Sears 153.326762 40 GAL, 153.326663 50 GAL, 153.326563 55 GAL, 153.326763 40 GAL, 153.326463 40 GAL User Manual

...

Owner’s Manual

POWER MISER™ 6

ELECTRIC

WATER HEATER

FOR POTABLE WATER HEATING ONLY.

NOT SUITABLE FOR SPACE HEATING.

MODEL NO.

153.326362 30 Gal.

153.326363 30 Gal.

153.326462 40 Gal.

153.326463 40 Gal.

153.326562 55 Gal.

153.326563 55 Gal.

153.326662 50 Gal. Medium

153.326663 50 Gal. Medium

153.326762 40 Gal. Medium

153.326763 40 Gal. Medium

153.326862 50 Gal. Short

153.326863 50 Gal. Short

GAMA certification applies to all residential electric water heaters with capacities of 20 to 120 Gallons. Input rating of 12kW or less.

SAVE THIS MANUAL FOR FUTURE REFERENCE.

• Safety Instructions

• Installation

• Operation

• Care and Maintenance

• Troubleshooting

• Parts List

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

PRINTED 0707 185796-000

www.sears.com

SAFE INSTALLATION, USE AND SERVICE

Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater.

Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use or service this water heater.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates an imminently

DANGER

WARNING

hazardous situation which, if not avoided, could result in death or injury.

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

CAUTION indicates a potentially

CAUTION

All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and how to avoid the risk of injury.

The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.

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 listed, including formaldehyde.

hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, could result in property damage.

IMPORTANT DEFINITIONS

• Sears Service Center: The Sears Service Center has the ability equivalent to a licensed tradesman in the fields of plumbing and

electrical work including a thorough understanding of the requirements of the National Electrical Code as it relates to the installation of electric water heaters. The Sears Service Center also has a thorough understanding of this instruction manual, and is able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer.

GENERAL SAFETY

TABLE OF CONTENTS

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

GENERAL SAFETY ............................................................................................................................................................................. 3

TABLE OF CONTENTS ....................................................................................................................................................................... 4

INTRODUCTION ................................................................................................................................................................................ 5

PRODUCT SPECIFICATIONS ............................................................................................................................................................ 5

MATERIALS AND BASIC TOOLS NEEDED ........................................................................................................................................ 6

Materials Needed ........................................................................................................................................................................ 6

Basic Tools .................................................................................................................................................................................. 6

Additional Tools Needed When Sweat Soldering ....................................................................................................................... 6

INSTALLATION INSTRUCTIONS ...................................................................................................................................................7-16

Removing the Old Water Heater .............................................................................................................................................. 7,8

Facts to Consider About the Location ......................................................................................................................................... 8

Insulation Blankets ...................................................................................................................................................................... 8

Facts to Consider About the Convertible Lower Element ........................................................................................................ 8,9

Water Piping ........................................................................................................................................................................... 9,10

T & P Valve and Pipe Insulation ................................................................................................................................................. 10

Temperature-Pressure Relief Valve ..................................................................................................................................... 10,11

Filling the Water Heater ............................................................................................................................................................. 11

Converting the Lower Element ............................................................................................................................................. 11-14

Wiring .................................................................................................................................................................................... 14,15

Wiring Diagrams ....................................................................................................................................................................... 16

SERVICE AND ADJUSTMENT .................................................................................................................................................... 17-22

Temperature Regulation ........................................................................................................................................................... 17

Thermostats .............................................................................................................................................................................. 1 7

Temperature Settings ................................................................................................................................................................ 17

Upper and Lower Thermostat Adjustments......................................................................................................................... 17,18

Anode Rod Inspection ............................................................................................................................................................... 18

Temperature-Pressure Relief Valve Operation ......................................................................................................................... 18

Draining ................................................................................................................................................................................ 18,19

Thermostat Removal/Replacement .......................................................................................................................................... 19

Element Cleaning/Replacement ......................................................................................................................................... 19-22

Drain Valve Washer Replacement ............................................................................................................................................ 22

Service ....................................................................................................................................................................................... 22

TROUBLESHOOTING GUIDE .................................................................................................................................................... 23-25

Start Up Conditions ................................................................................................................................................................... 23

Thermal Expansion ............................................................................................................................................................ 23

Strange Sounds ................................................................................................................................................................. 23

Operational Conditions ....................................................................................................................................................... 23-25

Smelly Water ..................................................................................................................................................................23,24

“Air” in Hot Water Faucets .................................................................................................................................................. 24

Rumbling Noise .................................................................................................................................................................. 24

High Temperature Shut Off System .................................................................................................................................... 24

Not Enough or No Hot Water ......................................................................................................................................... 24,25

Water Is Too Hot .................................................................................................................................................................. 2 5

Leakage Checkpoints .......................................................................................................................................................... 25,26

REPAIR PARTS LIST .................................................................................................................................................................. 27-29

NOTES ......................................................................................................................................................................................... 30,31

WARRANTY ...................................................................................................................................................................................... 32

INTRODUCTION

Thank You for purchasing a Sears water heater. Properly

installed and maintained, it should give you years of trouble free service. It is strongly suggested that this new water heater be professionally installed, contact the local Sears Service Center or any Sears store. They will arrange for prompt, quality installation by Sears authorized contractors.

Abbreviations Found In This Instruction Manual:

UL – Underwriters Laboratories Inc.

NEC – National Electrical Code

ANSI – American National Standards Institute

• Read the “General Safety” section, page 3 of this manual first and then the entire manual carefully. If you don’t follow the safety rules, the water heater will not operate properly. It could cause DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE.

This manual contains instructions for the installation, operation, and maintenance of this electric water heater. It also contains warnings throughout 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 THIS ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER.

• The installation must conform with the instructions in this manual; electric company rules; and Local Codes, or in the absence of Local Codes, with the current edition of the NEC - National Electrical Code, NFPA 70. This publication is available from your local government or public library or electric company or by writing Underwriters Laboratories Inc., 333 Pfingsten Road, Northbrook, IL 60062.

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

• Carefully plan the place where you are going to put the water heater. Correct electrical wiring and connections are very important in preventing death from possible electrical shock and fires.

Examine the location to ensure the water heater complies with the “Facts to Consider About the Location” section.

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 the California Office of the State Architect, 400 P Street, Sacramento, CA 95814.

Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248-CMR 2.00; State Plumbing Code and 248-CMR 5.00. In the Commonwealth of Massachusetts, this product must be installed by a licensed plumber or gasfitter.

PRODUCT SPECIFICATIONS

TANK

MODEL GALS.PER HOUR WIRE SIZE* BREAKER

NUMBER DIA. HEIGHT @900F Rise UPPER LOWER (GAUGE) SIZE (AMPS)

153.326362 30 18.0 (457) 46.5 (1181) 17.3 3800 3800 12 20

153.326363 30 18.0 (457) 46.5 (1181) 25.0 3800 5500 10 30

153.326462 40 18.0 (457) 59.5 (1511) 17.3 3800 3800 12 20

153.326463 40 18.0 (457) 59.5 (1511) 25.0 3800 5500 10 30

153.326562 55 20.5 (521) 60.25 (1530) 17.3 3800 3800 12 20

153.326563 55 20.5 (521) 60.25 (1530) 25.0 3800 5500 10 30

153.326662 50 23.0 (584) 49.0 (1245) 17.3 3800 3800 12 20

153.326663 50 23.0 (584) 49.0 (1245) 25.0 3800 5500 10 30

153.326762 40 20.5 (521) 44.0 (1118) 17.3 3800 3800 12 20

153.326763 40 20.5 (521) 44.0 (1118) 25.0 3800 5500 10 30

153.326862 47 26.5 (673) 34.0 (864) 17.3 3800 3800 12 20

153.326863 47 26.5 (673) 34.0 (864) 25.0 3800 5500 10 30

*Wiring size based on standard 60°C copper wire. If distance from fuse box to water heater is more than 90 feet, refer to your local electrical code.

CAPACITY

IN GALLONS

30 18.0 (457) 46.5 (1181)

40 18.0 (457) 59.5 (1511)

55 20.5 (521) 60.25 (1530)

50 23.0 (584) 49.0 (1245)

40 20.5 (521) 44.0 (1118)

50 26.5 (673) 34.0 (864)

DIMENSIONS

IN INCHES (mm)

RECOVERY RATE MINIMUM OR CIRCUIT

ELEMENT

WATTAGE

@ 240 VOLTS

MAXIMUM FUSE

MATERIALS AND BASIC TOOLS NEEDED

Materials Needed

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

EXPANSION TANKS FOR THERMAL EXPANSION CONDITIONS AVAILABLE IN 2 GALLONS , AND 5 GALLONS CAPACITY THROUGH LOCAL SEARS STORE OR

WATER HEATER INSTALLATION KIT WITH FLEXIBLE CONNECTORS FOR 3/4” OR 1/2” THREADED OR COPPER PLUMBING.

SERVICE CENTER.

Basic Tools

You may or may not need all of these tools, depending on your type of installation. These tools can be purchased at your local Sears store.

Pipe Wrench (2) Screwdriver 6 Foot Tape or Folding Rule Garden Hose Drill Pipe Dope or Teflon Tape

DRILL

SLOT-HEAD SCREWDRIVER

ROLL OF TEFLON TAPE (USE ON

WATER CONNECTIONS)

PHILLIPS SCREWDRIVER

DRAIN PANS AVAILABLE IN 20” DIAMETER FOR WATER HEATERS HAVING A DIAMETER 18” OR LESS, 24” DIAMETER FOR WATER HEATERS HAVING A DIAMETER 22” OR LESS AND AVAILABLE IN 28” DIAMETER FOR WATER HEATERS HAVING A DIAMETER 26” OR LESS.

Additional Tools Needed When Sweat Soldering

Tubing Cutters or Hacksaw Propane Torch Soft Solder Solder Flux Emery Cloth Wire Brushes

TUBING CUTTER

HACKSAW

PIPE DOPE (SQUEEZE TUBE)

USE FOR WATER CONNECTIONS

ROLL OF

EMERY CLOTH

3/4” (19 mm) WIRE BRUSH

PIPE WRENCHGARDEN HOSE 6 FOOT TAPE

PROPANE

TORCH

1/2” (13 mm) WIRE BRUSH

ROLL OF

LEAD-FREE

SOFT SOLDER

SOLDER

FLUX

INSTALLATION INSTRUCTIONS

Removing the Old Water Heater

1. Turn “OFF” electrical supply to the water heater.

FIGURE 1.

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.

4. Check again to make sure the electrical supply is turned

“OFF” to the water heater. Then unplug the water heater (cord set) or disconnect the electrical supply connection from the water heater junction box.

FIGURE 4.

5a. 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. This will avoid cutting off the 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.

2. Turn “OFF” the water supply to the water heater at the water

shut-off valve or water meter.

FIGURE 2.

3. Attach a hose to the water heater drain valve and put the

other end in a floor drain or outdoors. Open the water drain valve. Open a nearby hot water faucet which will relieve pressure in the water heater and speed draining.

FIGURE 3.

FIGURE 5a.

5b. If you have galvanized pipe 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. 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.

FIGURE 5b.

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.

• Sensors mounted in the drain pan that turn off the water supply to the entire home when water is detected in the drain pan.

• Water supply shut-off devices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater.

Facts to Consider About the Location

You should carefully choose an indoor location for the new water heater, because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance. This water

heater is not intended for outdoor installation.

Whether replacing an old water heater or putting the water heater in a new location, the following critical points must be observed.

• The location selected should be indoors as close to and as centralized with the water piping system as possible. This water heater, as well as all water heaters, will eventually leak. Do not install without adequate drainage provisions so water flow will not cause damage.

INSTALLATION IN RESIDENTIAL GARAGES: The water heater must be located and/or protected so it is not subject to physical damage by a moving vehicle.

• The location selection must provide adequate clearances for servicing and proper operation of the water heater.

Insulation Blankets

Insulation blankets are available to the general public for external use on electric water heaters but are not necessary with this product. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. Your water heater meets or exceeds the National Appliance Energy Conversation Act standards with respect to insulation and standby loss requirements, making an insulation blanket unnecessary.

Should you choose to apply an insulation blanket to this heater, you should follow these instructions below. Failure to follow these instructions can result in fire, serious personal injury, or death.

•

Do not cover the temperature and pressure relief (T & P) valve with an insulation blanket.

WATER HEATERS EVENTUALLY LEAK: Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak, the flow of water will not cause damage to the structure. When such locations cannot be avoided, a suitable drain pan should be installed under the water heater. Drain pans are available at your local Sears stores. Such drain pans must be piped to an adequate drain.

Water heater life depends upon water quality, water pressure and the environment in which the water heater is installed. Water heaters are sometimes installed in locations where leakage may result in property damage, even with the use of a drain pan piped to a drain. However, unanticipated damage can be reduced or prevented by a leak detector or water shutoff device used in conjunction with a piped drain pan. These devices are available from some plumbing supply wholesalers and retailers, and detect and react to leakage in various ways:

• Sensors mounted in the drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected.

• 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 for placement on the blanket directly over the existing labels.

Facts to Consider About the Convertible Lower Element

The Upper Element (if a double element model) is a conventional 3800 watt element which only operates at its rated wattage on 240 volts. (See rating plate on the water heater).

The Lower Element of the water heater can be converted from operation at 3800 watts to 5500 watts on a 240 volt system.

Read and follow water heater warnings and instructions. If after reading these instructions in this manual, you do not understand any portion, call Sears Service Center.

Before making the conversion to 5500 watts, check the (1) power supply . . . must be 240 volts, (2) wiring . . . 10 gauge AWG @ Type TW, 60°C or equivalent, and (3) Circuit breakers or fusing . . .capable of 30 amp loading. Also, the installation must conform with this manual, local codes and electric utility rules. Failure to comply can result in DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.

HOTTER WATER CAN SCALD: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy clothes washing, dish washing, and other sanitizing needs can scald and permanently injure you upon contact. Some people are more likely to be permanently injured by hot water than others. These include the elderly, children, the infirm, or physically/mentally handicapped. If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap, then you must take special precautions. In addition to using the lowest possible temperature setting that satisfies your hot water needs, a means such as a mixing valve, should be used at the hot water taps used by these people or at the water heater. Mixing valves are available at plumbing supply or hardware stores. Follow manufacturers instructions for installation of the valves. Before changing the factory setting on the thermostat, read the “Temperature Regulation” section in this manual.

See Figure 7 (below) for mixing valve usage.

FIGURE 6.

NOTE: Whether or not the element conversion is made the

model rating plate must be marked. Using a hard point ink pen, check the appropriate block within the model rating plate, which is located adjacent to the lower access panel.

Water Piping

FIGURE 7.

Figure 8 shows the attachment of the water piping to the water heater. The water heater is equipped with 3/4” water connections.

If a water heater is installed in a closed water supply system; such as one having a back-flow preventer, check valve, water meter with a check valve, etc... in the cold water supply; means must be provided to control thermal expansion. Contact the local utility or Sears Service Center on how to control this situation.

NOTE: If using copper tubing, solder tubing to an adapter before attaching the adapter to the water inlet connection. Do not solder the water supply lines directly to the cold water inlet. It will harm the dip tube and damage the tank.

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

1. Look at the top cover of the water heater. The hot water outlet is marked hot. Put two or three turns of teflon tape around the threaded end of the threaded-to-sweat coupling and around both ends of the 3/4” threaded nipple. Using flexible connectors, connect the hot water pipe to the hot water outlet of the water heater.

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

Secure all insulation using tape.

2. Look at the top cover of the water heater. The cold water inlet is marked cold. Put two or three turns of teflon tape around the threaded end of the threaded-to-sweat coupling and around both ends of the 3/4” threaded nipple. Using flexible connectors, connect the cold water pipe to the cold water inlet of the water heater.

NOTE: Your water heater is insulated to minimize heat loss from the tank. Further reduction in heat loss can be accomplished by insulating the hot water lines from the water heater.

FIGURE 9.

Temperature-Pressure Relief Valve

FIGURE 8.

T & P Valve and Pipe Insulation

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

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

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

The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA

4.4, and the code requirements of ASME.

If replaced, the valve must meet the requirements of local codes, but not less than a combination temperature and pressure relief valve certified as indicated in the above paragraph.

The valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater (150 psi = 1,035 kPa) and a discharge capacity not less than the water heater input rate as shown on the model rating plate. (For electric heaters, watts x 3.412 equals Btu/hr input rate)

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

The temperature-pressure relief valve must be installed directly into the fitting of the water heater designed for the relief valve.

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