Sears 153.31036 Water Heater User Manual
Contents
1. 7 16 Removing the Old Water al ters mo tme 7 8 Facts to Consider About the Location PN NS 8 CO non BE eect tte etree ees Nm 8 Facts to Consider About the Convertible Lower 8 9 Water WN RR m M 9 10 T amp P Valve and Pipe EON 10 Temperature Pressure Relief Valve ccccccccceccceeeeeseeeeneeeeneeeeseesneceaueecaneeteececeeseceeeesnseeaneetaneetaneesneenseeeseetseetseeeteneeseeeagess 10 11 FANO TE NE PE ic Ts 11 Convening the Lower Element R 12 14 E T 14 15 EE 16 SERVICE AND MAINTENANCE 17 22 Temper ature Regula ell sereen Dm 17 Bs deci M m 17 Tempa ACR ce OUI re sae es cece 17 Upper and Lower Th rmostatAOIUSITFIGITIS Decet pa dis ene sed E tesa imer Seit asc n ser pK rehenes 17 18 Arodge FROG INS PO ION sae os E E E AA A 18 Temperature Pressure Relief Valve Operation cccccccccseccccenceceeeeeeaeeeeeseeeeseeseeseeeeeseeeeeseueeeseeeeseueesseacessaaeesseaeessuseessneeesaeees 18 MMM MER E S 18 19 Thermostat a enc caue ee uiui sessi eue sa cadunt ee2. The grounding electrode conductor shall be of copper aluminum or copperclad aluminum The material shall be of one continuous length without a splice or joint b Rigid metal conduit intermediate metal conduit or electrical metallic tubing may be used for the grounding means if conduit or tubing is terminated in fittings approved for grounding c Flexible metal conduit or flexible metallic tubing shall be permitted for grounding if all the following conditions are met The length in any ground return path does not exceed 6 feet e The circuit conductors contained therein are protected by overcurrent devices rated at 20 amperes or less e The conduit or tubing is terminated in fittings approved for grounding For complete grounding details and all allowable exceptions refer to the current edition of the NEC National Electrical Code NFPA 70 4 A standard 1 2 conduit opening has been made the water heater junction box for the conduit connection 5 Wiring Diagrams see Wiring Diagrams section have been supplied showing the two most common types of connections between the water heater and the power supply You can easily see which type connection you have by removing the junction box cover on top of the water heater Two Wire Connection Diagrams is the most common requiring you to simply connect red to red black to black and the ground wire to the green ground screw in the junction box of the water h
3. Drain Valve Washer Drain Valve Washer TIPS TE thick 6 Heat Trap Nipple Cold Inlet 9003936 9004334 9004334 9003936 9003936 LowerAccessPanel 5500 9000396 000386 _ 9000396 2000896 _ 9000396 ee ee 9002300 MN Roto Swirl Dip Tube See NOTE B above 16 TerminalCover 9002276 9002276 17 f Terminal Cover CCT 9002438 9002438 9002438 Upper Element See NOTE A above 2 Pole Thermostat Two wire lead models tt 9002214 oma 9002214 esses These parts are also available at most Sears retail stores Also available at most hardware stores T Replaced only on return of damaged plate TT Refer to Wiring Diagram section for verification Not illustrated Now that you have purchased this water heater should a need ever The model number of the water heater will be found on the model exist for repair parts or service simply contact any Sears Service rating plate located near the access panel Center or call 1 800 4 MY HOME 1 800 469 4663 Be sure to provide all pertinent facts when you call or visit WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE All Parts listed may be ordered from any Sears stores and by calling FOLLOWING INFORMATION 1 800 366 PART 1 800 366 7278 Model Number Part Number If the parts you need are not stocked locally your order will be Serial Number Part Descripti
4. High Temperature Shut Off System in the Troubleshooting section During very cold weather the incoming water will also be colder and it will require a longer time to become heated The hot water usage may exceed the capacity of the water heater If so wait for water heater to recover after abnormal demand Also examine pipes and faucets for possible water leaks If you can not determine the problem then call the Sears Service Department WATER IS TOO HOT Adjust the thermostat to a lower setting See the Temperature Regulation section LEAKAGE CHECKPOINTS 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 Read this manual first Then before checking the water heater make sure the electric supply has been turned OFF and never turn the electric supply on before the tank is completely full of water Use this guide to check a Leaking water heater Many suspected Leakers are not leaking tanks Often the source of the water can be found and corrected If you are not thoroughly familiar with electric codes the water heater and safety practices contact your local Sears Service Center to check the water heater CAUTION Improper installation and use may res
5. MY HOME 1 800 469 4663 This warranty applies only while this product is in use SANS ORK United States Q This warranty gives you specific legal rights and you may also have other rights which vary from state to state A SA o m gt A O m 00 c A gt o E T gt I O TI Ti gt m z m o e N e The price of your water heater does not include a free checkup service call On water heater installation warrants the installation o rranged by Sears Sears A charge will be made on service calls due to poor or incomplete installation These include a Adjusting thermostat b Leaks in pipes or fittings Condensation MASTER PROTECTION AGREEMENTS Fast help by phone phone support from a Sears technician on Congratulations on making a smart purchase Your new Kenmore products requiring in home repair plus convenient repair scheduling product is designed and manufactured for years of dependable Power surge protection against electrical damage due to power operation But like all products it may require preventive maintenance fluctuations or repair from time to time That s when having a Master Protection Agreement can save you money and aggravation Rental reimbursement if repair of your covered product takes longer than promised Purchase a Master Protection Agreement now and protect yourself from unexpected hassl
6. Propane Torch Soft Solder Solder Flux Emery Cloth Wire Brushes TUBING CUTTER HACKSAW asy Vi R ROLL OF ROLL OF EMERY CLOTH LEAD FREE SOLDER SOFT SOLDER FLUX 3 4 19 mm WIRE BRUSH esar 1 2 13 mm WIRE BRUSH PROPANE TORCH INSTALLATION INSTRUCTIONS Removing the Old Water Heater The water passing out of the drain valve may be extremely hot To avoid being scalded make sure all connections are tight and that the water flow is directed away from any person 4 Check again to make sure the electrical supply is turned OFF to the water heater Then unplug the water heater cord set or disconnect the electrical supply connection from the water heater junction box FIGURE 4 5a If you have copper piping to the water heater the two copper water pipes can be cut with a hacksaw approximately four inches away from where they connect to the water heater This will avoid cutting off the pipes too short Additional cuts can be made later if necessary Disconnect the temperature pressure relief valve drain line When the water heater is drained disconnect the hose from the drain valve Close the drain valve The water heater is now completely disconnected and ready to be removed a ee ee eee CLEEEEEEEHETEEE FIGURE 1 2 Turn OFF the water supply to the water heater at the water shut off valve or water meter FIGURE 2 3 Attach a hose to the water hea
7. and the piping 4 Check all new water piping for leaks Repair as needed Converting the Lower Element These instructions only cover the conversion of the convertible element read this entire manual before attempting to install or operate the water heater The water heater is factory set to operate at 3800 watts The lower element can be converted to operate at 5500 watts Refer to Facts to Consider About the Convertible Lower Element section The Upper Element if double element model is a conventional 3800 watt element which only operates at its rated wattage on 240 volts See rating plate on the water heater The lower Element of the water heater can be converted from operation at 3800 watts to 5500 watts on a 240 volt system If after reading these instructions and this manual if you do not understand any portion call Sears Service Center A WARNING Fire Hazard Electric Shock Hazard Do not use this water heater with any voltage otherthan shown onthe model rating plate Failure to use the correct voltage shown on the model rating plate could result in death serious bodily injury or property damage Before making the conversion to 5500 watts check the 1 power supply must be 240 volts 2 wiring 10 gauge AWG Type TW 60 C or equivalent and 3 Circuit breakers or fusing capable of 30 amp loading Also the installation must conform with this manual local codes an
8. detect and react to leakage in various ways e Sensors mounted in the drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected Sensors mounted in the drain pan that turn off the water supply to the entire home when water is detected in the drain pan Water supply shut off devices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater CAUTION e Water heater must be located in a protective area INSTALLATION IN RESIDENTIAL GARAGES The water heater must be located and or protected so it is not subject to physical damage by a moving vehicle The location selection must provide adequate clearances for servicing and proper operation of the water heater Insulation Blankets Insulation blankets are available to the general public for external use on electric water heaters but are not necessary with this product The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters Your water heater meets or exceeds the National Appliance Energy Conversation Act standards with respect to insulation and standby loss requirements making an insulation blanket unnecessary Should you choose to apply an insulation blanket to this heater you should follow these instructions below Failure to follow these instructions can result in fire serious personal injur
9. humans D An excess of active hydrogen in the tank This is caused by corrosion protective action of the anode Smelly water may be eliminated or reduced in some water heater models by replacing the anode rod s with one of less active material and then chlorinating the water heater tank and all hot water lines Contact the local Sears Service Center for further information concerning an Anode Replacement Kit 9001453 and this Chlorination Treatment Anode replacement and chlorination of the tank are not covered by the water heater s limited warranty If the smelly water persists after the anode replacement and chlorination treatment then you should consider chlorinating or aerating your water supply Do not remove the anode leaving the tank unprotected By doing so all warranty on the water heater tank is voided AIR INHOT WATER FAUCETS A WARNING 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 be opened for several minutes at the kitchen sink before any electrical appliances which are connected to the hot water system are used such as a dishwas
10. meter FIGURE 34 6 Lift out the tab as shown to unclip the terminal cover from the thermostat The terminal cover can now be removed from the thermostat FIGURE 31 3 Attach a hose to the water heater drain valve and put the other end in a floor drain or outdoors Open the water heater drain valve Open a nearby hot water faucet which will relieve pressure in the water heater and speed draining SS LIFT OUT TAB TO UNCLIP TERMINAL COVER FROM THERMOSTAT FIGURE 32 UPPER AND LOWER THERMOSTAT WITH ADANGER HIGH LIMIT Burn hazard FIGURE 35 Waleralschalde 7 Disconnect the two wires on the element and unscrew the old element from the tank Keep hands clear of drain valve discharge 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 36 20 8 Clean the area around the element opening Remove any sediment from or around the element opening inside the tank 9 Ifyou are cleaning the element you have removed do so by scraping or soaking in vinegar or a de liming solution A WARNING Fire Hazard and Electric Shock Hazard Do not use replacement elements with any voltage other than shown on the model rating plate Failure to use the correct voltage shown on the model rating plate could result in death serious bodily injury
11. the thermostat from behind the thermostat bracket 6 Place the new thermostat in the bracket making sure it fits firmly against the tank T Attach the wires to the new thermostat NOTE Some of the terminals may require straight in wiring through an eye opening If wires are now looped recut and strip wire 3 8 to a straight length and insert 8 Put plastic terminal cover back in place 9 Replace the insulation cap with handle to cover the thermostat 10 Replace access panel then turn the electric power on Element Cleaning Replacement NOTE These instructions are written for element cleaning and element replacement for the lower element If it is necessary to clean or replace the upper element then repeat these instructions To remove the element from your tank in order to clean or replace it 4 Remove the two screws securing the access panel and WARN NG remove panel e Before removing any access panels or servicing the water heater make sure the electrical supply to the water heater is turned OFF e Failure to do this could result in death serious bodily injury or property damage FIGURE 33 5 Remove the insulation cap with handle 1 Before beginning turn OFF the electric power supply to the water heater EE 2222l22i2s22222224 sien DS eee ll TTT Pee EEE FIGURE 30 2 Turn off the water supply to the water heater at the water Shut off valve or water
12. valve discharge line and 2 the water manually discharged will not cause any bodily injury or property damage because the water may be extremely hot If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions and replace the temperature pressure relief valve with a new one 11 HOT TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE DO NOT PLUG OR CAP 6 AIR GAP FLOOR DRAIN FIGURE 10 Filling the Water Heater CAUTION Property Damage Hazard Avoid water heater damage Fill tank with water before operating Never use this water heater unless it is completely full of water To prevent damage to the tank and heating element the tank must be filled with water Water must flow from the hot water faucet before turning ON power To fill the water heater with water 1 Close the water heater drain valve by turning the handle to the right clockwise The drain valve is located on the lower front of the water heater 2 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 3 To insure complete filling of the tank allow air to exit by opening the nearest hot water faucet Allow water to run until a constant flow is obtained This will let air out of the water heater
13. CALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy clothes washing dish washing and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally handicapped If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs some type of tempering device such as a mixing valve should be used at the hot water taps used by these people or at the water heater Mixing valves are available at plumbing supply or hardware stores Follow manufacturers instructions for installation of the valves Before changing the factory setting of the thermostat see Temperature Settings table at right 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 Thermostats The thermostats of this water heater have been factory set at a position which approximates 120 F 49 C to reduce the risk of scald injury The upper thermostat is factory set at a position which approximates 120 F 49 C and is adjusta
14. Owner s Manual Kenmore POWER MISER 12 ELECTRIC WATER HEATER FOR POTABLE WATER HEATING ONLY NOT SUITABLE FOR SPACE HEATING MODEL NO 153 321342 30 Gal 153 321343 30 Gal 153 321442 40 Gal 153 321443 40 Gal 153 321542 55 Gal 153 321543 55 Gal 153 321642 66 Gal 153 321643 66 Gal 153 321842 80 Gal 153 321843 80 Gal e Safety Instructions Installation Operation Care and Maintenance Troubleshooting Parts List AWARNING Read and understand instruction manual and safety messages before installing operating or EFFICIENCY RATING CERTIFIED servicing this water heater ama Failure to follow instructions and safety messages could result in death or serious injury GAMA certification applies to all residential electric water Instruction manual must remain heaters with capacities of 20 to 120 Gallons Input rating of with water heater 12kW or less SAVE THIS MANUAL FOR FUTURE REFERENCE Sears Roebuck and Co Hoffman Estates IL 60179 U S A PRINTED 0707 www sears com 185798 000 SAFE INSTALLATION USE AND SERVICE Your safety and the safety of others is extremely important in the installation use and servicing of this water heater Many safety related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard Read and obey all safety messages and instructions throughout this m
15. R HEATING gt 2 FOR 3800 WATTS ELEMENT FIGURE 24 WIRING FOR 3 WIRE LEAD WATER HEATERS NON SIMULTANEOUS OPERATION 240 VOLT DOUBLE ELEMENT NOTE Some lower Hi Temp Limit Switches THREE TYPES OF FIELD may have 4 terminals Use only the CONNECTIONS A9 2 terminals on left YOU MAY HAVE z J UPPER TIME CLOCK SWITCH HI TEMP gt OPERATES BOTTOM ELEMENT ONLY LIMIT SWITCH TO ELECTRIC TO TIME L2 POWER SUPPLY L1 L2 L2 CLOCK SWITCH UPPER THERMOSTAT JUNCTION BOX INDICATOR YELLOW LAMP a BLUE BLACK OPTIONAL 2 OFF PEAK METER UPPER HEATING OPERATES BOTTOM ELEMENT ONLY TO ELECTRIC L2L1 TO OFF PEAK ELEMENT POWER SUPPLY L1 12 METER TO OFF PEAK OR 3 PHASE POWER SUPPLY JUNCTION BOX HI TEMP LIMIT YELLOW BLUE BLACK BLACK SWITCH 8 FOR TWO WIRE CONNECTION LOWER TO ELECTRIC FOR 5500 WATTS THERMOSTAT gt POWER SUPPLY L1 12 x O LOWER 4 HEATING eB ELEMENT FOR 3800 WATTS FIGURE 25 16 SERVICE AND ADJUSTMENT Temperature Regulation Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury A DANGER Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting HOTTER WATER CAN S
16. VE HOUSE COLD INLET THREADED THREADED WATER TO SWEAT TO SWEAT LINE COUPLING COUPLING 3 4 THREADED NIPPLE 3 3 4 THREADED NIPPLE TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE DO NOT CAP OR PLUG AIR GAP FLOOR DRAIN FIGURE 8 T amp P Valve and Pipe Insulation Remove insulation for T amp P valve and pipe connections from carton Fit pipe insulation over the incoming cold water line and the hot water line Make sure that the insulation is against the top cover of the heater Fit T amp P valve insulation over valve Make sure that the insulation does not interfere with the lever of the T amp P valve Secure all insulation using tape 10 PIPE INSULATION a 1 L L I L L t T amp P INSULATION FIGURE 9 Temperature Pressure Relief Valve WARNING Temperature pressure relief valve must comply with ANSI 221 22 CSA 4 4 and ASME code Properly sized temperature relief valve must be installed in opening provided e Can result in overheating and excessive tank pressure e Can cause serious injury or death This heater is provided with a properly certified combination temperature pressure relief valve by the manufacturer The valve is certified by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment of materials as meeting th
17. anual It is very important that the meaning of each safety message is understood by you and others who install use or service this water heater This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently hazardous A DANGER situation which if not avoided could result in death or injury WARNING indicates a potentially hazardous situation which if not avoided could result in death or injury CAUTION indicates a potentially hazardous situation which if not avoided may result CAUTION in minor or moderate injury CAUTION used without the safety alert CAUTION symbol indicates a potentially hazardous situation which if not avoided could result in property damage All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause lo
18. ble if a different water temperature is desired Read all warnings in this manual and on the water heating before proceeding ADJUSTABLE UPPER THERMOSTAT BEHIND UPPER ACCESS PANEL PANEL DUAL ELEMENT MODELS ONLY TEMPERATURE ADJUSTMENT KNOB ADJUSTABLE UPPER THERMOSTAT FIGURE 26 The lower thermostat is factory set at a position which approximates 120 F 49 C and is adjustable if a different water temperature is desired Read all warnings in this manual and on the water heating before proceeding TEMPERATURE ADJUSTMENT ADJUSTABLE THERMOSTAT FOR DUAL ELEMENT MODELS ADJUSTABLE LOWER THERMOSTAT WITH HIGH LIMIT FIGURE 27 Temperature Settings NOTE Water temperature range of 120 140 F 49 60 C recommended by most dishwasher manufacturers Time to Produce 2nd and 3rd Degree Burns on Adult Skin 160 F 71 C About 1 2 second 150 F 66 C About 1 1 2 seconds Temperature Setting 140 60 C Less than 5 seconds 130 F 54 C About 30 seconds 120 F 49 C More than 5 minutes Upper and Lower Thermostat Adjustments Refer to thermostat illustrations under Thermostats section A WARNING e Before removing any access panels or servicing the water heater make sure the electrical supply to the water heater is turned OFF e Failure to do this could result in death serious bodily injury or property damage NOTE It is not necessary to adjust the upp
19. c utility rules Failure to comply can result in DEATH SERIOUS BODILY INJURY OR PROPERTY DAMAGE LISTED 932N SERIAL NUMBER ELECTRIC WATER HEATER CAPACITY MODEL NUMBER U S GAL FACTORY EQUIPPED WITH UPPER LOWER ELEMENT ELEMENT MAXIMUM VOLTS WATTS WATTS MAXIMUM WORKING IFINSTALLEDAS PRESSURE WATTS A C ONLY FACTORY EQUIPPED P S I CHECK HERE OPTIONAL WATTAGE UPPER LOWER ELEMENT ELEMENT MAXIMUM CHECK HERE WATTS IF CONVERTED WATTS WATTS WARNING SEE CONVERSION INSTRUCTION FIGURE 6 NOTE Whether or not the element conversion is made the model rating plate must be marked Using a hard point ink pen check the appropriate block within the model rating plate which is located adjacent to the lower access panel Water Pipi ADANGER Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting HOTTER WATER CAN SCALD Water heaters are intended to produce hot water Water heated to a temperature which will satisfy 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
20. clockwise remove the hex cap below the screw handle e Remove the washer and put the new one in place e Screw the handle and cap assembly back into the drain valve and retighten using a wrench DO NOT OVER TIGHTEN Follow Filling the Water Heater instructions in the Installation Instructions section e Check for leaks e Turn ON electric power to the water heater YI N HANDLE AND CAP ASSEMBLY FIGURE 42 Service Before calling for repair service read the Start Up Conditions and Operational Conditions found in the Troubleshooting section of this manual If a condition persists or you are uncertain about the operation of the water heater let a qualified person check it out Contact Sears Repair Services at 1 800 4 MY HOME 1 800 469 4663 TROUBLESHOOTING THERMAL EXPANSION CAUTION Avoid water heater damage Install thermal expansion tank or device if necessary e Contact qualified installer or service agency Water supply systems may because of such events as high line pressure frequent cut offs the effects of water hammer among others have installed devices such as pressure reducing valves check valves back flow preventers etc to control these types of problems When these devices are not equipped with an internal by pass and no other measures are taken the devices cause the water system to be closed As water is heated it expands thermal expansion and closed sy
21. condensation loose connections or the temperature pressure 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 Note To check where threaded portion enters tank insert cotton swab between jacket opening and fitting If cotton is wet follow Draining instructions in the Service and Adjustment section and then remove fitting Put pipe dope or teflon tape on the threads and replace Then follow Filling the Water Heater instructions the Installation Instructions section REPAIR PARTS LIST KENMORE POWER MISER 12 ELECTRIC WATER HEATERS MODEL NUMBERS 153 321342 30 Gallon 153 321343 30 Gallon 153 321442 40 Gallon 153 321443 40 Gallon 153 321542 55 Gallon NOTE A UPPER ELEMENT These water heaters are equipped with 3800 watt elements LOWER ELEMENT These water heaters are equipped with factory installed convertible elements which be operated 3800 watts or 5500 watts Convertible elements are not offered as replacement parts ELEMENT ORDERING INFORMATION If a replacement 3800 watt 240 volt element is needed order part no 9000049 replacement element If at the time of installation the water heater was converted to operate at 5500 watts order part no 9000396 replacement element See model
22. cover can now be removed from the thermostat 9 6 LIFT OUT TAB TO UNCLIP TERMINAL COVER FROM THERMOSTAT Remove the screws from terminal 2 of the element and move the looped end of the wire aside The buss bar is labeled 5500 W Place the buss bar over terminals 2 and 3 with the 5500 W visible Install the extra TURN OFF POWER BEFORE SERVING TO REMOVE PULL ARROW AT TOP OF COVER FIGURE 16 FIGURE 17 screw provided into terminal 3 The wire removed from terminal 2 has a looped end It must remain looped and now be placed as shown on top of the buss bar over the opening of terminal 2 and secured using the remaining screw FIGURE 18 FIGURE 19 8 Tighten terminals 2 and 3 to ensure proper electrical connection A WARNING Failure to tighten screws can cause afire Failure to do this could result in death serious bodily injury or property damage Failure to tighten terminal screws can cause a fire which can result in DEATH SERIOUS BODILY INJURY OR PROPERTY DAMAGE 9 Replace terminal cover on thermostat making sure that the locking tabs on the terminal cover are in place A WARNING Thermostat must be flush against the tank Make sure terminal cover is in place and the insulation replaced Failure to do this could result in death serious bodily injury or property damage Make sure the thermostat is flush again
23. ctrical Code ANSI American National Standards Institute Read the General Safety section page 3 of this manual first and then the entire manual carefully If you don t follow the safety rules the water heater will not operate properly It could cause DEATH SERIOUS BODILY INJURY AND OR PROPERTY DAMAGE This manual contains instructions for the installation operation and maintenance of this electric water heater It also contains warnings throughout the manual that you must read and be aware of All warnings and all instructions are essential to the proper operation of the water heater and your safety Since we cannot put everything on the first few pages READ THIS ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER The installation must conform with the instructions in this manual electric company rules and Local Codes or in the absence of Local Codes with the current edition of the NEC National Electrical Code NFPA 70 This publication is available from your local government or public library or electric company or by writing Underwriters Laboratories Inc 333 Pfingsten Road Northbrook IL 60062 e fafter reading this manual you have any questions or do not understand any portion of the instructions call Sears Service Center Carefully plan the place where you are going to put the water heater Correct electrical wiring and connections are very important in preventing death from possible el
24. d electric utility rules Failure to comply can result in DEATH SERIOUS BODILY INJURY OR PROPERTY DAMAGE NOTE Whether or not the element conversion is made the model rating plate must be marked Using a hard point ink pen check the appropriate block within the model rating plate which is located adjacent to the lower access panel LISTED 932N SERIAL NUMBER ELECTRIC WATER HEATER CAPACITY MODEL NUMBER U S GAL FACTORY EQUIPPED WITH UPPER LOWER ELEMENT ELEMENT MAXIMUM VOLTS MAXIMUM CHECK HERE WORKING IF INSTALLED AS PRESSURE WATTS WATTS WATTS A C ONLY FACTORY EQUIPPED P S I OPTIONAL WATTAGE UPPER LOWER ELEMENT ELEMENT MAXIMUM CHECK HERE WATTS IF CONVERTED WATTS WATTS WARNING SEE CONVERSION INSTRUCTION FIGURE 11 Necessary element conversion parts are located in a small bag contained within the electrical junction box on top of the water heater CONVERSION PARTS BUSS BAR FIGURE 12 1 Before beginning the conversion turn OFF electric power supply to the water heater EPEEP ali FIGURE 13 2 The convertible element is located behind the lower access panel of the water heater Remove the two screws securing the access panel and remove panel FIGURE 14 3 Remove the insulation cap with handle to expose the terminal cover FIGURE 15 4 Lower Element Lift out the tab as shown to unclip the terminal cover from the thermostat The terminal
25. e all pertinent facts when you call or visit WHEN ORDERING REPAIR PARTS ALWAYS GIVE THE All Parts listed may be ordered from any Sears stores and by calling FOLLOWING INFORMATION 1 800 366 PART 1 800 366 7278 Model Number Part Number If the parts you need are not stocked locally your order will be SerialNumber Part Description electronically transmitted to a Sears Repair Parts Distribution Center for handling THIS IS A REPAIR PARTS LIST NOT A PACKING LIST 27 REPAIR PARTS LIST KENMORE POWER MISER 12 ELECTRIC WATER HEATERS MODEL NUMBERS G3 153 321643 66 Gallon 153 321842 80 Gallon 153 321843 80 Gallon NOTE A UPPER ELEMENT These water heaters are equipped with 3800 watt elements LOWER ELEMENT These water heaters are equipped with factory installed convertible elements which can be operated at 3800 watts or 5500 watts Convertible elements are not offered as replacement parts ELEMENT ORDERING INFORMATION If a replacement 3800 watt 240 volt element is needed order part no 9000049 replacement element If at the time of installation the water heater was converted to operate at 5500 watts order part no 9000396 replacement element See model rating plate If Converted box NOTE B These water heaters are equipped with a Roto Swirl dip tube to retard a build up of dissolved solids EE EAD Tid Part Description M reuse Ber e O O O a Drain Vave 3
26. e and expense 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 The Master Protection Agreement also helps extend the life of your new product Here s whats included in the Agreement Sears has over 12 000 professional repair specialists who have access to over 4 5 million quality parts and accessories That s the Expert Service by our 12 000 professional repair specialists kind of professionalism you can count on to help prolong the life of your new purchase for years to come Purchase your Master Protection Unlimited service and no charge for parts and labor on all Agreement today covered repairs Some limitations and exclusions apply For prices and additional No lemon guarantee replacement of your covered product if information call 1 800 827 6655 four or more product failures occur within twelve months SEARS INSTALLATION SERVICE Product replacement if your covered product can t be fixed For Sears professional Installation of home appliances garage door Annual Preventive Maintenance Check at your request no extra openers water heaters and other major home items in the U S A charge call 1 800 4 MY HOME For in home major brand repair service Call 24 hours a day 7 days a week U S A and Canada SEARS 1 WWW Sears com The model nu
27. e requirements for Relief Valves for Hot Water Supply Systems ANSI Z21 22 CSA 4 4 and the code requirements of ASME If replaced the valve must meet the requirements of local codes but not less than a combination temperature and pressure relief valve certified as indicated in the above paragraph The valve must be marked with a maximum set pressure not to exceed the marked hydrostatic working pressure of the water heater 150 psi 1 035 kPa and a discharge capacity not less than the water heater input rate as shown on the model rating plate For electric heaters watts x 3 412 equals Btu hr input rate For safe operation of the water heater the relief valve must not be removed from its designated opening nor plugged The temperature pressure relief valve must be installed directly into the fitting of the water heater designed for the relief valve Position the valve downward and provide tubing so that any discharge will exit only within 6 inches 153 mm above or at any distance below the structural floor Be certain that no contact is made with any live electrical part The discharge opening must not be blocked or reduced in size under any circumstances Excessive length over 30 feet 9 14 m or use of more than four elbows can cause restriction and reduce the discharge capacity of the valve CAUTION Temperature pressure relief valve discharge pipe must terminate at adequate drain No valve or other obstruction is
28. eater Three Wire Connection Diagram is used when you are connecting the water heater to a power supply that has a Time Clock or Off Peak meter To make these connections refer to block 1 or 2 in this wiring diagram for the type of system you have NOTE If you have purchased a three wire connection water heater but you are not on a Time Clock or Off Peak meter and have a standard two wire connection power supply simply follow the connection diagram in block 3 of the three wire connection diagram 6 Use wire nuts and connect the power supply wiring to the wires inside the water heater s junction box The water heater must be electrically grounded by the installer A green ground screw has been provided on the water heater s junction box Connect ground wire to this location 8 Replace the wiring junction cover using the screw provided CONDUIT FIGURE 23 Wiring Diagrams STANDARD WIRING FOR 2 WIRE LEAD WATER HEATERS NON SIMULTANEOUS OPERATION 240 VOLT DOUBLE ELEMENT WARNING e Before removing any access GROUND TERMINAL 7o panels or servicing the water 9 POWER SUPPLY heater make sure the electrical D supply to the water heater is turned OFF HI TEMP JUNCTION LIMIT BOX SWITCH Failure to do this could result in death serious bodily injury or property damage UPPER THERMOSTAT 5 lt o c c ING 02 NS LOWE
29. ectrical shock and fires Examine the location to ensure the water heater complies with the Facts to Consider About the Location section For California installation this water heater must be braced anchored or strapped to avoid falling or moving during an earthquake See instructions for correct installation procedures Instructions may be obtained from the California Office of the State Architect 400 P Street Sacramento CA 95814 Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248 CMR 2 00 State Plumbing Code and 248 CMR 5 00 In the Commonwealth of Massachusetts this product must be installed by a licensed plumber or gasfitter PRODUCT SPECIFICATIONS DIMENSIONS IN ae mm mm MODEL CAPACITY NUMBER 153 321342 153 321343 153 321442 153 321443 3 2 3 2 3 153 32164 153 32164 153 32184 153 32184 electrical code RECOVERY RATE GALS PER HOUR 90 F Rise ne 22 5 572 62 0 1 575 3800 3800 ELEMENT WATTAGE 240 VOLTS UPPER LOWER MAXIMUM FUSE OR CIRCUIT BREAKER SIZE AMPS MINIMUM WIRE SIZE GAUGE m pe ent E 3800 3800 3800 5500 EUN Sateen 3800 3800 3800 5500 3800 5500 250 24 0 610 62 0 1 575 3800 3800 3800 5500 303 26 0 660 62 0 1 575 3800 3800 3800 5500 Wiring size based on standard 60 C copper wire If distance from fies box to water heater is more than 90 feet refe
30. el for the correct voltage DO NOT use this water heater with any voltage other than the one shown on the model rating plate Failure to use the correct voltage can cause problems which can result in DEATH SERIOUS BODILY INJURY OR PROPERTY DAMAGE If you have any questions or doubts consult your electric company 14 A WARNING Fire Hazard Electric Shock Hazard Do not use this water heater with any voltage otherthan shown onthe model rating plate Failure to use the correct voltage shown on the model rating plate could result in death serious bodily injury or property damage If wiring from your fuse box or circuit breaker box was aluminum for your old water heater replace it with copper wire If you wish to reuse the existing aluminum wire have the connection at the water heater made by a competent electrician Contact your Sears salesperson to arrange for a professional electrician 1 Provide a way to easily shut off the electric power when working on the water heater This could be with a circuit breaker or fuse block in the entrance box or a separate disconnect switch 2 Install and connect a circuit directly from the main fuse or circuit breaker box This circuit must be the right size and have its own fuse or circuit breaker Refer to the chart in the Product Specifications section for the correct size wire and fuse or circuit breaker 3 If metal conduit is used for the grounding conductor a
31. epeat steps 10 through 14 15 Reconnect the two wires to the element and then check to make sure the thermostat remains firmly against the surface of the tank FIGURE 38 16 Replace terminal cover on thermostat making sure that the locking tabs on the terminal cover are in place LIFT OUT TAB TO UNCLIP TERMINAL COVER FROM THERMOSTAT UPPER AND LOWER THERMOSTAT WITH HIGH LIMIT FIGURE 39 17 Place the insulation cap with handle so that it completely covers the thermostat and element FIGURE 40 18 Replace access panel 19 Turn ON electric power to water heater LEN E TE HEB d ri E IL ji f it ual al el ud ud e ed p Ie 12 1 q 1 Ds E E E my E 1 7 CHO PERE am FIGURE 41 Drain Valve Washer Replacement WARNING e Before removing any access panels or servicing the water heater make sure the electrical supply to the water heater is turned OFF Failure to do this could result in death serious bodily injury or property damage NOTE For replacement use a 17 32 x 13 64 x 1 8 thick washer available at your nearest hardware store For ordering a replacement washer refer to the Repair Parts List section Before beginning turn OFF the electrical power supply to the water heater 22 Follow Draining instructions See Draining section Turning counter
32. er thermostat However if it is adjusted above the factory set point of 120 F 49 C it is recommended that it not be set higher than the lower thermostat setting The upper and lower thermostats are adjustable if a different water temperature is desired Read all warnings in the Temperature Regulation section before proceeding 1 Turn OFF the electric power to the water heater at the junction box WARNING e Before removing any access panels or servicing the water heater make sure the electrical supply to the water heater is turned OFF e Failure to do this could result in death serious bodily injury or property damage 2 Take off the upper and or lower access panel insulation cap with handle 3 The slotted adjustment using a screwdriver can be turned clockwise toincrease the temperature setting or counter clockwise to decrease the temperature setting 4 Replace the insulation cap with handle and access panel 5 Turn ON the power supply Anode Rod Inspection CAUTION Avoid water heater damage Inspection and replacement of anode as needed The anode rod is used to protect the tank from corrosion Most hot water tanks are equipped with an anode rod The submerged rod sacrifices itself 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 t
33. her 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 RUMBLING NOISE In some water areas scale or mineral deposits will build up on your heating elements This buildup will cause a rumbling noise Follow Element Cleaning Replacement instructions to clean and replace the elements HIGH TEMPERATURE SHUT OFF SYSTEM The water heater has a high limit shut off system with a reset button located on the thermostat Follow the resetting instructions which refer to the high limit behind the access panel NOTE If your water heater is connected to an Off Peak Clock and uses the 3 wire lead wiring diagram in the Wiring Diagram section then the water heater will have a high limit on both the 24 upper and lower thermostats Follow the instructions to reset the high limit behind the upper and lower access panels WARNING e Before removing any access panels or servicing the water heater make sure the electrical supply to the water heater is turned OFF Failure to do this could result in death serious bodily injury or property damage 1 Before beginning turn OFF electrical power supply to the water heater FIGURE 44 2 Remove the two screws securing the access panel and remove panel 3 Remove the
34. hing the adapter to the water inlet connection Do not solder the water supply lines directly to the cold water inlet It will harm the dip tube and damage the tank CAUTION Avoid water heater damage Install thermal expansion tank if necessary Do not apply heat to cold water inlet Contact qualified installer or service agency NOTE To protect against untimely corrosion of hot and cold water fittings it is strongly recommended that di electric unions or couplings be installed on this water heater when connected to copper pipe 1 Look at the top cover of the water heater The hot water outlet is marked hot Put two or three turns of teflon tape around the threaded end of the threaded to sweat coupling and around both ends of the 3 4 threaded nipple Using flexible connectors connect the hot water pipe to the hot water outlet of the water heater 2 Look at the top cover of the water heater The cold water inlet is marked cold Put two or three turns of teflon tape around the threaded end of the threaded to sweat coupling and around both ends of the 3 4 threaded nipple Using flexible connectors connect the cold water pipe to the cold water inlet of the water heater NOTE Your water heater is insulated to minimize heat loss from the tank Further reduction in heat loss can be accomplished by insulating the hot water lines from the water heater HOT FLEXIBLE SHUT OFF WATER CONNECTORS VAL
35. include the elderly children the infirm or physically mentally handicapped If anyone using hot water in your home fits into one of these groups or if there is a local code or state law requiring a certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at the hot water taps used by these people or at the water heater Mixing valves are available at plumbing supply or hardware stores Follow manufacturers instructions for installation of the valves Before changing the factory setting on the thermostat read the Temperature Regulation section in this manual See Figure 7 for mixing valve usage HOT WATER OUTLET COLD WATER INLET wef i TO COLD WATER INLET ON WATER HEATER FROM HOT WATER MIXING OUTLET ON VALVE WATER HEATER FIGURE 7 Figure 8 shows the attachment of the water piping to the water heater The water heater is equipped with 3 4 water connections If a water heater is installed in a closed water supply system such as one having a back flow preventer check valve water meter with a check valve etc in the cold water supply means must be provided to control thermal expansion Contact the local utility or Sears Service Center on how to control this situation NOTE If using copper tubing solder tubing to an adapter before attac
36. insulation cap with handle 4 Reset the high limit by pushing in the red button marked RESET FIGURE 45 5 Replace the insulation cap with handle so that it completely covers the thermostat and element 6 Replace the access panel 7 Turn ON electric power to the water heater If the high limit must be reset again call Sears Service Department to find out why the high limit turned OFF the electric power NOT ENOUGH OR NO HOT WATER In a new installation the water heater may be properly connected Make sure the cold water supply valve is open Review and check piping installation Make sure that the cold water line is connected to the cold water inlet to the water heater and the hot water line to the hot water outlet on the water heater Make sure the electrical supply to your water heater is ON Check for loose or blown fuses in your water heater circuit Circuit breakers weaken with age and may not handle their rated load and should be replaced Make certain the disconnect switch if used is in the ON position Check to see the electric service to your house has not been interrupted If this is the case contact the electric company Is the thermostat set to the desired temperature See Temperature Regulation section 25 7 If you had experienced very hot water and now no hot water the problem may be due to the high temperature shut off system See
37. ion tank s air pressure must be adjusted to match that pressure but must not be higher than 80 psi 23 WATER HEATER 3 COLD WATER PRESSURE INLET FITTING REDUCING c VALVE WITH BY PASS 2 d PRESSURE GAUGE INLET COLD WATER SHUT OFF RECOMMENDED INSTALLATION VERTICAL MOUNTING WATER HEATER COLD WATER INLET FITTING FLOOR CEILING JOIST ETC STRAPPING 3 PRESSURE REDUCING VALVE WITH BY PASS y INLET COLD WATER SHUT OFF 1 EXPANSION TANK 2 PRESSURE GAUGE 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 Operational Conditions SMELLY WATER In each glass lined water heater there is installed one anode rod see parts section for corrosion protection of the tank Certain water conditions will cause a reaction between this rod and the water The most common complaint associated with the anode rod is one of a rotten egg smell This odor is derived from hydrogen sulfide gas dissolved in the water The smell is the result of four factors which must all be present for the odor to develop A Aconcentration of sulfate in the supply water B Little or no dissolved oxygen in the water C A sulfate reducing bacteria within the water heater This harmless bacteria is non toxic to
38. ized temperature and pressure relief valve must be installed in opening provided Failure to do this could result in death serious bodily injury or property damage ADANGER Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting A WARNING Fire Hazard Electric Shock Hazard Do not use this water heater with any voltage other than shown on the model rating plate Failure to use the correct voltage shown on the model rating plate could result in death serious bodily injury or property damage TABLE CONTENTS SAFE INSTALLATION USE 24 ool 2 eee ee eee ee 2 GENERAL AFET ne ee ae cee ee eee ee ee eee 3 TABLE OF Se 6 ig ah eee 4 NTRODUCTION eee 5 PRODUCTI SPECIRICAHNON t eee 5 MATERIALS AND BASIC TOOLS NEEDED ee ee ee Eta dd DUE 6 ee eee are PEI Oe eer E mcm 6 6 Additional Tools Needed When Sweat Soldering 6 INSTALLATION NI HPSPOUQes T
39. mber of your water heater is found on the model rating plate on the front of the water heater Sears Roebuck and Co Hoffman Estates IL 60179 U S A
40. ne ee cp n REND LIE C DEIN EE I I SENTI Eee 19 Element Cleanng ReplacemeNi 19 22 Drain valve Washer Replacement nc e Rot ac etos RS UE 22 Nel E d P s MN RN REN cc 22 TRJUBLESFOOTN S GUIDE M 23 26 ao E M E A MEUM eee 23 Tham EXP N O eee 23 BU ANUS UNC cece se eee cee roues dmn a ee cet cease A ected jesesiacece E I MU ME TM EE 23 Operational Conditions cee re ca ee eee t 23 25 WN e DER E P O 23 24 AK O FOC oo al giis ee ec s m S 24 PRIM 24 Migh Temperature SYSTE NO cmm 24 or NO 25 eee eee eee Emm 25 Leak Oe Eoo oom 26 27 28 29 30 31 WARRANT oc E ee ee ere ee ee ee ee ee ee eee eee eee eee eee 32 INTRODUCTION Thank You for purchasing a Sears water heater Properly installed and maintained it should give you years of trouble free service It is strongly suggested that this new water heater be professionally installed contact the local Sears Service Center or any Sears store They will arrange for prompt quality installation by Sears authorized contractors Abbreviations Found In This Instruction Manual UL Underwriters Laboratories Inc NEC National Ele
41. o keep the tank in operating condition Anode deterioration depends on the water conductivity not necessarily water condition A corroded or pitted anode rod indicates high water conductivity and should be checked and or replaced more often than an anode rod that appears to be intact Replacement of a depleted anode rod can extend the life of your water heater Inspection should be conducted by calling Sears Service Center At a minimum the anode s should be checked annually after the warranty period 18 Temperature Pressure Relief Valve Operation The temperature pressure relief valve must be manually operated at least once a year ADANGER Burn hazard Hot water discharge Keep clear of relief valve discharge outlet The temperature pressure relief valve must be manually operated at least once a year Caution should be taken to ensure that 1 no one is in front of or around the outlet of the temperature pressure relief valve discharge line and 2 the water manually discharged will not cause any property damage or bodily injury The water may be extremely hot TEMPERATURE PRESSURE RELIEF VALVE DISCHARGE PIPE FIGURE 28 If after manually operating the valve it fails to completely reset and continues to release water immediately close the cold water inlet to the water heater follow the draining instructions and replace the temperature pressure relief valve with a new one Failure to install and main
42. on electronically transmitted to a Sears Repair Parts Distribution Center for handling THIS IS A REPAIR PARTS LIST NOT A PACKING LIST 28 NOTES NOTES NOTES 6 By ORO ROO AR CAROASSY OA OLDIE LOL DELS REVO SL SDL SA LD SAS DEAS ONS te A e X 12 YEAR LIMITED WARRANTY ON WATER HEATER gt Q Na For twelve years from date of purchase if this water heater is installed and operated in a single family home in accordance 2 5 Q em with the owner s manual instructions and all local applicable plumbing codes Sears will 1 supply free water heater parts for e gt 69 those that are defective in material or workmanship and 2 supply free water heater for one that develops a leak 65 M 6 For the second through twelfth year from purchase date you must pay the labor cost for installation of water heater eS Q For commercial institutional industrial or residential use by two or more families the above limited warranty is only for two Q years During second year you must pay the labor cost for water heater installation R D 6S 1 YEAR EXCLUSIVE KENMORE LABOR WARRANTY e 69 For the first year from the date of purchase Sears will free of charge supply and install new water heater parts for defective QD AS OK ones or a new water heater for that develops a leak Q SS WARRANTY SERVICE e D To obtain warranty service call 1 800 4
43. or property damage Replacement elements must 1 be the same voltage and 2 no greater wattage than listed on the model rating plate affixed to the water heater 10 A new gasket should be used in all cases to prevent a possible water leak See Element Gasket in the Repair Parts List Chart Place the new element gasket on the thread side of the cleaned or new element and screw into tank securing tightly using an element wrench FIGURE 37 11 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 12 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 13 To insure complete filling of the tank allow air to exit by opening the nearest hot water faucet Allow water to run until a constant flow is obtained This will let air out of the water heater and the piping CAUTION Improper installation and use may result in property damage Fill tank with water before operation Never use this water heater unless it is completely full of water To prevent damage to the tank and heating element the tank must be filled with water Water must flow from the hot water faucet before turning ON power 14 Check element for water leaks If leakage occurs tighten element or repeat steps 2 and 3 remove element and reposition gasket Then r
44. own and drained for an extended period the drain valve should be left open with hose connected allowing water to terminate to an adequate drain 6 Close the drain valve 7 Follow Filling the Water Heater instructions in the Installation Instructions section 8 Turn ON power to the water heater CAUTION Improper installation and use may result in property damage Fill tank with water before operation Never use this water heater unless it is completely full of water To prevent damage to the tank and heating element the tank must be filled with water Water must flow from the hot water faucet before turning ON power Thermostat Removal Replacement WARNING e Before removing any access panels or servicing the water heater make sure the electrical supply to the water heater is turned OFF Failure to do this could result in death serious bodily injury or property damage 1 Turn OFF the electrical power to the water heater at the junction box 2 Remove the access panel and the insulation cap with handle 3 Lift out the tab as shown below to unclip the terminal cover from the thermostat The terminal cover can now be removed from the thermostat LIFT OUT TAB TO UNCLIP TERMINAL COVER FROM THERMOSTAT LOWER THERMOSTAT WITHOUT HIGH LIMIT UPPER AND LOWER THERMOSTAT WITH HIGH LIMIT FIGURE 29 4 Disconnect wires from the thermostat 5 Remove
45. r to your m 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 Em is LJ D ws gt a s 4 md cr dumb p ul C d pu ud e e MAUI EXPANSION TANKS FOR THERMAL EXPANSION CONDITIONS AVAILABLE IN 2 GALLONS AND 5 GALLONS CAPACITY THROUGH LOCAL SEARS STORE OR SERVICE CENTER DRAIN PANS AVAILABLE IN 20 DIAMETER FOR WATER HEATERS HAVING A DIAMETER 18 OR LESS 24 DIAMETER FOR WATER HEATERS HAVING A DIAMETER WATER HEATER INSTALLATION KIT WITH FLEXIBLE CONNECTORS FOR 3 4 OR 1 2 THREADED OR COPPER PLUMBING Basic Tools You may or may not need all of these tools depending on your type of installation These tools can be purchased at your local Sears store Pipe Wrench 2 Screwdriver 6 Foot Tape or Folding Rule Garden Hose Drill Pipe Dope or Teflon Tape SLOT HEAD SCREWDRIVER BB PHILLIPS SCREWDRIVER ROLL OF TEFLON TAPE USE ON WATER CONNECTIONS PIPE DOPE SQUEEZE TUBE USE FOR WATER CONNECTIONS GARDEN HOSE 6 FOOT TAPE PIPE WRENCH 22 OR LESS AND AVAILABLE IN 28 DIAMETER FOR WATER HEATERS HAVING A DIAMETER 26 OR LESS Additional Tools Needed When Sweat Soldering Tubing Cutters or Hacksaw
46. rating plate If Converted box NOTE B These water heaters are equipped with a Roto Swirl dip tube to retard a build up of dissolved solids Model No uS Part Description 153 321342 153 321343 153 321442 153 321443 153 321542 BusBaKt O o 9001691 9001591 9001591 9001591 9001591 Drain Valve 3 brain Valve Washer DEER EK 6 Feat Trap Nipple Coa ney 9003921 9003921 9003915 9003915 9003036 5500 T 9000396 9000396 ra 9 Lower Thermostat wIHr Limit 3 wire lead models Tt 9002300 2 9002300 Roto Swirl Dip Tube See NOTE B above 716 TemialCove SSS 9002276 9002276 9002276 7 TemialGoer 900238 9002438 Upper Flement See NOTE A above 724 2 Pole Thermostat Two wire lead models Tf 9002214 9002214 9002214 These parts are also available at most Sears retail stores Also available at most hardware stores T Replaced only on return of damaged plate TT Refer to Wiring Diagram section for verification Not illustrated Now that you have purchased this water heater should a need ever The model number of the water heater will be found on the model exist for repair parts or service simply contact any Sears Service rating plate located near the access panel Center or call 1 800 4 MY HOME 1 800 469 4663 Be sure to provid
47. st the tank the terminal cover is in place and the insulation is replaced Failure to do so can result in DEATH SERIOUS BODILY INJURY OR PROPERTY DAMAGE 10 Replace the insulation cap with handle so that it completely covers the thermostat and element FIGURE 20 11 Replace the access panel FIGURE 21 12 Complete wiring to the water heater or if completed turn ON electric power to the water heater after filling the tank with water FIGURE 22 CAUTION Improper installation and use may result in property damage Fill tank with water before operation Never use this water heater unless it is completely full of water To prevent damage to the tank and heating element the tank must be filled with water Water must flow from the hot water faucet before turning ON power Wiring You must provide all wiring of the proper size outside of the water heater You must obey local codes and electric company requirements when you install this wiring If you are not familiar with electric codes and practices or if you have any doubt even the slightest doubt in your ability to connect the wiring to this water heater obtain the service of a competent electrician Contact your Sears salesperson to arrange for a professional electrician WATER HEATERS EQUIPPED FOR ONE VOLTAGE ONLY This water heater is equipped for one type voltage only Check the rating plate near the bottom access pan
48. stems do not allow for the expansion of heated water The water within the water heater tank expands as it is heated and increases the pressure of the water system If the relieving point of the water heater s temperature pressure relief valve is reached the valve will relieve the excess pressure The temperature pressure relief valve is not intended for the constant relief of thermal expansion This is an unacceptable condition and must be corrected It is recommended that any devices installed which could create a closed system have a by pass and or the system have an expansion tank to relieve the pressure built by thermal expansion in the water system 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 Thermal Expansion Tank Specifications Dimensions in Inches Fitting In Gallons On Tank 153 331020 2 8 203 mm 12 3 4 323 mm 3 4 Male 153 331050 5 11 279 mm 14 3 4 375 mm 3 4 Male Expansion Tank Sizing Chart Tank Capacity Pipe Inlet Water Pressure Water Heater Capacity Gallons Expansion Tank Capacity Needed Highest recorded inlet water pressure in a 24 hour period regulated water pressure NOTE Expansion tanks are pre charged with a 40 psi air charge If the inlet water pressure is higher than 40 psi the expans
49. tain a new properly listed temperature pressure relief valve will release the manufacturer from any claim which might result from excessive temperature or pressure If the temperature pressure relief valve on the appliance weeps or discharges periodically this may be due to thermal expansion Your water heater may have a check valve installed in the water line or a water meter with a check valve Consult your local Sears Service Center for further information Do not plug the temperature pressure relief valve Drainin A DANGER Burn hazard Hot water discharge Keep hands clear of drain valve discharge The water heater should be drained if being shut down during freezing temperatures Also periodic draining and cleaning of sediment from the tank may be necessary WARNING e Before removing any access panels or servicing the water heater make sure the electrical supply to the water heater is turned OFF e Failure to do this could result in death serious bodily injury or property damage 1 Before beginning turn OFF the electric power supply to the water heater 2 CLOSE the cold water inlet valve to the water heater 3 OPEN a nearby hot water faucet and leave open to allow for draining 4 Connect a hose to the drain valve and terminate to an adequate drain or outdoors 5 OPEN the water heater drain valve to allow for tank draining NOTE If the water heater is going to be shut d
50. ter drain valve and put the other FIGURE 5a end in a floor drain or outdoors Open the water drain valve Open a nearby hot water faucet which will relieve pressure 5b If you have galvanized pipe to the water heater loosen the in the water heater and speed draining two galvanized pipes with a pipe wrench at the union in each line Also disconnect the piping remaining to the water heater These pieces should be saved since they may be needed when reconnecting the new water heater Disconnect the temperature pressure relief valve drain line When the water heater is drained disconnect the hose from the drain valve Close the drain valve The water heater is now completely FIGURE 3 disconnected and ready to be removed Burn hazard Hot water discharge Keep hands clear of drain valve discharge FIGURE 5b Mineral Buildup or Sediment May Accumulate e This causes the water heater to become much heavier than normal If spilled could cause staining 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 Facts to Consider About the Location You should carefully choose an indoor location for the new water heater because the placement is a very important consideration for the safety of the occupants in the building and for the most economical use of the appliance This water hea
51. ter is not intended for outdoor installation Whether replacing an old water heater or putting the water heater in a new location the following critical points must be observed The location selected should be indoors as close to and as centralized with the water piping system as possible This water heater as well as all water heaters will eventually leak Do not install without adequate drainage provisions so water flow will not cause damage CAUTION All water heaters eventually leak Donotinstall without adequate drainage WATER HEATERS EVENTUALLY LEAK Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak the flow of water will not cause damage to the structure When such locations cannot be avoided a suitable drain pan should be installed under the water heater Drain pans are available at your local Sears stores Such drain pans must be piped to an adequate drain Water heater life depends upon water quality water pressure and the environment in which the water heater is installed Water heaters are sometimes installed in locations where leakage may result in property damage even with the use of a drain pan piped to a drain However unanticipated damage can be reduced or prevented by a leak detector or water shut off device used in conjunction with a piped drain pan These devices are available from some plumbing supply wholesalers and retailers and
52. to be placed between the relief valve and the tank Do not connect tubing directly to discharge drain unless a 6 inch air gap is provided To prevent bodily injury hazard to life or property damage the relief valve must be allowed to discharge water in quantities should circumstances demand If the discharge pipe is not connected to a drain or other suitable means the water flow may cause property damage The Discharge Pipe e Shall not be smaller in size than the outlet pipe size of the valve or have any reducing couplings or other restrictions e Shall not be plugged or blocked e Shall be of material listed for hot water distribution e Shall be installed so as to allow complete drainage of both the temperature pressure relief valve and the discharge pipe e Shall terminate at an adequate drain e Shall not have any valve between the relief valve and tank Water temperature over 125 F 52 C can cause severe burns instantly resulting in severe injury or death Children the elderly and the physically or mentally disabled are at highest risk for scald injury A DANGER Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting The temperature pressure relief valve must be manually operated at least once a year Caution should be taken to ensure that 1 no one is in front of or around the outlet of the temperature pressure relief
53. ult in property damage Fill tank with water before operation 26 Never use this water heater unless it is completely full of water To prevent damage to the tank and heating element the tank must be filled with water The water must flow from the hot water faucet before turning ON power A Condensation may be seen on pipes in humid weather or pipe connections may be leaking B Small amounts of water from the temperature pressure relief valve may be due to thermal expansion or high water pressure in your area C The temperature pressure relief valve may be leaking at the tank fitting D The element may be leaking at the tank fitting A WARNING e Before removing any access panels or servicing the water heater make sure the electrical supply to the water heater is turned OFF Failure to do this could result in death serious bodily injury or property damage Turn electrical power OFF remove access panel and insulation cap with handle If leaking around element follow proper draining instructions and remove element Reposition or replace gasket on element Place element into opening and tighten securely Then follow Filling the Water Heater instructions in the Installation Instructions section E Water from drain valve may be due to the valve being opened slightly The drain valve may be leaking at the tank fitting G Water in the water heater bottom or on the floor may be from
54. w level exposure to some of the substances listed including formaldehyde IMPORTANT DEFINITIONS e Sears Service Center The Sears Service Center has the ability equivalent to a licensed tradesman in the fields of plumbing and electrical work including a thorough understanding of the requirements of the National Electrical Code as it relates to the installation of electric water heaters The Sears Service Center also has a thorough understanding of this instruction manual and is able to perform repairs strictly in accordance with the service guidelines provided by the manufacturer GENERAL SAFETY AWARNING CAUTION Read and understand instruction Improper installation and use may result manual and safety messages in property damage before installing operating or servicing this water heater Do not operate water heater if flood damaged Failure to follow instructions and Inspect and replace the anode as needed safety messages could result in Install in location with drainage death or serious injury Fill tank with water before operation l Be alert for thermal expansion Instruction manual must remain l with water heater Refer to instruction manual for installation and service A WARNING A WARNING e Before removing any access panels or servicing the water heater make sure the electrical supply to the water heater is turned OFF Overheated water can cause water tank explosion Properly s
55. y or death e Do cover the temperature and pressure relief T amp P valve with an insulation blanket Do not cover the instruction manual Keep it on the side of the water heater or nearby for future reference e Do obtain new warning and instruction labels for placement on the blanket directly over the existing labels Facts to Consider About the Convertible Lower Element The Upper Element if a double element model is a conventional 3800 watt element which only operates at its rated wattage on 240 volts See rating plate on the water heater The Lower Element of the water heater can be converted from operation at 3800 watts to 5500 watts on a 240 volt system Read and follow water heater warnings and instructions If after reading these instructions in this manual you do not understand any portion call Sears Service Center A WARNING Fire Hazard Electric Shock Hazard Do not use this water heater with any voltage other than shown onthe model rating plate Failure to use the correct voltage shown on the model rating plate could result in death serious bodily injury or property damage Before making the conversion to 5500 watts check the 1 power supply must be 240 volts 2 wiring 10 gauge AWG Type TW 60 C or equivalent and 3 Circuit breakers or fusing capable of 30 amp loading Also the installation must conform with this manual local codes and electri
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