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Kenmore 305 Water Heater User Manual

Contents

1. a pm EE fait EEE QUEM T T T RAD SENE SE H 1 i 1 1 1 1 EFE YEE H H H 0 1 1 1 1 T f 1 pul ice 1 1 1 1 ao 1 1 1 1 qoem D a nn eee 1 1 1 1 t 1 i 1 re T T 1 T PM Sean T 1 1 T S nde ono e T 1 1 1 ef a T 1 1 1 Water Flow gpm t 1 1 1 M 1 1 1 1 1 1 1 M 1 1 1 1 1 1 1 1 in nh 1 1 1 1 1 1 1 1 a te 1 1 1 1 1 1 1 1 mt ne i 1 1 dee rn Fer 1 1 mm jer ea i 1 0 T i H GENE EE ei ee ari apes ini oie Soh sii on 1 1 1 1 Pressure Loss ft he
2. 22 Operating Instructions nanne 22 Sequence of Operation 22 Features Available on Temperature Controllers 22 Temperature Adjustment 23 Temperature Options without a Temperature Controllers anar E E 24 Temperature 24 Setting the Controller to Mute 24 Operating Your Water Heater 25 Maintenance 26 Cleaning 26 Vent System ciii ac ere tara 26 REIR D ROT e 26 Temperature 26 Lime Scale Build up 26 Snow Accumulation sss 26 Visual Inspection of Flame 26 Troubleshooting nennen 27 30 Error Code Table ences 27 28 Troubleshooting for Common Issues 29 Accessing Operating Information 29 Water Quality xs ere tete ere e Cre ne 29 Flushing the Heat Exchanger Error Code LC or 00 30 Wiring Diagram nanne eenen 31 Service and Adjustment 32 Repair Parts Llst o ide e 32 Kenmore Tankless Water Heater Accessories 32 Notes oie re
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4. This is not an engineered drawing it is intended only as a guide and not as a replacement for professionally engineered project drawings This Y Pressure Regulator drawing is not intended to describe a complete system it is up to the contractor engineer to determine the necessary components and ES 3 4 Union Circulating Pump configuration of the particular system being installed This drawing does not imply compliance with local building code requirements it is the PNY Check Valve Fed Boiler Drain Valve responsibility of the contractor engineer to ensure installation is in accordance with all local building codes Confer with local building kK Pressure Relief Valve Solenoid Valve officials before installation 305 8 505 Outdoor Manual Figure 7 Optional Piping for Circulation Systems NOTE Applications using this piping arrangement reduces the warranty to the following 3 years on heat exchanger 3 year on parts Full warranty will be maintained if an Water Heater Equipment List QTY on demand recirculation system in incorporated Refer to the Limited Warranty Water Heaters 1 Plumbing Installation 1 Kit Optional 3 4 Fittings Include 2 Unions 2 Ball Valves 2 Drain Valves and For this application 1 Pressure Relief Valve Pump should be controlled by an Aquastat Timer or Combination Aquastat and Timer Pump to be sized to maintain circulation loop temperature A min
5. CLLL IIIS 7 A 00 AIR SUPPLY INLET VENT TERMINAL AREA WHERE TERMINAL IS NOT PERMITTTED Description Clearance above grade veranda porch deck or balcon Clearance to window or door that may be opened Clearance to permanently closed window Judo __ horizontal distance of 2 feet 61 cm from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside corner Clearance to inside corner Clearance to each side of center line extended above meter regulator assembl Clearance to service regulator vent outlet En by i B RETE NNUS MUN nlet to any other appliance 10 feet 3 m horizontall earance above paved sidewalk or paved driveway located on public property 0 Clearance under veranda porch deck or balcony Avent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings L G H J K M Q Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor For clearances not specified in ANSI Z223 1 NFPA 54 or CSA B149 1 clearances are in accordance with local installation codes and the requirements of the gas supplier 305 amp 505 Outdoor Manual Additional Clearance Vent Terminal Local codes supersede these clearances Avoid termination locations near a dryer vent Avoid termina
6. Fast help by phone we call it Rapid Resolution phone openers water heaters and other major home items in the U S A support from a Sears representative on all products Think of or Canada call 1 800 4 MY HOME us as a talking owner s manual Power surge protection against electrical damage due to power fluctuations 305 amp 505 Outdoor Manual 5 CUSTOMER RESPONSIBILITIES Thank You for purchasing a Kenmore water heater Properly installed and maintained it should give you years of trouble free service If you should decide that you want the new water heater professionally installed by Sears call 1 800 4 MY HOME They will arrange for prompt quality installation by Sears authorized contractors Abbreviations Found In This Instruction Manual CSA Canadian Standards Association ANSI American National Standards Institute NFPA National Fire Protection Association ASME American Society of Mechanical Engineers GAMA Gas Appliance Manufacturers Association Important Information About This Water Heater This manual has been prepared to acquaint you trained service technician with the installation operation and maintenance of the on demand water heater and provide important safety information in these areas Service to the on demand system should only be performed by a trained service technician READ THE ENTIRE MANUAL BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER HEATER The in
7. This warranty gives you specific legal rights and you may also have other rights which vary from state to state SEARS ROEBUCK AND CO Dept 817WA Hoffman Estates IL 60179 OY OY Oy OY 5 NY Oe NUNS DED GEE NEE NTE NSS ETET NOOK The price of your water heater does not include a free checkup service call On water heater installations arranged by Sears Sears warrants the installation A charge will be made on service calls due to poor or incomplete installation These include a Adjusting thermostat b Condensation c Leaks in pipes or fittings Master Protection Agreements Congratulations on making a smart purchase Your new 250 Food Loss Protection annually for any food spoilage Kenmore product is designed and manufactured for years that is the result of mechanical failure of any covered of dependable operation But like all products it may require refrigerator or freezer preventive maintenance 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 10 discount off the regular price of any non covered repair The Master Protection Agreement also helps extend the life of your service and related installed parts new product Here s what the Agreement includes Once you purchase the Agreement a simple phone ca
8. Indicator Electronic control board monitors inlet outlet water Priority Button temperature temperature set point and water ie flow rate Thermostat Tor an 0 1 Combustion fan energized Purges combustion ON OFF chamber Button Spark igniter begins sparking Gas control valve opens to minimum fire rate Flame rod proves ignition Description 1 o Igniter stops Sparking Error Codes When a fault is detected an error code 3 Normal Operation flashes at the temperature In Use Indicator Indicates that hot water is being supplied Electronic control board monitors flame rod i e a hot water tap is open fan motor frequency outlet water temperature controller temperature set point and water flow Sd O turm the waler heater OS OEF rate Priority Button Indicates that this controller is setting the Indicator temperature Priority can be switched to Gas control valve modulates gas input to required another controller by pressing its Priority firing rate Button when no hot water is running Combustion fan speed is adjusted for the required firing rate Th ermostat Increases or decreases the temperature Water flow control valve is adjusted as needed ES setting 4 Shutdown Sequence Figure 11 Electronic control board senses water flow rate less than 0 5 GPM Gas control valve closes Water flow control valve resets to standby
9. 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 All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances WARNING This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This appliance can cause low level exposure to some of the substances included in the Act IMPORTANT DEFINITIONS 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 have a thorough understanding of this instruction manual Service Agency A service agency also must have ability equivalent to a licensed tradesman in the fields of plumbing air supply venting and gas suppl
10. 1 2 psi 3 5 kPa 13 84 in W C The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at yw test pressures equal to or greater than 1 2 psi 3 5 kPa 13 84 in W C The appliance should be located in an area where water leakage of the unit or connections will not result in damage to the area adjacent to the appliance or to lower to floor ground ren floors of the structure When such locations cannot be avoided itis recommended that a suitable metal drain pan adequately drained be installed under the appliance The Figure 1 pan must not restrict combustion air flow The flow of combustion and ventilation air shall not be Table 4 to Combustibles to Non Combustibles obstructed This appliance is not suitable for use in an application such MEER 305 505 305 505 as a pool or spa heater that uses chemically treated water Top of dc inches 2 inches This appliance is suitable for filling large or whirlpool bath 305 mm 51 mm tubs with potable water Clearances from Appliance 10 305 amp 505 Outdoor Manual Electrical Connection Table 1 to Combustibles to Non Combustibles en The water heater must be electrically grounded in Back of Heater accordance with local codes or in the absence of local codes with the most recent edition of the National pub of
11. 2 to 5 water heaters and allow them to function as one hot Water heaters should be installed less than 18 inches water source apart so that the cables will reach between units and to prevent temperature fluctuations cold water sandwich The Multi Unit connection kit includes a PC board and et ae effect when the water is shut off and turned back on one Multi Unit connection cable Refer to the instructions that come with the accessory Temperature settings can only be changed on the for complete installation information controller for the primary unit Table 5 Number of Connected Water Heaters 2 Unit connection cable or 1 Multi Unit connection kit T Multi Unit connection kit and Multi Unit connection cable 1 Multi Unit connection kit and 2 Multi Unit connection cables SSE 11 81 Multi Unit connection kit and 3 Multi Unit connection cables 20 305 amp 505 Outdoor Manual TEMPERATURE CONTROLLER INSTALLATION Location Outdoor models are supplied with one remote control unit Additional controllers can also be installed The controller should be out of reach of small children Avoid locations where the controller may become hot near the oven or radiant heater Avoid locations in direct sunlight The digital display may be difficult to read in direct sunlight Avoid locations where the temperature controller could be splashed with liquids Do not ins
12. 8 Technical Data rrr 9 Pressure Drop Curve 9 Outlet Flow Data 9 Installation Instructions nnee 10 General Instructions unne 10 Clearances from 10 Attachment of the Water Heater 11 Electrical Connection sss 11 Gas Supply dice eerte t eS 11 General Instructions 11 Pipe Sizing Procedure Example 12 Water Pipillg reae re eren 13 General Instructions unne enen 13 Pressure Relief 13 Freeze Protection an onnnnennenenen 13 14 Recommended Piping For Basic Installation 15 Recommended Piping For Circulation Systems 16 Optional Piping For Circulation Systems 17 Venting Instructions 18 Additional Clearances Vent Terminal 19 High Altitude Installations 20 Connecting Multiple Water Heaters 20 Temperature Controller Installation 21 Location e E doo es 21 Configurations essen 21 Cable Lengths And Size 21 Mounting The Controller 21 Description of Operation
13. Electrical Code ANSI NFPA 70 In Canada all electrical Er mm mm wiring should be in accordance with local codes and Sides of 1 8 inches the Canadian Electrical Code CSA C22 1 Part 1 Do Heater 152 mm 3 2 mm not rely on the gas or water piping to ground the water Floor 12 inches heater A screw is provided in the junction box for the Ground 305 mm 51 mm grounding connection The clearance for servicing is 24 inches in front of the The water heater requires 120 VAC 60 Hz power from water heater a properly grounded circuit Attachment of the Water Heater A disconnect switch must be provided and installed for A the incoming 120 VAC power It should be a type that is pe Qus suitable for outdoor use Check the National Electrical Code ANSI NFPA 70 and your local codes for a proper switch type to use in your area The wiring diagram is located on the Technical Sheet attached to the inside of S the front cover wall installation A Id Jp use brackets um La pg l gl TTET gl L olo O Figure 2 1 Identify the installation location and confirm that the installation will meet all required clearances 2 Securely attach the water heater to the wall using a
14. ONLY Figure 15 WIRING DIAGRAM NEUTRAL ANTI HEATER MODULATING SOD COMBUSTION FAN FLAME ROD FLAME DETECTING CIRCUIT REMOTE CONTROLLER 305 amp 505 Outdoor Manual 31 SERVICE AND ADJUSTMENT Contact Sears Service Center at 1 800 4 MY HOME 1 800 469 4663 For the convenience of the Qualified Service Technician a Technical Data Sheet has been placed inside the front cover of the water heater The Technical Data Sheet includes the following important information for Servicing and or Troubleshooting the water heater Electric schematic Wiring Diagram for the water heater and the voltage and or resistance readings that should be measured at each component connection Procedure for Setting the Gas Pressure Dip Switch Settings Operation of the Remote Controller Error Codes and Suggested Remedies Repair Parts List For exploded parts diagrams and a part number listing refer to the Parts List located inside the front cover of the water heater Note Usethe 305 Parts List for model numbers 154 330040 and 154 330050 Usethe 505 parts List for model numbers 154 330080 and 154 330090 Kenmore Tankless Water Heater Accessories Part Number Description 701022 001 Standard Controller A maximum of 4 temperature controllers can be installed for a water heater or bank of water heaters for convenient temperature adjustment 9006486005 3 4 Fittings f
15. keys are pressed or to turn the beeps back on press and hold both the Aand buttons until a beep is heard approximately 5 seconds 24 305 amp 505 Outdoor Manual OPERATING YOUR WATER HEATER FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance does not have a pilot Itis equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand do not try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any ga
16. position Combustion fan runs for a short period of time at low speed 5 Standby Mode Electronic control board monitors watertemperature and remote controls Freeze protection is activated as needed 22 305 amp 505 Outdoor Manual TEMPERATURE ADJUSTMENT Water temperature over 125 F 52 can cause servere burns instantly resulting in severe injury or death A DANGER 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 For systems with storage tanks the water temperature in certain situation may vary up to 30 F 16 7 C higher or lower at the point of use such as bathtubs showers 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 us
17. recommended effects of thermal expansion Contact a plumbing service that installers attend a product knowledge class to ensure agency or your retail supplier regarding the installation of customer satisfaction and warranty coverage Failure to a thermal expansion tank NOTE Reference Figures 4 7 comply with state and local codes pertaining to water to see if your installation recommends the use of a thermal heater installations may void the warranty expansion tank This appliance is not to be installed indoors Should overheating occur or the gas supply fail to shut off Use only parts certified with the appliance A qualified installer or service technician should install the turn off the manual gas control valve to the appliance appliance inspect it and leak test it before use Keep the air intake location free of chemicals such as The installation must conform with local codes or in the chlorine or bleach that produce fumes These fumes ANSI Z223 1 NFPA 54 or the Natural Gas and Propane appliance Installation Code CSA B149 1 The appliance when installed must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 or the Canadian Electrical Code CSA C22 1 The appliance and its appliance main gas valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of
18. relief valve must be rated up to 150 psi and to at least the maximum BTU hr of the appliance The discharge from the pressure relief valve should be piped to the ground or into a drain system to prevent exposure or possible burn hazards to humans or other plant or animal life Follow local codes Water discharged from the relief valve could cause severe burns instantly scalds or death See Figure 4 The pressure relief valve must be manually operated once a year to check for correct operation Therelief valve should be added to the hot water outlet line according to the manufacturer s instructions DO NOT place any other type valve or shut off device between the relief valve and the water heater Do not plug the relief valve and do not install any reducing fittings or other restrictions in the relief line The relief line should allow for complete drainage of the valve and the line Ifa relief valve discharges periodically this may be due to thermal expansion in a closed water supply system Contact the water supplier or local plumbing inspector on how to correct this situation Do not plug the relief valve Neither this water heater nor the American National Standard ANSI Z21 10 3 Canadian Standard CSA 4 3 requires a combination temperature and pressure relief valve for this appliance However local codes may require a combination temperature and pressure relief valve Freezing Protection The freeze pro
19. use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions 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 Sears Roebuck and Co Hoffman Estates IL 60179 U S A PRINTED IN THE U S A 0409 www sears com PART NO 316052 001 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 this manual and on your own water heater to warn you and others of a potential injury hazard Read and obey all safety messages and instructions throughout this manual It is very important that the meaning of each safety message is understood by you and others who install use or service this water heater This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently hazardous situation which if not avoided will DANGER 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
20. water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water Safety Features Overheat The appliance will automatically shut down when the appliance exceeds a predetermined temperature Flame Failure The appliance will automatically shut down if the burner flame is extinguished Power Failure The appliance will cut off the gas if it loses electrical power 305 amp 505 Outdoor Manual Any alteration to the appliance or its controls can be dangerous and will void the warranty Always check the water temperature before entering a shower or bath Power Surge Fuse A glass fuse protects against overcurrent If the fuse blows then all indicator lamps will be off Fusible Link In case the overheat feature does not prevent the temperature from rising then the fusible link will break shutting off the appliance TABLE OF CONTENTS Safe Installation Use and 2 Safety Precautions 2 Safety Behaviors and Practices 3 Safety Features evene 3 Table of Contents 4 Product Warranty 5 Consumer Responsibilities 6 Product Specifications nnn 7 DIMENSIONS sanar overeen verven
21. 0 200 67 140 265 543 12 305 amp 505 Outdoor Manual WATER PIPING General Instructions manual water control valve must be placed in the water inlet connection to the water heater before it is connected to the water line Unions may be used on both the hot and cold water lines for future servicing and disconnection of the unit The piping including soldering materials and components connected to this appliance must be approved for use in potable water systems Purge the water line to remove all debris and air Debris will damage the water heater Toxic chemicals such as those used for boiler water treatment are not to be introduced to the potable water used for space heating If the appliance will be used as a potable water source it must not be connected to a system that was previously used with a nonpotable water heating appliance Ensure that the water filter on the water heater is clean and installed See Flushing the Heat Exchanger Pressure Relief Valve An approved pressure relief valve is required by the American National Standard ANSI 221 10 3 Canadian Standard CSA 4 3 for all water heating systems The relief valve must comply with the standard for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems ANSI Z21 22 and or the standard Temperature Pressure Temperature and Pressure Relief Valves and Vacuum Relief Valves CAN1 4 4 The
22. 0 C by adjustment of a dip switch Set dip switch 5 to ON to obtain 140 F water temperature setting Set dip switch 5 to OFF default to obtain 120 F water temperature setting Figure 12 Temperature Ranges This water heater will attempt to provide hot water at the temperature setting even when the water flow is varied or when more than 1 tap is in use The water heater can deliver water at only one temperature setting at a time The available temperatures for a given model are provided below Table 8 moa Temperature Settings Available F 3o05Seres 98 100 102 104 1 108 115 120 126 130 135 140 505 Series 98 100 102 104 1 108 115 120 128 130 135 140 Temp inCelsus 37 3 40 4t 42 43 4e 4e 82 54 57 6o Re setting the Maximum Temperature Temperature settings from 125 140 F 52 60 C are available by setting dip switch 6 to ON in the SW1 bank of 8 dip switches Table 9 Suggested temperatures are These temperatures are suggestions only Kitchen 120 F 49 C A temperature lower than 98 F 37 C can be obtained Shower 98 110 F 37 43 C at the tap by mixing with cold water To change the temperature scale from Celsius to Fahrenheit or visa versa press and hold the On Off button for 5 seconds while the water heater is OFF Setting Controller to Mute To eliminate the beeps when
23. 88 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 USA 1 800 361 6665 Canada Para pedir servicio de reparaci n Au Canada pour service en francais a domicilio y para ordenar piezas 1 800 LE FOYER 1 888 SU HOGAR 1 800 533 6937 1 888 784 6427 S www sears ca Sears Registered Trademark Trademark Service Mark of Sears Brands LLC Marca Registrada Marca de F brica SM Marca de Servicio de Sears Brands LLC MC Marque de commerce VP Marque d pos e de Sears Brands LLC Sears Brands LLC 36 305 amp 505 Outdoor Manual
24. If the water heater is not of the gas type that the building is supplied with DO NOT connect the water heater Contact Sears for the proper unit to match the gas type Check the gas supply pressure immediately upstream at a location provided by the gas company Supplied gas pressure must be within the limits shown in the Specifications section Before placing the appliance in operation all joints including the heater must be checked for gas tightness by means of leak detector solution soap and water or an equivalent nonflammable solution as applicable Since some leak test solutions including soap and 305 amp 505 Outdoor Manual 11 Pipe Sizing Procedure Example The gas supply must be capable of handling the entire gas load at the location Gas line sizing is based on gas type the pressure drop in the system the gas pressure supplied and gas line type Refer to the National Fuel Gas Code NFPA 54 for proper gas line sizing The below information is provided as an example 1 Determine the cubic feet per hour of gas required by dividing the gas input on the rating plate by the heating value of the gas available from the local gas company The gas input needs to include all gas products at the location and the maximum BTU usage at full load when all gas products are in use Gas Input of the water heater BTU HR Cubic Feet per Hour CFH Heating Value of Gas BTU FT 2 Use the table for your gas type to find t
25. Owner s Manual Kenmore 305 and 505 Models Direct Vent Tankless Water Heaters FOR OUTDOOR APPLICATIONS ONLY MODEL NO 154 330040 154 330050 154 330080 154 330090 Natural Gas Propane Gas Natural Gas Propane Gas 305 Series 305 Series 505 Series 505 Series ENERGY STAR TEE 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 INSTALLER AFFIX THESE INSTRUCTIONS TO OR ADJACENT TO THE WATER HEATER OWNER RETAIN THESE INSTRUCTIONS AND WARRANTY FOR FUTURE REFERENCE RETAIN THE ORIGINAL RECEIPT AS PROOF OF PURCHASE oren Safety Instructions Installation Operation Care and Maintenance Troubleshooting For Your Safety AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS e Do nottry to light any appliance e Do not touch any electrical switch do not
26. Valve Supply Line 1 2 Minimum Normally Open N Solenoid Valve Route to Floor Drain This is not an engineered drawing it is intended only as a guide and not as a replacement for professionally engineered project drawings This drawing is not intended to describe a complete system It is up to the contractor engineer to determine the necessary components and configuration of the particular system being installed This drawing does not imply compliance with local building code requirements it is the responsibility of the contractor engineer to ensure installation is in accordance with all local building codes Confer with local building officials before installation 305 amp 505 Outdoor Manual 3 4 Ball Valve 3 4 Union Check Valve kK Pressure Relief Valve Figure 5 Recommended Piping for Basic Installation Water Heater 3 4 Hot Water Supply Line For Building Fixtures KEY 7 Pressure Regulator Circulating Pump KX Boiler Drain Valve Solenoid Valve Equipment List QTY Water Heaters 1 Plumbing Installation 1 Kit Optional 3 4 Fittings Include 2 Unions 2 Bali Valves 2 Drain Valves and 1 Pressure Relief Valve Gas Supply 3 4 Cold Water Sup This is not an engineered drawing It is intended only as a guide and not as a replacement for professionally engineered project drawings This drawing is not intended to describe a complete system It is up to the co
27. ad 50 delta T Temperature Rise F 75 100 305 amp 505 INSTALLATION INSTRUCTIONS Only properly trained and qualified installers should It is highly recommended that all installers attend a install this appliance The warranty may be voided due product knowledge class to improper installation or installation by a non qualified installer General Instructions 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 A WARNING in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leakage This Do not use substitute materials type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent pressure relief valve operation water discharged from the valve due 7 to excessive pressure build up The pressure relief valve is This appliance must be installed by a state qualified or not intended for the constant relief of thermal expansion licensed contractor It is the responsibility of the person This condition is not covered under the limited warranty having the water heater installed to ensure the installing A properly sized thermal expansion tank should be contractor has proper licenses and permits for installing installed on all closed systems to control the harmful water heaters in your location It is highly
28. changer surface for hot spots which indicate blockage due to scale buildup Refer to instructions in manual for flushing heat exchanger Measure resistance of safety circuit Ensure high fire and low fire manifold pressure is correct Check for improper conversion of product Check for restrictions in air flow around unit and vent terminal Check for low water flow in a circulating system causing short cycling Check for foreign materials in combustion chamber and or exhaust piping Check for clogged heat exchanger Check sensor wiring for damage Measure resistance of sensor Clean sensor of scale build up Replace sensor Check sensor wiring for damage Measure resistance of sensor Clean sensor of scale build up Replace sensor Check for restrictions in air flow around unit and vent terminal Check sensor wiring for damage Measure resistance of sensor Clean sensor of scale build up Ensure fan blade is tight on motor shaft and is in good condition Replace sensor Check modulating gas solenoid valve wiring harness for loose or damaged terminals Measure resistance of valve coil Ensure fan will turn freely Check wiring harness to motor for damaged and or loose connections Measure resistance of motor winding If blank screen is present on remote control then the flow control has shorted Unplug flow control If remote lights up and unit starts operating then replace flow control assembly Ensure flame rod is t
29. eT Te pe nexus 33 35 4 305 amp 505 Outdoor Manual PRODUCT WARRANTY 12 Year Limited Warranty on Heat Exchanger For 12 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 codes Sears will supply a free heat exchanger for one that develops a leak For the second through twelfth year from purchase date you must pay the labor cost for installation of the heat exchanger 5 Year Limited Warranty on Parts For 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 codes if a part fails due to material or workmanship Sears will supply a free replacement part 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 heat exchanger 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 the United States For Commercial institutional industrial or residential use by two or more families the above limited warranty for heat exchanger leaks is effective for five years from date of purchase and the above parts warranty is effective for three years from the date of purchase
30. ghtly depending on the temperature setting and the inlet water temperature o Specifications are subject to change without prior notice The maximum inlet gas pressure must not exceed the value specified by the manufacturer The minimum value listed is for the purpose of input adjustment 305 amp 505 Outdoor Manual 7 A B 4 Foe i j Ce gt QUI 0 DIM DESCRIPTION 305 Series 505 Series in mm in mm 5 en 98045 D __ Height with brackets 25464644 254 6464 Connection from wal 41 10 41 104 From base to gas connection K From base to cold connection From base to hot connection This is the minimum dimension from the wall The wall bracket is adjustable to allow an additional 1 57 inches 40 mm 8 305 amp 505 Outdoor Manual TECHNICAL DATA Pressure Drop Curve 45 40 100 90 35 80 30 70 25 60 50 20 15 40 30 10 Pressure Loss psi 20 10 Water Flow gpm eet ES E i 1 dates BIE a param a a emmen E EEE 1 t 1 1 t 1 4 1 1
31. he pipe size required for your cubic feet per hour of gas and your pipe length Example The heating value of natural gas for your location is 1020 BTU FT The gas input is 199 000 BTU HR Additional appliances at the location require 75 000 BTU HR Therefore the cubic feet per hour 199 000 75 000 1020 268 6 FT HR If the pipe length is 100 ft then the 1 inch pipe size capable of supplying 304 FT HR of natural gas will be adequate TABLE 2 Pipe Sizing Table Natural Gas Schedule 40 Metallic Pipe Inlet Pressure less than 2 psi 55 inches W C Pressure Drop 0 3 inches W C Specific Gravity 0 60 cubic feet per hour Pipe Size inches 34 1 14 1127 10 273 514 1060 1580 2 1 7 too 30 151 284 583 873 40 120 243 499 747 so ma 25 42 o 6 104 195 400 600 go s tor 54 _ 90 83 157 322 482 20 s 12 209 127 TABLE 3 Pipe Sizing Table Propane Gas Schedule 40 Metallic Pipe Inlet Pressure 11 inches W C Pressure Drop 0 5 inches W C Specific Gravity 1 50 cubic feet per hour Pipe Size inches 10 291 608 1150 2350 20 200 418 787 1620 4 137 287 54 mo 5 122 255 480 985 60 231 434 892 80 101 212 400 821 100 94 197 372 15 185 349 716 150 84 175 330 677 115 74 155 292 60
32. hree holes in the wall as shown 3 Run the cable between the controller and the water heater or the controller and the other controller 4 Remove the face plate from the temperature controller using a screwdriver 5 Connect the cable to the temperature controller 6 Mount the controller to the wall using the holes drilled in step 2 7 Disconnect the power from the water heater 8 Remove the cover of the water heater 9 Remove the plastic cover from the PCB and electrical connections 10 Thread the cable through the access hole at the base of the unit and connect the wires to the controller terminals on the right hand side bottom of the PCB 11 Secure the controller cable using the clamp provided 12 Replace plastic cover over PCB and then replace the cover of the water heater Outline of Controller securing screw wiring hole securing screw CONNECTION TERMINALS EE A 4 CONTROL CABLE Pm s 1 i I en ee 3 3 E 0 9 eG Oo ame ei A EZ esi 2 CABLE CLAMP Figure 10 305 amp 505 Outdoor Manual 21 DESCRIPTION OF OPERATION This appliance is one of the most advanced water opened and goes out when the
33. imum of 3 GPM flow is recommended for the circulation system A 3 4 Gas Connection The pump should be sized to overcome the E pressure loss through the water heater supply and return plumbing Pump to be of bronze or stainless construc Lo tion Gas Supply 24401 HG Note Water heater outlet temperature cannot be adjusted when circulation pump is running Minimum 3 4 Hot Water Supply Line Minimum 3 4 Cold Water Supply Line Optional 2 6 Gallon Storage Tank To eliminate cold water sandwich effect caused by frequent On Off operation Expansion Tank Building Fixture Outlets KEY This is not an engineered drawing It is intended only as a guide and not as a replacement for professionally engineered project drawings This u Y Pressure Regulator drawing is not intended to describe a complete system It is up to the 3 4 Ball Valve contractor engineer to determine the necessary components and 3 4 Union Circulating Pump configuration of the particular system being installed This drawing does Tet not imply compliance with local building code requirements it is the PNY Check Valve KX Boiler Drain Valve responsibility of the contractor engineer to ensure installation is in accordance with all local building codes Confer with local building K Pressure Relief Valve 8 Solenoid Valve officials before installation 305 amp 505 Outdoor Manual 17 VENTING INSTRUCTIONS
34. ing of 104 F 40 C if power is interrupted NOTICE There may be a variation between the temperature displayed on the temperature controller and the temperature at the tap due to weather conditions or the length of pipe to the water heater Table 7 Time to Produce 2nd amp 3rd Degree Burns on Adult Skin About 1 2 second 150 F 66 C About 1 1 2 second 140 F 60 C 130 F 54 C 120 F 49 C 80 F 27 en 1 Press the Priority button Temperature Settings 160 F 71 C on the temperature controller The green Priority light will glow indicating that this controller is controlling the temperature and that the water heater is ready to supply hot water The priority can only be changed while no hot water is running Press the A or V buttons to obtain the desired temperature setting Hot water temp All hot water sources are able to provide water at this temperature setting until it is changed again at this or another temperature controller 305 amp 505 Outdoor Manual 23 Temperature Options without a Temperature Controller A WARNING 120 F 49 C 140 F 60 C Do not adjust the other dip switches unless specifically instructed to do so The default temperature setting for this appliance installed without a remote controller is 120 F 49 C If desired the temperature setting can be changed 140 4 4 F 6
35. ing the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at the hot water taps used by these people or at the water heater Mixing valves are available at plumbing supply or hardware stores Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat 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 The thermostat on the water heater has been factory set at 120 F to reduce the risk of scald injury It is adjustable and can be reset to the desired temperature setting Some states have a requirement for a lower setting If you need hotter water follow direction for temperature adjustment but beware of the warnings in this section NOTICE While any hot water is being provided the temperature setting can only be adjusted between 98 F and 110 F NOTICE Check local codes for the maximum water temperature setting allowed when used in nursing homes schools day care centers and all other public applications NOTICE If a newly installed unit with a temperature controller has not been powered for at least 6 hours then the temperature will return to the default sett
36. ll is all that it takes for you to schedule service You can call anytime day or night or schedule a service appointment online 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 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 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 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 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 Sears Installation Service extra charge For Sears professional installation of home appliances garage door
37. ly drain the unit if power is lost It is also recommended that a surge protector with terminals be installed that attaches to the PC board in the unit and allows the solenoid valves to operate if the unit is disabled due to an error code When the electrical power to the water heater fails the 3 4 solenoid valve closes stopping the flow of water into the heater and the 1 2 solenoid valve opens allowing the water heater and associated piping to drain Ensure that you run the drain for the solenoids to the outside environment to prevent discharging water inside the building causing water damage 305 amp 505 Outdoor Manual 13 14 NOTE Figure 4 Freeze Protection Piping Drawing Heat trace heat tape ALL water pipe and fittings located outside home attic crawl space or building structure ALL water pipe and fittings shown above the dashed line in the drawing Vacuum Breaker Water Heater 3 4 Gas Connection Gas Supply NOTE ALL pipe and fittings shown be should be located inside home structure The vacuum breaker line shou inside the building structure 3 4 Ball Valve 3 4 Union P Check Valve K Pressure Relief Valve ow dashed line d be located Y Pressure Regulator O Circulating Pump KX Boiler Drain Valve E Solenoid Valve or building Minimum 3 4 Hot Water 3 4 Minimum Minimum 3 4 Supply Line Normally Closed Cold Water Solenoid
38. nd 248 CMR 5 00 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 instructions labels orthe 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 305 amp 505 Outdoor Manual PRODUCT SPECIFICATIONS 305 Models 505 Models MODEL 154 330040 amp 154 330050 154 330080 amp 154 330090 Minimum gas consumption btu h 15 000 199 000 Natural Gas Maximum gas consumption btu h 180 000 Natural Gas 180 000 Propane Gas 199 000 Propane Gas Hot water capacity Min Max 0 6 7 5 GPM 0 6 9 4 GPM 2 3 28 4 L min 2 3 35 5 L MIN Hot water capacity 45 F rise 6 6 GPM 25 0 L min 7 4 GPM 28 0 L min Default Temperature Setting no controller 120 F 49 Temperature Controller Default Temperature 104 F 40 C Setting Selectable at 120 F 49 C or at 140 F 60 C 39 FC 18 b 209 Electrical Consumption 2 0 W Minimum Gas 5 0 inch W C Supply Pressure 8 0 inch W C Maximum Gas 10 5 inch W C Supply Pressure 13 5 inch W C Minimum flow may vary sli
39. nsure condensation collar was installed properly Ensure vent length is within limits Verify dip switches are set properly Ensure appliance is properly grounded Disconnect keypad Disconnect all 2 Unit or Multi Unit connections to isolate the problem Check power supply for loose connections Check power supply for proper voltage and voltage drops Ensure flame rod wire is connected Check flame rod for carbon build up Disconnect and reconnect all wiring harnesses on unit and PC board Check all components for electrical short Check gas solenoid valves for open or short circuits Remove bumer plate and inspect burner surface for condensation or debris 305 amp 505 Outdoor Manual 27 Thermal Fuse Over Temperature Warning Outgoing Water Temperature Sensor Heat Exchanger Outgoing Temperature Sensor Fault Combustion Air Temperature Sensor Modulating Solenoid Valve Signal Abnormal Scale Build up in Heat Exchanger when checking maintenance code history 00 is substituted for LC Nothing happens when water flow is activated Check gas type of unit and ensure it matches gas type being used Check for restrictions in air flow around unit and vent terminal Check for low water flow in a circulating system causing short cycling Ensure dip switches are set to the proper position Check for foreign materials in combustion chamber and or exhaust piping Check heat exchanger for cracks and or separations Check heat ex
40. ntractor engineer to determine the necessary components and configuration of the particular system being installed This drawing does not imply compliance with local building code requirements it is the responsibility of the contractor engineer to ensure installation is in accordance with all local building codes Confer with local building officials before installation 305 amp 505 Outdoor Manual 16 Figure 6 Recommended Piping for Circulation Systems NOTE Applications using this piping arrangement maintains full warranty For this application Pump should be controlled by an Aqua stat Timer or Combination Aquastat and Timer Pump to be sized to maintain circulation loop temperature The pump should be sized to overcome the pressure loss through the tank water heater and supply and return plumbing Pump to be of bronze or stainless construction IMPORTANT Connect the building return line to the hot water supply line as close as possible to the water heater ioi 3 4 Ball Valve Water Heater Eisen Water Heaters 1 Plumbing Installation 1 Kit Optional 3 4 Fittings Include 2 Unions 2 Ball Valves 2 Drain Valves and 1 Pressure Relief Valve af 3 4 Gas Connection Gas Supply Minimum 3 4 Cold Water Supply Line I Tank Water Heater to be Sized for Heat Loss of Circulation Loop Building Supply Electric Water Heater Building Fixtures Expansion Tank
41. ny of the holes in the wall installation brackets which are at the top and bottom of the water heater Ensure that the attachment strength is sufficient to support the DA weight Refer to the weight of the water heater in the Specifications section Figure 3 GAS SUPPLY General Instructions Black Hot White Neutral GROUND TERMINAL water may cause corrosion or stress cracking the piping shall be rinsed with water after testing unless it has been determined that the leak test solution is non corrosive Always use approved connectors to connect the unit to the gas line Always purge the gas line of any debris before connection to the water heater The gas supply line shall be gas tight sized and so installed as to provide a supply of gas sufficient to meet the maximum demand of the heater and all other gas consuming appliances at the location without loss of pressure Any compound used on the threaded joint of the gas piping shall be a type which resists the action of liquefied petroleum gas propane LPG Referto an approved pipe sizing chart if in doubt about the size of the gas line A manual gas control valve must be placed in the gas supply line to the water heater A union can be used on the connection above the shut off valve for the future servicing or disconnection of the unit Checkthe type of gas and the gas inlet pressure before connecting the water heater
42. ocedure Flushing the Heat Exchanger Refer to the section on Water Quality to see if your water needs to be treated or conditioned When checking maintenance code history 00 is substituted for LC Snow Accumulation Keep the area around flue terminal free of snow and ice The appliance will not function properly if the intake air or exhaust is impeded blocked or partially blocked by obstructions Visual Inspection of Flame The burner must flame evenly over the entire surface when operating correctly The flame must burn with a clear blue stable flame See the parts breakdown of the burner for the location of the view ports The flame pattern should be as shown in the figures below FRONT VIEW SATISFACTORY BLUE FLAME FLAME ROD UNSATISFACTORY FRONT VIEW YELLOW FLAME FLAME ROD Figure 13 26 305 amp 505 Outdoor Manual TROUBLESHOOTING This appliance has the ability to check its own operation continuously If a fault occurs an error code will flash 0 WARN NG on the Display of the temperature controller This assists with diagnosing the fault and may enable you Some of the checks below may need to be done by a to overcome a problem without a service call Please qualified service technician Call a service technician for any identify the code displayed when inquiring about service remedy that involves gas or electricity Call a service technician if you have any doubt or reservation abo
43. or solder connection to water supply and distribution piping Kit includes 2 Unions 2 Ball Valves 2 Drain Valves and 1 Pressure Relief Valve 9006487005 3 4 Fittings for threaded connection to water supply and distribution piping Kit includes 2 Unions 2 Ball Valves 2 Drain Valves and 1 Pressure Relief Valve 9006490005 2 Unit Connection Cable 9006491005 Multi Unit Connection Kit 9006492005 Multi Unit Connection Cable 9006493005 Recess Box for installing water heater between wall studs 32 305 amp 505 Outdoor Manual NOTES 305 amp 505 Outdoor Manual 33 NOTES 34 305 amp 505 Outdoor Manual NOTES 305 amp 505 Outdoor Manual 35 Your Home For expert troubleshooting and home solutions advice manage ji home www managemyhome 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 4
44. ouching flame when unit fires Check all wiring to flame rod for damage Remove flame rod and check for carbon build up clean with sand paper Check inside burner chamber for any foreign material blocking flame at flame rod Measure micro amp output of sensor circuit with flame present Replace flame rod Flush heat exchanger See Flushing the Heat Exchanger section Clean inlet water supply filter On new installations ensure hot and cold water lines are not reversed Check for bleed over Isolate unit from building by turning off hot water line to building Isolate the circulating system if present Open your pressure relief valve if water is flowing there is bleed over in your plumbing Ensure you have at least the minimum flow rate required to fire unit Ensure turbine spins freely Measure the resistance of the water flow control sensor Check for DC shorts at components 305 amp 505 Outdoor Manual Troubleshooting for Common Issue don t have any hot water when I open the tap Make sure there is gas water and electricity to the water heater power is turned on and the gas is turned on When I was using the hot water the water got cold If you adjusted the flow from the tap to lessen it you may have gone below the minimum flow required This water heater requires a minimum flow rate to operate See the specification page for the flow rate of your model Decrease the temperature setting at the temperat
45. s control which has been under water a OPERATING INSTRUCTIONS STOP Read the safety information above Set the thermostat to lowest setting Turn off all electric power to the appliance using the ON OFF button This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Locate the manual gas valve on the side of the heater Turn the manual valve clockwise to the full OFF position _Manual Valve CLOSE VA 6 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above If you don t smell gas go to the next step Turn the manual gas valve counterclockwise to the full ON position Turn on all electric power to the appliance using the ON OFF button Set the thermostat to desired setting Open a hot water tap If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier See manual for additional information TO TURN OFF GAS TO APPLIANCE 1 Turn off all electric power to the appliance using the ON OFF button 2 Set the thermostat to lowest setting 3 Locate the manual gas vae on the side of ihe heater Turn the manual val
46. stallation must conform with these instructions and the local code authority having jurisdiction In the absence of local codes installations shall comply with the following In the United States The National Fuel Gas Code ANSI Z223 1 NFPA 54 This publication is available from the Canadian Standards Association 8501 East Pleasant Valley Rd Cleveland Ohio 44131 or The National Fire Protection Association 1 Batterymarch Park Quincy MA 02269 f after reading this manual you have any questions or do not understand any portion of the instructions call the Sears Service Center Carefully plan the place where you are going to put the water heater Correct combustion vent action and vent pipe installation are very important in preventing death from possible carbon monoxide poisoning and fires 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 a
47. tall in locations where it can be adjusted by the public Configurations A maximum of 4 temperature controllers can be installed for a water heater or bank of water heaters Controllers can only be wired in parallel Controllers cannot be wired in series If 4 temperature controllers are installed simultaneously press the Priority and On Off buttons on the fourth controller until a beep sounds Controllers Water Heater Wire controllers in parallel Figure 9 Cable Length and Size The cable for the temperature controller should be a non polarized two core cable with a minimum gauge of 22 AWG The maximum cable length from each controller to the water heater depends on the total number of wired controllers connected to the water heater Table 6 Number of Wired Maximum Cable Length for each Controllers Controller to Water Heater 328 ft 100 m 164 ft 50 m 65 ft 20 m Mounting the Controller WARNING Do not attempt to connect the temperature controllers with the power on There is 120 volt potential next to the temperature controller connections inside the unit Do not connect the temperature controller to the 120VAC terminals provided for the optional solenoid drain valves All service and wiring should be performed by a registered installer Follow the procedure below to install additional controllers 1 Determine a suitable location for the controller 2 Make t
48. tap is closed Installation heaters available It provides a continuous supply of of the temperature controller is highly recommended hot water at a preset temperature This appliance is The temperature controller can set the temperature direct vent where air is brought in from the outside and within a specific range and can provide error codes to combustion gases are exhausted to the outside diagnose any problems While electricity water and gas supplies are connected The temperature of the outgoing hot water is constantly this appliance produces hot water whenever a hot water monitored This appliance may adjust the water flow tap is open in order to maintain the temperature setting The Ignition is electronic There is no pilot light consuming water flow may vary from summer to winter due to the gas while the water heater is not being used The gas difference in ground water temperature burner lights automatically when the hot water tap is OPERATING INSTRUCTIONS Sequence of Operation Features Available on Temperature Controllers 1 Water Flow Begins The temperature controller is supplied with the Water Flow Sensor sends a pulse to the electronic appliance Dimensions inches 3 5 W x 4 75 H x 0 75 D control board Electronic control board senses flow greater than 0 6 GPM i iri i FIC Firing Sequence begins Temperature Ian 2 Firing Sequence Display JOU Approx Water Temp In Use Indicator Priority
49. tection features include electrical heating elements and intermittent firing of the burner Freeze protection may be disabled if electricity or gas is not supplied or if there is an error preventing the water heater from functioning Loss of freeze protection may result in water damage from a burst heat exchanger or water lines The installation of auto drain down solenoid valves is optional However it is strongly recommended that these valves be installed to prevent damage from freezing in case the normal freeze protection should become disabled Any product damage due to freezing will not be covered by the warranty In addition the solenoid valves should be connected electrically to a surge protector with terminals that attaches to the PC board in the unit This allows the solenoid valves to operate if the water heater is disabled due to an error code The solenoid valves and the surge protector with terminals are available for purchase separately NOTICE Warranty does not cover damage due to freezing When electrical power and gas are supplied to the water heater it will not freeze in environments as cold as 30 F when protected from direct wind exposure In the event of a power failure at temperatures below freezing the water heater should be drained of all water to prevent freezing damage The unit may be drained manually However it is highly recommended that drain down solenoid valves be installed that will automatical
50. ter lines 8 Operate the pump and allow the cleaning solution to circulate through the water heater for at least 45 minutes 9 Turn off the pump a Rinse the cleaning solution from the water H3 old Water Line heater as follows a Remove the free end of the drain hose H3 from the pail b Close service valve V2 and open shutoff Hot Water Line valve V4 Do not open shutoff valve V3 Circulating Pump c Allow water to flow through the water heater for 5 minutes H2 d Close service valve V1 and open shutoff valve V3 5 gallon pail of 10 Disconnect all hoses virgin food grade white vinegar or virgin food grade citric acid 11 Remove the in line filter at the cold water inlet and clean out any residue Place filter back into unit 13 Restore electrical power to the water heater KEY 3 4 Ball Valve n Pressure Regulator 3 4 Union O Circulating Pump J Check Valve KX Boiler Drain Valve K Pressure Relief Valve A Solenoid Valve Figure 14 30 305 amp 505 Outdoor Manual FROST SENSING 3A FUSE SWITCH ARRESTER VARISTOR WATER FLOW SENSOR WATER FLOW SENSOR os CIRCUIT WATERFLOW CONTROLDEVICE BY PASS FLOW CONTROL DEVICE 69 BY PASS FLOW GON ROL DEVICE SO RELAY DRIVING CIRCUIT PASS SERVO MODEL ONLY OUTGOING WATER KAS THERMISTOR HEAT EXCHANGER STOR THERMISTOR INDOOR MODEL
51. tion locations near commercial cooking exhaust 0 30 m to an inside corner 50 mm between water heater terminals at same level INSIDE CORNER Figure 8 305 amp 505 Outdoor Manual HIGH ALTITUDE INSTALLATIONS Set dip switches 2 and 3 to the values shown in table below for your altitude The default setting for the appliance is 0 2000 ft 0 610 m with switches No 2 and A WARNING No 3 in the OFF position 1 7 DO NOT adjust the other dip switches unless specifically instructed to do so 0 2000 ft 2001 5200 ft 5201 7700 ft 7701 10200 ft Table 4 0 610 610 1585 m 1585 2377 m 2378 3109 m Switch No Switch No Switch No Switch No ON ON ON ON 0 F F ON WN gt ON OO N OO WD O WN gt CONNECTING MULTIPLE HEATERS The 2 Unit connection cable is an optional accessory Guidelines that connects 2 water heaters and allows them to HOF water source Do not install both the 2 Unit connection cable and the Multi Unit connection kit because they are not designed The Multi Unit connection kit and Multi Unit connection to operate together cables are optional accessories that connect
52. ton press the On Off button Water Quality Consideration of care for your water heater should include evaluation of water quality If the water quality exceeds the target levels provided in the table you may want to treat or condition the water Source Part 143 National Secondary Drinking Water Regulations O Maximum Level Chlorides Up to 10 mg L Up to 0 3 mg L Up to 0 05 mg L 651065 TDS Total Dissolved Up to 500 mg L Solids Up to 5 mg L 305 amp 505 Outdoor Manual 29 Flushing the Heat Exchanger Error Code LC or 00 An LC or 00 error code indicates the unit is beginning to lime up and must be flushed Failure to flush the appliance will cause damage to the heat exchanger Damage caused by lime build up is not covered by the units warranty After flushing reset the LC fault code by turning off the power to the unit and turning the power back on Water Heater Disconnect electrical power to the water heater 2 Close the shutoff valves on both the hot water and cold water lines V3 and V4 3 Connect pump outlet hose H1 to the cold water line at service valve V2 Connect drain hose H3 to service valve V1 Pour approximately 4 gallons of virgin food grade white vinegar or citric acid into pail 6 Place the drain hose H3 and the hose H2 to the pump inlet into the cleaning solution 7 Open both service valves V1 and V2 on the hot water and cold wa
53. ure controller or increase the water flow White smoke comes out of the exhaust During colder weather when the exhaust temperature is much hotter than the outside air the exhaust fumes condense producing water vapor When I open a hot tap do not immediately get hot water Hot water must travel through your plumbing from the water heater to the faucet The time period for hot water to reach your fixture is determined by the amount of water in the plumbing system between the water heater and the fixture water pressure and the flow rate of the fixture After turn off the hot water tap the fan on the water heater continues to run The fan is designed to continue running for a short time after the flow of water stops This is to ensure constant water temperatures during rapid starting and stopping as well as exhausting any residual gas flue products from the unit Accessing Operating Information To display the most recent error codes press and hold the On Off button for 2 seconds While holding the Off button press the A button The last 9 error codes will flash one after the other To exit this mode press the On Off and A button as before To display the water flow through the water heater press and hold the A button for 2 seconds and without releasing the A button press the On Off button To display the outlet water temperature press and hold the V button for 2 seconds and without releasing the V but
54. ut performing the remedy yourself Table 10 Error Codes Fault No burner operation freeze Service Call Check for possible freeze damage to heat exchanger mode Air Supply or Exhaust Blockage Ensure approved venting materials are being used Check that nothing is blocking the flue inlet or exhaust Check all vent components for proper connections Ensure vent length is within limits Ensure condensation collar was installed correctly Verify dip switches are set properly Check fan for blockage No Ignition Check that the gas is turned on at the water heater gas meter or cylinder Ensure gas type and pressure is correct Ensure gas line meter and or regulator is sized properly Bleed all air from gas lines Verify dip switches are set properly Ensure appliance is properly grounded Disconnect all 2 Unit or Multi Unit connections to isolate the problem Ensure igniter is operational Check igniter wiring harness for damage Check gas solenoid valves for open or short circuits Remove burner cover and ensure all burners are properly seated Remove burner plate and inspect burner surface for condensation or debris Flame Failure Check that the gas is turned on at the water heater and gas meter Check for obstructions in the flue outlet Ensure gas line meter and or regulator is sized properly Ensure gas type and pressure is correct Bleed all air from gas lines Ensure proper venting material was installed E
55. ve clockwise to the full OFF position 7N 305 amp 505 Outdoor Manual 25 MAINTENANCE A WARNING Turn off the electrical power supply the manual gas valve and the manual water control valve whenever servicing the unit Repairs and maintenance should be performed by a qualified service technician The appliance should be inspected annually by a qualified service technician Verify proper operation after servicing Cleaning It is imperative that control compartments burners and circulating air passageways of the appliance be kept clean Clean as follows 1 Turn off and disconnect electrical power Allow to cool Remove and clean the water inlet filter d Remove the front panel by removing 4 screws Use pressurized air to remove dust from the main burner heat exchanger and fan blades Do not use a wet cloth or spray cleaners on the burner Do not use volatile substances such as benzene and thinners They may ignite or fade the paint 5 Use soft dry cloth to wipe cabinet Vent System The vent system should be inspected at least annually for blockages or damage Motors Motors are permanently lubricated and do not need periodic lubrication Keep fan and motor free of dust and dirt by cleaning annually Temperature Controller Use a soft damp cloth to clean the temperature controller Do not use solvents Lime Scale Build up If you receive Error Code LC refer to the pr
56. y 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 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 FIRE AND EXPLOSION HAZARD Can result in serious injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Storage of or use of gasoline or other flammable vapors or liquids in the Flammable Vapors vicinity of this or any other appliance can result in serious injury or death Read and follow water heater warnings and instructions Sears Roebuck and Co 2 305 amp 505 Outdoor Manual Safety Behavior and Practices Keep the area around the appliance clear and free from combustible materials gasoline and other flammable vapors and liquids Do not use this appliance if any part has been under

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