Kenmore 153331242 User Manual WATER HEATER Manuals And Guides LR708077

KENMORE Water heater, Gas Manual LR708077 KENMORE Water heater, Gas Owner's Manual, KENMORE Water heater, Gas installation guides

User Manual: Kenmore 153331242 153331242 KENMORE WATER HEATER - Manuals and Guides View the owners manual for your KENMORE WATER HEATER #153331242. Home:Plumbing Parts:Kenmore Parts:Kenmore WATER HEATER Manual

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Owner's ManuaJ

POWER MISERTM 12

ULTRA LOW NO×

GAS WATER HEATER

FOR POTABLE WATER HEATING ONLY.

NOT SUITABLE FOR SPACE HEATING.

NOT FOR USE iN MOBILE HOMES.

MODEL NO.

153.331242 40 Gallon

153.331252 50 Gallon

This water heater meets the new ANSI Z21.10.1 standard that

deals with the accidental or unintended ignition of flammable

vapors, such as those emitted by gasoline.

manual and safety messages

before installing, operating or

servicing this water heater.

Failure to follow instructions and

safety messages could result in

death or serious injury.

Instruction manual must remain

with water heater.

•Safety Instructions

•Installation

•Operation

• Care and Maintenance

.Troubleshooting

.Parts List

For Your Safety

AN ODORANT iS ADDED TO THE GAS USED BY THIS WATER HEATER.

WARNING: if the information in these

instructions is not followed exactly, a fire

or explosion may result causing property

damage, personal injury or death.

--Do not store or use gasoline or other

flammable vapors and liquids in the

vicinity of this or any other appliance,

-- WHAT TO DO IF YOU SMELL GAS:

•Do not try to light any appliance.

Do not touch any electrical switch; do

not use any phone in your building.

Immediately call your gas supplier

from a neighbor's phone. Follow the

gas supplier's instructions.

• If you cannot reach your gas supplier,

call the fire department.

--Installation and service must be

performed by a qualified installer,

service agency orthe gas supplier.

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

PRINTED IN THE U.S.A 0707 _tVVW,SeatS,COJ'_ PART NO. 186192-000

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 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, could result

in death or injury.

WARNING indicates a potentially hazardous

situation which, if not avoided, could result

in death or injury.

CAUTION indicates apotentially 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

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,

manual and safety messages

before installing, operating or

servicing this water heater.

Failure to follow instructions and

safety messages could result in

death or serious injury.

Instruction manual must remain

with water heater.

Fire Hazard

For continued protection against

riskof fire:

-Do not install water heater on

carpeted floor.

-Do not operate water heater if

flood damaged.

Wafer temperature over 125°F

(52°C) can cause severe burns

instantly resulting in severe injury

or death.

Children, the elderly, and the

physically or mentally disabled

are at highest riskforscald injury.

Feel water before bathing or

showering.

Temperature limiting valves are

available

Read instruction manual for safe

temperature setting.

Fire or Explosion Hazard

, Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this or any otller

appliance.

* Avoid all ignition sources if you smell LP gas.

*Do not expose water heater control to excessive gas

pressure,

, Use only gasshown on ratingplate

- 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.

Explosion Hazard

•Overheated water can cause

watertank explosion.

• Properly sized temperature

and pressure relief valve must

be installed in opening

provided.

Breathing Hazard - Carbon Monoxide Gas

.Install vent system in accordance with

codes.

. Do not operate water heater if flood

damaged.

• High altitude orifice must be installed for

J_!_i}_ -"'°_:_'_'''_:i':'_ operation above 2,000 feet (610 m).

.,,:. ::,, ,_:,:._! •Do not operate if soot buildup.

o,_1:_:_, _,..:_:,o • Do not obstruct water heater air intake

with insulating jacket.

_,,dlll:ll

,_it_; _ •Do not place chemical vapor emitting!_ products near water heater.

b= Gas and carbon monoxide detectors

are available.

Breathing carbon monoxide can cause brain damage or

death. Always read and understand instruction manual.

improper installation and use may result

in property damage.

Do not operate water heater if flood damaged.

Inspect and replace anode.

- Install in location with drainage.

• Fill tank with water before operation.

Be alert for thermal expansion.

Refer to instruction manual for installation and service.

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

SAFETY PRECAUTIONS .............................................................................................................................. 3

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

CUSTOMER RESPONSIBILITIES .........................................................................................................................................5

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

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

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

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

TYPICAL INSTALLATION .......................................................................................................................................................... 7

INSTALLATION INSTRUCTIONS ......................................................................................................................................8-17

Removing the Old Water Heater ............................................................................................................................... 8

Facts to Consider About the Location .................................................................................................................. 9-10

Insulation Jackets ................................................................................................................................................... 10

Combustion Air and Ventilation Appliances in Unconfined Spaces ........................................................................ 11

Combustion Air and Ventilation Appliancesin Confined Spaces ........................................................................ 11-12

Water Piping ...................................................................................................................................................... 12-13

T & P Valve and Pipe Insulation ........................................................................................................................ 13-14

Temperature Pressure Relief Valve ................................................................................................................... 13-14

Filling the Water Heater .......................................................................................................................................... 15

Venting ............................................................................................................................................................... 15-16

Gas Piping ......................................................................................................................................................... 16-17

Sediment Trap ........................................................................................................................................................ 17

OPERATING INSTRUCTIONS ......................................................................................................................................... 18-19

Lighting & Operating Label ..................................................................................................................................... 18

Temperature Regulation ......................................................................................................................................... 19

SERVICE AND ADJUSTMENT ........................................................................................................................................20-22

Tank (Sediment) Cleaning ...................................................................................................................................... 20

Venting System Inspection ..................................................................................................................................... 20

Burner Inspection ................................................................................................................................................... 20

Removing the Burner Door Assembly .................................................................................................................... 21

Ultra Low NOx Natural Gas Burner ........................................................................................................................ 21

Replacing the Pilot Assembly ................................................................................................................................. 21

Replacing the Thermocouple .................................................................................................................................. 22

External Inspection & Cleaning of the Flame Arrestor ............................................................................................ 22

Cleaning the Combustion Chamber and Flame Arrestor ........................................................................................ 22

Replacing the Burner DoorAssembly ..................................................................................................................... 23

Piezoelectric Igniter System ................................................................................................................................... 23

Testing the Igniter System ...................................................................................................................................... 23

Removing and Replacing the Gas Control Valve/Thermostat ................................................................................ 24

Housekeeping ......................................................................................................................................................... 24

Anode Rod Inspection ............................................................................................................................................ 24

Temperature-Pressure Relief Valve Operation ....................................................................................................... 25

Draining .................................................................................................................................................................. 25

Drain Valve Washer Replacement .......................................................................................................................... 25

Service .................................................................................................................................................................... 25

TROUBLESHOOTING GUIDE ........................................................................................................................................ 26-30

Start Up Conditions ........................................................................................................................................... 26-27

Thermal Expansion ........................................................................................................................................... 26

Strange Sounds ................................................................................................................................................ 26

Draft Hood Operation ........................................................................................................................................ 26

Condensation .................................................................................................................................................... 27

Smoke/Odor ...................................................................................................................................................... 27

Operational Conditions ........................................................................................................................................... 27

Smelly Odor ...................................................................................................................................................... 27

Air in Hot Water Faucets ................................................................................................................................... 27

High Temperature Shut-Off System .................................................................................................................. 27

Troubleshooting Items ....................................................................................................................................... 28-30

PARTS ORDER LIST ................................................................................................................................................................31

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

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 1-8OO-4-MY-HOME e_'.They

will arrange for prompt, quality installation by Sears authorized

contractors.

Abbreviations Found In This Instruction Manual:

CSA - Canadian Standards Association

ANSI -American National Standards Institute

NFPA - National Fire Protection Association

ASME -American Society of Mechanical Engineers

GAMA - Gas Appliance Manufacturers Association

This gas-fired water heater is design certified by CSA

INTERNATIONAL under American National Standard/CSA

Standard for Gas Water Heaters ANSI Z21.10.1 • CSA 4.1

(current edition).

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 DEATH, SERIOUS BODILY INJURY AND/OR

PROPERTY DAMAGE.

This manual contains instructions for the installation, operation,

and maintenance of the gas-fired 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 first few pages, READ THE

ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR

OPERATE THE WATER HEATER.

The installation must conform with these instructions and

the local code authority having jurisdiction. In the absence

of local codes, installations shall comply with the current

edition of 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 fires. See

figure 1.

Examine the location to ensure the water heater complies

with the Facts to Consider About the Location 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 the California

Office of the State Architect, 400 P Street, Sacramento, CA

95814.

Complies with 10 ng/J SCAQMD rule #1121 and districts

having equivalent NOx requirements.

RECOVERY MINIMUM DIMENSIONS IN

TANK INPUT RATE GALS. VENT PIPE DIAMETER INCHES (mm)

CAPACITY IN TYPE OF RATE PER HOUR @ INCHES INCHES HEIGHT TO

MODEL NUMBER GALS (LTRS) GAS (Btu/hr) 9O°F RISE (ram) (ram) JACKET TOP

I53.331242 40 (151) NATURAL 40,000 41.0 3" (76) OR 4" (102) 20" (508) 58 3/8" (1,483)

I53.331252 50 (189) NATURAL 40,000 41.0 3" (76) OR 4" (102) 22" (559) 57 3/8" (1,457)

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

TH ERMAL EXPANSION

CONDITIONS AVAILABLE

IN 2 GALLONS

(7,6 LITERS) AND

5GALLONS (18,9 LITERS)

CAPACITY THROUGH

LOCAL SEARS STORE

OR SERVICE CENTER.

.:r.'_'Jt:t:!L!!

IL!

WATER HEATER iNSTALLATION KiT WITH

FLEXIBLE CONNECTORS FOR 3/4"

(19,06 ram) OR 1/2" (12,7 ram) THREADED OR

COPPER PLUMBING AND FLEXIBLE WATER

HEATER GAS CONNECTOR WITH FITTINGS,

'///J

DRAIN PANS AVAILABLE iN

20" (506 ram) DIAMETER FOR

WATER HEATERS HAVING A

DIAMETER 18" (457 mm) OR

LESS, 24" (610ram) DIAMETER

FOR WATER HEATERS HAVING

A DIAMETER 22" (559 mm)

OR LESS AND AVAILABLE IN

28" (711 rnm) DIAMETER FOR

WATER HEATERS HAVING A

DIAMETER 26" (660 ram) OR

LESS.

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 DRILL

SLOT-HEAD SCREWDRIVER

PHILLIPS SCREWDRIVER

TIN SNIPS

ROLL OF TEFLON

TAPE (USE ONLY ON

WATER CONNECTIONS)

PiPE DOPE

(SQUEEZE TUBE)

USE FOR WATER AND GAS

CONNECTIONS

GARDEN HOSE 6 FOOT TAPE PIPE WRENCH

Additional Tools Needed

When Sweat Soldering

Tubing Cutters or Hacksaw

Propane Tank

Soft Solder

Solder Flux

Emery Cloth

Wire Brushes

TUBING CUTTER

PROPANE

TORCH

HACKSAW

ROLL OF

EMERY CLOTH

3/4" (19 ram) WIRE BRUSH

1/2" (13 ram) WIRE BRUSH

ROLL OF LEAD-FREE

SOFT SOLDER

SOLDER

FLUX

GET TO KNOW YOUR WATER HEATER - GAS MODELS

A Vent Pipe JDrip Leg (Sediment Trap) S Flue Baffle

BDrafthood KInner Door T Thermostat

CAnode L Outer door U Drain Valve

D Hot Water Outlet M Union V Pilot and Main Burner

EOutlet N Inlet Water Shut-off Valve W Flue

F Flexible Water Connections O Cold Water Inlet X Drain Pan

G Gas Supply P Inlet Dip Tube YPiezo Igniter

H Manual Gas Shut-off Valve Q Temperature-Pressure Relief Valve

I Ground Joint Union R Rating Plate

*INSTALL IN ACCORDANCE

WITH LOCAL CODES.

*DRIP LEG AS REQUIRED

BY LOCAL CODES.

TO VENT TERMINATION

ON ROOF

INSTALL THERMAL EXPANSION

TANK OR DEVICE IF WATER

HEATERIS INSTALLED INA

CLOSED WATERSYSTEM

*ALL PIPING MATERIALS TO BE

SUPPLIED BY CUSTOMERS.

VACUUM RELIEF

VALVE

_INSTALLPER

LOCALCODES

FIGURE 1.

(T) THERMOSTAT

GAS CONTROL KNOB

b1° /

WATER TEMPERATURE

(ADJUSTING DIAL)

"OFF .... PILOT .... ON"

POSITION POSITION POSITION

TOP VIEW

(V) PILOT & MAIN BURNER

MAIN BURNER PILOT TUBING

BURNER

TUBE

PILOT

THERMOCOUPLE

IGNITER ROD

Removing the Old Water Heater

.* %

®;

FIGURE 2.

QTurn "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. FIGURE 3,

Q Turn "OFF" the water to

supply

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. FIGURE 4,

Check to make the is "OFF" to the

again sure gas supply

water heater. Then disconnect the gas supply connection from

the gas control valve.

Attach 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. To 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. FmGURE5.

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.

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 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.

, Burn hazard

,Hot water discharge,

•Keep hands clear of drain

valve discharge.

Facts to Consider About

the Location

Carefully choose an indoor location for the new water heater.

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:

• Select a location indoors as close as practical to the gas

vent or chimney to which the water heater vent is going to be

connected, and as centralized with the water piping system

as possible.

• Selected location must provide adequate clearances for

servicing and proper operation of 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.

Fire or Explosion Hazard

" De not store or use gasol ne or other flammable

vapors and liquids in the vicinity of this or any other

appliance.

- Avoid all ignition sources if you smell LP gas.

.Do not expose water tleater control to excessive gas

pressure.

, Use only gas shown on rating plate

, Maintain required clearances to combustibles.

• Keep gnition sources away from faucets after

extended period of non-use.

Read instruction manual before

installing, using or servicing

water heater.

Prope_y Damage Hazard

• AH water heaters eventually leak

,Do not install without adequate drainage

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 Sears or hardware store. Such a drain pan must have a

minimum length and width of at least 2 inches (51 mm) greater than

the water heater dimensions and must be piped to an adequate

drain. The pan must not restrict combustion air flow.

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. 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.

INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS

(VAPORS) ARE LIKELY TO BE PRESENT OR STORED

(GARAGES, STORAGEAND UTILITYAREAS, ETC.): Flammable

liquids (such as gasoline, solvents, 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 pilot light or

main burner. The resulting flashback and fire can cause death

or serious burns to anyone in the area. Even though this water

heater is a flammable vapor 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.

Also, the water heater must be located and/or protected so it is

not subject to physical damage by a moving vehicle.

Fire Hazard

For continued protection against

riskof fire:

-Do not install water heater on

carpeted floor.

•Do not operate water heater if

flood damaged.

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 inches (76.2mm) 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.

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.

Minimum clearances between the water heater and combustible

construction are 0 inch at the sides and rear, 4 inches (102 mm)

at the front, and 6 inches (153 mm) from the vent pipe, see

Figure 8. Clearance from the top of the jacket is 8 inches (203

mm) on most models. Note that a lesser dimension may be

allowed on some models, refer to the label attached adjacent

to the gas control valve on the water heater.

TOP VIEW TOP ViEW

OF CLOSET OF CLOSET

WITHOUT DOOR WiTH DOOR

II 0" rvlIN, =========_ (104 ram)

0" MINo

FIGURE8.

Breathing Hazard - Carbon Monoxide Gas

12" MAX.

_t3r_ cm)

FRONT VIEW t

OF DOOR

AIR DUCT

FIGURE 9,

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 directly from outdoors (direct vent).

Propellants of aerosol sprays and volatile compounds, (cleaners,

chlorine based chemicals, refrigerants, etc.) in addition to being

highly flammable in many cases, will also change to corrosive

hydrochloric acid when exposed to the combustion products of

the water heater. The results can be hazardous, and also cause

product failure.

Insulation Blankets

Insulation blankets available to the general public for external

use on gas water heaters are not necessary with Kenmore

products. The purpose of an insulation blanket is to reduce the

standby heat loss encountered with storage tank heaters. Your

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.

- Install water heater in accordance

with the instruction manual and

NFPA 54.

•To avoid injury, combustion and

ventilation air must be taken from

outdoors.

•Do not place chemical vapor

emitting products near water

heater,

Breathing carbon monoxide can cause brain damage or

death. Always read and understand instruction manual.

A gas water heater cannot operate properly without the correct

amount of air for combustion, see Figure 9. Do not install in a

confined area such as a closet, unless you provide air as shown

in the Locating The New Water Heater 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.

Breathing Hazard - Carbon Monoxide Gas

• Do not obstruct water heater air

intake with insulating blanket.

• Gas and carbon monoxide detectors

are ava lable.

• Install water heater in accordance

with the instruction manual.

Breathing carbon monoxide can cause brain damage or

death. Always read and understand instruction manual.

,_11_ WARNING

Should you choose to apply an insulation blanket to this

heater, you should follow these instructions (See Figure 1 for

identification of components mentioned below). 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 draft hood.

• Do not cover the outer door, thermostat or temperature &

pressure relief valve.

• Do not allow insulation to come within 2" (50.8 mm) 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.

• DoobtainnewwarningandinstructionlabelsfromSearsfor

placementontheblanketdirectlyovertheexistinglabels.

• Doinspecttheinsulationblanketfrequentlytomakecertain

itdoesnotsag,therebyobstructingcombustionairflow.

Combustion Air and Ventilation for

Appliances Located in Unconfined Spaces

UNCONFINED SPACE is space whose volume is not less than

50 cubic feet per 1,000 Btu per hour (4.8 m 3 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 Ventilation for Appliances

Located in Confined Spaces.

Combustion Air and Ventilation for

Appliances Located in Confined Spaces

CONFINED SPACE is a space whose volume is less than

50 cubic feet per 1,000 Btu per hour (4.8 m3 per kW) of the

aggregate input rating of all appliances installed in that space.

A. ALL AIR FROM INSIDE BUILDINGS:

(See Figure 9 on page 10 and Figure 10 below)

The confined space shall be provided with two permanent

openings communicating directly with an additional room(s) of

sufficient volume so that the combined volume of all spaces

meets the criteria for an unconfined space. The total input of all

gas utilization equipment installed in the combined space shall

be considered in making this determination. Each opening shall

have a minimum free area of one square inch per 1,O00 Btu per

hour (22 cm2/kW) of the total input rating of all gas utilization

equipment in the confined space, but not less than 100 square

inches (645 cm2). One opening shall commence within 12 inches

(30 cm) of the top and one commencing within 12 inches (30

cm) of the bottom of the enclosures.

___OP ENINGS

FIGURE 10,

B. ALL AIR FROM OUTDOORS: (See Figures 9, 11,12,13 and 13A)

The confined space shall be provided with two permanent

openings, one commencing within 12 inches (30 cm) of the top

and one commencing within 12 inches (30 cm) from the bottom

of the enclosure. The openings shall communicate directly, or

by ducts, with the outdoors or spaces (crawl or attic) that freely

communicate with the outdoors.

CHIMNEY OR

GAS VENT VENTILATION LOUVERS

OUTLET MR

'WATERHEATER

FURNACE

INLETAIR DUCT

ALT. INLET AiR VENTILATION LOUVERS

FIGURE II.

When directly communicating with the outdoors, each opening

shall have a minimum free area of 1 square inch per 4,0go Btu

per hour (5.5 cm2/kW) of total input rating of all equipment in

the enclosure. See Figure 11.

When communicating with the outdoors through vertical

ducts, each opening shall have a minimum free area of

1 square inch per 4,000 BTU per hour (5.5 cm2/kW) of

total input rating of all equipment in the enclosure. See

Figure 12.

CHIMNEY OR GAS VENT

VENTiLATiON LOUVERS

_.,_'(EAOH END OF ATT'C)

AIR OUTLET

_WATER HEATER

INLET AIR DUCT

IIl ll LfJL ilq--- 'Nos,'cR,oo..

ABOVE FLOOR)

FIGURE 12.

When communicating with the outdoors through horizontal

ducts, each opening shall have a minimum free area of

1 square inch per 2,000 BTU per hour (11 cm2/kW) of

total input rating of all equipment in the enclosure. See

Figure 13.

When ducts are used, they shall be of the same cross-

sectional area as the free area of the openings to which

they connect. The minimum short side dimension of

rectangular air ducts shall not be less than 3 inches

(76.2 ram). See Figure 13.

_WATER HEATER 1

FIGURE 13.

_ OUTLET A{R DUCT

i_ INLET AIR DUCT

Alternatively a single permanent opening may be used when

communicating directly with the outdoors, or with spaces that

freely communicate with the outdoors. The opening shall

have a minimum free area of 1 square inch per 3,000 BTU

per hour (8.3 cm2/kW) of total input rating of all equipment in

the enclosure. See Figure 13A.

GAS VENT

OPENING

LOCATION

FIGURE 13A,

Louvers and Grilles: In calculating free area, consideration

shall be given to the blocking effect of louvers, grilles or

screens protecting openings. Screens used shall not be

smaller than 1/4 inch (6.4 mm) mesh. If the free area through

a design of louver or grille is known, it should be used in

calculating the size opening required to provide the free area

specified. If the design and free area is not known, it may be

assumed that wood louvers will be 20-25 percent free area

and metal louvers and grilles will have 60-75 percent free

area. Louvers and grilles shall be fixed in the open position

or interlocked with the equipment so that they are opened

automatically during equipment operation.

Special Conditions Created by Mechanical Exhausting or

Fireplaces: operation of exhaust fans, ventilation systems,

clothes dryers or fireplaces may create conditions requiring

special attention to avoid unsatisfactory operation of installed

gas utilization equipment.

Water Piping

Water temperature over 125°F

(52°0) can cause severe burns

instantly resulting in severe injury

or death.

Children, elderly, and the

physically or mentally disabled

a re at highest riskfor scald injury

Feel water before bathing or

showering

Temperature limiting valves are

available

Read instruction manual for safe

temperature setting.

HOTTER WATER CAN SCALD:

Water heaters are intended to produce hot water. Water

heated to a temperature which will satisfy space heating,

clothes washing, dish washing, cleaning 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. See Figure 14. Valves

for reducing point of use temperature by mixing cold and hot

water are also available. Follow manufacturer's instructions

for installation of the valves. Before changing the factory

setting on the thermostat, read the Temperature Regulation

section in this manual.

HOT WATER _ COLD WATER

OUTLET IN.LET

TEMPEREE_

WATER OUTL

TO COLD WATER

FROM WATERHEATER

*MIXING BeT WATER

VALVE OUTLET ON

WATER HEATER

FIGURE 14,

Toxic Chemical Hazard

• Do not connect to non-potable water system.

Thiswaterheatershallnotbe connectedto anyheating

systemsorcomponent(s)usedwithanon-potablewaterheating

appliance.

Allpipingcomponentsconnectedtothisunitforspaceheating

applicationsshallbesuitableforusewithpotablewater.

Toxicchemicals,suchasthoseusedforboilertreatmentshall

notbeintroducedintothissystem.

Watersupplysystemsmay,becauseofsucheventsashighline

pressure,frequentcut-offsortheeffectsofwaterhammer,have

installeddevicessuchaspressurereducingvalves,checkvalves,

backflowpreventers,etc.tocontrolthesetypesofproblems.

Whenthesedevicesarenotequippedwithaninternalby-pass,

andnoothermeasuresaretaken,thedevicescausethewater

systemtobeclosed.Aswaterisheated,itexpands(thermal

expansion)andclosedsystemsdonotallowfortheexpansion

ofheatedwater.

Thewaterwithinthewaterheatertankexpandsasitisheated

andincreasesthepressureofthewatersystem.Iftherelieving

pointofthewaterheater'stemperature-pressurereliefvalve

is reached,thevalvewillrelievetheexcesspressure.The

temperature-pressurerelief valve is not intended for the

constant relief of thermal expansion. This is an unacceptable

condition and must be corrected. It is recommended that any

devices installed which could create a closed system have a

by-pass and/or the system have an expansion tank to relieve the

pressure built by thermal expansion in the water system. Refer

to the Thermal Expansion section under Troubleshooting Guide

or contact local plumbing authority or local Sears Service Center

on how to control this situation.

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.

Property Damage Hazard

•Avoid water heater damage.

,Install thermal expansion tank if necessary.

-Do not apply heat to cold water inlet.

- Contact qualified installer or Sears Service Center.

Look at the top 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 314" NPT threaded nipple. Using

flexible connectors, connect the cold water pipe to the cold

water inlet of the water heater.

NOTE: This water heater is super 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.

INSTALLATION COMPLETED USING

INSTALLATION KIT

FLEXIBLE

WATER SHUTOFF

CONNECTORS VALVE

HOT WATER _ COLD WATER

THREADED TO THREADED TO

SWEAT COUPLIN SWEAT COUPLING

3/4"THREADED_3/4"THREADED

COUPLING COUPLING

DRAFT HOOD

_"TEMPERATURE-

PRESSURE

RELIEF VALVE

_"-DISCHARGE PIPE

(Do not cap or plug)

FIGURE 15,

AIR

GAP

- FLOOR DRAIN

T&PValve and Pipe insulation

Remove insulation for T & P valve and pipe connections from

carton.

Figure 15 shows the typical attachment of the water piping to

the water heater. The water heater is equipped with 3/4" NPT

water connections.

NOTE: If using copper tubing, solder tubing to an adapter

before attaching the adapter to the cold water inlet

connection. Do not solder the cold water supply line directly

to the cold water inlet. It will harm the dip tube and damage

the tank.

• Look at the top cover of the water heater. The 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" NPT threaded nipple. Using flexible

connectors, connect the hot water pipe to the hot water outlet

on the water heater.

TEFLON® is aregistered trademark of E.I. Du Pont De Nemours and Company.

PiPE

iNSULATION FLUE PiPE

FIGURE 15A.

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.

FitT&Pvalveinsulationovervalve.Makesurethattheinsulation

doesnotinterferewiththeleveroftheT&Pvalve.

Secureallinsulationusingtape.

Temperature-Pressure Relief Valve

Explosion Hazard

-Temperature-pressure relief valve

must comply with ANSI Z21.22

and ASME code.

- Properly sized temperature-

pressure relief valve must be

installed in opening provided.

-Can result in overheating arid

e×cessive tank pressure.

-Can cause serious inJury or death.

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 as meeting the requirements for Relief Valves for Hot

Water Supply Systems, ANSI Z21.22 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 = 1,035kPa) and a discharge capacity not less

than the water heater input rate as shown on the model rating

plate.

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.

Position the valve downward and provide tubing so that any

discharge will exit only within 6 inches (153 mm) above, or

at any distance below the structural floor, see Figure 16. Be

certain that no contact is made with any live electrical part.

The discharge opening must not be blocked or reduced in

size under any circumstances. Excessive length, over 30 feet

(9.14 m), or use of more than four elbows can cause restriction

and reduce the discharge capacity of the valve.

No valve or other obstruction is to be placed between the relief

valve and the tank. Do not connect tubing directly to discharge

drain unless a 6 inch air gap is provided. To prevent bodily

injury, hazard to life, or property damage, the relief valve must

be allowed to discharge water in quantities should circumstances

demand. If the discharge pipe is not connected to a drain or other

suitable means, the water flow may cause property damage.

HOT WATER COLD WATER

OUTLET INLET

SHUTOFF

VALVE

HOT _S_

\TEMPERATURE-PRESSURE

RELIEF VALVE

_---DISCHARGE PIPE

(Donotcaporplug)

FIGURE 16.

Water Damage Hazard

.Temperature-pressure relief valve discharge

pipe must terminate at adequate drain.

The Discharge Pipe:

• Shall not be smaller in size than the outlet pipe size of the

valve, or have any reducing couplings or other restrictions.

• Shall not be plugged or blocked.

• Shall be of material listed for hot water distribution.

• Shall be installed so as to allow complete drainage of both

the temperature-pressure relief valve, and the discharge

pipe.

• Shall terminate at an adequate drain.

• Shall not have any valve between the relief valve and tank.

Water temperature over t25°F

(52°C) can cause severe burns

instantly resulting in severe injury

or death.

Children, the elderly, and the

physically or mentally disabled

are at highest risk for scald injury,

Feel water before bathing or

showering.

Temperature limiting valves are

available.

Read instruction manual for safe

temperature setting

Thetemperature-pressurereliefvalvemustbemanuallyoperated

atleastonceayear.Cautionshouldbetakentoensurethat

(1)nooneisinfrontoforaroundtheoutletofthetemperature-

pressurereliefvalvedischargeline,and(2)thewatermanually

dischargedwillnotcauseanybodilyinjuryorpropertydamage

becausethewatermaybeextremelyhot.

Ifaftermanuallyoperatingthevalve,itfailstocompletelyreset

andcontinuestoreleasewater,immediatelyclosethecoldwater

inlettothewaterheater,followthedraininginstructions,and

replacethetemperature-pressurereliefvalvewithanewone.

Filling the Water Heater

Property Damage Hazard

• Avoid water heater damage.

• Fill tank with water before operating.

Never use this water heater unless it is completely full of water.

To prevent damage to the tank, the tank must be filled with water.

Water must flow from the hot water faucet before turning "ON"

gas to the water heater.

To fill the water heater with water:

Close the water heater drain valve by inserting a flat head

screwdriver in the slot on the stem and turn to the right

(clockwise). The drain valve is on the lower front of the water

heater.

• Open the cold water supply valve to the water heater.

NOTE: The cold water supply valve must be left open

when the water heater is in use.

To insure complete filling of the tank, allow air to exit by

opening the nearest hot water faucet. Allow water to run until

a constant flow is obtained. This will let air out of the water

heater and the piping.

Check all water piping and connections for leaks. Repair as

needed.

Venting

VENT DAMPERS - Any vent damper, whether it is operated

thermally or otherwise must be removed if its use inhibits proper

drafting of the water heater.

Thermally Operated Vent Dampers: Gas-fired water heaters

having thermal efficiency in excess of 80% may produce a

relatively low flue gas temperature. Such temperatures may

not be high enough to properly open thermally operated vent

dampers. This would cause spillage of the flue gases and may

cause carbon monoxide poisoning.

Vent dampers must bear evidence of certification as complying

with the current edition of the American National Standard

ANSI Z21.68 (ANSI Z21.66 & 67, respectively, cover electrically

and mechanically actuated vent dampers). Before installation

of any vent damper, consult your local Sears Service Center or

Breathing Hazard -Carbon Monoxide Gas

- Vent dampers must be certified

in accordance with ANSI Z21.68.

• Vent damper must permit proper

drafti ng of water heater

• *L:t'_" ..;:_:::_,,, • installproperlysizedventing.

1,**,:,_:{ -Do not install without venting

;,_![.ii_- outdoors.

- Do notinstallwithoutdrafthood

.,i_m,._mm_._._._..,j_p,j:.,m_b_• If common vented install in

_l_i_ !.i'!_,;_l_ accordanoewith NFPA 54

v- lll_b_ -,-4 , Be alert for obstructed or deterio-

_ rated vent system to avoid

[]_ serious injury or death

Breathing carbon monoxide can cause brain damage or

death. Always read and understand instruction manual

the local gas supplier for further information.

To insure proper venting of this gas-fired water heater, the correct

vent pipe diameter must be utilized. Any additions or deletions

of other gas appliances on a common vent with this water

heater may adversely affect the operation of the water heater.

Consult your gas supplier if any such changes are planned.

For replacement heater installations where pre-existing venting

is used, the venting must be inspected for obstructions and if

deterioration is present, it must be replaced.

For proper venting in certain installations, a larger diameter vent

pipe may be necessary. Consult your local Sears Service Center

or gas supplier to aid you in determining the proper venting for

your water heater from the vent tables in the current edition of

the National Fuel Gas Code ANSI Z223.1/NFPA 54.

Periodically check the venting system for signs of obstruction or

deterioration and replace if needed.

The combustion and ventilation air flow must not be

obstructed.

The water heater with draft hood installed must be connected

to a chimney or listed vent pipe system, which terminates to the

outdoors. Never operate the water heater unless it is vented

to the outdoors and has adequate air supply to avoid risks of

improper operation, explosion or asphyxiation.

For proper draft hood attachment, the draft hood legs may

be angled slightly inward.

Place the draft hood legs in the receiving holes on the top

of the water heater. The legs will snap in the holes to give a

tight fit. Secure the legs to top with sheet metal screws. See

Figure 17.

Place the vent pipe over the draft hood. With the vent pipe

in position, drill a small hole through both the vent pipe and

draft hood. Secure them together with a sheet metal screw.

Obstructed or deteriorated vent systems may present serious

health risk or asphyxiation.

SHE _4ETA SCREWS (o_,_ _o,4d÷@

LEGS

NSIX£TH O_4AF7 HOOD WHH

THE FOR SCREWS PROV_DCD

FIGURE 17.

The vent pipe from the water heater must be no less than the

diameter of the draft hood outlet on the water heater and must

slope upward at least 1/4 inch per linear foot (21 mm per meter).

See Figure 18.

I II PERLINEARFOOT

CHIMNEY

FIGURE 18,

All vent gases must be completely vented to the outdoors of the

structure (dwelling). Install only the draft hood provided with the

new water heater and no other draft hood.

Vent pipes must be secured at each joint with sheet metal

screws.

There must be a minimum of 6 inches (153 mm) clearance

between single wall vent pipe and any combustible material.

Fill and seal any clearance between single wall vent pipe

and combustible material with mortar mix, cement, or other

noncombustible substance. For other than single wall, follow

vent pipe manufacturer's clearance specifications. To insure a

tight fit of the vent pipe in a brick chimney, seal around the vent

pipe with mortar mix cement.

Breathing Hazard - Carbon Monoxide Gas

•iq_,.:o

. Flue gases may escape if vent

pipe is not connected.

• Do not store corrosive chemicals

in vicinity of water heater.

• Chemical corrosion of flue and

vent system can cause serious

injury" or death.

• Contact a qualified installer or

service agency.

Breathing carbon monoxide can cause brain damage

or death Always read and understand instruction manual.

Failure to have required clearances between vent piping and

combustible material will result in a fire hazard.

Be sure vent pipe is properly connected to prevent escape of

dangerous flue gases which could cause deadly asphyxiation.

Chemical vapor corrosion of the flue and vent system may occur

if air for combustion contains certain chemical vapors. Spray can

propellants, cleaning solvents, refrigerator and air conditioner

refrigerants, swimming pool chemicals, calcium and sodium

chloride, waxes, bleach and process chemicals are typical

compounds which are potentially corrosive.

Gas Piping

Fire and Explosion Hazard

• Do not use water heater with

any gas other than the gas

shown on the rating plate.

-Excessive pressure to gas

control valve can cause serious

injury or death

• Turn off gas lines during

installation.

Contact qualified installer or

service agency.

Make sure the gas supplied is the same type listed on the

model rating plate. The inlet gas pressure must not exceed

14 inch water column (3.5kPa) for natural and propane gas (L.R)

gas. The minimum inlet gas pressure listed on the rating plate

is for the purpose of input adjustment. If the gas control valve

is subjected to pressures exceeding 1/2 pound per square inch

(3.5kPa), the damage to the gas control valve could result in a

fire or explosion from leaking gas.

If the main gas line shutoff serving all gas appliances is used, also

turn "OFF" the gas at each appliance. Leave all gas appliances

shut "OFF" until the water heater installation is complete.

A gas line of sufficient size must be run to the water heater.

Consult the current edition of National Fuel Gas Code ANSI

Z223.1/NFPA 54 and your gas supplier concerning pipe size.

There must be:

• A readily accessible manual shut off valve in the gas supply

line serving the water heater.

• A drip leg (sediment trap) ahead of the gas control valve to

help prevent dirt and foreign materials from entering the gas

control valve.

• A flexible gas connector or a ground joint union between the

shut off valve and control valve to permit servicing of the

unit.

Be sure to check all the gas piping for leaks before lighting the

water heater. Use a soapy water solution, not a match or open

flame. Rinse off soapy solution and wipe dry.

The minimum inlet gas pressure shown on the rating plate is that

which will permit firing at the rated input.

Breathing Hazard o Carbon Nono×id÷ Gas

,}lgh attache office rn}o_stbe in,stalled fat

oper_or_ _ove 2,000 feet (610 m).

*Corltsct a qualified i_'stalle_ or serwoe

agelncy

Breathing carbo_ mese;< de can cause b_'as dama_}e or

death Always _ead arid ar_deF'stard r_st_uction m_r_uai

Water heaters covered in this manual have been tested and

approved for installation at elevations up to 2,000 feet (610

m) above sea level. For installation above 2,000 feet (610 m),

the water heater's Btu input should be reduced at the rate of

4 percent for each 1,000 feet (305 m) above sea level which

requires replacement of the burner orifice in accordance with the

National Fuel Gas Code ANSI Z223.1/NFPA 54. Contact your

local gas supplier for further information.

Failure to replace the standard orifice with the proper high

altitude orifice when installed at elevations above 2,000 feet

(610 m) could result in improper and inefficient operation of the

appliance, producing carbon monoxide gas in excess of the safe

limits. This could result in serious injury or death. Contact your

local gas supplier for any specific changes that may be required

in your area.

Sediment Traps

Fire and Explosion Hazard

- Contaminants in gas lines can

cause fire or explosion.

• Clean ail gas piping before

installation.

- Install drip leg in accordance with

NFPA 54.

Contaminants in the gas lines may cause improper operation

of the gas control valve that may result in fire or explosion.

Before attaching the gas line be sure that all gas pipe is clean

on the inside. To trap any dirt or foreign material in the gas

supply line, a drip leg (sometimes called a sediment trap) must

be incorporated in the piping. The drip leg must be readily

accessible. Install in accordance with the Gas Piping section.

Refer to the current edition of the National Fuel Gas Code,

ANSI Z223.1tNFPA 54.

A sediment trap shall be installed as close to the inlet of the water

heater as practical at the time of water heater installation. The

sediment trap shall be either a tee fitting with a capped nipple

in the bottom outlet or other device recognized as an effective

sediment trap. If a tee fitting is used, it shall be installed in

conformance with one of the methods of installation, shown in

Figures 19 and 20.

Fire and Explosion Hazard

• Use joint compound or tape

compatiblewith propane.

Leak teat before operating

heater.

-Disconnect gas piping and

shut-off valve before pressure

testing system

GROUNDUNIONJOINT!_1

(OPTIONAL)

GAS CONTROL

VALVE

3" MIN. I DRIP LEG

(76.2 mm) SEDIMENT TRAP)

Use pipe joint compound or Teflon tape marked as being resistant

to the action of petroleum (Propane [L.P.]) gases.

The appliance and its gas connection must be leak tested before

placing the appliance in operation.

The appliance and its individual shutoff valve shall be

disconnected from the gas supply piping system during any

pressure testing of that system at test pressures in excess of

1/2 pound per square inch (3.5 kPa). It shall be isolated from

the gas supply piping system by closing its individual manual

shutoff valve during any pressure testing of the gas supply piping

system at test pressures equal to or less than 1/2 pound per

square inch (3.5 kPa).

Connecting the gas piping to the gas control valve of the water

heater can be accomplished by either of the two methods shown

in Figures 19 and 20.

TEFLON is a registeredtrademark of E.I. Du Pont De Nemours and Company.

FIGURE 19. GAS PIPING WITH FLEXIBLE CONNECTOR.

GROUND(OPTIONAL)UNIONJOINT _! _

BLACK PIPE GAS CONTROL

VALVE

3' MtN. I

(76.2 mm) SEDIMENT TRAP)

FIGURE 20. GAS PIPING WITH ALL

SLACK IRON PiPE TO GAS CONTROL.

,Im_diatelycabyeargassupplierfroma

neighb<)¢ephoneFollowthegassuppgeSe

inatraetions,

•ifyoucannotreachyour _e suppiier,ca_lthe _rs

dtheeaftirewaterheater,

OO ROTUSETHiSAPPUA_E iFTHEREHASBEENAN

IGR_IONOFVAPORSIm_iate_ enidaq_i_ se_ics

technicianto inspectthe appliance,Waterheaters

eaNect_ to atla_bievaporsignitionwiilshowa

d_scoloratlenontheairintakegrldandrequire

_p_asementof theentirewaterheater,

LIGHTINGINSTRUCTIONS

STOP.__s_m_Jve _at_u rs_alltheeafaty_mmge

_ors li_htingthepiiot

2, Re_ve the outerdoor:

3. Turnthetemperaturedal_ounters_osk_se_ to_s

Deprssstheresetba_ona!!the way

in and_EB_ATELY depress_he

igniterbuttonuntil youheara loud

click.Observethepilot throughthe

viewporLBenot reteaeethereset

huron.Repeatimmediatelyif plot

PUSHBUTTON

RE:ET !3_0_,;r t20 _ F

pilotdoesnet_ightbythefourth

attempt_th theigeiter,repeatsteps

4°7,Continuetoholdthebuttonfor

a_m (I)_nuteafterthepilotislit,,

Releasetheresetb_ttonan_R_1_pep

backup,_lut shouldremainIlL_e

pilot light goesout,repeatsteps3°7, iGNITER

Depressthe dialstopandt_m

tothe"OFP _sition

aesumola_dwaftten(I_)mlnutss.

ff you_hensmellgas,STOP!Fo{Iow"B_'in_e safety

warningabove.Ifyoudonotsmellgasgo to the next

step. :::,o,,°Bet,

to'PILOT",

i_PORTANT:Ifthepilotwil_nots_yBtdtefseveralthe,

@pressthed_! stopand_m _a ¢or_r__eobto '_FF",

thensaily_r se_ce technicianorgassupplier`

I_RTART: tfthe resetbutton(seegrspNeat step3)does

notpepopwhe_released,stopandimmediatelyshutoff

t_e gasatthelinevalveortank.gaiiyour se_ieetechnician

8. Turnthegascon#el knob

countersloekwiaa_

to "ON'L

& Betthe_eratare dialto

l& Replacetheoo_rdoor:

Temperature Regulation

Due to the nature of the typical gas water heater, the water

temperature in certain situations may vary up to 30F ° (16.7 C °)

higher or lower at the point of use such as, bathtubs, showers,

sink, etc.

Water temperature over 125°F

(52°C) can cause severe burns

instantly resulting in severe injury

ordeath.

Children, the elderly, and the

physically or mentally disabled

are at highest riskforscald injury,

Feel water before bathing or

showering,

Temperature limiting valves are

available

Read instruction manual for safe

temperature setting.

HOTTER WATER CAN SCALD: Water heaters are intended to

produce hot water. Water heated to a temperature which will

satisfy space heating, 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 manufacturer's instructions

for installation of the valves. Before changing the factory setting

on the thermostat See Figures 21 and 22.

Never allow small children to use a hot water tap, or to draw their

own bath water. Never leave a child or handicapped person

unattended in a bathtub or shower.

NOTE: Awater temperature range of 120°F-140°F (49°C-60°C)

is recommended by most dishwasher manufacturers.

The thermostat of this water heater has been factory set at its

lowest position. It is adjustable and must be reset to the desired

temperature setting for energy efficient operation at the minimum

water temperature setting that meets your hot water needs. To

reduce the risk of scald injury, 120°F (49°C) is preferred starting

point. Some states have a requirement for a lower setting.

Align the index bar on the thermostat with the desired water

temperature as shown in Figure 21.

Turn the water temperature dial clockwise ( f'_ ) to increase

the temperature, or counterclockwise ( _ ) to decrease the

temperature.

Should overheating occur or the gas supply fail to shut off, turn

off the manual gas control valve to the appliance.

Robertshaw Gas Valve

_,,_,__Gas Control Knob 130°F 120°F

Reset ---4_-_._L_. Dial Stop Bar /Bar

Button _=_ 140°F _. i_/

-- _,.u - Bar q

_"----2C2_/_ _'-Temperature Dial/__

FIGURE 21.

I60°F (7I°C) About 1/2 second

I50°F (66°C) About 1-1/2 seconds

I40°F (60°C) Less than 5 seconds

I30°F (54°C) About 30 seconds

I20°F (49°C) More than 5 minutes

80°F (27°C)

FmGURE 22.

Tank (Sediment) Cleaning Burner inspection

Sediment build-up on the tank bottom may create varying

amount of noise and if left in the tank will cause permanent

tank failure. In some water areas, you may not be able to drain

all sediment deposits by simply draining the tank. in these

cases Mag-Erad (part no. 23600) can be used to help remove

the sediment deposits. This may be ordered from the Sears

Service Center. For ordering, refer to the Parts Order List

section.

Flood damage to a water heater may not be readily visible or

immediately detectable. However, over a period of time a flooded

water heater will create dangerous conditions which can cause

DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.

Contact a Sears Service Center to replace a flooded water

heater. Do not attempt to repair the unit[ It must be replaced[

At least once a year a visual inspection should be made of the

main burner. See Figure 23.

Vent System Inspection

Carbon Monoxide and Fire Hazard

,Flue gases may escape if vent pipe

is not connected

,Be ale_ for obstructed, sooted or

_'>"-:; de_erbrated vent system to avoid

}1{_1: serious njury or death.

•Do _ot store corrosive chemicals

in the vicinity of water heater

• Chemic! corrosion o_ flue and vent

system can cause serious injury of

death,

Breathing cadxm monoxide can cause brain damage or

death. A_ways read and understand instruct:ion manual

CORRECT FLAME

SOFT BLUE

FIGURE 23,

Inspect burner flames through viewport. Flames should be very

small with a blue haze and small amounts of yellow or orange at

the edges. After several minutes of operation the burner screen

may glow red. If large flames are observed at anytime shut-off

unit and contact a Sears Service Center.

At least once a year a visual inspection should be made of the

venting system. You should look for:

Obstructions which could cause improper venting. The

combustion and ventilation air flow must not be obstructed.

Damage or deterioration which could cause improper venting

or leakage of combustion products.

Rusted flakes around top of water heater.

Be sure the vent piping is properly connected to prevent

escape of dangerous flue gasses which could cause deadly

asphyxiation.

Obstructions and deteriorated vent systems may present serious

health risk or asphyxiation.

Chemical vapor corrosion of the flue and vent system may occur

if air for combustion contains certain chemical vapors. Spray can

propellants, cleaning solvents, refrigerator and air conditioner

refrigerants, swimming pool chemicals, calcium and sodium

chloride, waxes, bleach and process chemicals are typical

compounds which are potentially corrosive.

If when inspecting the vent system you find sooting or

deterioration, something is wrong. Call the local gas supplier to

correct the problem and clean or replace the flue and venting

before resuming operation of the water heater.

Removing the Burner Door Assembly

Turn offthe gas to the water heater at the manual gas

shut-off valve (Figure 3).

Turn the gas control knob on the combination gas control

valve/thermostat clockwise to the "OFF" position (Figure 1).

NOTE: Depress the dial stop on Robertshaw valve before

turning the gas control knob. See Lighting Instructions on

the water heater.

Remove the outer door.

Remove the two screws securing the burner door

assembly to the combustion chamber. (Figure 24).

GAS VALVE/

THERMOSTAT

THERMOCOUPLE_

MAN_FOLD

TUBE

PiEZO

iGNITER

BUTTON

PILOT

TUBE

Ultra Low NOx Natural Gas Burner

Check the burner to see if it is dirty or clogged. The burner

may be cleaned with soft paint brush (Figure 26). Do not use

a wire brush or any tool that may damage the burner screen.

Important: Do not use the burner if the burner screen is

damaged. NOTE: Damage may be rips or holes in the burner

screen. Discoloration is normal.

PILOT ASSEMBLY _

BURNER /\USE BRUSH ON THIS SURFACE

DOOR TWO PIECE WIRE

SCREW(2) CONNECTOR

DOOR

FIGURE 26,

Replacing the Pilot Assembly

FIGURE 24,

5. Disconnect the thermocouple (right-hand thread), pilot

tube, the igniter wire from the igniter button, and manifold

tube at the thermostat.

(Figure 25).

6. Grasp the manifold tube and push down slightly to free

the manifold tube, pilot tube, and thermocouple.

7. Carefully remove the burner door assembly from the

combustion chamber. Be sure not to damage internal

parts.

ROBERTSHAW GAS VALVE

_ (_,t_ PILOT TUBE

THERMOCOUPLE "_

MANIFOLD TUBE _

FIGURE 25,

1. Follow the instructions in "Removing the Burner Door

Assembly" section to remove the assembly.

2. Remove the retainer clip securing the two piece wire

connector to the burner door assembly. (Note the orientation

of the retainer clip). Insert the tip of a large flat head

screwdriver between the clip and the top of the two piece

wire connector. Carefully rotate the screwdriver to raise the

clip. It may be necessary to remove the connector one side

at a time. (See Figure 27.)

3. Locate where the thermocouple connects to the rear of the

pilot assembly, and pull the thermocouple tip from the rear of

the pilot assembly.

4. Remove the nut securing the pilot assembly to the burner

and keep it for reuse later.

5. Use a 1/2" open end wrench, to loosen the nut securing the

pilot tube to the pilot. To prevent any bending use a pair of

pliers to steady the pilot bracket.

6. Remove the old pilot assembly (including the igniter wire)

from the burner door assembly.

7. Insert the pilot tube into the new pilot assembly. Important:

The new pilot assembly comes with an orifice. This orifice

must be installed when replacing the pilot assembly.

IMPORTANT: Do not operate this water heater without the

orifice in place.

8. Use a 1/2" open end wrench, to tighten the nut securing the

pilot tube to the pilot. To prevent any bending use a pair of

pliers to steady the pilot bracket.

9. Use the nut removed in a previous step to secure the new

pilot assembly to the burner.

10. Insert the igniter wire through the burner door and reconnect

the thermocouple to the pilot assembly. See "Replacing the

Thermocouple" section.

11. Reinstall the two piece wire connector. NOTE: The pilot

tube must be at the top followed by the igniter wire then the

thermocouple.

12. Follow the instructions in "Replacing the Bumer Door

Assembly" section to reinstall the assembly.

Replacing the Thermocouple

1. Remove the Burner DoorAssembly as directed

previously.

2. Remove the retainer clip from the back of the two piece

wire connector and remove the two piece wire connector

from the assembly (Figure 27).

3. Pull the thermocouple from the pilot assembly

(Figure 31 ).

IMPORTANT: Be careful not to bend or alter the position of the

pilot assembly components.

4. Push the new thermocouple through the holes in the

pilot bracket. Insert the thermocouple tube into the holes

provided in the pilot assembly until it clicks into place.

Leave a small straight section entering and leaving the

two piece wire connector section for easier removal/

service.

5. Position the new thermocouple through the opening of

the two piece wire connector (Figure 27). NOTE: The pilot

tube should be located at the top followed by the igniter

wire then the thermocouple.

6. See "Replacing the Burner DoorAssembly" section.

PILOT IGNITER

THERMOCOUPLE TUBE WIRE

TWO PIECE

WIRE CONNECTOR

DOOR

FIGURE 27.

Cleaning the Pilot Assembly

1, Follow the procedure outlined in "Removing the

Burner Door Assembly".

2, Use a soft bristle brush to remove any debris that

may have collected on the pilot. Note: Clean any

debris found in the air slots at the base of the pilot.

See Figure 28,

3, Follow the steps in "Replacing the Burner Door

Assembly" section to reassemble.

PILOT b

IGNITER_

External Inspection & Cleaning of the

Flame Arrestor

Although not likely to occur, if debris collects on the flame

arrestor, use a vacuum, compressed air, or a soft bristle brush

to remove it. NOTE: If unable to inspect or clean the flame

arrestor from underneath, follow the "Cleaning the Combustion

Chamber and Flame Arrestor" section instructions.

Flashligh L

Mirror \

• •

FIGURE 29

Cleaning the Combustion Chamber and

Flame Arrestor

Follow procedure outlined in "Removing the Burner Door

Assembly" section.

Use a vacuum cleaner/shop vac to remove all loose

debris in the combustion chamber (Figure 30). Use

compressed air to clear any dust or debris that may have

accumulated in the flame arrestor.

Reassemble following the procedure under the "Replacing

the Burner Door Assembly" section.

FIGURE 28.

Replacing the Burner Door Assembly

Fire or ExpJosion Hazard

,Tighten both manifo d door screws securely.

• Remove arty fiberglass between gasket and

combustion chamber

,R÷pla_ v_ewpo_ if @ass is missing o_ damaged_

,Replace twe piece wire co_necter if missing o_

removed.

• Repiace door gasket Fdamaged.

,Falure te folow these instructions can result in

death= expos.ion, or fire.

Read instruction manua_ before

insta/ing, using or servicing

water }}eater

1. Check the door gasket for damage or imbedded debris

prior to installation.

Exp!osion Hazard

.Replace viewpo_ if @ass is

missing or damaged

, Faiiure _o do so can resu!t in

death, explosion, o_ fire

2. Inspect the viewport for damage and replace as required.

3. Insert the burner door assembly into the combustion

chamber and slide it completely forward. Note: When

inserting the burner door assembly, tip the burner end up

slightly to ensure it engages with the burner bracket.

4. Inspect the door gasket and make sure there is no

fiberglass insulation between the door gasket and the

combustion chamber (See Figure 30).

5. Replace the two screws, which secure the burner door

assembly to the combustion chamber and tighten

securely. Once the burner door assembly is tightened,

visually inspect the door gasket between the burner door

assembly and the combustion chamber for spaces or

gaps that would prevent a seal. IMPORTANT: Do not

operate the water heater if the door gasket does not

create a seal between the burner door assembly and the

combustion chamber.

6. Reconnect the manifold tubing, pilot tubing, and

thermocouple to the thermostat. Do not cross-thread

or apply any thread sealant to these fittings. The

thermocouple nut should be started and turned all the

way in by hand. An additional 1/2 - 3/4 turn with a 7/16"

open end wrench will then be sufficient to seat the

Iockwasher.

7. Reconnect the igniter wire.

8. Turn gas supply on and refer to the "Operating Instructions".

GAS CONTROL VALVE

THERMOSTAT __ \

BURNER DOOR

ASSEMBLY--"_

FIGURE 30.

9. Check for leaks by brushing on an approved noncorrosive

leak detection solution. Bubbles will show a leak. Correct

any leak found.

10. Replace the outer door.

Piezoelectric Igniter System

The piezoelectric igniter system consists of the igniter button,

electrode, and wire. The pilot is ignited by an electric spark

generated when the igniter button is pressed. The electrode

should be centered between the pilot and thermocouple. (See

Figure 31 ). Use only factory authorized piezoelectric igniter

parts for replacement.

PILOT

PILOT BRACKET

ELEOTROD ,

THERMO

m--SNAP-ON CONNECTOR_

ELECTRODE

FIGURE 31.

Testing the Igniter System

Turn off the gas to the water heater at the manual gas shut-off

valve. Watch the electrode tip while activating the igniter. A

visible spark should jump from the electrode. To avoid shock,

do not touch the burner or any metal part on the pilot or pilot

assembly. If no spark is visible, check the wire connections

and make sure the electrode is not broken. Replace the

electrode if defective. NOTE: The electrode is part of the pilot

assembly and cannot be replaced separately. Dirt and rust on

the pilot or electrode tip can prevent the igniter spark. Wipe

clean with a damp cloth and dry completely. Rust can be

removed from the electrode tip and metal surfaces by lightly

sanding with an emery cloth or fine grit sandpaper.

Removing and Replacing the Gas Control

Valve/Thermostat

IMPORTANT: The gas control valve/thermostat is a standard

valve with a right-hand thread thermocouple. Use only factory

authorized replacement parts.

Removing the Gas Valve:

1. Turn the gas control knob on the combination gas control

valve/thermostat clockwise to the "OFF" position. NOTE:

Depress the dial stop on Robertshaw valves before turning

the gas control knob. See Lighting Instructions on the water

heater.

2. Turn off the gas at the manual shut-off valve on the gas

supply pipe (Figure 3).

3. Drain the water heater. Refer to "Draining" section and

follow the procedure.

4. Disconnect the igniter wire from the igniter. NOTE: First

remove the igniter from the bracket by depressing front and

rear holding tabs and lift. Next remove igniter bracket from

the gas valve. Disconnect the thermocouple (right-hand

threads), pilot tube, and manifold tube at the gas control

valve/thermostat (Figure 25).

5. Refer to "Gas Piping" section and disconnect the ground

joint union in the gas piping. Disconnect the remaining

pipe from the gas control valve/thermostat.

6. To remove the gas valve, thread a correctly sized pipe into

the inlet and use it to turn the gas valve (counterclockwise.)

Do not use pipe wrench or equivalent to grip body.

Damage may result, causing leaks. Do not insert any sharp

objects into the inlet or outlet connections. Damage to the

gas valve may result.

Replacing the Gas Valve:

To replace the gas control valve/thermostat, reassemble

in reverse order. When replacing the gas valve, thread a

correctly sized pipe into the inlet and use it to turn the gas

valve (clockwise.) DO NOT OVER TIGHTEN, damage may

result.

Be sure to use approved Teflon e tape or pipe joint

compound on the gas piping connections and fitting on

the back of the gas control valve that screws into tank.

Be sure to remove the pilot ferrule nut from the new gas

control valve/thermostat.

Turn the gas supply on and check for leaks. Test all

connections by brushing on an approved noncorrosive

leak-detection solution. Bubbles will show a leak. Correct

any leak found.

Be sure tank is completely filled with water before lighting

and activating the water heater. Follow the "Operating

Instructions"

If additional information is required, contact Sears Service

at: 1-800-4-MY-HOME _"_(1-800-469-4663).

TEFLON is a registered trademark of E.I. Du Pont De Nemours and Company.

Housekeeping

Vacuum around base of water heater for dust, dirt, and lint on

regular basis.

Fire and E×,plosion Hazard

,Do not ebslruct _yombustion air

o_#ings at the bottom of the

water heate_:

Do not use o{ store flammable

raper products such as gasoline,

solvents or adhesives is the

_me room or area _ear water

heater or other appliance

Visibly inspect flame arrestor a_

cleae if accumulated _int

Can cause sedous injury or

death

AT LEAST ONCE EVERY SIX MONTHS A VISUAL

iNSPECTION SHOULD BE MADE OF THE FLAME

ARRESTOR, CLEAN IF LINT ACCUMULATIONS ARE

NOTICED,

INSTALLED IN SUITABLE AREA: To insure sufficient ventilation

and combustion air supply, proper clearances from the water

heater must be maintained. See Facts to Consider About the

Location section. Combustible materials such as clothing,

cleaning materials, or flammable liquids, etc. must not be placed

against or adjacent to the water heater because they could

catch on fire.

Anode Rod Inspection

Property Damage Hazard

-Avoid water heater damage.

-Inspection and replacement of anode red required.

The anode rod is used to protect the tank from corrosion. Most

hot water tanks are equipped with an anode rod. The submerged

rod deteriorates to protect the tank. Instead of corroding the tank,

water ions attack and eat away the anode rod. This does not

affect the water's taste or color. The rod must be maintained to

keep the tank in operating condition.

Anode deterioration depends on water conductivity, not

necessarily water condition. A corroded or pitted anode rod

indicates high water conductivity and should be checked and/

or replaced more often than an anode rod that appears to be

intact. Replacement of a depleted anode rod can extend the

life of your water heater. Inspection should be conducted by

calling the Sears Service Center for an authorized contractor.

At a minimum, the anode(s) should be checked annually after

the warranty period.

Temperature=Pressure Relief Valve Operation

The temperature-pressure relief valve must be manually operated

at least once a year.

* Burn hazard

, Hotwater discharge.

,Keep clear of relief valve

discharge outlet.

When checking the temperature-pressure relief valve operation,

make sure that (1) no one is in front of or around the outlet of

the temperature-pressure relief valve discharge line, and (2) that

the water discharge will not cause any property damage, as the

water may be extremely hot, see Figure 32.

TEMPERATURE-PRESSURE

RELIEF VALVE

DISCHARGEPIPE

FIGURE 32.

If after manually operating the valve, it fails to completely reset

and continues to release water, immediately close the cold water

inlet to the water heater, follow the draining instructions, and

replace the temperature-pressure relief valve with a new one.

If the temperature-pressure relief valve on the appliance weeps

or discharges periodically, this may be due to thermal expansion.

You may have a check valve installed in the water line or a water

meter with a check valve. Consult the Sears Service Center

for further information. Do not plug the temperature-pressure

relief valve.

Draining

• Burn hazard

• Hot water discharge.

• Keep hands clear of drain

valve discharge.

The water heater should be drained if being shut down during

freezing temperatures. Also periodic draining and cleaning of

sediment from the tank may be necessary.

1. Turn the gas control knob to the "OFF" position.

2. CLOSE the cold water inlet valve to the water heater.

OPEN a nearby hot water faucet and leave open to allow for

draining.

Connect a hose to the drain valve and terminate to an

adequate drain.

OPEN the water heater drain valve to allow for tank

draining.

NOTE: if the water heater is going to be shut down and

drained for an extended period, the drain valve should be

left open with hose connected allowing water to terminate

to an adequate drain.

6. Close the drain valve.

7. Follow the lighting instructions in the Lighting section to restart

the water heater.

Drain Valve Washer Replacement

(See Figure 33)

1. Turn "OFF" gas supply to water heater.

2. Follow "Draining" instructions.

3. Turning counter clockwise ( _ ), remove the cap.

4. Unscrew the stem by turning it counter clockwise (('%), and

remove it from the drain valve body.

5. Remove the bottom washer and put the new one in place.

6. Re-insert the stem into the drain valve body and retighten the

cap to the body using a wrench. DO NOT OVER TIGHTEN.

7. Follow instructions in the Filling The Water Heater section.

8. Check for leaks.

9. Follow the lighting instructions in the Lighting section to restart

the water heater.

CAP

WASHER

STEM

FIGURE 33.

Service

Before calling for repair service, read the Start Up Conditions

and Operational Conditions found in the Troubleshooting Guide

of this manual.

If a condition persists or you are uncertain about the operation of

the water heater, let the Sears Service Center check it out.

Contact Sears Service Center at:

1-800-4-MY-HOME _¢(1-800-469-4663).

Start Up Conditions

Thermal Expansion

Property Damage Hazard

• Avoid water heater damage.

•Install thermal expansion tank or device if necessary.

= Contact qualified installer or service agency.

Water supply system may, because of such events as high line

pressure, frequent cut-offs and the effects of water hammer have

installed devices such as pressure reducing valves, check valves,

back flow preventers, etc., to control these types of problems.

When these devices are not equipped with an internal by-pass,

and no other measures are taken, the devices cause the water

system to be closed. As water is heated, it expands (thermal

expansion) and closed systems do not allow for the expansion

of heated water.

The water within the water heater tank expands as it is heated and

increases the pressure of the water system. If the relieving point

of water heater's temperature-pressure relief valve is reached,

the valve will relieve the excess pressure. The temperature-

pressure relief valve is not intended for the constant relief

of thermal expansion. This is an unacceptable condition and

must be corrected.

It is recommended that any devices installed which could

create a closed system have a by-pass and/or the system have

an expansion tank or device to relieve the pressure built by

thermal expansion. Thermal expansion tanks are available from

Sears stores and through the Sears Service Centers. Contact

the local plumbing inspector, water supplier and/or the Sears

Service Center for assistance in controlling these situations,

see Figure 34.

Thermal Expansion Tank Specifications

Model

Number

I53.331020

I53.331050

Tank

Capacity

In Gallons

Dimensions Pipe

in Inches Fitting

Diameter Length On Tank

8 (203 ram) 12-3/4 (323 ram) 3/4" Mate

11 (279 ram) 14-3/4 (375 ram) 3/4" Mate

Expansion

Tank

Capacity

Needed

Expansion Tank Sizing Chart

Inlet* Water Heater Capacity (Gallons)

Water

Pressure 30 40 50 66 82

40 psi 2 2 2 5 5

50 psi 2 2 2 5 5

60 psi 2 2 2 5 5

70 psi 2 2 5 5 5

80 psi 2 5 5 5 5

*Highest recorded inlet water pressure in a 24 hour period or

regulated water pressure.

NOTE: Expansion tanks are pre=charged with a 40 psi air

charge. If the inlet water pressure is higher than 40 psi, the

expansion tank's air pressure must be adjusted to match

that pressure, but must not be higher than 80 psi.

WATER HEATER (3)

Hr_r r,n/r_ /COLD WATER PRESSURE

_,, -_v_%/,_ INLET FiTTiNG REDUCING

r_ _ _ VALVEWiTH

I I BY-PASS

PRESSURE GAUGE

WATER SHUT-OFF

.RECOMMENDED INSTALLATION

(VERTICAL MOUNTING)

WATER HEATER

COLD WATER

INLET FiTTiNG

HOT COLD

(3)

PRESSURE

REDUCING

VALVEWiTH

(t) BY-PASS

EXPANSION j

TANK_

PRESSURE GAUGE _NLETCOLD

WATER SHUT"OFF

ALTERNATE RECOMMENDED iNSTALLATION

(HORIZONTAL MOUNTING)

FIGURE 34,

Strange Sounds

Possible noises due to expansion and contraction of some metal

parts during periods of heat-up and cool-down do not represent

harmful or dangerous conditions.

Condensation causes sizzling and popping within the burner area

during heating and cooling periods and should be considered

normal. See Condensation section.

Draft Hood Operation

Check draft hood operation by performing a worst case

depressurization of the building. With all doors and windows

closed, and with all air handling equipment and exhaust fans

operating such as furnaces, clothes dryers, range hoods and

bathroom fans, a match flame should still be drawn into the

draft hood of the water heater with its burner firing. If the flame

is not drawn toward the draft hood after 15 minutes of burner

operation, shut off water heater and make necessary air supply

changes to correct.

Condensation

Whenever the water heater is filled with cold water, some

condensate will form while the burner is on. A water heater may

appear to be leaking when in fact the water is condensation. This

usually happens when:

• A new water heater is filled with cold water for the first time.

•Burning gas produces water vapor In water heaters,

particularly high efficiency models where flue temperatures

are lower.

• Large amounts of hot water are used in a short time and the

refill water in the tank is very cold.

Moisture from the products of combustion condense on the

cooler tank surfaces and form drops of water which may fall

onto the burner or other hot surfaces to produce a "sizzling" or

"frying" noise.

Excessive condensation can cause pilot outage due to water

running down the flue tube onto the main burner and putting

out the pilot.

Because of the suddenness and amount of water, condensation

water may be diagnosed as a "tank leak". After the water in

the tank warms up (about 1-2 hours), the condition should

disappear.

Do not assume the water heater is leaking until there has been

enough time for the water in the tank to warm up.

An undersized water heater will cause more condensation.

The water heater must be sized properly to meet the family's

demands for hot water including dishwashers, washing machines

and shower heads.

Excessive condensation may be noticed during the winter and

early spring months when incoming water temperatures are at

their lowest.

Good venting is essential for a gas fired water heater to operate

properly as well as to carry away products of combustion and

water vapor.

Smoke Odor

It is not uncommon to experience a small amount of smoke and

odor during the initial start-up. This is due to burning off of oil

from metal parts, and will disappear in a short while.

Operational Conditions

Smelly Odor

In each water heater there is installed at least one anode rod (see

parts section) for corrosion protection of the tank. Certain water

conditions will cause a reaction between this rod and the water.

The most common complaint associated with the anode rod is

one of a "rotten egg smell". This odor is derived from hydrogen

sulfide gas dissolved in the water. The smell is the result of four

factors which must all be present for the odor to develop:

a concentration of sulfate in the supply water.

little or no dissolved oxygen in the water.

a sulfate reducing bacteria within the water heater. (This

harmless bacteria is non-toxic to humans.)

an excess of active hydrogen in the tank. This is caused by

the corrosion protective action of the anode.

Smelly water may be eliminated or reduced in some water heater

models by replacing the anode(s) with one of less active material,

and then chlorinating the water heater tank and all hot water

lines. Contact Sears Service for further information concerning

an Anode Replacement Kit #9001453 and this Chlorination

Treatment. Anode replacement and chlorination of the tank are

not covered by the water heater's limited warranty.

If the smelly water persists after the anode replacement and

chlorination treatment, it may be necessary to chlorinate or aerate

your water supply to eliminate the problem.

Do not remove the anode leaving the tank unprotected. By

doing so, all warranty on the water heater tank is voided.

"AIR" In Hot Water Faucets

• Flammable hydrogen

gases may be present.

,Keep all ignition sources

away from faucet when

turning on hot water.

HYDROGEN GAS: Hydrogen gas can be produced in a hot

water system that has not been used for a long period of time

(generally two weeks or more). Hydrogen gas is extremely

flammable and explosive. To prevent the possibility of injury

under these conditions, we recommend the hot water faucet,

located farthest away, be opened for several minutes before

any electrical appliances which are connected to the hot water

system are used (such as a dishwasher or washing machine).

If hydrogen gas is present, there will probably be an unusual

sound similar to air escaping through the pipe as the hot water

faucet is opened. There must be no smoking or open flame near

the faucet at the time it is open.

High Temperature Shut Off System

This water heater is equipped with an automatic gas shutoff

system. This system works when high water temperatures

are present. The high temperature shutoff is built into the gas

control valve. It is non-resettable. If the high temperature shutoff

activates, the gas control valve must be replaced. Turn "OFF"

the entire gas supply to the water heater and contact your gas

supplier.

PROBLEM

BURNER WILL NOT IGNITE

POSSIBLE CAUSE(S) CORRECTIVE ACTION

Pilot not lit

Thermostat set too low

No gas

Dirt in the gas lines

Pilot line clogged

Main burner line clogged

Non-functioning thermocouple

Non-functioning thermostat

Heater installed in a confined area

1. Light pilot

I 2. Turn temp. dial to desired temperature

3. Check with gas utility company

i4. Notify utility-install trap in gas line

I 5. Clean, locate source and correct

I 6. Clean, locate source and correct

7. Replace thermocouple

i 8. Replace thermostat

I 9. Provide fresh air ventilation

SMELLY WATER Sulfides in the water 1. Replace the anode with a special anode

PILOT WILL NOT LIGHT

PILOT WILL NOT REMAIN LIT

Air in gas line

No gas

Dirt in gas lines

Pilot line or orifice clogged

Cold drafts

Thermostat ECO switch open

Non-functioning igniter

Flammable vapor incident

HIGH OPERATION COSTS

INSUFFICIENT HOT WATER

i 9. Low gas pressure

10. Air for combustion obstructed

11. Pilot dirty

1. Air in gas line

2. Dirt in gas lines

i 3. Pilot line or orifice clogged

i4. Thermocouple connection loose

I 5. Non-functioning thermocouple

6. Cold drafts

i 7. Flammable vapor incident

I 8. Low gas pressure

i 9. Air for combustion obstructed

10. Pilot dirty

1. Thermostat set too high

I 2. Sediment or lime in tank

i 3. Water heater too small for job

i4. Wrong piping connections

5. Leaking faucets

i 6. Gas leaks

I 7. Wasted hot water

I 8. Long runs of exposed piping

9. Hot water piping in exposed wall

1. Thermostat set too low

I 2. Sediment or lime in tank

i 3. Water heater too small

i4. Wrong piping connections

5. Leaking faucets

i 6. Wasted hot water

I 7. Long runs of exposed piping

8. Hot water piping in outside wall

9. Low gas pressure

1. Insufficient air

i 2. Flue clogged

I 3. Low gas pressure

I 4. Improper calibration

5. Thermostat set too low

i 6. Water heater too small

I 7. Wrong piping connections

i 8. Wasted hot water

SLOW HOT WATER

RECOVERY

1. Bleed the air from the gas line

2. Check with gas utility company

i 3. Notify utility-install dirt trap in gas line

i4. Clean, locate source and correct

I 5. Locate source and correct

6. Replace thermostat

i 7. Replace igniter pilot assembly

i 8. Eliminate flammable vapor source(s)

Call 1-800-4-MY-HOME _)(1-800-469-4663)

9. Check with gas utility company

10. See service and adjustment section for

inspection and cleaning of flame arrestor

& burner

11. Clean pilot

1. Bleed the air from the gas line

2. Notify utility-install dirt trap in gas line

i 3. Clean, locate source and correct

i 4. Finger tighten; then 1/2 turn with wrench

I 5. Replace thermocouple

6. Locate source and correct

i 7. Eliminate flammable vapor source(s)

Call 1-800-4-MY-HOME _ (1-800-469-4663)

I 8. Check with gas utility company

i 9. See service and adjustment section for

inspection and cleaning of flame arrestor

& burner

10. Clean pilot

1. Set temperature dial to lower setting

2. Drain/flush-provide water treatment if

needed

i3. Install adequate heater

i4. Correct piping-dip tube must be in cold

inlet

5. Repair faucets

i 6. Check with utility-repair at once

I 7. Advise customer

8. Insulate piping

i9. Insulate piping

1. Turn temperature dial to desired setting

2. Drain/flush-provide water treatment if

needed

I 3. Install adequate heater

4. Correct piping-dip tube must be in cold

inlet

i 5 Repair faucets

I 6. Advise customer

7. Insulate piping

i8. Insulate piping

i 9. Check with gas utility company

1. Provide ventilation to water heater.

Check flue way, flue baffle, and burner

i 2. Clean flue, locate source and correct

I 3. Check with gas utility company

14. Replace thermostat

5. Turn temperature dial to desired setting

i6. Install adequate heater

I 7. Correct piping-dip tube must be in cold

inlet

i 8. Advise customer

PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION

DRIP FROM RELIEF VALVE 1. Excessive water pressure 1. Use a pressure reducing valve and relief

valve

2. Closed water system 2. See "Thermal Expansion"

THERMOSTAT FAILS TO 1. Non-functioning thermostat 1. Replace thermostat

SHUT OFF 2. Improper calibration 2. Replace thermostat

COMBUSTION ODORS 1. Insufficient air 1. Provide ventilation to water heater.

Check flue

way, flue baffle, and burner

2. Water heater flue or vent system blocked. 2. Clean, locate source and correct

3. Heater installed in a confined area 3. Provide fresh air ventilation

1. Flammable vapor incident 1. Call 1-800-4-MY-HOME _'(1-800-469-4663)

SMOKING AND CARBON

FORMATION (SOOTING)

CONDENSATION

BURNER FLAME FLOATS

AND LIFTS OFF PORTS

1. Temperature setting too low

1. Orifice too large

2. High gas pressure

3. Water heater flue or vent system blocked.

4. Cold drafts

5. Dirty burner screen

1. Increase the temperature setting

1. Replace with correct orifice

2. Check with gas utility company

3. Clean flue and burner-locate source and

correct

4. Locate source and correct

5. Clean burner screen. See "Ultra Low

NOx Natural Gas Burner" section of this

manual.

FLAME BURNS AT ORIFICE 1. Non-functioning thermostat 1. Replace thermostat

2. Low gas pressure 2. Check with gas utility company

3. Non-functioning burner 3. Replace burner assembly

PILOT FLAME TOO SMALL 1. Pilot line or orifice clogged 1. Clean, locate source and correct

2. Low gas pressure 2. Check with gas utility company

3. Dirty pilot 3. Clean pilot

Section B: Pilot light will not remain lit or repeatedly goes out.Section A: Pilot light will not light.

_. ICheck the manual gas shut-off valve to |

[Is the gas turned on? _NO l_tsee if it is in the open position, if it is open 1

-_S |then contact the gas utility company.

"_ [While repeatedly depressing the igniter button,

iHave you bled all the air | _. hold down the reset button until the pilot is lit and

from tile pilot tube and _ _lnlalntalns a stable flame, then slowly release the

[gas suppy ne? J [reset button

YES

lSthe igniter producing a _NO ._i Follow the Testing the Igniter Systemi

k? -]V linstructions in this manual I

YES

"_ I Follow the Replacing the Pilot Assembly

ils the pilot tube and/or orifice LN O _kJinstructi°ns found in this manual to access

[free from dirt and debris? F "Vlpilot tube and orifice Clean as needed and

YES |reinstall pilot tube and orifice*

Is the pilot free from dirt and _NO _1 Follow the Cleaning the Pilot Assembly I

[debr s? jr'- -V| nstruct ons found n ths manua.*

YES

Is the pilot protected from cold b. I Eliminate any drafts See the i

drafts that could prevent it INO _p_"Site Location" instructions found I

from lighting "lin this manual

YES

Rem°ve the burner d°°r assembly / iClean the flame arrestor i

Is the flame arrestor free from dirt or

debris? See "Removing tile Burner _NO m_. I withe soft bristle brush I

Door Assembly" section of the manual _or vacuum cleaner ]

fo_mova nstruct ons _

YES

_the water heater for a Flammable Vapor (FV) event, i

If the flame arrestor show signs of discoloration, shut-off the gas

supply to the water heater at the manual gas shut-off valve, then

contact Sears Service at: 1-8O0-4-MY-HOMB ® (1-800-469-4663)

This procedure requires the removal of water heater components.

s the thermocouple securely [ Make sure the thermocouple is securely]

onnected to the gas controt iNO_oonnected Fingertightenthengivea |

alve/thermostat? [ --ladditional 1/2 turn with a wrench. J

YES

Test the thermocouple using the following procedure: Disconnect the thermooouple

from the gas control valve/thermostat. Using a multimeter with alligator clip leads,

attach the red lead to the body (copper part) of the thermooouple Attach the black

lead to the end (silver part) of the thermooouple that connects to the gas control valve/

thermostat Follow the instruction to light the pilot and watch the voltage readings on

the multimeter. After 45 seconds the meter should read 12 millivolts DC or more.*J

nn_< _h_fh_r_mn_,,nI_n_<<fh_ _<f? _" I Is the thermocoaple fully I _11

Does the thermocouple pass the test. _IIINOi_lseated in the pilot bracket? I

_ES YES _ " /

i _ Push the thermooouple

IReplace the thermocouple. _ I forward until it is fully seated in I

_'I the pilot bracket and retest I

I Follow the Replacing the Pilot Assembly

IIs the pilot tube and/or orifice ! _,.l instructions found in this manual to access

Ifree frOm dirt and debds? _ _lP ilOt tube and Orifice. Clean as needed and

YES [reinstall pilot tube and orifice _

IIs the pilot free from dirt and debris? k IFollow the Cleaning the Pilot Assembly

_NO _linstructions found in this manual* 1

YES

ICheck for insufficient combustion air|

Are there openings for _ b. [Install correct size make-up air openings per the 1

|make-up air to enter the _NO _lCombustion Air and Ventilation section in this 1

[room? J [manual.

YES

Are the openings of sufficient size? | _,.ICorrect size of openings to I

thSeesmanuaC°mbusti°nforrequAirrements.andVentilation section in rNO _1 allow sufficient air I

YES

INO_ Is there a furnace/air handler in the same room as the water heater? !

YES

Does the return air duct for the furnace/ IContact a local Heating,

air handler draw its air from a separate _NO

location than the water heater? See Facts _ IVentilation, Air-Conditioning

to Consider About the Location section and _& Refrigeration authorized

the Combust on A r sect on |service provider.

YES

"_ [Check the vent system for

IIs there proper drafting at the | _. Irestrictions/obstructions and check

_ draft hood? See Draft Hood _NO _the vent termination height. Refer to

IOperation section in this manual. | " Ithe Installation Instructions section of

YES [this manual for specific requirements.

Remove the burner door

assembly. Is the flame arrestor

and burner free from debris due to

excessive lint, dirt, dust or oi1?

YES

IRefer to the Service and Adjustment I

NO m_.lsection of this manual for information on I

--Icleaning the flame arrestor and burner. I

_Does the flame arrestor show signs of discoloration j_NO

YES 4,

i iReplace the gas control]

Shut-off the gas supply to the water heater at the _valve/thermostat.* ]

I manual gas shut-off valve, then contact Sears

|Service at: 1-800-4-MY-HOME ®(1-800-469-4663)

POWER MISER TM 12 GAS WATER HEATER

lTM 15°Gall°° I

S BURNER ASSEMBLY

@..,

Key No. Part Description 153,331242

1 Draft Hood 700795-020

2 Reducer Ring -Some Models 700795-021

3 Flue Baffle 9006436005

4 Heat Trap (Cold) - Some Models 9003915015

5 Heat Trap (Hot) - Some Models 9003915015

6 Cold Water Dip Tube 9002432005

7 Anode Rod 9003892005

8 T & P Relief Valve 9000728015

9 Drain Valve 9000058015

10 Gas Control Valve/Thermostat 9006440005

11 Outer Door 700795-018

12 Pilot Assembly (Natural Gas) 9006441005

13 Burner Door Assembly (Natural Gas/Low Nox)** 9006443005

14" Two Piece Wire Connector With Retainer Clip 9006449015

15 Burner Door Gasket 9006141015

16 Viewport Assembly 9006142015

17" Thermocouple 9000056015

18 Piezoelectric Igniter Button 9006143015

19 Flexible Manifold Tube 9006445015

20* Instruction Manual 186192-000

* Not Shown. ** Includes Inner Door Gasket

Model Numbers

153,331252

700795-020

700795-021

9006437005

9003915015

9002432005

9003892005

9000728015

9000058015

9006440005

700795-018

9006441005

9006443005

9006449015

9006141015

9006142015

9000056015

9006143015

9006445015

186192-000

Now that you have purchased your gas water heater, should a need

ever exist for repair parts or service, simply contact any Sears Service

Center or call 1-800-4-MY-HOME _ (1-800-469-4663). Be sure to

provide all pertinent facts when you call or visit.

WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE

FOLLOWING INFORMATION:

•MODEL NUMBER

•SERIAL NUMBER

•TYPE GAS- NATURAL

•PART DESCRIPTION

THiS IS A REPAIR PARTS LIST, NOT A PACKING LIST,

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:

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

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

For the second through the twelfth year from 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.

I-YEAR EXCLUSIVE KENMORE LABOR WARRANTY

For the first year from the date of purchase, Sears will, free of charge, supply and install new water heater parts for defective

ones or a new 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 specific legal rights, and you may also have other rights which vary from state to state.

Sears, Roebuck and Co., Dept. 817WA, Hoffrnan 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 c. Leaks in pipes or fittings e. Condensation

b. Lighting pilot d. Improper venting

MASTER PROTECTION AGREEMENTS

Congratulations on making a smart purchase. Your new Kenmore <R'

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.

on products requiring in-home repair, plus convenient repair

scheduling,

Power surge protection against electrical damage due to power

fluctuations.

Purchase a Master Protection Agreement now and protect yourself

from unexpected hassle and expense.

The Master Protection Agreement also helps extend the life of your

new product. Here's what's included in the Agreement:

Rental reimbursement if repair of your covered product takes

longer than promised.

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.

Expert Service by our 12,000 professional repair specialist.

Unlimited service and no charge for parts and labor on all

covered repairs.

"No-lemon" guarantee - replacement of your covered product if

four or more product failures occur within twelve months.

Sears has over 12,000 professional repair specialists, who have

access to over 4.5 million quality parts and accessories. That's the

kind of professionalism you can count on to help prolong the life of your

new purchase for years to come. Purchase your Master Protection

Agreement today!

Some limitations and exclusions apply. For prices and additional

information call 1-800-827-6655.

Product replacement if your covered product can't be fixed. SEARS iNSTALLATiON SERVICE

Annual Preventive Maintenance Check at your request - no extra

charge.

Fast help by phone - phone support from a Sears technician

Far Sears professional Installation of home appliances, garage door

openers, water heaters, and other major home items, in the U.S.A.,

call 1-800-4-MY-HOME _.

For in-home major brand repair service

Call 24 hours a day, 7 days a week (U.S.A. and Canada)

1-800-4-MY-HOME ®

(1-800-469-4663)

www.sears.com

The model number of your water heater is found on the model rating plate on the front of the water heater.

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

Kenmore 153331242 User Manual WATER HEATER Manuals And Guides LR708077

KENMORE Water heater, Gas Manual LR708077 KENMORE Water heater, Gas Owner's Manual, KENMORE Water heater, Gas installation guides

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