Sears 153.332040, 153.332060, 153.332070, 153.332050 User Manual
Owner’s Manual
THE ECONOMIZER™ 6
GAS WATER HEATER
POWER VENTED GAS MODELS
WITH HOT SURFACE IGNITION
FOR POT ABLE WA TER HEA TING ONL Y.
NOT SUIT ABLE FOR SP ACE HEA TING .
NOT FOR USE IN MOBILE HOMES.
MODEL NO.
153.332040 40 Gallon Nat
153.332050 50 Gallon Nat
153.332060 40 Gallon LP
153.332070 50 Gallon LP
• Safety Instructions
• Installation
• Operation
• Care and Maintenance
• Troubleshooting
• Parts List
For Your Safety
AN ODORANT IS ADDED TO THE GAS USED BY THIS W ATER HEA TER.
C3 Technology® Gas Water Heaters meet
the new ANSI Z21.10.1 standard that deals
with the accidental or unintended ignition
of flammable vapors, such as those
emitted by gasoline.
ADVERTENCIA
Si no puede leer o entender el inglés y necesita el manual instructivo
y/o etiquetas en español puede obtenerlos llamando al
1-800-821-2017. NO TRATE DE INSTALAR O OPERAR ESTE
CALENTADOR DE AGUA si no entiende la información en las etiquetas
o en el manual instructivo. No hacer caso de esta advertencia podría
resultar en la MUERTE O GRA VES LESIONES CORPORALES.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A
1PRINTED IN THE U.S.A. 0905 www.sears.com P ART NO. 185249-000
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.
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.
IMPORTANT DEFINITIONS
• 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.
© Sears, Roebuck and Co.
2
SAFETY PRECAUTIONS
3
TABLE OF CONTENTS
SAFE INST ALLA TION, USE AND SERVICE.................................................................................................................................... 2
SAFETY PRECAUTIONS ................................................................................................................................................................. 3
TABLE OF CONTENTS .................................................................................................................................................................... 4
CUSTOMER RESPONSIBILITIES................................................................................................................................................... 5
PRODUCT SPECIFICA TIONS.........................................................................................................................................................5
MATERIALS AND BASIC TOOLS NEEDED .................................................................................................................................... 6
TYPICAL INSTALLA TION.................................................................................................................................................................. 7
INST ALLA TION INSTRUCTIONS .............................................................................................................................................. 8-21
Removing the Old Water Heater ............................................................................................................................................. 8
Facts to Consider About the Location .............................................................................................................................. 9-10
Insulation Blankets.................................................................................................................................................................10
Combustion Air and Ventilation for Appliances Located in Unconfined Spaces ............................................................. 10
Combustion Air and Ventilation for Appliances Located in Confined Spaces ............................................................10-11
Water Piping ...................................................................................................................................................................... 12-13
Temperature-Pressure Relief Valve ............................................................................................................................... 13-14
Gas Piping ......................................................................................................................................................................... 14-15
Sediment Traps ......................................................................................................................................................................15
Filling the Water Heater ......................................................................................................................................................... 15
Blower Assembly Installation .......................................................................................................................................... 15-16
Vent Connections to Blower Assembly ................................................................................................................................. 17
Venting and Installation ......................................................................................................................................................... 17
Condensation ......................................................................................................................................................................... 17
Maximum Vent Lengths.......................................................................................................................................................... 17
Venting ..................................................................................................................................................................................... 18
Vent Terminal Installation ................................................................................................................................................ 18-19
Vertical Vent Through Roof..................................................................................................................................................... 19
Vertical Vent Termination Restrictions ..................................................................................................................................19
Vent Pipe Preparation ...................................................................................................................................................... 20-21
OPERA TING INSTRUCTIONS................................................................................................................................................. 22-23
Lighting and Operating Label ............................................................................................................................................... 22
Temperature Regulation ........................................................................................................................................................ 23
FOR YOUR INFORMATION......................................................................................................................................................
Start Up Conditions .......................................................................................................................................................... 24-25
Operational Conditions .......................................................................................................................................................... 25
SERVICE AND ADJUSTMENT ................................................................................................................................................. 25-27
Venting System Inspection .................................................................................................................................................... 25
Burner Operation and Inspection ................................................................................................................................... 25-26
Burner Cleaning .....................................................................................................................................................................26
Housekeeping ........................................................................................................................................................................ 26
Anode Rod Inspection ............................................................................................................................................................ 26
Temperature-Pressure Relief Valve Operation ............................................................................................................. 26-27
Draining ................................................................................................................................................................................... 27
Drain Valve Washer Replacement ........................................................................................................................................27
Service .....................................................................................................................................................................................27
LEAKAGE CHECKPOINTS ............................................................................................................................................................ 28
TROUBLESHOOTING GUIDELINES ...................................................................................................................................... 29-30
REPAIR PARTS LIST...................................................................................................................................................................... 31
WARRANTY.....................................................................................................................................................................................32
24-25
4
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 S tandards Institute
• NFPA - National Fire Protection Association
• ASME - American Society of Mechanical Engineers
• GAMA - Gas Appliance Manufacturer’s Association
• UL - Underwriters Laboratories Inc.
This gas-fired water heater is listed by Underwriters Laboratories Inc.
under American National S tandard/CSA Standard for Gas W ater Heaters
ANSI Z21.10.1 • CSA 4.1 (current edition).
PREPARING FOR THE INSTALLATION
1. Read the “Safety Precautions” 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
DEA TH, SERIOUS BODILY INJUR Y AND/OR PROPERTY DAMAGE.
This manual contains instructions for the installation, operation, and
maintenance of the gas-fired 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 THE ENTIRE MANUAL BEFORE
A TTEMPTING TO INST ALL OR OPERATE THE W ATER HEA TER.
2. 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 National Fuel Gas Code ANSI Z223.1/
NFPA 54 and the National Electrical Code, NFP A 70. These publications
are available from The National Fire Protection Association, 1
Batterymarch Park, Quincy , MA 02269.
3. The water heater when installed must be grounded in accordance
with the local codes, or in the absence of local codes, the National
Electrical Code NFPA 70.
4. If after reading this manual you have any questions or do not
understand any portion of the instructions, call the local gas utility or
the Sears Service Center.
5. 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
“Facts to Consider About the Location” section in this manual.
6. 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 Office of the St ate Architect, 400 P S treet,
Sacramento, CA 95814.
7. 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.
8. Complies with SCAQMD rule #1 121 and districts having equivalent
NOx requirements.
PRODUCT SPECIFICATIONS
TANK RECOVERY MINIMUM
CAPACITY INPUT RATE GALS. VENT PIPE DIAMETER DIMENSIONS IN
MODEL IN GALS. TYPE OF RATE PER HOUR INCHES INCHES INCHES (mm) HEIGHT
NUMBER (LTRS) GAS (Btu/hr) @ 90°F RISE (mm) (mm) TO JACKET TOP
153.332040 40 (151) NATURAL 40,000 44 2 (51) 18 1/2 (470) 55 (1,397)
153.332050 50 (189) NATURAL 40,000 44 2 (51) 20 (508) 56 3/4 (1,441)
153.332060 40 (151) PROPANE 40,000 44 2 (51) 18 1/2 (470) 55 (1,397)
153.332070 50 (189) PROPANE 40,000 44 2 (51) 20 (508) 56 3/4 (1,441)
5
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 T ANKS FOR
THERMAL EXPANSION
CONDITIONS AV AILABLE
IN 2 GALLONS
(7.6 LITERS) AND
5 GALLONS (18.9 LITERS)
CAP ACITY THROUGH
LOCAL SEARS STORE OR
SERVICE CENTER.
WA TER HEA TER INST ALLATION KIT WITH
FLEXIBLE CONNECTORS FOR 3/4”
(19.05 mm) OR 1/2” (12.7 mm) THREADED OR
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
DRAIN PANS A V AILABLE IN 20”
(508 mm) DIAMETER FOR
WA TER HEA TERS HA VING A
DIAMETER 18” (457 mm) OR
LESS, 24” (610mm) DIAMETER
FOR WATER HEATERS HA VING
A DIAMETER 22” (559 mm) OR
LESS AND A V AILABLE IN 28”
(711 mm) DIAMETER FOR
WA TER HEA TERS HA VING A
DIAMETER 26” (660 mm) OR
LESS.
Additional Tools Needed
When Sweat Soldering
• Tubing Cutters or Hacksaw
• Propane Tank
• Soft Solder
• Solder Flux
• Emery Cloth
• Wire Brushes
TUBING CUTTER
PROPAN E
TORCH
PHILLIPS SCREWDRIVER
ROLL OF TEFLON
TAPE (USE ONL Y ON
WATER CONNECTIONS)
GARDEN HOSE
6 FOOT TA PE
TIN SNIPS
PIPE DOPE
(SQUEEZE TUBE)
USE FOR WA TER AND GAS
CONNECTIONS
PIPE WRENCH
3/4” (19 mm) WIRE BRUSH
1/2” (13 mm) WIRE BRUSH
6
HACKSAW
ROLL OF
EMERY CLOTH
ROLL OF LEAD-FREE
SOFT SOLDER
SOLDER
FLUX
TYPICAL INSTALLATION
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A Vent Pipe–Exhaust
B Vent Terminal
C Vent Adapter-Rubber Boot
D Blower Assembly
E Cold Water Inlet
F Inlet Water Shut-off Valve
G Union
H Inlet Dip Tube
J Anode**
* ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS.
** LOCATED UNDER THE BLOWER ASSEMBLY.
K Hot Water Outlet
L Outlet Receptacle (115 VAC)
M Temperature-Pressure Relief Valve
N Flue
O Flue Baffle Assembly**
P Insulation
Q Control Harness
R Rating Plate
S Gas Supply
T Manual Gas Shut-off Valve
U Ground Joint Union
NATURAL HOT SURFACE IGNITER & MAIN BURNER
SURFACE
IGNITOR
PROPANE HOT SURF ACE IGNITER & MAIN BURNER
SURFACE
IGNITOR
V Drip Leg (Sediment Trap)
W Drain Valve
X Gas Valve-Thermostat
Y Drain Pan
Z Air Intake Screen - Base Pan
AA Inner Door
BB Outer Door
CC HSI Burner Assembly
DD Air Intake Screen -
Blower Assembly
EE FV Sensor Assembly
HOT
SENSOR
HOT
*CAUTION: 115 VAC IN CONTROL HARNESS
AND INSIDE OUTER DOOR
GAS MODELS
WITH HOT SURF ACE IGNITION
& 2", 3" OR 4" PVC VENT CAPABILITY
SENSOR
TEMPERATURE INDICA TORS
TEMPERATURE ADJUSTMENT BUTTONS
FIGURE 1.
7
INSTALLATION INSTRUCTIONS
Removing the Old Water Heater
4. Att ach a hose to the water heater drain
valve and put the other end in a floor
drain or outdoors. Open the water
heater drain valve. Open a nearby hot
water faucet which will relieve
pressure in the water heater and speed
draining. The water passing out of the
drain valve may be extremely hot. T o
avoid being scalded, make sure all
connections are tight and that the water
flow is directed away from any person,
see Figures 2 and 5.
5. Disconnect the vent pipe from the blower assembly where it connects
to the water heater. In most inst allations the vent pipe can be lifted off
after any screw or other attached devices are removed. Make sure
existing vent complies with maximum and minimum vent lengths on
page 17.
6. If you have copper piping to the water heater, the two copper water
pipes can be cut with a hacksaw approximately four inches away
from where they connect to the water heater, see Figure 6. This will
avoid cutting off pipes too short. Additional cuts can be made later if
necessary. Disconnect the temperature-pressure relief valve drain
line. When the water heater is drained, disconnect the hose from the
drain valve. Close the drain valve. The water heater is now completely
disconnected and ready to be removed.
FIGURE 5.
FIGURE 2.
1. Turn “OFF” the gas supply to the water
heater.
If the main gas line Shut-off 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.
2. 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.
3. Check again to make sure the gas supply is “OFF” to the water
heater. Then disconnect the gas supply connection from the gas
control valve.
FIGURE 3.
FIGURE 4.
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 temperaturepressure 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.
8
FIGURE 7.
FACTS TO CONSIDER ABOUT THE LOCA TION
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 for use in manufactured (mobile) homes
or outdoor installation.
Whether replacing an old water heater or putting the water heater in a
new location, the following critical points must be observed:
1. Select a location indoors as close as practical to the vent terminal or
location to which the water heater vent piping is going to be connected,
and as centralized with the water piping system as possible.
2. Selected location must provide adequate clearances for servicing
and proper operation of the water heater.
Installation of the water heater must be accomplished in such a manner
that if the tank or any connections should leak, the flow will not cause
damage to the structure. For this reason, it is not advisable to install the
water heater in an attic or upper floor. When such locations cannot be
avoided, a suitable drain pan should be installed under the water heater.
Drain pans are available at your local hardware store. Such a drain pan
must have a minimum length and width of at least 2" (5.1 cm) greater than
the water heater dimensions and must be piped to an adequate drain.
The pan must not restrict combustion air flow.
FIGURE 8.
Also, the water heater must be located and/or protected so it is not
subject to physical damage by a moving vehicle.
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 shut-off device used in conjunction with a piped drain pan. These
devices are available from some plumbing supply wholesalers and
retailers, and detect and react to leakage in various ways:
• Sensors mounted in the drain pan that trigger an alarm or turn off the
incoming water to the water heater when leakage is detected.
• Sensors mounted in the drain pan that turn off the water supply to the
entire home when water is detected in the drain pan.
• Water supply shut-off devices that activate based on the water
pressure differential between the cold water and hot water pipes
connected to the water heater.
• Devices that will turn off the gas supply to a gas water heater while at
the same time shutting off its water supply .
INSTALLA TIONS IN AREAS WHERE FLAMMABLE LIQUIDS (VAPORS)
ARE LIKELY TO BE PRESENT OR STORED (GARAGES, STORAGE AND
UTILITY AREAS, ETC.): Flammable liquids (such as gasoline, solvent s,
propane (LP or butane, etc.) and other substances (such as adhesives,
etc.) emit flammable vapors which can be ignited by a gas water heater’s
hot surface igniter or main burner. The resulting flashback and fire can
cause death or serious burns to anyone in the area. This water heater is
equipped with a FV sensor for detecting the presence of flammable
vapors, see Figure 8. When the sensor detects those vapors, the unit
will shut down and not operate. Should this happen, please refer to the
troubleshooting guide on pages 29-30. Even though this water heater is
a flammable vapors ignition resistant water heater and is designed to
reduce the chances of flammable vapors being ignited, gasoline and
other flammable substances should never be stored or used in the same
vicinity or area containing a gas water heater or other open flame or
spark producing appliance.
This water heater must not be installed directly on carpeting. Carpeting
must be protected by metal or wood panel beneath the appliance extending
beyond the full width and depth of the appliance by at least 3" (7.6 cm) in
any direction, or if the appliance is installed in an alcove or closet, the
entire floor must be covered by the panel. Failure to heed this warning
may result in a fire hazard.
Minimum clearances between the water heater and combustible
construction are 0 inch at the sides and rear, 5" (12.7 cm) from the front
9
and 12" (30.5 cm) from the top. (Standard clearance.) If clearances
stated on the heater differ from standard clearances, install water heater
according to clearances stated on the heater.
Adequate clearance for servicing this appliance should be considered
before installation, such as changing the anodes, etc.
A minimum clearance of 5" (12.7 cm) must be allowed for access to
replaceable parts such as the thermostats, drain valve and relief valve.
When installing the heater, consideration must be given to proper location.
Location selected should be as close to the wall as practicable and as
centralized with the water piping system as possible.
FIGURE 9.
flammable in many cases, will also react to form corrosive hydrochloric
acid when exposed to the combustion products of the water heater .
The results can be hazardous, and also cause product failure.
INSULA TION BLANKETS
Insulation blankets are available to the general public for external use
on gas water heaters but are not necessary with Kenmore products.
The purpose of an insulation blanket is to reduce the standby heat loss
encountered with storage tank heaters. Y our 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.
A gas water heater cannot operate properly without the correct amount
of air for combustion. Do not install in a confined area such as a closet,
unless you provide air as shown in the “Facts to Consider About the
Location” section. Never obstruct the flow of ventilation air. If you
have any doubts or questions at all, call your gas supplier. Failure to
provide the proper amount of combustion air can result in a fire or
explosion and cause death, serious bodily injury , or property damage.
FIGURE 10.
If this water heater will be used in beauty shops, barber shops, cleaning
establishments, or self-service laundries with dry cleaning equipment,
it is imperative that the water heater or water heaters be installed so
that combustion and ventilation air be taken from outside these areas.
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorine based chemicals, refrigerants, etc.) in addition to being highly
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions (For identification of components
mentioned below, see Figure 1). Failure to follow these instructions
can restrict the air flow required for proper combustion, potentially
resulting in fire, asphyxiation, serious personal injury or death.
Do not apply insulation to the top of the water heater, as this will
•
interfere with safe operation of the blower assembly.
•
Do not cover the outer door, thermostat or temperature & pressure
relief valve.
•
Do not allow insulation to come within 2" (5.1 cm) 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.
COMBUSTION AIR AND VENTILATION FOR
APPLIANCES LOCATED IN UNCONFINED SP ACES
UNCONFINED SPACE is space whose volume is not less than
50 cubic feet per 1,000 Btu per hour (4.8 cubic meters per kW) of the
aggregate input rating of all appliances installed in that space. Rooms
communicating directly with the space in which the appliances are
installed, through openings not furnished with doors, are considered a
part of the unconfined space.
In unconfined spaces in buildings, infiltration may be adequate to provide
air for combustion, ventilation and dilution of flue gases. However, in
buildings of tight construction (for example, weather stripping, heavily
insulated, caulked, vapor barrier, etc.), additional air may need to be
provided using the methods described in “Combustion Air and V entilation
for Appliances Located in Confined S paces.”
COMBUSTION AIR AND VENTILATION FOR
APPLIANCES LOCATED IN CONFINED SP ACES
CONFINED SPACE is a sp ace whose volume is less than 50 cubic feet
per 1,000 Btu per hour (4.8 cubic meters per kW) of the aggregate
input rating of all appliances installed in that space.
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