WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This appliance can cause low-level exposure to some of the substances included in the Act.
IMPORTANT DEFINITIONS
Qualified Technician: A qualified technician must have ability equivalent to a licensed tradesman in the fields of plumbing, air supply,
venting, and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters. The qualified technician must also have a thorough understanding of this instruction manual.
Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing, air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters. The service agency must also have a thorough understanding of this instruction manual, and be able to perform
repairs strictly in accordance with the service guidelines provided by the manufacturer.
Gas Supplier: The natural gas or propane utility or service who supplies gas for utilization by the gas burning appliances within this application. The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the natural gas meter or propane storage tank of a building. Many gas suppliers also offer service and inspection of appliances within the building.
FIRE AND EXPLOSION HAZARD
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.
© Sears, Roebuck and Co. 2 305 & 505 Outdoor Manual
Can result in serious injury or death
Do not store or use gasoline or other
Safety Behavior and Practices
Keep the area around the appliance clear and free from combustible materials, gasoline, and other flammable vapors and liquids.
Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control
which has been under water.
Safety Features
Overheat: The appliance will automatically shut down when the appliance exceeds a predetermined temperature.
Flame Failure: The appliance will automatically shut down if the burner flame is extinguished.
Power Failure: The appliance will cut off the gas if it loses electrical power.
Any alteration to the appliance or its controls can be dangerous and will void the warranty.
Always check the water temperature before entering a shower or bath.
Power Surge Fuse: A glass fuse protects against overcurrent. If the fuse blows then all indicator
lamps will be off.
Fusible Link: In case the overheat feature does not prevent the temperature from rising then the fusible
link will break shutting off the appliance.
305 & 505 Outdoor Manual 3
Safe Installation, Use and Service ........................... 2
Safety Precautions .................................................... 2
Safety Behaviors and Practices ............................ 3
Safety Features ..................................................... 3
Table of Contents ...................................................... 4
Product Warranty ...................................................... 5
Consumer Responsibilities ...................................... 6
Product Specifications ............................................. 7
Dimensions ................................................................ 8
Technical Data ........................................................... 9
Pressure Drop Curve ............................................ 9
Outlet Flow Data ................................................... 9
Installation Instructions .......................................... 10
General Instructions ............................................ 10
Clearances from Appliance ................................. 10
Attachment of the Water Heater ......................... 11
Electrical Connection .......................................... 11
Gas Supply ............................................................... 11
General Instructions ........................................... 11
Pipe Sizing Procedure- Example ...................... 12
Water Piping ............................................................. 13
General Instructions............................................ 13
Pressure Relief Valve.......................................... 13
Freeze Protection........................................... 13-14
Recommended Piping For Basic Installation ...... 15
Recommended Piping For
Circulation Systems ............................................ 16
Optional Piping For Circulation Systems ............ 17
Venting Instructions ................................................ 18
Additional Clearances - Vent Terminal ................ 19
High Altitude Installations ...................................... 20
Connecting Multiple Water Heaters ....................... 20
Temperature Controller Installation ....................... 21
Location .............................................................. 21
Configurations ..................................................... 21
Cable Lengths And Size ..................................... 21
Mounting The Controller ..................................... 21
Description of Operation ........................................ 22
Operating Instructions ............................................ 22
Sequence of Operation ....................................... 22
Features Available on Temperature Controllers.. 22
Temperature Adjustment ........................................ 23
Temperature Options without a Temperature
Controller ............................................................. 24
Temperature Ranges ........................................... 24
Setting the Controller to Mute ............................. 24
Operating Your Water Heater ................................. 25
Maintenance ............................................................. 26
Cleaning .............................................................. 26
Vent System ........................................................ 26
Motors ................................................................. 26
Temperature Controller ........................................ 26
Lime/Scale Build-up ............................................ 26
Snow Accumulation ............................................. 26
Visual Inspection of Flame .................................. 26
Troubleshooting ................................................. 27-30
Error Code Table ............................................ 27-28
Troubleshooting for Common Issues .................. 29
Accessing Operating Information ........................ 29
Water Quality ....................................................... 29
Flushing the Heat Exchanger
(Error Code: LC or 00) ........................................ 30
Wiring Diagram ........................................................ 31
Service and Adjustment ......................................... 32
Repair Parts List .................................................. 32
Kenmore Tankless Water Heater Accessories .... 32
Notes .................................................................... 33-35
4 305 & 505 Outdoor Manual
12 Year Limited Warranty on Heat Exchanger
For 12 years from the date of purchase, if this water heater is installed and operated in a single family home in accordance with the owner's manual instructions and all local codes, Sears will supply a free heat exchanger f\_r one that develops a leak.
For the second through twelfth year from purchase date, you must pay the labor cost l\_r installation of the heat exchanger
5 Year Limited Warranty on Parts
For 5 years from the date of purchase, if this water heater is installed and operated in a single f:amily home in accordance with the owner's manual instructions and all local codes, if a part f:ails due to material or workmanship,
Sears will supply a free replacement part.
1 Year Exclusive Kenmore Labor Warranty
For the first year from the date of purchase, Sears will, free of charge, supply and install new water heater parts l\_r detective ones or a new heat exchanger l\_r one that develops a leak.
Warranty Service
To obtain warranty sela:ice, call 1-800-4-MY-HOME¢_) (1-800-469-4663). This warranty applies only while this product is in the United States.
For Commercial, institutional, industrial, or residential use by two or more families, the above limited warranty for heat exchanger leaks is effective f\_r five years from date of purchase and the above parts warranty is effective f\_r
three years from the date of purchase. This warranty gives you specific legal rights and you may also have other rights which vary from state to state.
SEARS, ROEBUCK AND CO., Dept.817WA, Hoffman Estates, IL 60179
The price of your water heater does not include a free checkup service call. On water heater installations arranged by Sears, Sears
warrants the installation.
A charge will be made on service calls due to poor or incomplete installation. These include:
a. Adjusting thermostat b. Condensation c. Leaks in pipes or fittings
Master Protection Agreements
Congratulations on making a smart purchase. Your new Kenmore ® product is designed and manufactured for years
of dependable operation. But like all products, it may require preventive maintenance or repair from time to time. That's when
having a Master Protection Agreement can save you money and aggravation.
The Master Protection Agreement also helps extend the life of your new product. Here's what the Agreement* includes:
Parts and labor needed to help keep products operating properly under normal use, not just defects. Our coverage
goes well beyond the product warranty. No deductibles, no
functional failure excluded from coverage-- real protection.
Expert service by a force of more than 10,000 authorized Sears service technicians, which means someone you can trust will be working on your product.
Unlimited service calls and nationwide service, as often as you want us, whenever you want us.
"No-lemon" guarantee - replacement of your covered product if four or more product failures occur within twelve months.
Product replacement if your covered product can't be fixed.
Annual Preventive Maintenance Check at your request - no extra charge.
Fast help by phone - we call it Rapid Resolution - phone support from a Sears representative on all products. Think of
us as a "talking owner's manual." Power surge protection against electrical damage due to
power fluctuations.
305 & 505 Outdoor Manual 5
$250 Food Loss Protection annually for any food spoilage that is the result of mechanical failure of any covered
refrigerator or freezer.
Rental reimbursement if repair of your covered product takes longer than promised.
10% discount off the regular price of any non-covered repair service and related installed parts.
Once you purchase the Agreement, a simple phone call is all that it takes for you to schedule service. You can call anytime day or night,
or schedule a service appointment online. The Master Protection Agreement is a risk free purchase. If you
cancel for any reason during the product warranty period, we will provide a full refund. Or, a prorated refund anytime after the
product warranty period expires. Purchase your Master Protection Agreement today!
Some limitations and exclusions apply. For prices and additional information in the U.S.A. call 1-800-827-6655.
* Coverage in Canada varies on some items. For full details, call Sears Canada at 1-800-361-6665.
Sears Installation Service
For Sears professional installation of home appliances, garage door openers, water heaters, and other major home items, in the U.S.A.
or Canada call 1-800-4-MY-HOME ®.
Thank You for purchasing a Kenmore water heater. Properly installed and maintained, it should give you years of trouble free service. Ifyou should decide that you want the new water heater professionally installed by Sears call
1-800-4-MY-HOME ®. They will arrange for prompt, quality
installation by Sears authorized contractors.
Abbreviations Found In This Instruction Manual:
For California installation, this water heater must be braced, anchored, or strapped to avoid falling or moving during an earthquake. See instructions for correct installation procedures. Instructions may be obtained from California's Office of the State Architect,
1102 Q Street, Suite 5100, Sacramento, CA 95811. Instructions can also be downloaded to your computer at www.dsa.dgs.ca.gov/Pubs.
CSA- Canadian Standards Association
ANSI- American National Standards Institute
NFPA- National Fire Protection Association
ASME - American Society of Mechanical Engineers
GAMA- Gas Appliance Manufacturers Association
ImportantInformationAboutThisWaterHeater:
This manual has been prepared to acquaint you (trained service technician) with the installation, operation, and maintenance of the on-demand water heater and provide important safety information in
these areas. Service to the on-demand system should only be
performed by a trained service technician. READ THE ENTIRE MANUAL BEFOREATTEMPTING 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 Code ANSI Z223.1/NFPA 54. This publication is available
from the Canadian Standards Association, 8501 East Pleasant Valley Rd, Cleveland Ohio 44131, or The
National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.
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.
Excessive Weight Hazard
Usetwoormorepeopletomoveandinstallthewaterheater. Failuretodosocanresultininjury(includingbackinjury).
IMPORTANT: Do not remove any permanent instructions, labels, or the data label from either the outside of the water heater or on the inside of water heater panels.
Remove exterior packaging and place installation components aside.
Inspect all parts for damage prior to installation and start-up.
Completely read all instructions before attempting to assemble and install this product.
After installation, dispose of/recycle all packaging materials.
If after reading this manual you have any questions or
do not understand any portion of the instructions, call the Sears Service Center.
Carefully plan the place where you are going to put the water heater. Correct combustion, vent action, and vent
pipe installation are very important in preventing death from possible carbon monoxide poisoning and fires.
Examine the location to ensure the water heater
complies with the Installation Instructions section in this manual.
6 305 & 505 Outdoor Manual
MODEL
Minimum gas consumption btu/h Maximum gas consumption btu/h
Hot water capacity (Min - Max) * 0.6 - 7.5 GPM 0.6 - 9.4 GPM
Hot water capacity (45°F rise) 6.6 GPM (25.0 L/min) 7.4 GPM (28.0 L/min) Default Temperature Setting (no controller) 1200 F (490 C)
Temperature Controller Default Temperature 1040 F (400 C)
Setting Maximum Temp Setting (Residential) Selectable at 1200 F (490 C) or at 1400 F (600 C) Minimum Temperature Setting 980 F (370 C)
Weight 46 Ib (20.9 kg)
Efficiency Rating 83% Noise Level 49 dB
Electrical Normal 50 W 55 W Consumption Standby 2.0 W
Anti-Frost Protection 100 W
By-Pass Control Fixed Electronic Minimum Gas Natural Gas 5.0 inch W.C.
Supply Pressure Propane 8.0 inch W.C. Maximum Gas Natural Gas 10.5 inch W.C.
Supply Pressure Propane 13.5 inch W.C.
Type of Appliance Direct Vent, Temperature controlled continuous flow gas hot water system
Operation With Or Without Temperature Controls, Mounted In Kitchen, Bathroom, Etc.
Approved Gas Type Natural Gas Or Propane - Ensure Unit Matches Gas Type It's Being Installed On.
Connections Gas Supply: 3/4" Mnpt, Cold Water Inlet: 3/4" Mnpt, Hot Water Outlet: 3/4" Ignition System Direct Electronic Ignition
Electric Connections Appliance: Ac 120 Volts, 60hz. Temperature Control: Dc 12 Volts (Digital) Water Temperature Control Simulation Feedforward And Feedback. Water Supply Pressure Minimum Water Pressure: 20 Psi (Recommended 30-80 Psi For Maximum Performance)
Maximum Water Supply Pressure 150 PSI Temperature Control Cable Non-Polarized Two Core Cable (Minimum 22 Awg)
Star Qualified Yes I Yes
Energy
305 Models
154.330040 & 154.330050
15,000
180,000 Natural Gas 199,000 Natural Gas
180,000 Propane Gas 199,000 Propane Gas
(2.3 - 28.4 L/min) (2.3 - 35.5 L/MIN)
I
505 Models
154.330080 & 154.330090
Minimum flow may vary slightly depending on the temperature setting and the inlet water temperature.
Specifications are subject to change without prior notice. The maximum inlet gas pressure must not exceed the value specified by the manufacturer. The minimum value listed
is for the purpose of input adjustment.
305 & 505 Outdoor Manual 7
+,,el
++D
K
DIM DESCRIPTION 305 Series 505 Series
A Width 14 (355.6) 14 (355.6) B Depth * 9.8 (249.5) 9.8 (249.5) C Height- Unit 22.9 (582) 22.9 (582)
D Height- with brackets 25.4 (646.4) 25.4 (646.4)
E Hot Water Outlet - from wall * 3.8 (96) 3.8 (96) F Hot Water Outlet - from center 4.3 (110) 4.3 (110)
G Cold Water Inlet - from wall * 3.0 (76) 3.0 (76)
H Cold Water Inlet - from center 1.1 (27) 1.1 (27)
I Gas Connection - from wall * 4.1 (104) 4.1 (104)
J Gas Connection - from center 3.5 (89) 3.5 (89)
From base to gas connection 1.6 (40) 1.6 (40)
K From base to cold connection 2.0 (50) 2.0 (50)
From base to hot connection 1.6 (41) 1.6 (41)
* This is the minimum dimension from the wall. The wall bracket is adjustable to allow an additional 1.57 inches (40 mm).
in. (mm) in. (mm)
8 305 & 505 Outdoor Manual
Pressure Drop Curve
45
40
35
3O
o_ 25
v
09 09
o 20
d
-' 15
09 09
n 10
Outlet Flow Data
305 505 i--
/
4 6 8 10 12
Water Flow (gpm)
100 9O 8O
70 m
6O 50
_J
4O
30 2O a_
10
d)
1..
o
E 6.0
c_
o')
v
0
ii
9.0
8.0
7.0
5.0
4.0
a.o
2.0
1.0
0.0
0 25 50 75 100
delta T - Temperature Rise (°F)
125 150
305 & 505 Outdoor Manual 9
Only properly trained and qualified installers should install this appliance. The warranty may be voided due
to improper installation or installation by a non-qualified installer.
It is highly recommended that all installers attend a product knowledge class.
General Instructions
Donot use substitute materials.
Use only parts certified with the appliance.
This appliance must be installed by a state qualified or licensed contractor. It is the responsibility of the person having the water heater installed to ensure the installing contractor has proper licenses and permits for installing water heaters in your location. It is highly recommended that installers attend a product knowledge class to ensure customer satisfaction and warranty coverage. Failure to comply with state and local codes pertaining to water heater installations may void the warranty.
This appliance is not to be installed indoors.
Aqualified installer or service technician should install the appliance, inspect it, and leak test it before use.
The installation must conform with local codes or, in the absence of local codes, with the National Fuel Gas Code,
ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code, CSA B149.1.
The appliance, when installed, must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/ NFPA 70, or the Canadian Electrical Code, CSA C22.1.
The appliance and its appliance main gas valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.5 kPa) (13.84 in W.C.).
The appliance must be isolated from the gas supply piping system by closing itsindividual manual shutoffvalve during any pressure testing of the gas supply piping system at test pressures equal to or greater than 1/2 psi (3.5 kPa) (13.84 in W.C.).
The appliance should be located inan area where water leakage of the unit or connections will not result in damage to the area adjacent to the appliance or to lower
floors of the structure. When such locations cannot be avoided, it is recommended that a suitable metal drain pan,
adequately drained, be installed under the appliance. The pan must not restrict combustion airflow.
The flow of combustion and ventilation air shall not be obstructed.
This appliance isnot suitable for use in an application such as a pool or spa heater that uses chemically treated water. (This appliance is suitable for filling large or whirlpool bath tubs with potable water.)
As water is heated, it expands (thermal expansion). In a dosed system, the volume of water will grow.As the volume of water grows, there will be a corresponding increase in water pressure due to thermal expansion.Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent pressure relief valve operation: water discharged from the valve due to excessive pressure build up. The 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. Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank. NOTE: Reference Figures 4-7 to see ifyour installation recommends the use of a thermal expansion tank.
Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance.
Keep the air intake location free of chemicals such as chlorine or bleach that produce fumes. These fumes can damage components and reduce the life of your appliance.
Clearances from Appliance
to top
tos_
to floor/ground
Figure 1
Table 1: to Combustibles to Non-Combustibles
305/505 305/505
Top of 12 inches 2 inches
Heater (305 mm) (51 mm)
10 305 & 505 Outdoor Manual
Table 1: to Combustibles to Non-Combustibles
Back of
Heater
0 (zero) 0 (zero)
Front of 24 inches 24 inches
Heater (610 mm) (610 mm)
Sides of 6 inches 1/8inches
Heater (152 mm) (3.2 mm)
Floor/ 12 inches 2 inches
Ground (305 mm) (51 mm)
The clearance for servicing is 24 inches in front of the water heater.
Attachment of the Water Heater
I°_° 0 o°° --
wall installation
brackets
Electrical Connection
The water heater must be electrically grounded in
accordance with local codes or in the absence of local codes with the most recent edition of the National
Electrical Code, ANSI/NFPA 70. In Canada, all electrical wiring should be in accordance with local codes and the Canadian Electrical Code, CSA C22.1 Part 1. Do
not rely on the gas or water piping to ground the water
heater. A screw is provided in the junction box for the grounding connection.
The water heater requires 120 VAC, 60 Hz power from
a properly grounded circuit. A disconnect switch must be provided and installed for the incoming 120 VAC power. Itshould be a type that is
suitable for outdoor use. Check the National Electrical
Code, ANSI/NFPA 70 and your local codes for a proper
switch type to use in your area. The wiring diagram is
located on the Technical Sheet attached to the inside of the front cover.
Figure 2
1. Identify the installation location and confirm that the installation will meet all required clearances.
2. Securely attach the water heater to the wall using any of the holes in the wall installation brackets which are
at the top and bottom of the water heater. Ensure that the attachment strength is sufficient to support the weight. Refer to the weight of the water heater in the Specifications section.
General Instructions
A manual gas control valve must be placed in the gas supply line to the water heater. A union can be used on
the connection above the shut off valve for the future servicing or disconnection of the unit.
Check the type of gas and the gas inlet pressure before connecting the water heater. If the water heater is not of the gas type that the building is supplied with, DO NOT connect the water heater. Contact Sears for the proper unit to match the gas type.
Check the gas supply pressure immediately upstream at a location provided by the gas company. Supplied gas pressure must be within the limits shown in the Specifications section.
Before placing the appliance in operation all joints including the heater must be checked for gas tightness by means of leak detector solution, soap and water, or an equivalent nonflammable solution, as applicable. (Since some leak test solutions, including soap and
PCB
i 120vAcco..EcTe,o22,RES
_ liGROUN_
SW{TCH
Figure 3
water, may cause corrosion or stress cracking, the
piping shall be rinsed with water after testing, unless it has been determined that the leak test solution is non-
corrosive.)
Always use approved connectors to connect the unit to the gas line. Always purge the gas line of any debris
before connection to the water heater.
The gas supply line shall be gas tight, sized, and so
installed as to provide a supply of gas sufficient to meet
the maximum demand of the heater and all other gas
consuming appliances at the location without loss of pressure.
Any compound used on the threaded joint of the gas
piping shall be a type which resists the action of liquefied petroleum gas (propane / LPG).
Refer to an approved pipe sizing chart if in doubt about the size of the gas line.
305 & 505 Outdoor Manual 11
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