Sears 153.33262 User Manual

Use & Care Guide

Model No.

153.332620 40 Gallon Tall

153.332640 50 Gallon Tall

Kenmore Elite®

Gas Water Heater

For potable water heating only.
Not suitable for space heating.
Not for use in mobile homes.

INSTALLER: Affix these instructions to or near
the water heater.

OWNER: Retain these instructions for future
reference.

FOR YOUR SAFETY: An odorant is added to
the gas used by this water heater.

ADVERTENCIA

Si no puede leer o entender el inglés y necesita el manual de
instrucciones en español, puede solicitarlo al 1-800-821-2017. NO
TRATE DE INSTALAR U OPERAR ESTE CALENTADOR DE AGUA
SI NO ENTIENDE LAS INSTRUCCIONES. No hacer caso de esta
advertencia podría originar lesiones graves o mortales.

P/N 317997-000 (0810)

Sears Brands Management Corporation,
Hoffman Estates, IL 60179 U.S.A.

www. kenmore.com
www.sears.com

1

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 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, 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.

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

• Qualifi ed Technician: A qualifi ed technician must have ability equivalent to a licensed tradesman in the fi elds 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 fi red water heaters. The qualifi ed technician must also be familiar with the design features and use of fl ammable vapor
ignition resistant water heaters, and have a thorough understanding of this instruction manual.

• Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fi elds 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 fi red 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.

SAFETY PRECAUTIONS

WARNING

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death

Do not store or use gasoline or other
flammable vapors and liquids in the vicinity of this
or any other appliance. Storage of or use of

FLAMMABLES

Flammable Vapors

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 Brands Management Corporation

2

Do not operate water heater if flood damaged.
Install in location with drainage.
Fill tank with water before operation.
Be alert for thermal expansion.

Refer to instruction manual for installation and service.

Improper installation and use may result

in property damage.

Fire or Explosion Hazard

Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.

Avoid all ignition sources if you smell Natural or LP gas.
Do not expose water heater control to excessive gas
pressure.

Use only gas shown on rating plate.
Maintain required clearances to combustibles.
Keep ignition sources away from faucets after extended

period of non-use.

Read instruction manual before

installing, using or servicing

water heater.

Breathing Hazard - Carbon Monoxide Gas

Install vent system in accordance with
codes.

Do not operate water heater if flood
damaged

Heater should not be installed for High
Altitude operation above 10,100 feet
(3,078 m).

Do not operate if soot buildup.

Do not obstruct water heater air intake
with insulating jacket.

Do not place chemical vapor emitting
products near water heater.

Gas and carbon monoxide detectors
are available.

Breathing carbon monoxide can cause brain damage or death.
Always read and understand instruction manual.

3

TABLE OF CONTENTS

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

Important Definitions ................................................................................................................................................. 2

SAFETY PRECAUTIONS ........................................................................................................................... 2-3

Table of Contents ................................................................................................................................................... 4-5

PRODUCT WARRANTY ................................................................................................................................ 6

CUSTOMER RESPONSIBILITIES ................................................................................................................. 7

PRODUCT SPECIFICATIONS ...................................................................................................................... 8

MATERIALS AND BASIC TOOLS NEEDED .................................................................................................. 9

TYPICAL INSTALLATION ............................................................................................................................ 10

Get to know your Water Heater .............................................................................................................................. 10

IMPORTANT INFORMATION ABOUT THIS WATER HEATER ....................................................................11

Installation Checklist ................................................................................................................................................11

INSTALLATION INSTRUCTIONS ........................................................................................................... 12-14

Removing the Old Water Heater ............................................................................................................................. 12

Location Requirements ........................................................................................................................................... 13

Site Location ........................................................................................................................................................... 13

Clearances and Accessibility .................................................................................................................................. 14

High Altitude Installation ......................................................................................................................................... 14

GAS SUPPLY ............................................................................................................................................... 15

Gas Requirements .................................................................................................................................................. 15

Gas Piping .............................................................................................................................................................. 15

Gas Pressure .......................................................................................................................................................... 15

Gas Pressure Testing.............................................................................................................................................. 15

COMBUSTION AIR SUPPLY & VENTILATION ...................................................................................... 17-20

Unconfined Space ................................................................................................................................................... 17

Confined Space ...................................................................................................................................................... 17

All Air from Inside the Building ................................................................................................................................ 17

All Air from Outdoors ............................................................................................................................................... 18

Louvers and Grilles ................................................................................................................................................. 18

Vent Pipe System ................................................................................................................................................... 19

Draft Hood Installation ....................................................................................................................................... 19-20

Vent Pipe Size ........................................................................................................................................................ 20

Vent Connectors ..................................................................................................................................................... 20

Chimney Connection ............................................................................................................................................... 20

Vertical Exhaust Gas Vent ...................................................................................................................................... 20

WATER SYSTEM PIPING ....................................................................................................................... 21-22

Piping Installation .................................................................................................................................................... 21

Closed System/Thermal Expansion ........................................................................................................................ 22

Temperature and Pressure Relief Valve ................................................................................................................. 22

T&P Relief Valve and Pipe Insulation ........................................................................................................................ 23

4

ELECTRICAL ............................................................................................................................................... 24

Electrical Connections ............................................................................................................................................ 24

Solar Installation ..................................................................................................................................................... 24

Wiring Diagram ....................................................................................................................................................... 24

OPERATING YOUR WATER HEATER ...................................................................................................25-30

Lighting Instructions ................................................................................................................................................ 25

Water Heater Operation .......................................................................................................................................... 26

Checking the Draft .................................................................................................................................................. 26

Burner Flames ........................................................................................................................................................ 27

Emergency Shut Down ........................................................................................................................................... 27

Water Temperature Regulation .......................................................................................................................... 27-28

Powered Anode Rod Operation .............................................................................................................................. 28

SERVICE AND ADJUSTMENT .................................................................................................................... 29

Draining and Flushing ............................................................................................................................................. 29

Routine Preventive Maintenance ............................................................................................................................ 29

Temperature and Pressure Relief Valve ................................................................................................................. 29

MAINTENANCE OF YOUR WATER HEATER ........................................................................................ 30-32

Replacement Parts ................................................................................................................................................. 30

Removing the Manifold/Burner Assembly ............................................................................................................... 30

Removing the Burner from the Manifold/Burner Assembly .................................................................................... 30

Replacing the Flame Sense/Hot Surface Igniter Assembly .................................................................................... 30

External Inspection & Cleaning of the Air Intake Chamber Screen ........................................................................ 31

Cleaning the Combustion Chamber and Air Diverter Assembly ............................................................................. 31

Replacing the Manifold/Burner Assembly ............................................................................................................... 31

Removing and Replacing the Gas Control Valve/Thermostat ................................................................................ 32

TROUBLESHOOTING GUIDE ................................................................................................................ 33-35

Start Up Conditions ................................................................................................................................................. 33

Operational Conditions ........................................................................................................................................... 34

Service .................................................................................................................................................................... 34

Leakage Checkpoints ............................................................................................................................................. 35

Pressurized Combustion Chamber System Operational Checklist ........................................................................ 36

TROUBLESHOOTING CHART ............................................................................................................... 36-37

ELECTRONIC CONTROL DISPLAY TROUBLESHOOTING .................................................................. 38-40

TROUBLESHOOTING FLOWCHART .......................................................................................................... 41

PARTS ORDER LIST ................................................................................................................................... 42

5

PRODUCT WARRANTY

12 - YEAR LIMITED WARRANTY ON WATER HEATER

For twelve 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 applicable plumbing codes, Sears will:

1. Supply free water heater parts for those that are defective in material or workmanship.

2. Supply a free water heater for one that develops a leak.

For the second through twelfth year from the purchase date, you must pay the labor cost for installation of parts or water heater.

For commercial, institutional, industrial or residential use by two or more families, the above limited warranty is only for two years. During
the second year you must pay the labor cost for parts or water heater installation.

If governmental regulations prohibit Sears from furnishing a comparable model replacement water heater under this warranty, Sears will
furnish a new water heater of comparable output as permitted by such governmental regulations; however, the Owner will be charged
for the additional cost associated with the changes made to comply with such governmental regulations.

Replacements furnished under this warranty do not carry a new warranty; and are only covered by the unexpired portion of the original
warranty.

1 - YEAR EXCLUSIVE KENMORE LABOR WARRANTY

For the fi rst year from the date of purchase, Sears will, free of charge, supply and install new water heater parts for defective ones or a
new water heater for one that develops a leak.

WARRANTY SERVICE

To obtain warranty service, call 1-800-4-MY-HOME® (1-800-469-4663).
This warranty applies only while this product is in use in the United States.
This warranty gives you specifi c legal rights, and you may also have other rights which vary from state to state.

SEARS BRANDS MANAGEMENT CORPORATION, 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 fi ttings

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.

$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.

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

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

®

.

us as a “talking owner’s manual.”

Power surge protection• against electrical damage due to
power fluctuations.

6

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
prompt, quality installation by Sears authorized contractors.

Abbreviations Found In This Instruction Manual:

®

. They will arrange for

• 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 gas water heater was manufactured to voluntary safety
standards to reduce the likelihood of a fl ammable vapor ignition
incident. New technology used in meeting these standards makes this
product more sensitive to installation errors or improper installation
environments. Please review the Installation Checklist section and
make any required installation upgrades or changes.

This manual contains instructions for the installation, operation,
and maintenance of the gas-fi red water heater. It also contains
warnings through out the manual that you must read and be aware
of. All warnings and all instructions are essential to the proper
operation of the water heater and your safety. Since we cannot put
everything on the fi rst few pages, READ THE ENTIRE MANUAL

BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER
HEATER.

• Massachusetts Code requires this water heater to be installed in

accordance with Massachusetts 248-CMR 2.00: State Plumbing
Code and 248-CMR 5.00.

• Complies with 40 Ng/J NOx requirements of Texas and most

California AQM Districts.

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, 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.

• 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.

• 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 fi res. See Figure 1.

• Examine the location to ensure the water heater complies with

the Installation Instructions section in this 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 Offi ce 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.

7

PRODUCT SPECIFICATIONS

MODEL

NUMBER

153.332620 40 (151) Natural 40,000 42.6 3 (76) or 4 (102) 20 (508) 58 (1473)

153.332640 50 (189) Natural 40,000 42.6 3 (76) or 4 (102) 22 (559) 57.13 (1451)

TANK CAPACITY

IN GALS (LTRS)

TYPE

OF

GAS

INPUT

RATE

(Btu/hr)

RECOVERY

RATE GALS.

PER HOUR

@ 90°F RISE

MINIMUM

VENT PIPE

DIA. INCHES

(mm)

DIAMETER

INCHES

(mm)

HEIGHT TO

JACKET TOP

INCHES (mm)

8

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
(7.6 LITERS) AND
5 GALLONS (18.9 LITERS)
CAPACITY THROUGH
LOCAL SEARS STORE
OR SERVICE CENTER.

WATER HEATER INSTALLATION KIT
WITH FLEXIBLE CONNECTORS FOR 3/4”
(19.05 mm) 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 Tefl on Tape

SLOT-HEAD SCREWDRIVER

DRILL

METAL DRAIN PANS AVAILABLE
IN 20” (508 mm) DIAMETER
FOR WATER HEATERS HAVING
A DIAMETER 18” (457 mm) OR
LESS, 24” (610mm) DIAMETER
FOR WATER HEATERS HAVING A
DIAMETER 22” (559 mm) OR LESS
AND AVAILABLE IN 28” (711 mm)
DIAMETER FOR WATER HEATERS
HAVING A DIAMETER 26” (660 mm)
OR LESS.

ADDITIONAL TOOLS NEEDED
WHEN SWEAT SOLDERING

• Tubing Cutters or Hacksaw

• Propane Torch

• Soft Solder

• Solder Flux

• Emery Cloth

• Wire Brushes

TUBING CUTTER

PROPANE

TORCH

PHILLIPS SCREWDRIVER

ROLL OF TEFLON

TAPE (USE ONLY ON

WATER CONNECTIONS)

GARDEN HOSE

6 FOOT TAPE

TIN SNIPS

PIPE DOPE

(SQUEEZE TUBE)

USE FOR WATER AND GAS

CONNECTIONS

PIPE WRENCH

3/4” (19 mm) WIRE BRUSH

1/2” (13 mm) WIRE BRUSH

9

HACKSAW

EMERY CLOTH

ROLL OF LEAD-FREE

SOFT SOLDER

ROLL OF

SOLDER

FLUX

TYPICAL INSTALLATION

GET TO KNOW YOUR WATER HEATER - GAS MODELS

A Vent Pipe

B Draft hood
C Anode (Not Shown)
D Hot Water Outlet
E Insulation
F Gas Supply Piping
G Manual Gas Shut-off Valve
H Ground Joint Union
I Drip Leg (Sediment Trap)
J Inner Door

* INSTALL IN ACCORDANCE

WITH LOCAL CODES.

* DRIP LEG AS REQUIRED

BY LOCAL CODES.

* ALL PIPING MATERIALS

TO BE SUPPLIED BY
CUSTOMERS.

TO VENT TERMINATION

ON ROOF

A

L

D

R

F

G

H

I

W

B

E

X

Z

S

V

U

J

ZZ

K Outer door
L Union
M Inlet Water Shut-off Valve
N Cold Water Inlet
O Inlet Dip Tube
P Temperature & Pressure Relief Valve
Q Rating Plate
R Flue Baffl e
S Gas Control Valve/Thermostat
T Drain Valve

INSTALL THERMAL EXPANSION

TANK IF WATER HEATER IS

INSTALLED IN A CLOSED

WATER SYSTEM

M

N

VACUUM RELIEF

O

Q

T

YY

VALV E

*INSTALL PER

LOCAL CODES

P

DISCHARGE PIPE

(DO NOT CAP OR PLUG.)

6” MAXIMUM

FLOOR DRAIN

AIR GAP

(S) GAS CONTROL VALVE/THERMOSTAT

IMPORTANT:

WHEN BRUSHING ON AN
APPROVED NONCORROSIVE
LEAK DETECTION SOLUTION,
DO NOT SPLASH SOLUTION
ONTO ELECTRICAL CON­NECTIONS (SEE PAGE 27).

MANIFOLD TUBE

POWER SUPPLY
TRANSFORMER
CONNECTOR

(U) NATURAL GAS BURNER ASSEMBLY

MANIFOLD DOOR GASKET

MANIFOLD COMPONENT
BLOCK W/ RETAINER CLIP

BURNER

BURNER

FLAME SENSE

HOT SURFACE

IGNITER

MANIFOLD DOOR ASSEMBLY

U Main Burner
V Flue
W Suitable Metal Drain Pan
X Control Display
Y Power Supply Transformer

(

Shown detached from Heater)

YY Pressure Switch
(

Shown detached from Heater)

Z Air Intake Chamber
ZZ FV Sensor (

IGNITER/
FLAME
SENSE
CONNECTOR

MANIFOLD DOOR ASSEMBLY

MANIFOLD

TUBE

VIEW PORT

Shown without Bracket)

PRESSURE
SWITCH/FAN,
FV SENSOR
CONNECTOR

DISPLAY, ANODE
ROD CONNECTOR

IGNITER / FLAME SENSE
CONNECTOR WIRE

IGNITER / FLAME SENSE
CONNECTOR WIRE

MANIFOLD TUBE

Y

IMPORTANT: DO NOT USE AN E XTENSION C ORD TO CONNECT
THE WATER HEATER TO AN ELECTRICAL OUTLET.

K

FIGURE 1.

10

IMPORTANT INFORMATION ABOUT THIS WATER HEATER

This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident.
The new technology used in meeting these standards makes this product more sensitive to installation errors. Please review the following
checklist and make any required installation upgrades or changes.

Questions? Contact Sears at (1-800-469-4663)

.

Installation Checklist

Water Heater Location

Water heater location is important and can affect system
performance. Please check the following:

□ Installation area free of corrosive elements and flammable

materials.

□ Centrally located with the water piping system (For new

installations). Located as close to the gas piping, vent pipe
system and 120VAC outlet as possible.

□ Located indoors and in a vertical position. Protected from

freezing temperatures.

□ Proper clearances from combustible surfaces

maintained and not installed directly on a carpeted floor.

□ Provisions made to protect the area from water damage.

Metal drain pan installed and piped to an adequate drain.

□ Sufficient room to service the water heater. See Clearances

and Accessibility section of this manual.

□ Water heater not located near an air moving device.
□ Is the installed environment dirty (excessive amounts of lint,

dirt, dust, etc.)? If so, the air intake chamber louvers located
on the side of the water heater will need to be cleaned
periodically. Refer to the maintenance section of your water
heater’s manual for information on cleaning the “Air Intake
Chamber Screen”.

Combustion Air Supply and Ventilation

Check for sufficient combustion air supply. Insufficient air for the
combustion of gas will result in a inferior burner flame “yellow­lazy”, thereby allowing smoking and carbon formation (sooting) to
build up in the combustion chamber.

Is the water heater installed in a closet or other small, enclosed
space? If so:

□ Are there openings for make-up air to enter and exit the

room/area?

□ Are the openings of sufficient size? Remember, if there are

other gas-fired or air-consuming appliances in the same
room, you need more make-up air. Refer to the Location
Requirements section of this water heater manual for
specific requirements.

Fresh air not taken from areas that contain negative pressure
producing devices such as exhaust fans, dryers, fireplaces, etc.

□ Is there a furnace/air handler in the same room space as

the water heater? If so, has a return air duct system been
attached that exits the room? If so, check for leaks on the
air duct system. If no air duct system is present, correct
immediately by contacting a local Heating, Ventilation, Air­Conditioning & Refrigeration (HVAC-R) authorized service
provider

□ Fresh air supply free of corrosive elements and

flammable vapors.

.

Vent Pipe System

Check for proper drafting at the water heater draft hood. Refer
to the “Checking the Draft” section of this manual for the test
procedure. If the procedure shows insufficient draft is present,
please check the following

.

□ Draft hood properly installed.
□ Vent connectors securely fastened with screws and

supported properly to maintain six inch clearance.

□ Vent connector made of approved material and sized

correctly.

□ Vent pipe system installed according to all local and state

codes or, in the absence of local and state codes, the
“National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current
edition.

□ Flue baffle properly positioned in the flue tube.
□ Check the vent system for restrictions/obstructions and

check the vent termination height. Refer to the “Combustion
Air and Ventilation” section of this water heater manual for
specific requirements.

□ Recheck for sufficient combustion air supply.

Water System Piping

□ Temperature and pressure relief valve properly installed with

a discharge line run to an open drain and protected from
freezing.

□ All piping properly installed and free of leaks.
□ Heater completely filled with water.
□ Closed system pressure build-up devices installed.
□ Mixing valve (when applicable) installed per manufacturer’s

instructions (See Water Temperature Regulation section).

Gas Supply and Piping

□ Gas type is the same as that listed on the water heater rating

plate.

□ Gas line equipped with shut-off valve, union, and drip leg.
□ Use pipe joint compound or teflon tape marked as being

resistant to the action of petroleum gases.

□ Adequate pipe size and approved pipe material.
□ An approved noncorrosive leak detection solution used

to check all connections and fittings for possible gas leaks.
Correct any leak found.

Electrical Supply

□ Water heater to be located as close as possible to a 120VAC

outlet (extension cord is not allowed).

□ Electrical supply installed according to all local and state

codes or, in the absence of local and state codes, the
“National Electrical Code”, ANSI/NFPS 70 current edition.

□ Ductwork is the same cross-sectional area as the

openings.

11

INSTALLATION INSTRUCTIONS

Removing the Old Water Heater

1

MANUAL GAS
SHUT-OFF VALVE

GROUND
JOINT
UNION

CHECK WITH
LOCAL UTILITY
FOR MINIMUM HEIGHT

3” MINIMUM

DRIP LEG

6

3

SUITABLE
DRAIN

FIGURE 2.

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

If the main gas line shutoff valve

serving all gas appliances is used,
also shut “OFF” the gas at each
appliance. Leave all gas appliances
shut “OFF” until the water heater
installation is completed. See
Figures 2 and 3.

5

2

DISCHARGE PIPE

4

FIGURE 3.

(DO NOT CAP

OR PLUG)

6” MAXIMUM
AIR GAP

4. Attach a hose to the water heater
drain valve and put the other end
in a fl oor drain or outdoors. (See
Figures 2 and 5.) Open the water
heater drain valve.

FIGURE 5.

5. Disconnect the vent pipe from the draft hood where it connects
to the water heater. In most installations the vent pipe can
be lifted off after any screw or other attached devices are
removed. Dispose of the draft hood. The new water heater
has a draft hood which must be used for proper operation.

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.

2. Open a nearby hot water faucet
until the water is no longer hot.
When the water has cooled,
turn “OFF” the water supply to
the water heater at the water
shut off valve or water meter.
Some installations require that
the water be turned off to the
entire house. See Figures 2

FIGURE 4.

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 6.

If you have galvanized pipes to the water heater, loosen
the two galvanized pipes with a pipe wrench at the union in
each line. Also disconnect the piping remaining to the water
heater. See Figure 7. These pieces should be saved since
they may be needed when reconnecting the new water heater.
Disconnect the temperature-pressure relief valve drain line.
When the water heater is drained, disconnect the hose from
the drain valve. Close the drain valve. The water heater
is now completely disconnected and ready to be removed.
Mineral buildup or sediment may have accumulated in the
old water heater. This causes the water heater to be much
heavier than normal and this residue, if spilled out, could
cause staining.

FIGURE 7.

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Location Requirements

WARNING

If flammable liquids or vapors have spilled or leaked in the area
of the water heater, leave the area immediately and call the fire
department from a neighbor’s home. Do not attempt to clean the
spill until all ignition sources have been extinguished.

Carbon Monoxide Poisoning Hazard

Do not install in a mobile home.

Doing so can result in carbon monoxide poisoning and death.

The FVIR System is designed to reduce the risk of flammable
vapor-related fires. Flammable liquids (such as gasoline,
solvents, propane, 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.

FIGURE 8.

FV Sensor

This heater is equipped with a FV sensor for detecting the
presence of flammable vapors. 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 38-40
(numbers 9,11,12). 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.

WARNING

FLAMMABLES

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death

Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this or any other
appliance. Storage of or use of gasoline or other
flammable vapors or liquids in the vicinity of this or
any other appliance can result in serious injury or
death.

Read and follow water heater warnings and
instructions

Do not use or store flammable products such as gasoline,
solvents, or adhesives in the same room or area near the
water heater. If such flammables must be used, all gas burning
appliances in the vicinity must be shut off and their pilot lights
extinguished. Open the doors and windows for ventilation while
flammable substances are in use.

Flammable Vapors

WARNING

Fire or Explosion Hazard

• Read instruction manual before installing, using or
servicing water heater.

• Improper use may result in fire or explosion.

• Maintain required clearances to combustibles.

Keep combustibles such as boxes, magazines, clothes, etc. away
from the water heater area.

Site Location

• Select a location near the center of the water piping system.
The water heater must be installed indoors and in a vertical
position on a level surface. DO NOT install in bathrooms,
bedrooms, or any occupied room normally kept closed.

• Locate the water heater as close to the chimney or gas vent
as practical. Consider the vent system piping and combus­tion air supply requirements when selecting the water heater
location. The venting system must be able to run from the
water heater to termination with minimal length and elbows.

• Locate the water heater near the existing gas piping. If
installing a new gas line, locate the water heater to minimize
the pipe length and elbows.

• The water heater should be located in an area not subject
to freezing temperatures. Water heaters located in
unconditioned spaces (i.e., attics, basements, etc.) may
require insulation of the water piping and drain piping to
protect against freezing. The drain and controls must be
easily accessible for operation and service. Maintain proper
clearances as specified on the water heater.

• Do not locate the water heater near an air-moving device.
The operation of air-moving devices such as exhaust fans,
ventilation systems, clothes dryers, fireplaces, etc., can af­fect the proper operation of the water heater. Special atten­tion must be given to conditions these devices may create.
Flow reversal of flue gases may cause an increase of carbon
monoxide inside of the dwelling (Figure 10).

• The water heater is to be located as close as possible to
a 120VAC outlet. NOTE: all electrical wiring should be in
accordance to the NEC and all local/state electrical codes
(extension cord is not allowed).

NOTE: This water heater must be installed according to all local and
state codes or, in the absence of local and state codes, the “National
Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edition and the
“National Electrical Code”, ANSI/NFPS 70 current edition.

13

EXHAUST FAN

IMPORTANT: The water heater should be located in an area where
leakage of the tank or connections will not result in damage to the
area adjacent to the water heater or to lower floors of the structure.
Due to the normal corrosive action of water, the tank will eventually
leak after an extended period of time. Also any external plumbing
leak, including those from improper installation, may cause early
failure of the tank due to corrosion if not repaired. If the homeowner
is uncomfortable with making the repair a qualified technician should
be contacted. A suitable metal drain pan should be installed under
the water heater as shown below, to help protect the property from
damage which may occur from condensate formation or leaks in
the piping connections or tank. The pan must limit the water level
to a maximum depth of 1-3/4” and be two inches wider than the
heater and piped to an adequate drain. Locate the water heater
near a suitable indoor drain. Outside drains are subject to freezing
temperatures which can obstruct the drain line. The piping should be
at least 3/4” ID and pitched for proper drainage.

FIGURE 9.

1-3/4”

max.

At least 2” greater

than the water heater.

Pipe to an
adequate drain

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

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

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

REVERSE FLOW
OF GASES

FIGURE 10.

Clearances and Accessibility

NOTE: Minimum clearances from combustible materials are
stated on the label on the front of the heater adjacent to the gas
control valve/thermostat of the water heater.

The water heater is certified for installation on a combustible
floor.

• IMPORTANT: If installing over carpeting, the carpeting must

be protected by a metal or wood panel beneath the water
heater. The protective panel must extend beyond the full
width and depth of the water heater by at least five inches
(127mm) in any direction; or if in an alcove or closet installa­tion, the entire floor must be covered by the panel.

• Figure 11 may be used as a reference guide to locate the

specific clearance locations. A minimum of 5 inches of front
clearance should be provided for inspection and service.

6” min. at
Single Wall
Vent Pipe

0” min.
Back

Top View

12” min.
Top to
Ceiling

0” min.
Sides

0” min.
Air Inlet
Chamber

5” min.
Front

Minimum Clearance Locations

FIGURE 11.

High Altitude Installation

This water heater should not be installed for operation at
elevations above 10,100 ft. (3,078 m).

14