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Kenmore 9-Year Manufacturer's Warranty

1. The water heater should be located in an area not subject to freezing temperatures Water heaters located in unconditioned spaces i e attics basements etc may require insulation of the water piping and drain piping to protect against freezing The drain and controls must be easily accessible for operation and service Maintain proper clearances as specified on the rating plate Do not locate the water heater near an air moving device The operation of air moving devices such as exhaust fans ventilation systems clothes dryers fireplaces etc can affect the proper operation of the water heater Special attention must be given to conditions these devices may create Flow reversal of flue gases may cause an increase of carbon monoxide inside of the dwelling Figure 8 Ifthe water heater is located in an area that is subjected to lint and dirt it may be necessary to periodically clean the base ring filter and flame arrestor see External Inspection amp Cleaning of the Flame arrestor This water heater is not for use in manufactured mobile homes or outdoor installation NOTE This water heater must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition SN fi EXHAUST FAN REVERSE FLOW OF GASES FIGURE 8 CAUTION All water heaters eventually leak Donotinstall wi
2. The connector must be installed above the extreme bottom of the chimney to prevent potentially blocking the flue gases The connector must be firmly attached and sealed to prevent it from falling out Toaidin removing the connector a thimble or slip joint may be used The connector must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney Figure 19 LISTED LINED d 2 FT MINIMUM ABOVE ANY OBJECT WITHIN 10FT HORIZONTALLY 3 FT MINIMUM SUPPORT STRAP MAINTAIN CLEARANCE DO NOT EXTEND VENT BEYOND EDGE OF CHIMNEY CONNECTOR CHIMNEY TERMINATION VENT SYSTEM FIGURE 19 Do not terminate the vent connector in a chimney that has not been certified for this purpose Some local codes may prohibit the termination of vent connectors in a masonry chimney Vertical Exhaust Gas Vent Vertical exhaust gas vents must be installed with U L listed type B vent pipe according to the vent manufacturer s instructions and the terms of its listing It must be connected to the water heater s draft hood by a listed vent connector or by directly originating at the draft hood opening Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer s instructions Gas vents must be supported to prevent damage joint separation and maintain clearances to combustible materials 2
3. Trademark of KCD IP LLC in the United States or Sears Brands LLC in other countries Marca Registrada Marca de F brica de KCD IP LLC en Estados Unidos o Sears Brands LLC in otros pa ses MC Marque de commerce Marque d pos e de Sears Brands LLC
4. Vent Pipe System This water heater uses a non direct single pipe vent system to remove exhaust gases created by the burning of fossil fuels Air for combustion is taken from the immediate water heater location or is ducted in from the outside see Combustion Air Supply and Ventilation This water heater must be properly vented for the removal of exhaust gases to the outside atmosphere Correct installation of the vent pipe system is mandatory for the proper and efficient operation of this water heater and is an important factor in the life of the unit The vent pipe must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition The vent pipe installation must not be obstructed so as to prevent the removal of exhaust gases to the outside atmosphere IMPORTANT The use of vent dampers is not recommended by the manufacturer of this water heater Although some vent dampers are certified by CSA International this certification applies to the vent damper device only and does not mean they are certified for use on this water heater U L recognized fuel gas and carbon monoxide CO detectors are recommended in all applications and should be installed 19 using the manufacturer s instructions and local codes rules or regulations IMPORTANT If you lack the necessary skills required to properly install this venting sys
5. e If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier SAFE INSTALLATION USE AND SERVICE Your safety and the safety of others is extremely important in the installation use and servicing of this water heater Many safety related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard Read and obey all safety messages and instructions throughout this manual It is very important that the meaning of each safety message is understood by you and others who install use or service this water heater This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death gt DANGER indicates an imminently hazardous situation which if not avoided will result in death or injury WARNING indicates a potentially hazardous situation which if not avoided could result WARNING in death or injury CAUTION indicates a potentially hazardous situation which if not avoided could result CAUTION in minor or moderate injury CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided could result in property damage DANGER All safety messages will generally tel
6. 3 Reset the thermal switch by depressing the small button in the center of the thermal switch Follow the Lighting Instructions found on the front of your water heater The gas control valve thermostat includes a temperature limiting ECO Energy Cut Off system that will shut off the water heater if the water temperature exceeds 189 F 87 C for 155 F models or 199 F 93 C for 180 F models See the data plate for your model Should the water temperature get too high the Diagnostic Status Light will flash a code 4 flashes indicating an over temperature condition and the main burner will be shut off If a high temperature condition occurs turn the main gas supply OFF and have the water heater repaired by a qualified service technician Contact Sears at 1 800 4 MY HOME 1 800 469 4663 to request service Leakage Checkpoints 6 MAXIMUM AIR GAP FIGURE 44 AWARNING Read and understand instruction manual and safety messages before installing operating or servicing this water heater Failure to follow instructions and safety messages could result in death or serious injury Instruction Manual must remain with water heater 36 Read this manual first Then before checking the water heater make sure the gas supply has been turned OFF and never turn the gas ON before the tank is completely full of water Never use this water heater unless it is completely filled w
7. 000 IMPORTANT The area must be open and be able to provide the proper air requirements to the water heater Areas that are being used for storage or contain large objects may not be suitable for water heater installation Water heaters installed in open spaces in buildings with unusually tight construction may still require outdoor air to function properly In this situation outside air openings should be sized the same as for a confined space Modern home construction usually requires supplying outside air into the water heater area Confined Space For the correct and proper operation of this water heater ample air must be supplied for the combustion ventilation and dilution of flue gases Small enclosures and confined areas must have two permanent openings so that sufficient fresh air can be drawn from outside of the enclosure One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure as shown in Figure 12 The size of each opening free area is determined by the total BTUH input of all gas utilization equipment i e water heaters furnaces clothes dryers etc and the method by which the air is provided The BTUH input can be found on the water heater rating plate Additional air can be provided by two methods 1 All air from inside the building 2 All air from outdoors 12 MAXIMUM CLOSET OR PERMANENT OTHER OPENINGS TO CONFINED THE O
8. A single wall metal vent connector cannot pass through any interior wall When installing a vent connector please note the following See Figures 19 21 e Install the vent connector avoiding unnecessary bends which create resistance to the flow of vent gases Install without dips or sags with an upward slope of at least 1 4 inch per foot Joints must be fastened by sheet metal screws or other approved means It must be supported to maintain clearances and prevent separation of joints and damage The length of the vent connector cannot exceed 75 of the vertical vent height The vent connector must be accessible for cleaning inspection and replacement e Vent connectors cannot pass through any ceiling floor firewall or fire partition e It is recommended but not mandatory that a minimum 12 inches of vertical vent pipe be installed on the draft hood prior to any elbow in the vent system IMPORTANT Existing vent systems must be inspected for obstructions corrosion and proper installation Chimney Connection IMPORTANT Before connecting a vent to a chimney make sure the chimney passageway is clear and free of obstructions The chimney must be cleaned if previously used for venting solid fuel appliances or fireplaces Also consult local and state codes for proper chimney sizing and application or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition
9. Tables 1 and 2 on the following page provide a sizing reference for commonly used gas pipe materials Consult the National Fuel Gas Code for the recommended gas pipe size of other materials NOTE Use pipe joint compound or teflon tape marked as being resistant to the action of petroleum Propane L P gases See Figure 11 1 Install a readily accessible manual shut off valve in the gas supply line as recommended by the local utility Know the location of this valve and how to turn off the gas to this unit 2 Install a drip leg if not already incorporated as part of the water heater as shown The drip leg must be no less than three inches long for the accumulation of dirt foreign material and water droplets 3 Install a ground joint union between the gas control valve thermostat and the manual shut off valve This is to allow easy removal of the gas control valve thermostat 4 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 Manual Gas Shut off Mii m Ground Joint 59 Union Check with local utility for minimum height 3 Minimum tA Drip Leg FIGURE 11 Gas Pressure the fuel is not spilled in the area of the water heater installation E or any source of ignition If the fuel is spilled while p
10. a Ea eL reat aeara n ik 34 36 otart UPLGONdItIONS zerrece A ie o etie te en e aaee 34 35 Operational Cohdiltlohns 5 di eer ate esa eerta Dh aa ex te A decken de 35 36 TROUBLESHOOTING CHART T T cece cette teeter ee eee eee nennen nen nene ne ns ete inneren enn inerenti 37 38 STATUS LIGHT AND DIAGNOSTIC TROUBLESHOOTING CHAR To ooooooooccncccnncnnncnnncnnnnnnnnnnnnnnnnnnnncnonoos 39 40 PILOT LIGHT TROUBLESHOOTING FLOWCHAR Toooooocccononnnononcnnnnnnnnnnnnnnnononnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnoss 41 PARTS ORDERS E terne Mte RET a Mp eR ERE ened 42 43 PRODUCT WARRANTY 9 YEAR LIMITED WARRANTY ON WATER HEATER For nine years from the date of purchase if this water heater is installed and operated in a single family home in accordance with the owner s manual instructions and all local applicable plumbing codes Sears will 1 Supply free water heater parts for those that are defective in material or workmanship 2 Supply a free water heater for one that develops a tank leak See notes below also For the second through ninth year from the purchase date you must pay the labor cost for installation of parts or water heater For commercial institutional industrial or residential use by two or more families the above limited warranty is only for two years During the second year you must pay the labor cost for parts or water heater installation If governmental regulations prohibit Sears from furnishing a comparable model replacement water
11. attempting to light or re light the pilot Make sure the view port is not missing or damaged See Figure 34 Make sure the tank is completely filled with water before lighting the pilot Check the rating plate near the gas control valve thermostat for the correct type of gas Do not use this water heater with any gas other than the one listed on the rating plate If you have any questions or doubts consult your gas supplier or gas utility Lighting the Pilot Read and follow the lighting instructions on the water heater s label 1 Turn the Control Knob to Pilot Press the Knob in fully and hold it in The knob will travel in about inch if it is set to Pilot correctly 3 Click the Igniter button continuously for up to 90 seconds or until the Status Light begins to blink for 90 seconds If the Status Light does not begin to blink after 90 seconds STOP Wait 10 minutes before attempting to relight the Pilot Repeat these steps 2 3 times if necessary The circuitry on this gas valve requires that your wait 10 minutes between lighting attempts If the Status Light blinks release the Control Knob and set temperature to desired setting Hot is approx 120 F If the Status Light Does Not Blink 1 Wait 10 minutes before another lighting attempt 2 Ifthe Status Light did not blink repeat the lighting procedure following the lighting instructions on the water heater s label Remove the outer door The Control Knob must
12. compatible with potable water Itis recommend that only full flow ball or gate valves are used in water piping installations The use of valves that may cause excessive restriction to water flow is not recommended Use only 95 5 tin antimony or other equivalent solder Any lead based solder must not be used Piping that has been treated with chromates boiler seal or other chemicals must not be used e Chemicals that may contaminate the potable water supply must not be added to the piping system Closed System Thermal Expansion CAUTION All water heaters eventually leak Donotinstall without adequate drainage As water is heated it expands thermal expansion In a closed system the volume of water will grow As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent temperature pressure relief valve operation water discharged from the valve due to excessive pressure build up The temperature pressure relief valve is not intended for the constant relief of thermal expansion This condition is not covered under the limited warranty A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion Thermal expansion tanks
13. 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 Anew water heater is filled with cold water for the first time e 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 dur
14. 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 igniter if defective 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 wire leads that connect to a thermal switch Removing the Gas Control Valve Thermostat 1 Turn the gas control temperature knob to the OFF position See the Lighting Instructions on the front of the water heater or in this manual Turn off the gas at the manual shut off valve on the gas supply pipe Figure 11 Drain the water heater Refer to the section of Draining and Flushing and follow the procedure Disconnect the igniter wire from the igniter lead wire Use needle nose pliers to disconnect the red and white thermopile wires Disconnect pilot tube 7 16 wrench and manifold tube 3 4 wrench at the gas control valve thermostat Figure 33 NOTE L P Gas systems use reverse left hand th
15. minutes between lighting attempts If the status light turns solid red release the gas control temperature knob and repeat steps 2 through 5 waiting 10 minutes before attempting to relight the pilot If the status light does not start blinking after three lighting attempts turn the gas control temperature knob to OFF and call a qualified service technician or your gas supplier DANGER Hotter water increases the risk of scald injury Consult the instruction manual before changing temperature Refer to the Lighting Instructions in the Installation Manual for more detailed troubleshooting information Turn the gas control temperature knob counterclockwise to the OFF setting The status light will stop blinking and stay on for a short time after the water heater is turned off See Figure A Checking the Draft AWARNING Burn Hazard Do not touch vent sat pr AREA CERT Doing so can result in burns After successfully lighting the water heater allow the unit to operate for 15 minutes and check the draft hood relief opening for proper draft Figure 26 Make sure all other appliances in the area are operating and all doors are closed when performing the draft test Pass a match flame around the relief opening of the draft hood A steady flame drawn into the opening indicates proper draft DRAFT HOOD RELIEF OPENING MATCH Y FIGURE 26 If the flame flutters or is blown ou
16. the water heater The valve s relief pressure must not exceed the working pressure of the water heater as stated on the rating plate IMPORTANT Only a new temperature and pressure relief valve should be used with your water heater Do not use an old or existing valve as it may be damaged or not adequate for the working pressure of the new water heater Do not place any valve between the relief valve and the tank The Temperature amp Pressure Relief Valve Must not be in contact with any electrical part Must be connected to an adequate discharge line Must not be rated higher than the working pressure shown on the rating plate of the water heater Discharge Line Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line Must not be capped blocked plugged or contain any valve between the relief valve and the end of the discharge line Must terminate a maximum of six inches above a floor drain or external to the building In cold climates it is recommended that the discharge line be terminated at an adequate drain inside the building Must be capable of withstanding 250 F 121 C without distortion Must be installed to allow complete drainage of both the valve and discharge line T amp P Relief Valve and Pipe Insulation The 1 Locate the temperature and pressure relief valve on the water heater also known as a T amp P relief valve See
17. to the OFF if the thermopile does not cool position the pilot valve is stuck open Turn the main down as quickly as expected when gas supply OFF Replace the gas control valve the unit is shut off This condition thermostat For instructions see Removing and can also occur if the gas control Replacing the Gas Control Valve Thermostat temperature knob has been turned If the pilot flame is not observed when the gas off and the pilot continues to control valve thermostat knob is set to the OFF operate because the pilot valve is position wait 10 minutes for the thermopile to cool stuck in the open position then attempt to relight the pilot by following the lighting instructions on the water heater s label If this condition returns replace the gas control valve thermostat See Removing and Replacing the Gas Control Valve Thermostat for instructions 40 PILOT LIGHT TROUBLESHOOTING FLOWCHART Section A Pilot light will not light new installation Is the manual gas shut off valve located in the supply line to the Turn the manual gas shut off valve to the on position and follow the lighting instructions on the front of the water heater water heater in the on position Have you bled all the air While repeatedly depressing the igniter from the pilot tube and NO button push in and hold the gas control gas supply line temperature knob until the pilot is lit and maintains a stable flame status
18. 0 Figures 20 and 21 IMPORTANT This gas vent must be terminated in a vertical position to facilitate the removal of the burnt gases An unused chimney flue or masonry enclosure may be used as a passageway for the installation of a gas vent Figure 21 Common combined venting is allowable with vertical type B vent systems and lined masonry chimneys as long as proper draft for the water heater is established under all conditions of operation IMPORTANT DO NOT common vent this water heater with any power vented appliance Figures 19 21 are examples of vent pipe system installations and may or may not be typical for your specific application Consult the National Fuel Gas Code NFPA 54 ANSI Z223 1 current edition and the guidelines set forth by prevailing local codes V LISTED VENT CAP 4 2 FT MINIMUM ABOVE ANY OBJECT 3 FT MINIMUM WITHIN 10 FT HORIZONTALLY SUPPORT Y EN TYPE B DOUBLE WALL VENT PIPE STRAP MAINTAIN CLEARANCE MAINTAIN SPECIFIED CLEARANCE VENT CONNECTOR SLOPE UP 1 4 IN PER FT MINIMUM VERTICAL GAS VENT SYSTEM WITH TYPE B DOUBLE WALL VENT PIPE FIGURE 20 Fm LISTED VENT CAP MAINTAIN MANUFACTURER S SPECIFIED MINIMUM CLEARANCE MAINTAIN SPECIFIED CLEARANCE SUPPORT STRAP MAINTAIN CLEARANCE VENT VENT CONNECTOR CONNECTOR SLOPE UP 1 4 IN PER FT MINIMUM UNUSED CHIMNEY FLUE OR MASONR
19. Figure 25 2 Locate the slit running the length of the T amp P relief valve insulation 3 Spread the slit open and fit the insulation over the T amp P relief valve See Figure 25 Apply gentle pressure to the insulation to ensure that it is fully seated on the T amp P Relief Valve Once seated secure the insulation with duct tape electrical tape or equivalent IMPORTANT The insulation and tape must not block the discharge opening or hinder access to the manual relief lever Figure 25 Ensure a discharge pipe is installed into the T amp P valve discharge opening per the instructions in this manual Locate the hot water outlet amp cold water inlet pipes to the water heater 5 Locate the slit running the length of a section of pipe insulation 6 Spread the slit open and slip the insulation over the cold water inlet pipe Apply gentle pressure along the length of the insulation to ensure that it is fully seated around the pipe Also ensure that the base of the insulation is flush with the water heater Once seated secure the insulation with duct tape electrical tape or equivalent 7 Repeat steps 5 and 6 for the hot water outlet pipe 8 Add additional sections of pipe insulation as needed T amp P RELIEF VALVE INSULATION C MANUAL RELIEF eit LEVER T amp P RELIEF VALVE T amp P RELIEF VALVE DRAIN LINE FIGURE 25 Lighting Instructions Read and understand these directions thoroughly before
20. NOT crimp or crease the pilot tube 11 Before you proceed to the next step install the new brass ferrule nut in the gas control valve thermostat s pilot tube opening HAND TIGHT ONLY 12 Follow the Replacing the Burner Manifold Assembly instructions to replace the manifold door Cleaning the Combustion Chamber and Flame arrestor 1 Follow procedure outlined in Removing the Manifold Burner Assembly 2 Use a vacuum cleaner shop vac to remove all loose debris in the combustion chamber Figure 39 Use compressed air to clear any dust or debris that may have accumulated in the flame arrestor COMBUSTION CHAMBER FLAME ARRESTOR DOOR P AD SQ IN FIGURE 39 3 Reassemble by following the procedure under Replacing the Manifold Burner Assembly Manifold Red Thermal Switch Wires Component Connection at Manifold Door Block Igniter Wire Passes through Center of Pilot Tube passes Thermopile Wires pass through Top Hole of through Bottom Hole of Manifold Component Block Largest Hole Manifold Component Block Manifold Component Block Smallest Hole FIGURE 38 31 Replacing the Manifold Burner Assembly AWARNING Explosion Hazard Tighten both manifold door screws securely Remove any fiberglass between gasket and combustion chamber Replace viewport if glass is missing or damaged Replace manifold component block i
21. OFF position 2 Before performing any maintenance it is important to turn off the gas supply to the water heater at the manual gas shut off valve This valve is typically located beside the water heater Note the position of the shut off valve in the open on position then proceed to turn it off Figure 11 3 With the unit shut off allow sufficient time for the water heater to cool before performing any maintenance Wire Pilot Red Wire lgniter Tube Left Side Wire Manifold Tube FIGURE 33 4 Remove the outer door 5 Disconnect the pilot tube 7 16 wrench the igniter wire from the igniter lead wire and manifold tube 3 4 wrench at the gas control valve thermostat Figure 33 NOTE L P Gas systems use reverse left hand threads on the manifold tube GAS CONTROL VALVE THERMOSTAT THERMOPILE AND SWITCH WIRE CONNECTIONS GAS CONTROL TEMPERATURE KNOB PIEZO IGNITER BUTTON PILOT TUBE f EN MANIFOLD TUBE VIEWPORT 9l Ar ey THERMAL SWITCH OUTER DOOR E Z MANIFOLD DOOR NOT SHOWN MANIEOLD SCHREW 2 MANIFOLD COMPONENT BLOCK FIGURE 34 6 Use needle nose pliers to disconnect the white thermopile wire from the gas control valve thermostat Figure 33 Then disconnect both red thermal switch wires from the thermal Switch on the old manifold door Figure 34 7 Grasp the manifold tub
22. Pilot and held in until the Status Light blinks Once the Status light blinks release the control knob and set knob to desired temperature setting HOT is approx 120 F For additional help visit www Lightmywaterheater com fire or explosion may result causing property damage personal injury or loss of life WARNING if you do not follow these instructions exactly a FLAMMABLE BEFORE LIGHTING ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A This appliance has a pilot which is lit E a lezo If you cannot reach your gas supplier call the fire elegie Spa spark gas eignen system Do notopen department e inner door of the appliance and try to light C Use only your hand to push in or turn the gas control the pilot by hand B BEFORE LIGHTING smell all around the appliance knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified area for gas Be sure to smell next to the floor dl because some gas is heavier than air and will service technician Force or attempted repair may result in a fire or explosion settle on the floor WHAT TO DO IF YOU SMELL GAS D Do not use this appliance if any part has been under water Immediately contact a qualified installer or e Do not try to light any appliance Do not touch any electric switch do not use any service agency to replace a flooded water heater Do not attempt to repair the unit It must be
23. RRESTER CLEAN IF LINT ACCUMULATIONS ARE NOTICED INSTALLED IN SUITABLE AREA To ensure sufficient ventilation and combustion air supply proper clearances from the water heater must be maintained See Installation Instructions 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 CAUTION Avoid water heater damage Inspection and replacement of anode rod 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 Exposed Pitted Exposed Support Anode Support Wire Rod Wire FIGURE 31 Anode deterioration depends on water conductivity not necessarily water condition A corroded or pitted anode rod 28 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 The anode rod should be inspected after a maximum of th
24. SION TANKS FOR THERMAL EXPANSION CONDITIONS AVAILABLE IN 2 GALLONS 7 6 LITERS AND 5 GALLONS 18 9 LITERS CAPACITY THROUGH LOCAL SEARS STORE OR SERVICE CENTER WATER HEATER INSTALLATION KIT WITH FLEXIBLE CONNECTORS FOR 3 4 AAA ANN d METAL DRAIN PANS AVAILABLE IN 20 DIAMETER FOR WATER HEATERS HAVING A DIAMETER 18 OR LESS AND IN 24 DIAMETER FOR WATER HEATERS HAVINGA DIAMETER OF 22 ORLESS 19 05 mm COPPER PLUMBING AND FLEXIBLE GAS CONNECTOR WITH FITTINGS BASIC TOOLS You may or may not need all these tools depending on your type of installation These tools can be purchased at your local Sears Store Pipe Wrenches 2 14 356 mm Screwdriver Tin Snips 6 1 82 m Tape or Folding Ruler Garden Hose Drill Pipe Dope or Teflon Tape ADDITIONAL TOOLS NEEDED WHEN SWEAT SOLDERING Tubing Cutters or Hacksaw Propane Torch Soft Solder Solder Flux Emery Cloth Wire Brushes PROPANE B 3 CSF CS TUBING CUTTER TORCH SLOT HEAD SCREWDRIVER SS TIN SNIPS PHILLIPS SCREWDRIVER ae UR HACKSAW EMERY CLOTH PIPE DOPE ROLL OF TEFLON SQUEEZE TUBE TAPE USE ONLY ON USE FOR WATER AND GAS WATER CONNECTIONS CONNECTIONS 3 4 19 mm WIRE BRUSH y a T SO ROLL OF LEAD FREE SOLDER GARDEN HOSE 6 FOOT TAPE PIPE WRENCH 1 2 13 mm WIRE BRUSH SOFT SOLDER FLUX TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER GAS MODELS A VentPipe J In
25. STIC CODE TROUBLESHOOTING CHART LED STATUS PROBLEM CORRECTIVE ACTION 0 FLASHES LED NOT LIT Pilot light is not lit or Thermopile Turn Gas Control Valve Thermostat knob to OFF has not yet reached normal Wait 10 minutes then attempt to relight Pilot by operating temperature following the lighting instructions on the water heater s label Until the Thermopile reaches its normal operating temperature the Status Light will not blink even if the Pilot is lit It may take up to 90 seconds of continuous Pilot operation before the Thermopile reaches normal operating temperature and the Status Light starts to blink If the Status Light does not blink after three lighting attempts check to make sure unit is getting gas Remove the outer door Press reset button Replace outer door Turn Gas Control Valve Thermostat knob to OFF Wait 10 minutes then attempt to light Pilot by following the lighting instructions on the water heater s label Look through the sight glass for the Pilot flame If Pilot is not visible the spark igniter or gas supply to the Pilot should be checked If the Pilot is visible and the Status Light does not blink after 90 seconds of continuous Pilot operation the Pilot flame may not be heating the Thermopile sufficiently weak Pilot or the Thermopile may be defective or wiring connectors may be loose Replace outer door and verify proper operation after servicing NOTE If the water heater has been operating but
26. UTSIDE OR SPACE ADDITIONAL ROOMS WITHIN THE BUILDING 12 MAXIMUM FIGURE 12 All Air from Inside the Building When additional air is to be provided to the confined area from additional room s within the building the total volume of the room s must be of sufficient size to properly provide the necessary amount of fresh air to the water heater and other gas utilization equipment in the area If you are unsure that the structure meets this requirement contact your local gas utility company or other qualified agency for a safety inspection Each of the two openings shall have a minimum free area of 1 square inch per 1 000 BTUH of the total input rating of all gas utilization equipment in the confined area but not less than 100 square inches Figure 13 CONFINED SPACE PERMANENT OPENINGS 1 SQUARE INCH 1000 BTUH MINIMUM 100 SQ IN FIGURE 13 All Air from Outdoors Outdoor fresh air can be provided to a confined area either directly or by the use of vertical and horizontal ducts The fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors Attic or crawl spaces cannot be closed and must be properly ventilated to the outside Ductwork must be of the same cross sectional area as the free area of the opening to which they connect The minimum dimension of rectangular air ducts cannot be less than three inches The size of each of the two openings is
27. Use amp Care Guide Model No 153 331830 40 Gallon Short 153 331840 40 Gallon 153 331851 AO Gallon L P 153 331882 50 Gallon Kenmore LOW LEAD COMPLIANT Gas Water Heater For potable water heating only Not suitable for space heating Not for use in mobile homes INSTALLER Affix these instructions to or near the water heater OWNER Retain these instructions for future reference FOR YOUR SAFETY An odorant is added to the gas used by this water heater ADVERTENCIA Si no puede leer o entender el ingl s y necesita el manual de instrucciones en espa ol puede solicitarlo al 1 800 821 2017 NO TRATE DE INSTALAR U OPERAR ESTE CALENTADOR DE AGUA SI NO ENTIENDE LAS INSTRUCCIONES No hacer caso de esta advertencia podr a originar lesiones graves o mortales P N 320390 000 1110 Sears Brands Management Corporation Hoffman Estates IL 60179 U S A www kenmore com www sears com 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 ofthis or any other appliance WHATTODOIFYOUSMELL GAS e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions
28. Y ENCLOSURE VENTING THROUGH A CHIMNEY WITH TYPE B DOUBLE WALL VENT PIPE FIGURE 21 x Maintain vent pipe clearance requirements to local state and or the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition NFPA 211 Standard for Chimneys Fireplaces Vents and Solid Fuel Buming Appliances states that these chimneys are intended to be installed in accordance with the installation instructions provided with each chimney support assembly Minimum air space clearance to combustible materials should be maintained as marked on the chimney sections WATER SYSTEM PIPING Piping Installation Piping fittings and valves should be installed according to the installation drawing Figure 22 If the indoor installation area is subject to freezing temperatures the water piping must be protected by insulation The water supply pressure should not exceed 80 psi If this occurs a pressure reducing valve with a bypass should be installed in the cold water inlet line This should be placed on the supply to the entire house in order to maintain equal hot and cold water pressures IMPORTANT Heat cannot be applied to the water fittings on the heater as they may contain nonmetallic parts If solder connections are used solder the pipe to the adapter before attaching the adapter to the hot and cold water fittings IMPORTANT Always use a good grade of joint compound and be certain that all fittings are drawn up tight 1 In
29. add een enea iin eia d e eda 20 Vertical Exhaust Gas Ventura n Eee oven ab sib aset wed evi ded eda e cbe eee 20 WATER SYSTEM PIPING teet Herc ine testet cete seen rae e re ERR eER cram 21 22 Piping Installation tt i et e oe etd it e eg t ttu 21 Closed System Thermal Expansion 15 icc eet tte ce denn cited esee eoe nt chu eae e Cc 22 Temperature and Pressure Relief Valve sssssssssssssesssssseeeenee en ne nnn nennen enne rrr rnnt nni n nnne rrertnr neis 22 T amp P Relief Valve and Pipe INSUItiON oooooonnnncnnnnnncnncnnnnoconnoncncnnncnnnnncnnnnnnnnno nn nnnnncnnnnn nennen nenne nrtrr nnns snnt nne 22 OPERATING YOUR WATER HEATER sion a as 23 26 Lighting Instr ctlOris iecit Aa 23 24 Checking the Draft itt eee hb lin 25 BUNGE dz OO 25 Emergency Shut DOWN teet tte c ett teet ten qt eios 25 Water Temperat re Regulatiori eet dirette ani dedica 25 26 Operating the Temperature Control System sssssssssssssssssee rra nn cnn raro rn nennen err enne enne 26 SERVICE AND ADJUSTMENT T a a aaa a aaa ere n ae aea rrr rrr rra reni enirn rrr rire tirer renis 27 29 Vent System Inspections eerte t o ete ee Ea 27 B rner INSPectiOn autos A A lastest A ert dde RR eod eae adi 27 Burner Cleaning 3 22 ttp dde tdt des te ad 27 Housekeeplirig dert e A td E ld thee etel en tte o mete entendu 28 Anode Rod Inspection oe te PE e een rt t e te o tee e E eene ae ORTU 28 Temperature Pressure R
30. ain it does not sag thereby obstructing combustion air flow Clearances and Accessibility NOTE Minimum clearances from combustible surfaces are stated on the label adjacent to the gas control valve thermostat of the water heater The water heater is certified for installation on a combustible floor e IMPORTANT If installing over carpeting the carpeting must be protected by a metal or wood panel beneath the water heater The protective panel must extend beyond the full width and depth of the water heater by at least three inches 76 2mm in any direction or if in an alcove or closet installation the entire floor must be covered by the panel e Figure 10 may be used as a reference guide to locate the specific clearance locations A minimum of 24 inches of front clearance should be provided for inspection and service SIDES FIGURE 10 Filling the Water Heater 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 turning the handle to the right clockwise The drain valve is on the lower front of the water heater e 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 ensure complete fil
31. al Switch This water heater is designed to automatically shut off in the event of the following 1 The pilot flame is extinguished for any reason 2 The water temperature exceeds 195 F 91 C 3 Excessive build up of dust on the base ring filter or flame arrestor See Maintenance of your Water Heater Section 4 The ignition of flammable vapors Athermopile is used to determine if a pilot flame is present and will shut off the gas supply to the main burner and the pilot if the flame is absent This unit is also equipped with a thermal switch designed to shut off the gas supply in the event the water heater has been exposed to flammable vapors e g spilled gasoline poor combustion caused by insufficient combustion air or improper venting If the thermal switch opens 1 Check the flame arrestor for signs of high temperature blue or black discoloration See Figure 39 2 Ifthere are signs of high temperature or that the thermal switch has opened inspect your installation for problems with venting combustion air supply or a possible flammable vapor event See Pilot Light Troubleshooting Flowchart section Correct any issues prior to resetting the thermal switch If you suspect a flammable vapor incident has occurred do not use this appliance Immediately call a qualified technician to inspect the appliance Water heaters subjected to a flammable vapors ignition will require replacement of the entire water heater
32. an normal a higher thermostat setting may be required to meet the increased demand When leaving your home for extended periods vacations etc turn the temperature dial to its lowest setting This will maintain the water at low temperatures with minimum energy losses and prevent the tank from freezing during cold weather Operating the Temperature Control System List of status codes are shown at top of gas control valve thermostat FIGURE 29 26 Water Temperature Adjustment The water temperature setting can be adjusted from 55 F to 155 F Turn the Gas Control Temperature Knob to the desired setting temperature NOTE Some models are certified for 180 F outlet temperatures See the Data Plate on the front of the water heater for the maximum outlet temperature NOTE The temperatures indicated are approximates The actual temperature of the heated water may vary Operating Modes and Settings Standard Mode The controller adjusts the water heater to maintain the temperature set by the user The Vacation Setting VAC sets the controller at approximately 55 F This setting is recommended when the water heater is not in use for a long period of time This effectively turns the controller temperature setting down to a temperature that prevents the water in the water heater from freezing while still conserving energy Status Light Code Normal Flashes O Flashes Indicates Control Of
33. 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 For additional information see the Troubleshooting Guide later in this manual Temperature and Pressure Relief Valve AWARNING Temperature pressure relief valve must comply with ANSI Z21 22 CSA 4 4 and ASME code Properly sized temperature pressure relief valve must be installed in opening provided Can result in overheating and excessive tank pressure Can cause serious injury or death V remperatuie and Pressure Relief T amp P Valve Optional Top T amp P Relief Valve Not shown Discharge Pipe Do Not Cap or Plug Drain line 3 4 ID minimum 1 minimum rG Maximum Air Gap FIGURE 24 22 For protection against excessive pressures and temperatures a temperature and pressure relief valve must be installed in the opening marked T amp P RELIEF VALVE See Figure 24 This valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of listed equipment or materials as meeting the requirements for Relief Valves for Hot Water Supply Systems ANSI Z21 22 The function of the temperature and pressure relief valve is to discharge water in large quantities in the event of excessive temperature or pressure developing in
34. be set to Pilot and held in continuously while clicking the igniter button about once per second for up to 90 seconds To observe the Pilot remove the outer door and look through the view port sight glass 3 Continue clicking the Igniter button for up to 90 seconds until Pilot lights Once the Pilot is lit continue to hold the Control Knob in until the Status Light begins to blink 5 Release Control Knob and set Knob to desired temperature setting Hot is approx 120 F 6 Replace outer door If the Pilot Does Not Light 1 Wait 10 minutes before another lighting attempt If the pilot does not light the Igniter may not be sparking or the unit may not be getting gas or on a new installation there may still be air in the gas line Each time the Igniter button is clicked you should be able to see the spark by looking through the sight glass you may have to darken the room lights to see the spark You do not have to push the Control Knob in to check the Igniter button Simply OPERATING YOUR WATER HEATER 23 AVWARNING Explosion Hazard Replace view port if glass is missing or damaged Failure to do so can result in death explosion or fire look through the sight glass while clicking the Igniter button and look for a spark If you can t see a spark when the Igniter button is clicked check the wiring connections from the Igniter button and make sure they are tight If you see the Igniter spark try relight
35. ck the Base Ring Filter and Flame Arrestor for blockage due to lint or dust Are both the Air Filter and Flame Arrestor clean Refer to the Maintenance of your Water Heater section of this manual for information on cleaning the flame arrestor and burner Does the flame arrestor show signs of discoloration Reassemble the heater press the thermal switch and attempt to return the heater to service Does the pilot remain lit YES N Set to desired temperature YES o Shut off the gas supply to the water heater at the manual gas shut off valve and contact Sears Service at 1 800 MY HOME 1 800 469 4663 Does the diagnostic status light on the gas control valve thermostat give a two flash error code NO Go to section C Refer to the Replacing the Pilot Assembly instructions in the manual Reassemble and restore to service same location manual for specific requirements If you are still having difficulty keeping the pilot lit Contact Sears at 1 800 4 MY HOME 1 800 469 4663 to request service NOTE If you are still experiencing difficulties after following the steps in sections A B and C please contact Sears Service at 1 800 MY HOME 1 800 469 4663 THERMAL SWITCH LOCATION FIGURE 45 41 DEED ORDER LIST KENMORE 9 YEAR GAS WATER HEATER MODEL NUMBERS Dre Model Numbers K
36. combustion air 1 Provide ventilation to water heater Check flue RECOVERY way flue baffle and burner 2 Water heater flue or vent system 2 Clean flue locate source and correct blocked 3 Low gas pressure 3 Check with gas utility company 4 Improper calibration 4 Replace thermostat 5 Base Ring Filter blocked with lint dust 5 Clean filter See External Cleaning amp Inspection of the Base Ring Filter section 6 FVIR Flame Arrestor blocked with lint 6 Clean filter See Cleaning the Combustion dust Chamber and Flame Arrestor section DRIP FROM RELIEF VALVE 1 Excessive water pressure Use a pressure reducing valve and relief 2 Heater stacking valve 3 Closed water system Lower the thermostat setting See Closed System Thermal Expansion THERMOSTAT FAILS TO 1 Thermostat not functioning properly SHUT OFF 2 Improper calibration COMBUSTION ODORS Insufficient combustion air Provide ventilation to water heater Check flue way flue baffle and burner Water heater flue or vent system 2 Clean locate source and correct blocked Heater installed in a confined area Provide fresh air ventilation Base Ring Filter blocked with lint dust Clean filter See External Cleaning amp Inspection of the Base Ring Filter section FVIR Flame Arrestor blocked with lint 5 Clean filter See Cleaning the Combustion Chamber and Flame Arrestor section SMOKING AND CARBON Insufficient combustion air Provide ventilat
37. cted 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 Burner Inspection 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 27 At least once a year a visual inspection should be made of the main burner and pilot burner See Figure 30 You should check for sooting Soot is not normal and will impair proper combustion Soot build up indicates a problem that requires correction before further use Turn OFF gas to water heater and l
38. cts 1 sq in per 4000 BTUH Figure 15 Horizontal Ducts 1 sq in per 2000 BTUH Figure 16 Single Opening 1 sq in per 3000 BTUH Figure 17 Example A water heater with an input rating of 50 000 BTUH using horizontal ducts would require each opening to have a minimum free area of 25 square inches Minimum free area 50 000 BTUH x 1 sq in 2000 BTUH 25 sq in These openings connect directly with the outdoors through a ventilated attic a ventilated crawl space or through an outside wall Consult the local codes of your area for specific ventilation and combustion air requirements GABLE VENT TO OUTDOORS INSTALL ABOVE INSULATION CONFINED ATTIC 1 SQ INCH PER 4000 BTUH ALTERNATE AIR INLET 1 SQ INCH PER OPEN 4000 BTUH FOUNDATION VENT ALL AIR FROM OUTDOORS INLET AIR FROM VENTILATED CRAWL SPACE OUTLET AIR TO VENTILATED ATTIC FIGURE 14 GABLE VENT e TO OUTDOORS INSTALL ABOVE a INSULATION OUTLET AIR TO ATTIC 1 SQ INCH PER 4000 BTUH CONFINED SPACE INLET AIR DUCT 1 SQ INCH PER 4000 BTUH 12 MAXIMUM ALL AIR FROM OUTDOORS THROUGH VENTILATED ATTIC FIGURE 15 1 SQ INCH PER 2000 BTUH CONFINED SPACE OUTDOOR AIR DUCTS 1 SQ INCH PER 2000 BTUH ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS FIGURE 16 ALTERNATIVE OPENING LOCATION 1 SQ INCH an PER 3000 BTUH CONFINED SPACE ALL AIR FROM OUTDOORS USING A SINGLE PERMANENT OPENING FIGURE 17
39. cts when TYPE GAS NATURAL OR PROPANE L P you call or visit PART DESCRIPTION WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE THIS IS A REPAIR PARTS LIST NOT A PACKING LIST FOLLOWING INFORMATION 42 NOTES 43 Get it fixed at your home or ours Your Home For troubleshooting product manuals and expert advice managemylife www managemylife com For repair in your home of all major brand appliances lawn and garden equipment or heating and cooling systems no matter who made it no matter who sold it For the replacement parts accessories and owner s manuals that you need to do it yourself For Sears professional installation of home appliances and items like garage door openers and water heaters 1 800 4 MY HOME 1 800 469 4663 Call anytime day or night U S A and Canada www sears com WWW Sears ca Our Home For repair of carry in items like vacuums lawn equipment and electronics call anytime for the location of your nearest Sears Parts amp Repair Service Center 1 800 488 1222 U S A 1 800 469 4663 Canada WWW Sears com www sears ca To purchase a protection agreement on a product serviced by Sears 1 800 827 6655 U S A 1 800 361 6665 Canada Para pedir servicio de reparacion a domicilio y para ordenar piezas 1 888 SU HOGAR 1 888 784 6427 www sears com Au Canada pour service en francais 1 800 LE FOYER 1 800 533 6937 www sears ca Sears Registered Trademark
40. d See Figures 2 and 3 Open a nearby hot water faucet until the water is no longer hot When the water has cooled turn OFF the water supply to the water heater at the water shut off valve or water meter Some installations require that the water be turned off FIGURE 4 to the entire house See Figures 2 and 4 Check again to make sure the gas supply is OFF to the water heater Then disconnect the gas supply connection from the gas control valve ADANGER Burn hazard Hotwater discharge Keep hands clear of drain valve discharge 12 Attach a hose to the water heater drain valve and put the other end in a floor drain or outdoors See Figures 2 and 5 Open the water heater drain valve 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 FIGURE 5 Disconnect the vent pipe from the draft hood where it connects to the water heater In most installations the vent pipe can be lifted off after any screw or other attached devices are removed Dispose of the draft hood The new water heater has a draft hood which must be used for proper operation 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 pipe
41. determined by the method in which the air is to be provided Refer to Table 4 to calculate the minimum free area for each opening Figures 14 15 16 and 17 are typical examples of each method Louvers and Grilles In calculating free area for ventilation and combustion air supply openings consideration must be given to the blocking effect of protection louvers grilles and screens These devices can reduce airflow which in turn may require larger openings to achieve the required minimum free area Screens must not be smaller than 1 4 mesh If the free area through a particular design of louver or grille is known it should be used in calculating the specified free area of the opening If the design and free area are not known it can be assumed that most wood louvers will allow 20 25 of free area while metal louvers and grilles will allow 60 75 of free area Louvers and grilles must be locked open or interconnected with the equipment so that they are opened automatically during equipment operation Keep louvers and grilles clean and free of debris or other obstructions 18 TABLE 4 Minimum Free Area of Permanent Openings for Ventilation and Combustion Air Supply All Air from Outdoors Only Based on total BTUH input rating for all utilizing equipment within the confined space Minimum Free Area Reference Opening Source Per Opening sq in Drawing Direct to outdoors 1 sq in per 4000 BTUH Figure 14 Vertical Du
42. e Continue to tighten until the nut is tight in the gas valve NOTE L P Gas systems use reverse left hand threads on the manifold tube 7 Connect the white thermopile wire to the gas control valve thermostat Then connect the red thermal switch wires to the thermal switch on the on the manifold door Figure 38 8 Reconnectthe igniter wire Figure 33 9 Turnonthe gas supply to the water heater at the manual gas shut off valve Figure 11 32 10 Follow the lighting instructions on the front of the water heater With the main burner lit check for leaks at the manifold and pilot connections by brushing on an approved noncorrosive leak detection solution or a mixture of hand dish washing soap and water one part soap to 15 parts water or childrens soap bubble solution Bubbles forming indicate a leak Correct any leak found Verify proper operation and then replace the outer door FLAME ARRESTOR BRACKET DOOR GASKET CLOSE UP INSIDE VIEW OF THE COMBUSTION CHAMBER TIP MANIFOLD TUBE BRACKET FIGURE 41 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 See Figure 42 reo y Pilot AX Thermopile Bracket Wire to Electrode Igniter Button FIGURE 42 Testing the Igniter System Turn off the gas to the water heater at the
43. e and push down slightly to free the manifold tube and pilot tube 8 Remove the screws 1 4 nut driver securing the manifold door to the combustion chamber Carefully remove the manifold door assembly from the combustion chamber BE SURE NOT TO DAMAGE ANY INTERNAL PARTS Removing the Burner from the Manifold Burner Assembly Natural Gas Low Nox amp L P Gas Burner 1 Take off the burner by removing the two 2 screws located underneath the burner IMPORTANT DO NOT remove the orifice 2 Check the burner to see if it is dirty or clogged The burner may be cleaned with soap and hot water Figure 35 BURNER BOTTOM VIEW FIGURE 35 Replacing the Pilot Thermopile Assembly 1 Follow the Removing the Burner Manifold Assembly instructions on the following pages to remove the manifold door assembly 2 Natural Gas LP Models Remove the burner to access the pilot thermopile assembly Remove and keep the screws securing the burner to the manifold Figure 35 3 Remove the screw securing the pilot thermopile assembly to the pilot bracket and keep for reuse later A Lift the retainer clip straight up from the back of the manifold component block using a flat blade screwdriver then remove the manifold component block from the manifold door Figure 36 IMPORTANT Be careful not to bend or alter the position of the pilot tube it will be used as a bending template for the new pilot assembly Note the placement o
44. e burner by following the Lighting Instructions on the front of the water heater or in this manual With the burner lit check the gas control valve thermostat supply line manifold tube and pilot tube connections for leaks Use an approved noncorrosive leak detection solution or a mixture of hand dish washing soap and water one part soap to 15 parts water or childrens soap bubble solution Bubbles forming indicate a leak Correct any leak found Be sure tank is completely filled with water before lighting and activating the water heater Follow the Lighting Instructions on the front of the water heater or in this manual If additional information is required Contact Sears at 1 800 4 MY HOME 1 800 469 4663 TEFLON is a registered trademark of E l Du Pont De Nemours and Company FVIR System Operational Checklist NOOR WN ZS Manifold gasket properly sealed Viewport not damaged or cracked Flame arrestor free of debris and undamaged Manifold component block properly installed No leaks at pilot and manifold connection Manifold door screws securely tightened Depress the button on the thermal switch TROUBLESHOOTING GUIDE Start Up Conditions Thermal Expansion CAUTION Avoid water heater damage Install thermal expansion tank or device if necessary Contact qualified installer or service agency As water is heated it expands thermal expansion In a closed system the volume of water w
45. e service agency must also have a thorough understanding of this instruction manual and be able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer Gas Supplier The natural gas or propane utility or service who supplies gas for utilization by the gas burning appliances within this application The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the natural gas meter or propane storage tank of a building Many gas suppliers also offer service and inspection of appliances within the building AWARNING Nha FIRE AND EXPLOSION HAZARD lammabl N j Can result in serious injury or death J Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Storage of or use of gasoline or other flammable vapors or liquids in the Fi e Vapors vicinity of this or any other appliance can result in serious injury or death Read and follow water heater warnings and instructions Sears Brands Management Corporation AWARNING Read and understand instruction manual and safety messages before installing operating or servicing this water heater Failure to follow instructions and safety messages could result in death or serious injury Instruction manual must remain with water heater ADANGER Water temperature over 125 F 52 C can cause severe burns instantly re
46. eave off until repairs are made because failure to correct the cause of the sooting can result in a fire causing death serious injury or property damage FIGURE 30 Burner Cleaning A DANGER Failure to properly reseal the combustion chamber will disable the flammable vapor ignition resistance feature of this water heater which could result in death or serious injury Contact your local Sears Service Center for assistance A Read instruction manual before installing using or servicing water heater Ifinspection ofthe burner shows that cleaning is required turn the gas control knob counterclockwise to the OFF position The burner needs to be removed for cleaning Call the Sears Service Center to remove and clean the burner and correct the problem that required the burner to be cleaned Housekeeping Vacuum around base of water heater for dust dirt and lint on a regular basis ADANGER e Do not obstruct combustion air openings at the bottom of the water heater Do not use or store flammable vapor products such as gasoline solvents or adhesives in the same room or area near water heater or other appliance At least annually check the base ring filter and flame arrester for any dust lint or debris that may have accumulated Clean as necessary Can cause serious injury or death AT LEAST ANNUALLY A VISUAL INSPECTION SHOULD BE MADE OF THE BASE RING FILTER AND FLAME A
47. elief Valve Operation oooooocicnnnnnncoononcconcnnccnncnonnnnnnononnnnnnnnnnnnnnnnnnn ner eren en nne n nennen nens 28 Draining and Flushirig sitet de e eee ds ne 28 29 Sla ec Beale 29 MAINTENANCE OF YOUR WATER HEATER sssssssssseseeeeenerenerner nnne nnne rennen nnns nnns sensns nnns sessi 30 33 Replacement Parts 2 tom id deed vase ed el aed tuba dea dov elt od ces Vo ed ee cut aed ov cha lee eb dau eua 30 External Inspection amp Cleaning of the Base Ring Filter sese emm eem 30 Removing the Manifold Burner Assembly sss eene nro 30 Removing the Burner from the Manifold Burner Assembly sssesssseeee eem 30 Replacing the eene nnns nen nn nnns nnne n rrr trs n ninh nennen rrr nnne nennen 30 31 Replacing the Pilot Pilot Tube Assembly sssssssssseeeee nene enne rra 31 Cleaning the Combustion Chamber and Flame arrestor ssssssssssseeeneeen enemies 31 Replacing the Manifold Burner Assembly sssssssssssseeneene ee eee nnne nemen nnne rennen rnnt nnns 32 Piezoelectric lgniter System 3 etd aereas RIA 32 Testing the Igniter System uci eroe er iras 32 Removing and Replacing the Gas Control Valve Thermostat sssssssseseee emere 33 FVIR System Operational Checklist sn cronain he a a a rra 33 TROUBLESHOOTING GUIDE A r eene rar a a r a aae
48. emperature limiting valves are available Read instruction manual for safe temperature setting It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during operation The water heater should be drained if being shut down during freezing temperatures To drain the tank perform the following steps 1 Turn off the gas to the water heater at the manual gas shut off valve 2 Open a nearby hot water faucet until the water is no longer hot 3 Close the cold water inlet valve Connect a hose to the drain valve and terminate it to an adequate drain or external to the building 5 Open the water heater drain valve and allow all of the water to drain from the tank Flush the tank with water as needed to remove sediment 6 Close the drain valve refill the tank and restart the heater as directed in this manual 29 If the water heater is going to be shut down for an extended period the drain valve should be left open IMPORTANT Condensation may occur when refilling the tank and should not be confused with a tank leak Service Before calling for repair service please read the Troubleshooting Guide in 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 MAINTENANCE OF YOUR WATER HEATER Replacemen
49. erature and Pressure Relief Valve 7 After piping has been properly connected to the water heater remove the aerator at the nearest hot water faucet Open the hot water faucet and allow the tank to completely fill with water To purge the lines of any excess air keep the hot water faucet open for 3 minutes after a constant flow of water is obtained Close the faucet and check all connections for leaks 21 In a closed system use a thermal expansion tank Cold Water J ses to Fixtures Outlet oy Hot Water LA L3 gt Main water supply da Pressure reducing Inlet Valve valve with bypass Union Temperature and Pressure Relief Valve Discharge Pipe Do Not Cap or Plug Drain line 3 4 al minimum 6 Maximum 1 minimum Air Gap gt A Massachussetts Install a vacuum relief pea Pan Y 4 in cold water line per tion 19 MGL 142 1 3 4 depth maximum Floor Drain EEE FIGURE 22 a TEMPERED WATER 2 TO FIXTURES COLD WATER UNTEMPERED HOT WATER MIXING VALVE SET TO 120 F 3 FOLLOW THE MIXING VALVE MANUFACTURER S INSTRUCTIONS FIGURE 23 Please note the following The system should be installed only with piping that is suitable for potable drinkable water such as copper CPVC or polybutylene This water heater must not be installed using iron piping or PVC water piping Use only pumps valves or fittings that are
50. ey No Part Description 153 331830 153 331840 153 331851 153 331882 Anode Rod 9003721 9003721 9003721 9001829 Base Ring Filter 9006660 9006616 9006616 9006660 Burner Head 9006136 9006136 9006603 9006136 Burner Orifice 9006698 9006698 9006700 9006698 Draft Hood 9006647 9006647 9006647 9006647 Drain Valve 9002402 9002402 9002402 9002402 Gas Control Valve Thermostat 9007884 9007884 9007890 9007884 Inlet Tube w Gasket 9006692 9003473 9003473 9006653 INIO AAN Inner Door Gasket 9006141 9006141 9006141 9006141 Instruction Manual 320390 000 320390 000 320390 000 320390 000 Manifold Door Assembly Con tains Manifold Tube Gasket Door Pilot Tube Thermopile Manifold Component 9007905 9007899 9007904 9007908 Block Thermal Switch Burner Head Burner Orifice and Pilot Assembly Nipple w Heat Trap 9003719 9003719 9003719 9003719 Outer Door 9006648 9006648 9006648 9006648 Pilot Assembly w Tubing and 9007876 9007876 9007877 9007876 Fittings T amp P Relief Valve 9000071 9000071 9000071 9000071 Thermopile 9007872 9007872 9007872 9007872 Manifold Component Block w Clip 9006449 9006449 9006449 9006449 e ajo Not Shown Now that you have purchased your gas water heater should MODEL NUMBER a need ever exist for repair parts or service simply contact SERIAL NUMBER any Sears Service Center or call 1 800 4 MY HOME 1 800 469 4663 Be sure to provide all pertinent fa
51. f Pilot Out e 1Flash Indicates Normal Operation A Solid Red Light indicates the valve thermostat is shutting down gas control Diagnostic Flashes If the water heater is not working look for the following diagnostic flashes after lighting the pilot For more details see the Status Light and Diagnostic Code Troubleshooting Chart 2Flashes Indicates Thermopile Voltage Low 4Flashes Indicates Overheat Failure 5Flashes Indicates Sensor Failure 7 Flashes Indicates Electronic Control Failure 8 Flashes See Status Light and Diagnostic Code Troubleshooting Chart SERVICE AND ADJUSTMENT Vent System Inspection A WARNING Flue gases may escape if vent pipe is not connected Be alert for obstructed sooted or deteriorated vent system to avoid serious injury or death Do not store corrosive chemicals in vicinity of water heater Chemical corrosion of flue and vent system can cause serious injury or death Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual 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 conne
52. f missing or removed Replace door gasket if damaged Failure to follow these instructions can result in death explosion or fire 1 Check the door gasket for damage or imbedded debris prior to installation 2 Inspect the view port for damage and replace as required 3 Insert the manifold burner assembly into the burner compartment making sure that the tip of the manifold tube engages in the slot of the bracket inside the combustion chamber Figures 40 amp 41 Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion chamber 5 Tighten the two screws which secure the burner manifold assembly to the combustion chamber There should be no space between the gasket part of the manifold door and combustion chamber IMPORTANT Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber 6 Reconnect the manifold tube 3 4 wrench and pilot tube 7 16 wrench to the gas control valve thermostat Do not cross thread or apply any thread sealant to the fittings IMPORTANT If you were supplied with a new ferrule nut in a parts kit follow these steps 1 Install the ferrule nut into the gas valve at the pilot tube location hand tight only 2 Insert the pilot tube into the ferrule nut until the tube bottoms out then tighten the nut with a 7 16 wrench until the crimp connection seals to the pilot tub
53. ged 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 COLD WATER PRESSURE INLET FITTING REDUCING VALVE WITH BY PASS HOT Cc COLD INLET COLD WATER SHUT OFF 2 PRESSURE GAUGE RECOMMENDED INSTALLATION VERTICAL MOUNTING WATER HEATER COLD WATER INLET FITTING FLOOR CEILING JOIST ETC STRAPPING 3 PRESSURE REDUCING x VALVE WITH 1 BY PASS EXPANSION TANK 2 we t PRESSURE GAUGE INLET COLD WATER SHUT OFF ALTERNATE RECOMMENDED INSTALLATION HORIZONTAL MOUNTING FIGURE 43 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 shut off water
54. has stopped and will not re light check the flame arrestor for signs of high temperature blue or black discoloration indicating a flammable vapor incident If you suspect a flammable vapor incident has occurred do not use this appliance Immediately call a qualified technician to inspect the appliance Water heaters subjected to a flammable vapors ignition will require replacement of the entire water heater NOTE Check the gas control valve thermostat and thermal switch for any loose wiring connections correct immediately RED LIGHT ON SOLID Pilot light was recently extinguished Turn Gas Control Valve Thermostat knob to OFF and the Thermopile is cooling Wait 10 minutes for the Thermopile to cool then attempt to relight Pilot by following the lighting instructions on the water heater s label NOTE This gas control valve thermostat has built in circuitry that requires waiting 10 minutes between lighting attempts Until the Thermopile reaches its normal operating temperature the Status Light will not blink even if the Pilot is lit It may take up to 90 seconds of continuous Pilot operation before the Thermopile reaches normal operating temperature and the Status Light starts to blink 1 FLASH EVERY 3 SECONDS Normal operation No corrective action necessary 2 FLASHES Pilot is lit but the Thermopile is Turn Gas Control Valve Thermostat knob to OFF not producing the required output The Thermopile is probably defective but lo
55. he water heater is marked on the water heater data plate The heating value of the gas BTU FT may be determined by consulting the local natural gas utility Table 2 LP Gas Capacity Table Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases at 11 inches water column pressure Based on a pressure drop of 0 5 inch water column Nominal Iron Pipe Length of Pipe Feet Size in 60 0 Example Input BTU requirement of the water heater 100 000 BTUH Total pipe length 80 feet 3 4 IPS required Additional tables are available in the latest edition of the National Fuel Gas Code ANSI 2223 1 16 AWARNING Carbon Monoxide Warning Follow all the local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition to properly install vent system Failure to do so can result in death explosion or carbon monoxide poisoning IMPORTANT Air for combustion and ventilation must not come from a corrosive atmosphere Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage The following types of installation not limited to the following will require outdoor air for combustion due to chemical exposure and may reduce but not eliminate the presence of corrosive chemicals in the air e beauty shops photo processing labs buildings with indoor pools e water heaters installed in la
56. heater life depends upon water quality water usage water temperature and the environment in which the water heater is installed Water heaters are sometimes installed in locations where leakage may result in property damage even with the use of a metal drain pan piped to a drain However unanticipated damage can be reduced or prevented by a leak detector or water shut off device used in conjunction with a piped metal drain pan These devices are available from some plumbing supply wholesalers and retailers and detect and react to leakage in various ways e Sensors mounted in the metal drain pan that trigger an alarm or turn off the incoming water to the water heater when water is detected e Sensors mounted in the metal drain pan that turn off the water supply to the entire home when water is detected in the drain pan e 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 e Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply 14 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 Con
57. heater under this warranty Sears will furnish a new water heater of comparable output as permitted by such governmental regulations however the Owner will be charged for the additional cost associated with the changes made to comply with such governmental regulations Replacements furnished under this warranty do not carry a new warranty and are only covered by the unexpired portion of the original warranty 1 YEAR EXCLUSIVE KENMORE LABOR WARRANTY For the 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 BRANDS MANAGEMENT CORPORATION Hoffman Estates IL 60179 The price of your water heater does not include a free checkup service call On water heater installations arranged by Sears Sears warrants the installation A charge will be made on service calls due to poor or incomplete installation These include a Adjusting thermostat b Condensation Master Protection Agreements Congratulations on making a smart purchase Your new Kenmore product is designed and manufactured for years of dependable operation But like all
58. hout escaping back into the room In the event of a flammable vapor incident the FVIR System disables the water heater by shutting off the gas supply to the water heater s burner and pilot preventing re ignition of any remaining flammable vapors in the area This will not prevent a possible fire explosion if the igniter is depressed and flammable vapors have accumulated in the combustion chamber with the pilot light off If you suspect a flammable vapor incident has occurred do not use this appliance Do not attempt to light this appliance or depress the igniter button if you suspect flammable vapors have accumulated inside or outside the appliance Immediately call a qualified technician to inspect the appliance Water heaters subjected to a flammable vapors incident will show a discoloration on the flame arrestor and require replacement of the entire water heater AWARNING o y ds N j y Flammable Vapors FIRE AND EXPLOSION HAZARD Can result in serious injury or death A vapors and liquids in the vicinity of this or any other appliance Storage of or use of gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance can result in serious injury or death Do not store or use gasoline or other flammable Read and follow water heater warnings and instructions Do not use or store flammable products such as gasoline solvents or adhesives in the same room or area near the water heate
59. iation 8501 East Pleasant Valley Rd Cleveland Ohio 44131 or The National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 f after reading this manual you have any questions or do not understand any portion of the instructions call the Sears Service Center e 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 nstallation Instructions section in this manual For California installation this water heater must be braced anchored or strapped to avoid falling or moving during an earthquake See instructions for correct installation procedures Instructions may be obtained from California s Office of the State Architect 1102 Q Street Suite 5100 Sacramento CA 95811 Instructions can also be downloaded to your computer at www dsa dgs ca gov Pubs Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248 CMR 2 00 State Plumbing Code and 248 CMR 5 00 Complies with 40 Ng J NOx requirements of Texas and most California AQM Districts WARNING Use two or more people to move and install the water heater Failure to do so can result in injury including back injury IMPORTANT Do not remove any permanent instructi
60. ill grow As the volume of water grows there will be a corresponding increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent temperature pressure relief valve operation water discharged from the valve due to excessive pressure build up The temperature pressure relief valve is not intended for the constant relief of thermal expansion This condition is not covered under the limited warranty A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion 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 43 Table 5 Thermal Expansion Tank Specifications Model Number Tank Dimensions Capacity in Inches Fitting In Gallons Length On Tank 153 331020 8 203 mm 12 3 4 323 mm 3 4 Male 153 331050 Pi A 279 mm 14 3 4 375 mm 3 4 Male Pipe Table 6 Expansion Tank Sizing Chart Inlet Water Pressure Water Heater Capacity Gallons Expansion Tank Capacity Needed Highest recorded inlet water pressure in a 24 hour period or regulated water pressure 34 NOTE Expansion tanks are pre char
61. ing the pilot by following the instructions on the water heater s label Insure that the gas supply is tuned on There may be air in the gas line and several lighting attempts may be needed to completely fill the line with gas and successfully light the pilot If the Pilot Lights but the Status Light Does Not Blink 1 If the pilot lights continue to hold the Control Knob in until the Status Light blinks If the pilot is lit and remains lit for 90 seconds and the Status Light still does not blink the thermopile connections may be loose the thermal switch may need to be reset or the thermopile may be defective Remove outer door 3 Press reset button on thermal switch referencing Figure 34 If switch clicks it may have tripped Check area for flammable vapors before trying to light Pilot Do not light the Pilot if flammable vapors are present Check flame arrestor for signs of discoloration which could be caused by flammable vapors If the flame arrestor is discolored do not attempt to relight the Pilot Have the water heater inspected by a qualified service technician 5 Check wiring connections from the thermopile and the thermal switch to the gas valve see Figure 33 Ensure that all wiring connections are tight Replace outer door 7 Wait 10 minutes and try to light Pilot according to the instructions on the water heater s label 8 While clicking the Igniter button continuously the Control Knob must be set to
62. ing 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 e a concentration of sulfate in the supply water little or no dissolved oxygen in the water e a sulfate reducing bacteria within the water heater This harmless bacteria is non toxic to humans anexcess 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 35 hot water lines Contact Sears Service fo
63. ion to water heater Check flue FORMATION SOOTING way flue baffle burner Low gas pressure Check with gas utility company Water heater flue or vent system 3 Clean locate source and correct blocked Thermostat not functioning properly Replace thermostat Heater installed in a confined area Provide fresh air ventilation Burner flame yellow lazy See Burner Flame Yellow Lazy Base Ring Filter blocked with lint dust Clean filter See External Cleaning amp Inspection of the Base Ring Filter section FVIR Flame Arrestor blocked with lint 8 Clean filter See Cleaning the Combustion dust Chamber and Flame Arrestor section Increase the temperature setting Refer to the Condensation sub section of this manual s Troubleshooting Guide BURNER FLAME FLOATS AND LIFTS OFF PORTS 2 3 Orifice too large High gas pressure 2 Water heater flue or vent system 3 blocked Cold drafts 4 1 1 BURNER FLAME TOO HIGH 1 Orifice too large 1 Replace with correct orifice 1 1 FLAME BURNS AT ORIFICE 1 Thermostat not functioning properly Replace thermostat 2 Low gas pressure 2 Check with gas utility company Replace with correct orifice Check with gas utility company Clean flue and burner locate source and correct 4 Locate source and correct PILOT FLAME 1 Pilot line or orifice clogged Clean locate source and correct TOO SMALL 2 Low gas pressure Check with gas utility company 38 STATUS LIGHT AND DIAGNO
64. iping Sy Before lighting an L P gas water heater smell all around the and theine capped appliance at floor level If you smell gas follow the instructions Ifthe gas lines are to be tested at a pressure less than 14 W C as given in the warning on the front page the water heater must be isolated from the gas supply piping system by closing its manual shut off valve When your L P tank runs out of fuel turn off the gas at all gas appliances including pilot lights After the tank is refilled all appliances must be re lit according to their manufacturer s instructions NOTE Air may be present in the gas lines and could prevent the pilot from lighting on initial start up The gas lines should be purged of air by a qualified technician after installation of the gas piping system While purging the gas piping system of air ensure that Table 1 Natural Gas Pipe Capacity Table Cu Ft Hr Capacity of gas pipe of different diameters and lengths in cu ft per hr with pressure drop of 0 3 in and specific gravity of 0 60 natural gas Nominal Iron Pipe Length of Pipe Feet Size in 10 20 30 40 50 60 70 80 90 100 125 150 175 200 After the length of pipe has been determined select the pipe size which will provide the minimum cubic feet per hour required for the gas input rating of the water heater By formula Gas Input of Water Heater BTU HR Cu Ft Per Hr Required 3 Heating Value of Gas BTU FT The gas input of t
65. ith 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 A Water at the draft hood is water vapor which has condensed out of the combustion products This is caused by a problem in the vent Contact a qualified technician B Condensation may be seen on pipes in humid weather or pipe connections may be leaking C The anode rod fitting may be leaking D Small amounts of water from temperature pressure relief valve may be due to thermal expansion or high water pressure in your area E The temperature pressure relief valve may be leaking at the tank fitting F Water from a drain valve may be due to the valve being slightly opened G The drain valve may be leaking at the tank fitting H Combustion products contain water vapor which can condense on the cooler surfaces of the tank Droplets form and drip onto the burner or run on the floor This is common at the time of start up after installation and when incoming water is cold Water in the water heater bottom or on the floor may be from condensation loose connections or the relief valve DO NOT replace the water heater until a full inspection of all possible water sources is made and necessary corrective steps taken Leakage from other appliances water lines or ground seepage should also be checked To check where threaded portion enters tank inse
66. l 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 Qualified Technician A qualified technician must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters The qualified technician must also be familiar with the design features and use of flammable vapor ignition resistant water heaters and have a thorough understanding of this instruction manual e Service Agency A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas supply including a thorough understanding of the requirements of the National Fuel Gas Code as it relates to the installation of gas fired water heaters Th
67. led per manufacturer s instructions See Water Temperature Regulation section Gas Supply and Piping Gas type is the same as that listed on the water heater rating plate Gas line equipped with shut off valve union and drip leg Use pipe joint compound or teflon tape marked as being resistant to the action of petroleum Propane L P gases Adequate pipe size and approved pipe material An approved noncorrosive leak detection solution used to check all connections and fittings for possible gas leaks If such a solution is not available use a mixture of dish washing soap and water one part soap to 15 parts water or children s soap bubble solution Bubbles forming indicate a leak Correct any leak found INSTALLATION INSTRUCTIONS Removing the Old Water Heater O e Sao oe MANUAL GAS n SHUTOFFVALVE ed O GROUND amp amp JOINT UNION CHECK WITH T DISCHARGE PIPE LOCAL UTILITY DO NOT CAP O FOR MINIMUM HEIGHT OR PLUG 1 3 MINIMUM n 3 ja i 6 MAXIMUM DRIP LEG AIR GAP SUITABLE Y DRAIN FIGURE 2 e Turn OFF the gas supply to the water heater If the main gas line shutoff valve serving all gas appliances is used also shut OFF the gas at each appliance Leave all gas appliances shut OFF until the water heater installation is complete
68. light will YES blink It may take up to 90 seconds of pilot operation before status light blinks Once status light blinks release the gas control temperature knob o Is the igniter producing a YE spark NO Follow the Testing the Igniter Set thermostat to desired temperature Section C Pilot light will not remain lit Complete this section after completing Section B Check for insufficient combustion air YES y Are the combustion air supply and ventilation openings of sufficient size See Combustion Air Supply and Ventilation section in this manual for requirements Correct size of openings to allow sufficient air Does the return air duct for the furnace air handler air conditioner draw its air from the same location as the water heater See the Location Requirements section Checking the Draft and the Combustion Air Supply section section in this manual YES YES Is there proper drafting at the drafthood See Contact a Heating and Air Conditioning service technician System section in this manual to relocate the return air duct The water heater s pilot can be extinguished when the heating or cooling system is turned on if the return air duct is in the Check the vent system for restrictions obstructions and check the vent termination height Refer to the Installation Instructions section of this Section B Pilot light repeatedly goes out Che
69. ling 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 CAUTION Avoid water heater damage Fill tank with water before operating GAS SUPPLY AWARNING Explosion Hazard Use a new CSA approved gas supply line Install a shut off valve Do not connect a natural gas water heater to an L P gas supply Do not connect an L P gas water heater to a natural gas supply Failure to follow these instructions can result in death explosion or carbon monoxide poisoning Gas Requirements IMPORTANT Read the rating plate to be sure the water heater is made for the type of gas you will be using in your home This information will be found on the rating plate located near the gas control valve thermostat If the information does not agree with the type of gas available do not install or light Call your dealer NOTE An odorant is added by the gas supplier to the gas used by this water heater This odorant may fade over an extended period of time Do not depend upon this odorant as an indication of leaking gas Gas Piping The gas piping must be installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition
70. logy used in meeting these standards makes this product more sensitive to installation errors Please review the following checklist and make any required installation upgrades or changes Questions Contact Sears at 1 800 4 MY HOME 1 800 469 4663 Installation Checklist Water Heater Location Water heater location is important and can affect system performance Please check the following Installation area free of corrosive elements and flammable materials Centrally located with the water piping system For new installations Located as close to the gas piping and vent pipe system as possible Located indoors and in a vertical position Protected from freezing temperatures Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor Provisions made to protect the area from water damage Metal drain pan installed and piped to an adequate drain Sufficient room to service the water heater See Clearances and Accessibility section of this manual Water heater not located near an air moving device Is the installed environment dirty excessive amounts of lint dirt dust etc If so the base ring filter located on the bottom of the water heater will need to be cleaned periodically Refer to the Maintenance of your Water Heater section of this manual for information on cleaning the base ring filter Combustion Air Supp
71. ly and Ventilation Check for sufficient combustion air supply Insufficient air for the combustion of gas will result in the flame becoming lazy thereby allowing heat to build up in the combustion chamber This excessive heat will cause a thermal switch on the door assembly to trip Is the water heater installed in a closet or other small enclosed space If so Are there openings for make up air to enter and exit the room area Are the openings of sufficient size Remember if there are other gas fired or air consuming appliances in the same room you need more make up air Refer to the Installation Instructions and Combustion Air Supply and Ventilation sections for specific requirements Make sure that fresh air is not taken from areas that contain negative pressure producing devices such as exhaust fans dryers fireplaces etc Is there a furnace air handler in the same room space as the water heater If so has a return air duct system been attached that exits the room If so check for leaks on the air duct system If no air duct system is present correct immediately by contacting a local Heating Ventilation Air Conditioning amp Refrigeration HVAC R authorized service provider Use a fresh air supply that is free of corrosive elements and flammable vapors 11 Fresh air openings must be sized correctly with consideration given to the blocking effec
72. n or replace orifice Replace igniter pilot assembly See Pilot Light Troubleshooting Flowchart section Remove and reconnect the wire leads at thermal switch confirm connections are tight and not loose Finger tighten then 1 4 turn with wrench Bleed the air from the gas line Check with gas utility company Check with gas utility company Notify utility install dirt trap in gas line Locate source and correct Replace thermostat Clean locate source and correct Replace thermopile See maintenance section for inspection and cleaning of flame arrester Clean filter See Cleaning the Combustion Chamber and Flame Arrestor section Replace water heater eliminate flammable vapors source Contact Sears Service Clean filter See External Cleaning amp Inspection of the Base Ring Filter section Set temperature dial to lower setting Drain flush provide water treatment if needed Install adequate heater Correct piping dip tube must be in cold inlet Repair faucets Check with utility repair at once Advise customer Insulate piping Insulate piping Turn temperature dial to desired setting Drain flush provide water treatment if needed Install adequate heater Correct piping dip tube must be in cold inlet Repair faucets Advise customer Insulate piping Insulate piping Check with gas utility company TROUBLESHOOTING CHART CONTINUED PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION SLOW HOT WATER 1 Insufficient
73. nadian Standards Association e ANSI American National Standards Institute NFPA National Fire Protection Association ASME American Society of Mechanical Engineers e GAMA Gas Appliance Manufacturers Association Important Information About This Water Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation environments Please review the Installation Checklist found at the end of the installation instructions section and make any required installation upgrades or changes 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 following In the United States The National Fuel Gas Code ANSI Z223 1 NFPA 54 This publication is available from the Canadian Standards Assoc
74. ner Door S Gas Control Valve Thermostat B Draft Hood K Outer Door T Drain Valve C Anode Not Shown L Union U Manifold Burner Assembly D Hot Water Outlet M Inlet Water Shut off Valve V Flue E Insulation N Cold Water Inlet W Metal Drain Pan F Gas Supply Piping O Inlet Dip Tube X Piezo Igniter G Manual Gas Shut off Valve P Temperature Pressure Relief Valve Y Base RingFilter H Ground Joint Union Q Rating Plate Drip Leg Sediment Trap R Flue Baffle INSTALLINACCORDANCE WITH LOCAL CODES DRIP LEG AS REQUIRED BY LOCAL CODES S GAS CONTROL VALVE THERMOSTAT Gas Control Temperature Knob TO VENT TERMINATION ON 120 F ROOF A INSTALL THERMAL EXPANSION TANK IF WATER HEATER IS INSTALLED IN A CLOSED WATER SYSTEM N Igniter Temperatures shown are approximates and may vary VACUUM RELIEF VALVE INSTALL PER INSTALL PER U MANIFOLD BURNER ASSEMBLY p E MAIN BURNER J MANIFOLD THERMOPILE A TUBE D E A Mb a J A pt MANIFOLD DOOR lA SENTER NBE a a DO NOT CAP OR PLUG DISCHARGE PIPE 6 MAXIMUM AIR GAP FLOOR DRAIN ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS FIGURE 1 10 IMPORTANT INFORMATION ABOUT THIS WATER HEATER This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident The new techno
75. ons labels or the data label from either the outside of the water heater or on the inside of water heater panels Remove exterior packaging and place installation components aside Inspect all parts for damage prior to installation and start up Completely read all instructions before attempting to assemble and install this product After installation dispose of recycle all packaging materials PRODUCT SPECIFICATIONS MODEL TANK CAPACITY INPUT RECOVERY MINIMUM DIAMETER DIMENSIONS NUMBER IN GALS LTRS RATE RATE GALS VENT PIPE INCHES INCHES mm Btu hr PER HOUR DIA INCHES mm HEIGHT TO 90 F RISE mm JACKET TOP 153 331830 40 151 Natural 40 000 3 76 or 4 102 20 508 47 75 1213 153 331840 40 151 Natural 40 000 3 76 or 4 102 18 457 58 14 1477 40 151 Propane 36 000 3 76 or 4 102 18 457 58 14 1477 LP 153 331882 50 189 Natural 40 000 3 76 or 4 102 20 508 57 28 1455 MATERIALS AND BASIC TOOLS NEEDED MATERIALS NEEDED To simplify the installation Sears has available the installation parts shown below You may or may not need all of these materials depending on your type of installation CS Gas Water Heater Installation Kit 9000105 CE Kit contains all the parts you connect L 1 E gt E E E gt gt gt hh gt GA gt C rD m EXPAN
76. ose voltage wiring connections or a weak Pilot flame can also cause this symptom 39 STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART LED STATUS PROBLEM CORRECTIVE ACTION 4 FLASHES The Gas Control Valve s Relight pliot and verify 4 flashes If 4 flashes are temperature sensor has detected observed turn Gas Control Valve Thermostat knob that the water temperature was too to OFF Turn Main Gas Supply OFF Replace the high Once this condition occurs Gas Control Valve Thermostat the Main Burner and the Pilot Light will be shut off Since the Pilot light will be off should this condition occur this Flash Code will only be displayed immediately after the Pilot has been relit Turn Gas Control Valve Thermostat knob to OFF 5 FLASHES The temperature sensor Turn Gas Control Valve Thermostat knob to OFF thermistor is defective Replace the Gas Control Valve Thermostat 7 FLASHES Gas Control Valve failure Turn Gas Control Valve Thermostat knob to OFF Turn Main Gas Supply OFF Gas Control Valve Thermostat 8 FLASHES This condition only appears if the Make sure that the gas control valve thermostat gas control temperature knob has knob is set to OFF Wait one minute Remove been turned off and the thermopile the outer door Look through the sight glass for continued to produce electric a pilot flame If a pilot flame is observed with the power This condition can occur gas control valve thermostat knob set
77. owers sink etc 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 See Figure 23 Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat see Figure 28 Using the lowest hot water temperature that meets your needs will also provide the most energy efficient operation of the water heater 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 A water temperature range of 120 F 140 F 49 C 60 C is recommended by most dishwasher manufac
78. products it may require preventive maintenance or repair from time to time That s when having a Master Protection Agreement can save you money and aggravation The Master Protection Agreement also helps extend the life of your new product Here s what the Agreement includes Parts and labor needed to help keep products operating properly under normal use not just defects Our coverage goes well beyond the product warranty No deductibles no functional failure excluded from coverage real protection Expert service by a force of more than 10 000 authorized Sears service technicians which means someone you can trust will be working on your product Unlimited service calls and nationwide service as often as you want us whenever you want us No lemon guarantee replacement of your covered product if four or more product failures occur within twelve months Product replacement if your covered product can t be fixed Annual Preventive Maintenance Check at your request no extra charge Fast help by phone we call it Rapid Resolution phone support from a Sears representative on all products Think of us as a talking owner s manual Power surge protection against electrical damage due to power fluctuations c Leaks in pipes or fittings 250 Food Loss Protection annually for any food spoilage that is the result of mechanical failure of any covered refrigerator or freezer G Rental
79. r If such flammables must be used all gas burning appliances in the vicinity must be shut off and their pilot lights extinguished Open the doors and windows for ventilation while flammable substances are in use If flammable liquids or vapors have spilled or leaked in the 13 area of the water heater leave the area immediately and call the fire department from a neighbor s home Do not attempt to clean the spill until all ignition sources have been extinguished A WARNING Read instruction manual before installing using or servicing water heater Improper use may result in fire or explosion Maintain required clearances to combustibles Keep combustibles such as boxes magazines clothes etc away from the water heater area Site Location Selectalocation near the center of the water piping system The water heater must be installed indoors and in a vertical position on a level surface DO NOT install in bathrooms bedrooms or any occupied room normally kept closed Locate the water heater as close to the chimney or gas vent as practical Consider the vent system piping and combustion air supply requirements when selecting the water heater location The venting system must be able to run from the water heater to termination with minimal length and elbows e Locate the water heater near the existing gas piping If installing a new gas line locate the water heater to minimize the pipe length and elbows
80. r further information concerning this chlorination treatment and an anode replacement kit 49001453 For short heaters use anode replacement kit 9006299 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 A WARNING Explosion Hazard 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 Safety Shut off and Therm
81. rbon monoxide detectors Read instruction manual before are available installing using or servicing water heater Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual CAUTION 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 TABLE OF CONTENTS SAFE INSTALLATION USE AND SERVICE cocococccccncncnnncncnococononnnnncnonononenennnnnnnonononancnnnnononnnnonaninnnnenennnnnnns 2 SAFETY PRECAUTIONS 2 ou A a A Re ads 2 3 PRODUCT WARRANTY 3 3 hrec apa kate Pe lin D ada rk ee ete Rete P didnt 6 CUSTOMER RESPONSIBILITIES oococccccnccccncncccnconononnnnnonononononenononononononnnnnnnnnnnonononnncnnnnnnnnnnnnneneneneninneninnns 7 PRODUCT SPECIFICATIONS 25 cc2 cc c c2 edencccuiesdegsscaedeccaddgeesidebedeodudiedadecdeTsssassaceseneadesvedasteccasigeaeassdesaheadese 8 MATERIALS AND BASIC TOOLS NEEDED ooocccccccnncnonononcnnnnnnnonononincnnnnnnnonononncncononnnnnononnnenennnnnnnonenananenennnons 9 TYPICAEINSTAEERATIONN iiiter iei eerte cad o he Esto sete emi dais een 10 IMPORTANT INFORMATION ABOUT THIS WATER HEATER oocccccocnccocononcnnnnncnoconononnnnnononononincnnnnnnnnnnnnonos 11 Installation Checkli
82. rder of the wires in the manifold component block Thermopile Connector e w Pilot Thermopile H Assembly Screw Burner and other fittings not show for clarity Manifold NEAN Y S Component END N 5 Sci eS Manifold Door FIGURE 36 Lift the pilot thermopile assembly including the igniter wire from the manifold assembly NOTE Read this step carefully before proceeding Use the old pilot pilot tube assembly as a guide bend the new pilot tube to match the old one Make only the bends closest to the pilot before going to the next step Thermopile Pilot Ox Igniter Es Pilot Thermopile Connector LON Assembly Thermopile Connector Thermal FIGURE 37 Route the new pilot tube new igniter wire and new thermopile wire through the opening in the manifold door Figure 38 Red Thermal Switch Wire Q Connects to the Gas Control Valve Thermostat White Thermopile Wire Connects to the Gas Control Valve Thermostat 8 Using the pilot thermopile assembly screw removed earlier reattach the new pilot thermopile assembly Reattach the burner to the manifold using the screws removed earlier NOTE make sure the burner scoop is oriented to the pilot side of the manifold tube Figure 35 9 Reinstall the manifold component block in the manifold door Figure 38 10 Carefully bend the new pilot tube to match the bend of the manifold tube NOTE When bending DO
83. reads on the manifold tube Refer to Gas Piping Figure 11 and disconnect the ground joint union in the gas piping Disconnect the remaining pipe from the gas control valve thermostat To remove the gas control valve thermostat thread a section of 4 gas pipe into the inlet and use it to turn the gas control valve thermostat 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 control valve thermostat may result Gas Control Valve Thermostat To replace the gas control valve thermostat reassemble in reverse order When replacing the gas control valve thermostat thread a section of 4 gas pipe into the inlet and use it to turn the gas control valve thermostat clockwise DO NOT OVER TIGHTEN damage may result Be sure to use approved Teflon tape or pipe joint compound on the gas piping connections and fitting on the back of the gas control valve that screws into tank 33 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 the water heater by brushing on an approved noncorrosive leak detection solution or a mixture of hand dish washing soap and water one part soap to 15 parts water or childrens soap bubble solution Bubbles forming indicate a leak Correct any leak found Check the operation of th
84. ree years and annually thereafter until the condition of the anode rod dictates its replacement NOTE artificially softened water requires the anode rod to be inspected annually Temperature Pressure Relief Valve Operation The temperature pressure relief valve must be manually operated at least once a year ADANGER e Burn hazard e Hot water discharge e 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 DISCHARGE PIPE FIGURE 32 If after manually operating the valve it fails to completely reset and continues to release water immediately close the manual gas shut off valve and the cold water inlet valve and call the Sears Service Center 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 and Flushing ADANGER Hotwater discharge burn hazard Keep clear of relief valve discharge unit T
85. reimbursement if repair of your covered product takes longer than promised 10 discount off the regular price of any non covered repair service and related installed parts Once you purchase the Agreement a simple phone call is all that it takes for you to schedule service You can call anytime day or night or schedule a service appointment online The Master Protection Agreement is a risk free purchase If you cancel for any reason during the product warranty period we will provide a full refund Or a prorated refund anytime after the product warranty period expires Purchase your Master Protection Agreement today Some limitations and exclusions apply For prices and additional information in the U S A call 1 800 827 6655 Coverage in Canada varies on some items For full details call Sears Canada at 1 800 361 6665 Sears Installation Service For Sears professional installation of home appliances garage door openers water heaters and other major home items in the U S A or Canada call 1 800 4 MY HOME CUSTOMER RESPONSIBILITIES Thank You for purchasing a Kenmore water heater Properly installed and maintained it should give you years of trouble free service If you should decide that you want the new water heater professionally installed by Sears call 1 800 4 MY HOME They will arrange for prompt quality installation by Sears authorized contractors Abbreviations Found In This Instruction Manual e CSA Ca
86. replaced phone in your building eImmediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions Gas Control Temperature Knob FIGURE A OFF POSITION l niter GAS CONTROL STOP It is imperative that you read all safety warnings before lighting the pilot Turn the gas control temperature knob counterclockwise Dto the OFF setting Wait ten 10 minutes to clear out any gas If you then smell gas STOP 0 B in the safety information above on this label If you do not smell gas go to the next step Turn the gas control temperature knob clockwise Cto PILOT See Figure B Press the gas control temperature knob all the way in and hold it in The knob should travel in about 1 4 inch 6 35 mm if it is set to PILOT correctly While holding the gas control temperature knob in click the igniter button continuously about once a second for up to 90 seconds or until Status Light begins to blink When the status light starts blinking release the gas control temperature knob Set the gas control temperature knob to the desired setting See Figure C FIGURE B PILOT POSITION CONTROL KNOB MAIN BURNER THERMOPILE A gt FIGURE D If the status light does not start blinking within 90 seconds repeat steps 2 through 5 up to THREE 3 times waiting 10 minutes between lighting attempts The circuitry in this advanced gas valve requires that you wait 10
87. rt cotton swab between jacket opening and fitting If cotton is wet follow draining instructions in the Draining and Flushing section and then remove fitting Put pipe dope or teflon tape on the threads and replace When you are finished follow the steps in Filling the Water Heater in the Installation Instructions earlier in this manual TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE S CORRECTIVE ACTION 1 Pilot not lit 2 Thermostat set too low 3 Main burner line clogged 4 Non functioning 5 6 7 BURNER WILL NOT IGNITE thermostat Base Ring Filter blocked with lint dust Heater installed in a confined area FVIR Flame Arrestor blocked with lint 1 Light pilot 2 Turn temp dial to desired temperature 3 Clean locate source and correct 4 Check status light codes and reference the Status Light and Diagnostic Code Troubleshooting Chart 5 Clean filter See External Cleaning amp Inspection of the Base Ring Filter section 6 Provide fresh air ventilation Clean filter See Cleaning the Combustion Chamber and Flame Arrestor section SMELLY WATER 1 Sulfides in the water 1 Replace the anode with a special anode See Smelly Odor section BURNER FLAME YELLOW LAZY Insufficient combustion air Low gas pressure Water heater flue or vent system blocked Main burner line clogged Base Ring Filter blocked with lint dust Heater installed in a confined area FVIR Flame Arrestor blocked wi
88. s 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 FIGURE 7 Location Requirements A WARNING Do not install in a mobile home Doing so can result in carbon monoxide poisoning and death The FVIR System is designed to reduce the risk of flammable vapor related fires The patented system protects your family by trapping the burning vapors within the water heater combustion chamber through the special flame arrestor The burning vapors literally burn themselves out wit
89. servation Act standards with respect to insulation and standby loss requirements making an insulation blanket unnecessary A WARNING Breathing Hazard Carbon Monoxide Gas Do not obstruct water heater air intake with insulating blanket Gas and carbon monoxide detectors are available Install water heater in accordance with the instruction manual Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual A 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 8 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 Do obtain new warning and instruction labels from Sears for placement on the blanket directly over the existing labels Do inspect the insulation blanket frequently to make cert
90. st totes rta ibid de tacetianteats 11 INSTALLATION INSTRUCTIONS ras t ote RE etae n ta ee e Lia ini 12 15 Removing the Old Water Heater icit pret E tido 12 Location Requirements eie A Edd 13 Site LoOcatiOn T e 13 14 Insulation Blankets 0 a teet RO taedet dis a tem idit etg ede 14 Clearances and Accessiblility 2 deett de et ee evan pede He etra in ee RE e 14 15 Filling the Water Heater cire ait oe AA qu Eee at d eva eodd 15 GAS SUPPLY c A A ER 15 16 Gas REQqUIESMENTS viii id dd a T eal eese vu b as pe te 15 CAS PIPING ii A ee ee ee 15 Gas Pressure iii ee ie e ecd eee Ge eevee e Ae ee ee e dae 16 Gas Pressure Testing neut toca inks Lee ase ge deed Le 16 EP Gas Online 16 COMBUSTION AIR SUPPLY amp VENTILATION ooococccccncnccncccccoconenonnnnnononononcncnnnnnnnnnnnnncanonennnnnononananinens 17 20 Wncontined Space tm eed et im e p D ber e PEE Ee ett ati 17 Confinied Space eicit hee a tr te etia de Ua oos AAA AA dap AAA dott uetus os ds 17 All Ait from Inside the Bullding io coe Pet eem ea a etii 17 18 AIM AIF from OUTtdoOrs u i aiii 18 Eouvers and Grllless tette twn te tenen a etu tetendit e m Mx 18 19 Vent Plpe System ad ic tee pee LU ee LU Debet i Pete M ees aaa 19 Dratt Hood Installation data tt D teta a ete alld poete de 19 Vent PIDE SiZe EN 19 Madeline oaea eaan rine ala aioe aaaea ea aaraa EE 19 20 Chimney Connections asino eii eee eiie e een ee n e da a iia
91. stall the water piping and fittings as shown in Figure 22 Connect the cold water supply 3 4 NPT to the cold water inlet fitting Connect the hot water supply 3 4 NPT to the hot water outlet fitting IMPORTANT Some models may contain energy saving heat traps to prevent the circulation of hot water within the pipes Do not remove the inserts within the heat traps 2 The installation of unions in both the hot and cold water supply lines is recommended for ease of removing the water heater for service or replacement 3 The manufacturer of this water heater recommends installing a mixing valve or an anti scald device in the domestic hot water line as shown in Figure 23 These valves reduce the point of use temperature of the water by mixing cold and hot water and are readily available for use 4 f installing the water heater in a closed water system install an expansion tank in the cold water line as specified under Closed System Thermal Expansion 5 Install a shut off valve in the cold water inlet line It should be located close to the water heater and be easily accessible Know the location of this valve and how to shut off the water to the heater 6 A temperature and pressure relief valve must be installed in the opening marked Temperature and Pressure T amp P Relief Valve on the water heater A discharge line must be added to the opening of the T amp P Relief Valve Follow the instructions under Temp
92. sulting in severe injury or death Children the elderly and the physically er mentally disabled are at highest riskforscald injury Feel water before bathing or showering Temperature limiting valves are available A WARNING Fire Hazard For continued protection against risk of fire Do not install water heater on carpeted floor Do not operate water heater if flood damaged AWARNING Overheated water can cause water tank explosion Properly sized temperature and pressure relief valve must be installed in opening provided Read instruction manual for safe temperature setting Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and Do A WARNING AWARNING Install vent system in accordance with codes not operate water heater if flood liquids in the vicinity of this or any other appliance damaged Avoid all ignition sources if you smell Natural or LP gas High altitude orifice must be installed for Do not expose water heater control to excessive gas E operation above 10 100 feet 3 048m pressure Do not operate if soot is present Use only gas shown on rating plate UV y Do not obstruct water heater air intake Maintain required clearances to combustibles with insulating jacket Keep ignition sources away from faucets after extended Do not place chemical vapor emitting period of non use products near water heater J a Gas and ca
93. t combustion products are escaping from the relief opening If this occurs do not operate the water heater until proper adjustments or repairs are made to the vent pipe system and or air supply requirements Burner Flames Inspect the burner flames through the viewport and compare them to the drawing in Figure 27 A properly operating burner should produce a soft blue flame Blue tips with yellow inner cones are satisfactory The tips of the flame may have a slight yellow tint The flame should not be all yellow or have a sharp blue orange color Contaminated air may cause an orange colored flame Contact a qualified technician if the flame is not satisfactory FIGURE 27 Emergency Shut Down IMPORTANT Should overheating occur or the gas supply fails to shut off turn off the water heater s manual gas control valve and call a qualified technician Water Temperature Regulation Water temperature over 125 F 52 C can cause servere burns instantly resulting in severe injury or death ADANGER 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 Due to the nature of the typical gas water heater the water temperature in certain situations may vary up to 30 F 16 7 C higher or lower at the point of use such as bathtubs sh
94. t Parts IMPORTANT The following maintenance procedures are for the FVIR System components and should be performed by a qualified technician Replacement parts may be ordered from Sears Parts and Service Centers or by calling 1 800 4 MY HOME 1 800 469 4663 When ordering replacement parts always have the following information ready 1 model serial and product number 2 type of gas 3 item number 4 parts description See the Parts Order List section for a list of available repair parts External Inspection amp Cleaning of the Base Ring Filter 1 Atleast annually check the base ring filter Figure 39 for any dust or debris that may have accumulated on the filter screen NOTE If the water heater is located in an area that is subjected to lint and dirt it may be necessary to check the base ring filter more frequently 2 Follow the Lighting Instructions to turn off the water heater and allow it to cool for 10 minutes before attempting to clean the base ring filter 3 Use a vacuum cleaner with a hose attachment to remove any dust or debris that may have accumulated on the filter NOTE If unable to inspect or clean the base ring filter follow the Cleaning the Combustion Chamber and Flame arrestor instructions 4 After the base ring filter has been cleaned follow the Lighting Instructions to return the water heater to service Removing the Manifold Burner Assembly Turn the gas control temperature knob to the
95. t of louvers and grilles Ductwork must be the same cross sectional area as the openings Vent Pipe System Check for proper drafting at the water heater draft hood Refer to the Checking the Draft section of this manual for the test procedure If the procedure shows insufficient draft is present please check the following Draft hood properly installed Vent connectors securely fastened with screws and supported properly to maintain six inch clearance Vent connector made of approved material and sized correctly Vent pipe system installed according to all local and state codes or in the absence of local and state codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 current edition Flue baffle properly positioned in the flue tube Check the vent system for restrictions obstructions and check the vent termination height Refer to the Combustion Air Supply and Ventilation section of this water heater manual for specific requirements Recheck for sufficient combustion air supply Water System Piping Temperature and pressure relief valve properly installed with a discharge line run to an open drain and protected from freezing All piping properly installed and free of leaks Heater completely filled with water Closed system pressure build up devices installed Mixing valve when applicable instal
96. tem you should not proceed but get help from a qualified technician Draft Hood Installation SHEET METAL SCREWS FOUR PROVIDED INSTALL THE DRAFT HOOD WITH THE FOUR SCREWS PROVIDED FIGURE 18 Align the legs of the draft hood with the slots provided Insert the legs and secure the draft hood to the water heater s top with the four screws provided as shown in Figure 18 Do not alter the draft hood in any way If you are replacing an existing water heater be sure to use the draft hood supplied with this water heater Vent Pipe Size It is important that you follow the guidelines in these instructions for sizing a vent pipe system If a transition to a larger vent size is required the vent transition connection must be made at the draft hood outlet Vent Connectors 1 Type B Double wall U L Listed Vent Pipe 2 Single wall Vent Pipe Maintain the manufacturer s specified minimum clearance from combustible materials when using type B double wall vent pipe Vent connectors made of type B double wall vent pipe material may pass through walls or partitions constructed of combustible material if the minimum listed clearance is maintained Maintain a six inch minimum clearance from all combustible materials when using single wall vent pipe IMPORTANT Single wall vent pipe cannot be used for water heaters located in attics and may not pass through attic spaces crawl spaces or any confined or inaccessible location
97. th lint dust Obstruction in main burner orifice PILOT WILL NOT LIGHT OR REMAIN LIT Non functioning igniter The thermal switch tripped Wire lead connection at thermal switch loose Thermopile connection loose Air in gas line Low gas pressure No gas Dirt in gas lines Cold drafts Thermostat exceeded flashes Pilot line or orifice clogged Non functioning thermopile Air for combustion limit was blink 4 temperature status light will obstructed FVIR Flame Arrestor blocked with lint dust Flammable vapors function actuated Base Ring Filter blocked with lint dust incident FVIR HIGH OPERATION COSTS Thermostat set too high Sediment or lime in tank Water heater too small for job Wrong piping connections Leaking faucets Gas leaks Wasted hot water Long runs of exposed piping Hot water piping in exposed wall INSUFFICIENT HOT WATER Thermostat set too low Sediment or lime in tank Water heater too small Wrong piping connections Leaking faucets Wasted hot water Long runs of exposed piping Hot water piping in outside wall Low gas pressure 37 Provide ventilation to water heater Check with gas utility company Clean locate source and correct Clean locate source and correct Clean filter See External Cleaning amp Inspection of the Base Ring Filter section Proper fresh air ventilation Clean filter See Cleaning the Combustion Chamber and Flame Arrestor section Clea
98. thout adequate drainage IMPORTANT The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure Due to the normal corrosive action of water the tank will eventually leak after an extended period of time Also any external plumbing leak including those from improper installation may cause early failure of the tank due to corrosion if not repaired If the homeowner is uncomfortable with making the repair a qualified technician should be contacted A suitable metal drain pan should be installed under the water heater as shown below to help protect the property from damage which may occur from condensate formation or leaks in the piping connections or tank The pan must limit the water level to a maximum depth of 1 3 4 and be two inches wider than the heater and piped to an adequate drain NOTE The pan must not restrict combustion air flow Locate the water heater near a suitable indoor drain Outside drains are subject to freezing temperatures which can obstruct the drain line The piping should be at least 3 4 ID and pitched for proper drainage DO NOT CAP OR PLUG 6 MAXIMUM AIR GAP AT LEAST 2 GREATER THAN THE DIAMETER OF THE WATER HEATER PIPED TO AN ADEQUATE DRAIN FIGURE 9 Water
99. turers The thermostat is adjusted to the pilot position when it is shipped from the factory Water temperature can be regulated by moving the temperature dial to the preferred setting The preferred starting point is 120 F at the HOT setting Align the knob with the desired water temperature as shown in Figure 19A There is a hot water scald potential if the thermostat is set too high NOTE Temperatures shown on the gas control valve thermostat are approximates The actual temperature of the heated water may vary Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance Gas Control Temperature Knob 120 F Mark Y Status Light TOUGH nor prd bf A M Y Igniter Temperatures shown are approximates and may vary IMPORTANT Adjusting the thermostat past the 120 F bar on the temperature dial will increase the risk of scald injury Hot water can produce first degree burns within Water Time for Permanent Burns Temperature Degree Burn 2nd amp 3rd Degree E Less Severe Burns Most Severe Burns U S Government Memorandum C P S C Peter L Armstrong Sept 15 1978 Time for 1st FIGURE 28 NOTE During low demand periods when hot water is not being used a lower thermostat setting will reduce energy losses and may satisfy your normal hot water needs If hot water use is expected to be more th
100. undry hobby or craft rooms water heaters installed near chemical storage areas Combustion air must be free of acid forming chemicals such as sulfur fluorine and chlorine These elements are found in aerosol sprays detergents bleaches cleaning solvents air fresheners paint and varnish removers refrigerants and many other commercial and household products When burned vapors from these products form highly corrosive acid compounds These products should not be stored or used near the water heater or air inlet Combustion and ventilation air requirements are determined by the location of the water heater The water heater may be located in either an open unconfined area or in a confined area or small enclosure such as a closet or small room Confined spaces are areas with less than 50 cubic feet for each 1 000 BTUH of the total input for all gas using appliances Unconfined Space A water heater in an unconfined space uses indoor air for combustion and requires at least 50 cubic feet for each 1 000 BTUH of the total input for all gas appliances The table below shows a few examples of the minimum square footage area required for various BTUH inputs TABLE 3 Minimum Square Feet with 8 Ceiling 188 281 375 469 563 657 Typical Room with 8 Ceiling BTUH Input 30 000 45 000 60 000 75 000 90 000 105 000 9 x 21 14 x 20 15x25 15 x 31 20 x 28 20 x 33 17 TABLE 3 120 000 135
101. urging the piping system of air follow the WHAT TO DO IF YOU SMELL A WARN N G GAS instructions on the cover of this manual LP Gas Only AWARNING Explosion Hazard Gas leaks can not always be detected by smell Gas suppliers recommend that you use a gas detector approved by UL or CSA Explosion Hazard For more information contact your gas supplier Ren dicho PP Have a qualified person make sure L P gas pressure If a gas leak is detected follow the What to do if you does not exceed 13 water column smell gas instructions on the cover of this manual Examples of a qualified person include licensed plumbers authorized gas company personnel and IMPORTANT The gas supply pressure must not exceed the maximum authorized service personnel supply pressure as stated on the water heater s rating plate The minimum supply pressure is for the purpose of input adjustment Failure to do so can result in death explosion or fire Gas Pressure Testing IMPORTANT This water heater and its gas connection must be leak tested before placing the appliance in operation Liquefied petroleum gas is over 5096 heavier than air and in the occurrence of a leak in the system the gas will settle at dfthe code requires the gas lines to be tested at a pressure fior level Basements crawl spaces closets and areas below oe i bier T eas deste piel ground level will serve as pockets for the accumulation of gas 9 PPly p

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