Use & Care Guide Model No. 153.331620 153.331630 153.331640 153.331651 153.331661 153.331670 153.331682 153.331690 30 Gallon Short 30 Gallon 30 Gallon (L.P.) 40 Gallon Short 40 Gallon 40 Gallon (L.P.) 50 Gallon 50 Gallon (L.P.) LOW LEAD COMPLIANT Kenmore Gas Water Heater ® For potable water heating only. Not suitable for space heating. Not for use in mobile homes. INSTALLER: Affix these instructions to or near the water heater. OWNER: Retain these instructions for future reference.
SAFE INSTALLATION, USE AND SERVICE Your safety and the safety of others is extremely important in the installation, use and servicing of this water heater. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual.
Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Avoid all ignition sources if you smell Natural or LP gas. Do not expose water heater control to excessive gas pressure. Use only gas shown on rating plate. Maintain required clearances to combustibles. Keep ignition sources away from faucets after extended period of non-use. Read instruction manual before installing, using or servicing water heater.
TABLE OF CONTENTS SAFE INSTALLATION, USE AND SERVICE ................................................................................................. 2 SAFETY PRECAUTIONS ........................................................................................................................... 2-3 PRODUCT WARRANTY ................................................................................................................................ 6 CUSTOMER RESPONSIBILITIES ......................................
OPERATING YOUR WATER HEATER ................................................................................................... 23-26 Lighting Instructions ........................................................................................................................................... 23-24 Checking the Draft .................................................................................................................................................. 25 Burner Flames ...........................
PRODUCT WARRANTY 6 - YEAR LIMITED WARRANTY ON WATER HEATER For six years from the date of purchase, if this water heater is installed and operated in a single-family home in accordance with the owner’s manual instructions and all local applicable plumbing codes, Sears will: 1. 2. Supply free water heater parts for those that are defective in material or workmanship. Supply a free water heater for one that develops a leak. See notes below also.
CUSTOMER RESPONSIBILITIES • Massachusetts Code requires this water heater to be installed in 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. accordance with Massachusetts 248-CMR 2.00: State Plumbing Code and 248-CMR 5.00.
PRODUCT SPECIFICATIONS MODEL NUMBER TANK CAPACITY IN GALS (LTRS) TYPE OF GAS INPUT RATE (Btu/hr) RECOVERY RATE GALS. PER HOUR @ 90°F RISE MINIMUM VENT PIPE DIA. INCHES (mm) DIAMETER INCHES (mm) DIMENSIONS INCHES (mm) HEIGHT TO JACKET TOP 153.331620 30 (114) Natural 35,500 36.34 3 (76) or 4 (102) 18 (457) 46.38 (1178) 153.331630 30 (114) Natural 35,500 36.34 3 (76) or 4 (102) 16 (406) 58.00 (1473) 153.331640 30 (114) Propane (L.P.) 32,000 32.75 3 (76) or 4 (102) 16 (406) 58.
MATERIALS AND BASIC TOOLS NEEDED MATERIALS NEEDED To simplify the installation Sears has available the installation parts shown below. You may or may not need all of these materials, depending on your type of installation. EXPANSION TANKS FOR THERMAL EXPANSION CONDITIONS AVAILABLE IN 2 GALLONS (7.6 LITERS) AND 5 GALLONS (18.9 LITERS) CAPACITY THROUGH LOCAL SEARS STORE OR SERVICE CENTER. WAT E R H E AT E R I N S TA L L AT I O N K I T WITH FLEXIBLE CONNECTORS FOR 3/4” (19.
TYPICAL INSTALLATION GET TO KNOW YOUR WATER HEATER - GAS MODELS A B C D E F G H I Vent Pipe Draft Hood Anode (Not Shown) Hot Water Outlet Insulation Gas Supply Piping Manual Gas Shut-off Valve Ground Joint Union Drip Leg (Sediment Trap) J K L M N O P Q R Inner Door Outer Door Union Inlet Water Shut-off Valve Cold Water Inlet Inlet Dip Tube Temperature-Pressure Relief Valve Rating Plate Flue Baffle S T U V W X Y Gas Control Valve/Thermostat Drain Valve Manifold/Burner Assembly Flue Metal Drain Pan Piezo
IMPORTANT INFORMATION ABOUT THIS WATER HEATER This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. The new technology used in meeting these standards makes this product more sensitive to installation errors. Please review the following checklist and make any required installation upgrades or changes. Questions? Contact Sears at 1-800-4-MY-HOME (1-800-469-4663).
INSTALLATION INSTRUCTIONS Removing the Old Water Heater 4. 5 2 6 1 MANUAL GAS SHUT-OFF VALVE GROUND JOINT UNION FIGURE 5. DISCHARGE PIPE (DO NOT CAP OR PLUG) CHECK WITH LOCAL UTILITY FOR MINIMUM HEIGHT 5. Disconnect the vent pipe from the draft hood where it connects to the water heater. In most installations the vent pipe can be lifted off after any screw or other attached devices are removed. Dispose of the draft hood. The new water heater has a draft hood which must be used for proper operation.
Location Requirements area of the water heater, leave the area immediately and call the fire department from a neighbor’s home. Do not attempt to clean the spill until all ignition sources have been extinguished. WARNING WARNING Carbon Monoxide Poisoning Hazard Fire or Explosion Hazard Do not install in a mobile home. • Read instruction manual before installing, using or servicing water heater. Doing so can result in carbon monoxide poisoning and death.
Insulation Blankets Insulation blankets available to the general public for external use on gas water heaters are not necessary with Kenmore products. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. Your Kenmore water heater meets or exceeds the National Appliance Energy Conservation Act standards with respect to insulation and standby loss requirements, making an insulation blanket unnecessary.
VENT BACK • Open the cold water supply valve to the water heater. NOTE: The cold water supply valve must be left open when the water heater is in use. • To ensure complete filling of the tank, allow air to exit by opening the nearest hot water faucet. Allow water to run until a constant flow is obtained. This will let air out of the water heater and the piping. • Check all water piping and connections for leaks. Repair as needed.
Gas Pressure the fuel is not spilled in the area of the water heater installation, or any source of ignition. If the fuel is spilled while purging the piping system of air follow the “WHAT TO DO IF YOU SMELL GAS” instructions on the cover of this manual. WARNING LP Gas Only WARNING Explosion Hazard • Gas leaks can not always be detected by smell. • Gas suppliers recommend that you use a gas detector approved by UL or CSA. • For more information, contact your gas supplier.
COMBUSTION AIR SUPPLY & VENTILATION WARNING TABLE 3 Carbon Monoxide Warning Follow all the local and state codes or, in the absence of local and state codes, the “National Fuel Gas Code”, ANSI Z223.1 (NFPA 54)- current edition to properly install vent system. 120,000 750 25 x 30 135,000 844 28 x 30 IMPORTANT: Failure to do so can result in death, explosion, or carbon monoxide poisoning. IMPORTANT: Air for combustion and ventilation must not come from a corrosive atmosphere.
gas utilization equipment in the area. If you are unsure that the structure meets this requirement, contact your local gas utility company or other qualified agency for a safety inspection. Each of the two openings shall have a minimum free area of 1 square inch per 1,000 BTUH of the total input rating of all gas utilization equipment in the confined area, but not less than 100 square inches (Figure 13).
using the manufacturer’s instructions and local codes, rules, or regulations. IMPORTANT: If you lack the necessary skills required to properly install this venting system, you should not proceed, but get help from a qualified technician. 1 SQ. INCH PER 2000 BTUH OUTLET CONFINED SPACE Draft Hood Installation OUTDOOR AIR DUCTS SHEET METAL SCREWS (FOUR PROVIDED) INLET DRAFT HOOD LEGS LEGS 1 SQ.
• • inspection, and replacement. Vent connectors cannot pass through any ceiling, floor, firewall, or fire partition. It is recommended (but not mandatory) that a minimum 12 inches of vertical vent pipe be installed on the draft hood prior to any elbow in the vent system. (Figures 20 and 21). IMPORTANT: This gas vent must be terminated in a vertical position to facilitate the removal of the burnt gases.
WATER SYSTEM PIPING Piping Installation Piping, fittings, and valves should be installed according to the installation drawing (Figure 22). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation. Hot Water Outlet Union IMPORTANT: Heat cannot be applied to the water fittings on the heater as they may contain nonmetallic parts.
Closed System/Thermal Expansion For protection against excessive pressures and temperatures, a temperature and pressure relief valve must be installed in the opening marked “T & P RELIEF VALVE.” (See Figure 24). This valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of listed equipment or materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22.
c o m OPERATING YOUR WATER HEATER 3. Click the Igniter button continuously for up to 90 seconds or until the Status Light begins to blink for 90 seconds. If the Status Light does not begin to blink after 90 seconds, STOP. Wait 10 minutes before attempting to relight the Pilot. Repeat these steps 2-3 times if necessary. . Failure to do so can result in death, explosion or fire. look through the sight glass while clicking the Igniter button and look for a spark.
FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. FLAMMABLE BEFORE LIGHTING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES A. This appliance has a pilot which is lit by a piezo- If you cannot reach your gas supplier, call the fire department. C.Use only your hand to push in or turn the gas control B.
Checking the Draft Water Temperature Regulation WARNING Water temperature over 125°F (52°C) can cause servere burns instantly resulting in severe injury or death. Burn Hazard Children, the elderly, and the physically or mentally disabled are at highest risk for scald injury. Do not touch vent. Feel water before bathing or showering. Doing so can result in burns. Temperature limiting valves are available. Read instruction manual for safe temperature setting.
Water Temperature Adjustment Gas Control/Temperature Knob The water temperature setting can be adjusted from 55°F to 155°F. Turn the Gas Control/Temperature Knob to the desired setting/temperature. 120°F Status Mark Light NOTE: Some models are certified for 180°F outlet temperatures. See the Data Plate on the front of the water heater for the maximum outlet temperature. VAC NOTE: The temperatures indicated are approximates. The actual temperature of the heated water may vary.
SERVICE AND ADJUSTMENT Vent System Inspection At least once a year, a visual inspection should be made of the main burner and pilot burner. See Figure 30. You should check for sooting. Soot is not normal and will impair proper combustion. Soot build-up indicates a problem that requires correction before further use. Turn “OFF” gas to water heater and leave off until repairs are made, because failure to correct the cause of the sooting can result in a fire causing death, serious injury, or property damage.
Housekeeping indicates high water conductivity and should be checked and/or replaced more often than an anode rod that appears to be intact. Replacement of a depleted anode rod can extend the life of your water heater. Inspection should be conducted by calling the Sears Service Center for an authorized contractor. The anode rod should be inspected after a maximum of three years and annually thereafter until the condition of the anode rod dictates its replacement.
operation. The water heater should be drained if being shut down during freezing temperatures. To drain the tank, perform the following steps: If the water heater is going to be shut down for an extended period, the drain valve should be left open. IMPORTANT: Condensation may occur when refilling the tank and should not be confused with a tank leak. 1. Turn off the gas to the water heater at the manual gas shut-off valve. 2. Open a nearby hot water faucet until the water is no longer hot. 3.
MAINTENANCE OF YOUR WATER HEATER Replacement Parts GAS CONTROL VALVE/THERMOSTAT GAS CONTROL/ TEMPERATURE KNOB IMPORTANT: The following maintenance procedures are for the FVIR System components and should be performed by a qualified technician. Replacement parts may be ordered from Sears Parts and Service Centers or by calling 1-800-4-MY-HOME (1-800-4694663). When ordering replacement parts, always have the following information ready: 1. model, serial, and product number 2. type of gas 3. item number 4.
as a bending template for the new pilot assembly. Note the placement/order of the wires in the manifold component block. Thermopile Connector Using the pilot/thermopile assembly screw removed earlier reattach the new pilot/thermopile assembly. Reattach the burner to the manifold using the screws removed earlier. NOTE: make sure the burner scoop is oriented to the pilot side of the manifold tube (Figure 35). 9. Reinstall the manifold component block in the manifold door (Figure 38). 10.
Replacing the Manifold/Burner Assembly 10. Follow the lighting instructions on the front of the water heater. With the main burner lit, check for leaks at the manifold and pilot connections by brushing on an approved noncorrosive leak detection solution, or a mixture of hand dish washing soap and water (one part soap to 15 parts water) or childrens soap bubble solution. Bubbles forming indicate a leak. Correct any leak found. Verify proper operation and then replace the outer door.
Removing and Replacing the Gas Control Valve/Thermostat IMPORTANT: The gas control valve/thermostat is a standard valve with wire leads that connect to a thermal switch. • Be sure to remove the pilot ferrule nut from the new gas control valve/thermostat. Removing the Gas Control Valve/Thermostat: • Turn the gas supply on and check for leaks.
TROUBLESHOOTING GUIDE NOTE: Expansion tanks are pre-charged with a 40 psi air charge. If the inlet water pressure is higher than 40 psi, the expansion tank’s air pressure must be adjusted to match that pressure, but must not be higher than 80 psi. Start Up Conditions Thermal Expansion As water is heated, it expands (thermal expansion). In a closed system, the volume of water will grow. As the volume of water grows, there will be a corresponding increase in water pressure due to thermal expansion.
Condensation hot water lines. Contact Sears Service for further information concerning this chlorination treatment and an anode replacement kit #9001453. (For short heaters, use anode replacement kit #9006299.) Anode replacement and chlorination of the tank are not covered by the water heater’s limited warranty. Whenever the water heater is filled with cold water, some condensate will form while the burner is on. A water heater may appear to be leaking when in fact the water is condensation.
appliance. Immediately call a qualified technician to inspect the appliance. Water heaters subjected to a flammable vapors ignition will require replacement of the entire water heater. Read this manual first. Then, before checking the water heater, make sure the gas supply has been turned “OFF”, and never turn the gas “ON” before the tank is completely full of water. 3. Reset the thermal switch by depressing the small button in the center of the thermal switch.
TROUBLESHOOTING CHART PROBLEM BURNER WILL NOT IGNITE POSSIBLE CAUSE(S) 1. 2. 3. 4. Pilot not lit Thermostat set too low Main burner line clogged Non-functioning thermostat 5. Base-Ring Filter blocked with lint/dust CORRECTIVE ACTION 1. 2. 3. 4. 6. 7. 5. Heater installed in a confined area FVIR Flame Arrestor blocked with lint/ 6. dust. 7. SMELLY WATER 1. Sulfides in the water BURNER FLAME YELLOWLAZY 1. 2. 3. Insufficient combustion air 1. Low gas pressure 2. Water heater flue or vent system 3.
TROUBLESHOOTING CHART (CONTINUED) PROBLEM SLOW HOT WATER RECOVERY POSSIBLE CAUSE(S) CORRECTIVE ACTION 1. Insufficient combustion air 1. 2. Water heater flue or vent system blocked Low gas pressure Improper calibration Base-Ring Filter blocked with lint/dust 2. 3. 4. 5. 3. 4. 5. Provide ventilation to water heater.
STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART LED STATUS 0 FLASHES (LED NOT LIT) PROBLEM CORRECTIVE ACTION Pilot light is not lit or Thermopile Turn Gas Control Valve/Thermostat knob to OFF. has not yet reached normal Wait 10 minutes, then attempt to relight Pilot by operating temperature. following the lighting instructions on the water heater’s label. Until the Thermopile reaches its normal operating temperature, the Status Light will not blink, even if the Pilot is lit.
STATUS LIGHT AND DIAGNOSTIC CODE TROUBLESHOOTING CHART PROBLEM CORRECTIVE ACTION 4 FLASHES LED STATUS The Gas Control Valve’s temperature sensor has detected that the water temperature was too high. Once this condition occurs, the Main Burner and the Pilot Light will be shut off. Since the Pilot light will be off, should this condition occur, this Flash Code will only be displayed immediately after the Pilot has been relit. Turn Gas Control Valve/Thermostat knob to OFF.
PILOT LIGHT TROUBLESHOOTING FLOWCHART Section A: Pilot light will not light (new installation). Section C: Pilot light will not remain lit. Complete this section after completing Section B.
PARTS ORDER LIST 5 KENMORE 6 YEAR GAS WATER HEATER 12 12 MODEL NUMBERS 153.331620 30 Gallon Short (Natural) 153.331630 30 Gallon Tall (Natural) 153.331651 40 Gallon Short (Natural) 153.331661 40 Gallon Tall (Natural) 153.331682 50 Gallon Tall (Natural) 8 1 15 3 7 14 4 9 2 6 17 13 11 Model Numbers Key No.
PARTS ORDER LIST 5 KENMORE 6 YEAR GAS WATER HEATER 12 12 MODEL NUMBERS 153.331640 30 Gallon Tall (LP) 153.331670 40 Gallon Tall (LP) 153.331690 50 Gallon Tall (LP) 8 1 15 3 7 14 4 9 2 6 17 13 11 Model Numbers Key No.
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