Kenmore 305 User Manual
Owner’s Manual
Kenmore
305 and 505 Models
Direct Vent Tankless Water Heaters
FOR OUTDOOR APPLICATIONS ONLY
MODEL NO.
154.330040
154.330050
154.330080
154.330090
Natural Gas
Propane Gas
Natural Gas
Propane Gas
305 Series
305 Series
505 Series
505 Series
Safety Instructions
Installation
Operation
Care and Maintenance
Troubleshooting
ENEROYSTAR
AWARNING
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 IS ADDED 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.
— 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.
— Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
PRINTED IN THE U.S.A 0409
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A
www.sears.com
PART NO. 316052-001
SAFE INSTALLATION, USE AND SERVICE
Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of
a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning
of each safety message is understood by you and others who install, use or service this water heater.
This is the safety aiert symboi. it is used to aiert you to potentiai personai injury hazards.
A
Obey aii safety messages that foiiow this symboi to avoid possibie injury or death.
.DANGER
^WARNING
^CAUTION
CAUTION
Aii safety messages wiii generaiiy teii you about the type of hazard, what can happen if you do not foiiow 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.
• 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.
DANGER indicates an imminentiy hazardous situation which, if not avoided, wiii
resuit in death or injury.
WARNiNG indicates a potentiaiiy hazardous situation which, if not avoided, couid resuit
in death or injury.
CAUTiON indicates a potentiaiiy hazardous situation which, if not avoided, couid resuit
in minor or moderate injury.
CAUTiON used without the safety aiert symboi indicates a potentiaiiy hazardous
situation which, if not avoided, couid resuit in property damage.
IMPORTANT DEFINITIONS
© Sears, Roebuck and Co.
2
SAFETY PRECAUTIONS
AWARNING
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
A
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.
305 & 505 Outdoor Manual
Safety Behavior and Practices
A WARNING
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
underwater. 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
TABLE OF CONTENTS
Safe Installation, Use and Service..................................2
Safety Precautions..........................................................2
Safety Behaviors and Practices
Safety Features........................................................3
Table of Contents............................................................4
Product Warranty
Consumer Responsibilities
Product Specifications
Dimensions
Technical Data
Pressure Drop Curve
Outlet Flow Data.......................................................9
Installation Instructions
General Instructions
Clearances from Appliance....................................10
Attachment of the Water Heater
Electrical Connection.............................................11
Gas Supply
General Instructions
Pipe Sizing Procedure - Example
Water Piping..................................................................13
General Instructions
Pressure Relief Valve
Freeze Protection
Recommended Piping For Basic Installation
Recommended Piping For
Circulation Systems
Optional Piping For Circulation Systems
Venting Instructions.......................................................18
Additional Clearances - Vent Terminal
High Altitude Installations
Connecting Multiple Water Heaters
Temperature Controller Installation
Location
Configurations........................................................21
Cable Lengths And Size
Mounting The Controller
Description of Operation
Operating Instructions...................................................22
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10
10
11
11
11
12
13
13
15
16
17
19
20
20
21
21
21
21
22
Sequence of Operation
3
5
6
7
8
9
9
Features Available on Temperature Controllers..22
Temperature Adjustment
Temperature Options without a Temperature
Controller
Temperature Ranges..............................................24
Setting the Controller to Mute.................................24
Operating Your Water Heater
Maintenance..................................................................26
Cleaning..................................................................26
Vent System
Motors.....................................................................26
Temperature Controller
Lime/Scale Build-up
Snow Accumulation................................................26
Visual Inspection of Flame
Troubleshooting
Error Code Table...............................................27-28
Troubleshooting for Common Issues
Accessing Operating Information
Water Quality..........................................................29
Flushing the Heat Exchanger
(Error Code: LC or 00)............................................30
Wiring Diagram
Service and Adjustment
Repair Parts List.....................................................32
Kenmore Tankless Water Heater Accessories.... 32
Notes........................................................................33-35
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27-30
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26
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29
31
32
305 & 505 Outdoor Manual
PRODUCT WARRANTY
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 for one
that develops a leak.
For the second through tW'clfth year from purchase date, you must pay the labor cost for 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 family home in
accordance with the owner’s manual instructions and all local codes, if a part fails 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 for
defective ones or a new heat exchanger for one that develops a leak.
Warranty Service
To obtain warranty seiv’ice, call l-800-4-MY-HOME(iD (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 for five years from date of purchase and the above parts warranty is effective for
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
• $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®.
CUSTOMER RESPONSIBILITIES
Thank You for purchasing a Kenmore water heater.
Properly installed and maintained, it should give you years
of trouble free service. If you should decide that you want
the new water heater professionally installed by Sears call
1-800-4-MY-HOME®. They will arrange for prompt, quality
installation by Sears authorized contractors.
Abbreviations Found In This Instruction Manual:
• CSA - Canadian Standards Association
• ANSI - American National Standards Institute
• NFPA- National Fire Protection Association
• ASME - American Society of Mechanical Engineers
• GAMA - Gas Appliance Manufacturers Association
Important Information About This Water Heater:
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 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 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.
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.
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.
A
WARNING
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,
iabels, 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.
305 & 505 Outdoor Manual
PRODUCT SPECIFICATIONS
MODEL
Minimum gas consumption btu/h 15,000
Maximum gas consumption btu/h 180.000 Natural Gas
Hot water capacity (Min - Max) * 0.6 - 7.5 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) 120° F (49° C)
Temperature Controller Default Temperature
Setting
Maximum Temp Setting (Residential) Selectable at 120° F (49° C) or at 140° F (60° C)
Minimum Temperature Setting 98° F (37° C)
Weight 46 lb (20.9 kg)
Efficiency Rating 83%
Noise Level 49 dB
Electrical
Consumption
By-Pass Control Fixed Electronic
Minimum Gas
Supply Pressure
Maximum Gas
Supply Pressure
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)
Energy Star Qualified Yes Yes
Normal 50 W 55 W
Standby 2.0 W
Anti-Frost Protection 100 W
Natural Gas 5.0 inch W.C.
Propane 8.0 inch W.C.
Natural Gas 10.5 inch W.C.
Propane 13.5 inch W.C.
305 Models 505 Models
154.330040 & 154.330050 154.330080 & 154.330090
199.000 Natural Gas
180.000 Propane Gas
(2.3 - 28.4 L/min)
104° F (40° C)
199.000 Propane Gas
0.6-9.4 GPM
(2.3 - 35.5 L/MIN)
* 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
DIMENSIONS
DIM DESCRIPTION
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).
305 Series
in. (mm)
505 Series
in. (mm)
305 & 505 Outdoor Manual
Pressure Drop Curve
V)
w
w
o
_l
CD
13
CD
CD
CD
TECHNICAL DATA
100
90
80
70
60
50
40
30
20
10
0
T3
CD
CD
JZ
CD
CD
o
_l
CD
U.
13
CO
CO
0
Outlet Flow Data
delta T - Temperature Rise (°F)
305 & 505 Outdoor Manual
INSTALLATION INSTRUCTIONS
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.
General Instructions
A WARNING
Do not 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.
A qualified 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/NFPA54, or the Natural Gas and Propane
Installation Code, CSAB149.1.
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/
NFPA70, or the Canadian Electrical Code, CSAC22.1.
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 its individual manual shutoff valve 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 in an 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 air flow.
The flow of combustion and ventilation air shall not be
obstructed.
This appliance is not 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.)
It is highly recommended that all installers attend a
product knowledge class.
• As water is heated, it expands (thermal expansion). In a
closed system, the volume of water will grow. As the volume
of water grows, there will be a corresponding increase
in water pressure due to thermal expansion.Thermal
expansion can cause premature tank failure (leakage). This
type of failure is not covered under the limited warranty.
Thermal expansion can also cause intermittent 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 if your 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
Table 1 :
Top of
Heater
to Combustibles to Non-Combustibles
305/505 305/505
12 inches
(305 mm)
2 inches
(51 mm)
10
305 & 505 Outdoor Manual
Table 1:
Back of
Heater
Front of 24 inches 24 inches
Heater (610 mm) (610 mm)
Sides of 6 inches 1/8 inches
Heater (152 mm) (3.2 mm)
Floor/ 12 inches 2 inches
Ground (305 mm) (51 mm)
to Combustibles to Non-Combustibles
0 (zero) 0 (zero)
The clearance for servicing is 24 inches in front of the
water heater.
Attachment of the Water Heater
wail 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, CSAC22.1 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. It should 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.
-(II)-
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.
GAS SUPPLY
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
(Black-Hot/White-Neutrai)
GROUND
TERMINAL
' OFF lx
TT
XDI^CONNECT
swifcH
.......
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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