Use & Care Guide Model No. 153.337021 40 Gallon Tall 153.337041 50 Gallon Tall 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. FOR YOUR SAFETY: An odorant is added to the gas used by this water heater.
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 ................................................................................................... 24-26 Lighting Instructions ................................................................................................................................................ 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.
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 153.337021 40 (151) Natural 40,000 40.94 3 (76) or 4 (102) 20 (508) 58.13 (1476) 153.337041 50 (189) Natural 40,000 40.94 3 (76) or 4 (102) 22 (558) 57.
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 Z AA BB * INSTALL IN ACCORDANCE WITH LOCAL CODES. * DRIP LEG AS REQUIRED BY LOCAL CODES.
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 Attach a hose to the water heater drain valve and put the other end in a floor drain or outdoors. (See Figures 2 and 5.) Open the water heater drain valve. 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.
Location Requirements WARNING WARNING Carbon Monoxide Poisoning Hazard Do not install in a mobile home. Doing so can result in carbon monoxide poisoning and death. FLAMMABLES The Flammable Vapor (FV) Sensor is designed to reduce the risk of flammable vapor-related fires. Flammable liquids (such as gasoline, solvents, propane, etc,) emit flammable vapors which can be ignited by a gas water heater’s spark igniter or main burner.
• • • Locate the water heater near the existing gas piping. If installing a new gas line, locate the water heater to minimize the pipe length and elbows. DISCHARGE PIPE (DO NOT CAP OR PLUG) The water heater should be located in an area not subject to freezing temperatures. Water heaters located in unconditioned spaces (i.e., attics, basements, etc.) may require insulation of the water piping and drain piping to protect against freezing.
VENT WARNING BACK Should you choose to apply an insulation blanket to this heater, you should follow these instructions (See Figure 1 for identification of components mentioned below). Failure to follow these instructions can restrict the air flow required for proper combustion, potentially resulting in fire, asphyxiation, serious personal injury or death.
GAS SUPPLY codes or, in the absence of local and state codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)-current edition. Tables 1 and 2 on the following page provide a sizing reference for commonly used gas pipe materials. Consult the “National Fuel Gas Code” for the recommended gas pipe size of other materials. NOTE: Use pipe joint compound or teflon tape marked as being resistant to the action of petroleum [Propane (L.P.)] gases. (See Figure 12.) 1.
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 IMPORTANT: WARNING • The area must be open and be able to provide the proper air requirements to the water heater. Areas that are being used for storage or contain large objects may not be suitable for water heater installation. • Water heaters installed in open spaces in buildings with unusually tight construction may still require outdoor air to function properly. In this situation, outside air openings should be sized the same as for a confined space.
TABLE 4 Minimum Free Area of Permanent Openings for Ventilation and Combustion Air Supply - All Air from Outdoors Only. CONFINED SPACE Based on total BTUH input rating for all utilizing equipment within the confined space. PERMANENT OPENINGS 1 SQUARE INCH/1000 BTUH (MINIMUM 100 SQ. IN.) Opening Source Minimum Free Area Per Opening (sq. in.) Reference Drawing *Direct to outdoors 1 sq. in, per 4000 BTUH Figure 15 Vertical Ducts 1 sq. in, per 4000 BTUH Figure 16 Horizontal Ducts 1 sq.
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 Draft Hood Installation OUTLET CONFINED SPACE Draft hood OUTDOOR AIR DUCTS Flue Damper INLET Draft hood Leg Tips* 1 SQ. INCH PER 2000 BTUH ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS FIGURE 17. * Twist or bend the leg tips to secure the draft hood to the flue damper FIGURE 19.
• • • The vent connector must be accessible for cleaning, 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. separation, and maintain clearances to combustible materials (Figures 21 and 22).
WATER SYSTEM PIPING Piping Installation IN A CLOSED SYSTEM USE A THERMAL EXPANSION TANK COLD WATER SUPPLY TO FIXTURES Piping, fittings, and valves should be installed according to the installation drawing (Figure 23). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation. PRESSURE REDUCING VALVE WITH BYPASS COLD WATER INLET HOT WATER OUTLET COLD WATER INLET VALVE (SHUT-OFF VALVE) The water supply pressure should not exceed 80 psi.
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 25). 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.
OPERATING YOUR WATER HEATER Lighting Instructions WARNING Read and understand these directions thoroughly before attempting to light or re-light the pilot. Make sure the view port is not missing or damaged. (See Figure 35.) Make sure the tank is completely filled with water before lighting the pilot. Check the rating plate near the gas control valve/thermostat for the correct gas. Do not use this water heater with any gas other than the one listed on the rating plate.
Checking the Draft line or at the point of use to further reduce the risk of scald injury. These devices can be obtained from a plumbing service agency or your retail supplier. WARNING Emergency Shut Down IMPORTANT: Should overheating occur or the gas supply fails to shut off, turn off the water heater’s manual gas control valve and call a qualified technician. Burn Hazard Water Temperature Regulation Do not touch vent. Doing so can result in burns.
160°F (Approx.) ON OFF C A B RY VE OT H Status Light 120°F Position HOT C RY E V OT H Time for 1st Degree Burn (Less Severe Burns) 110 (normal shower temp.) 116 (pain threshold) 116 35 minutes HOT • VAC • • LOW B A STATUS Water Temperature °F 110°F (Approx.) 45 minutes 122 1 minute 5 minutes 131 5 seconds 25 seconds 140 2 seconds 5 seconds VAC 149 1 second 2 seconds 70°F (Approx.
ELECTRICAL CONNECTIONS/WIRING DIAGRAM Electrical Connections WARNING Before plugging in the water heater, always make sure: • The Voltage and frequency correspond to that specified on the water heater. • The electrical outlet has the proper overload fuse or breaker protection. • Water heater to be located within 6 feet of 120VAC outlet. • Unit is to connect to a 120VAC electrical supply outlet (extension cord is not allowed). • The water heater and the outlet are properly grounded.
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 31. 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 Anode deterioration depends on water conductivity, not necessarily water condition. A corroded or pitted anode rod indicates high water conductivity and should be checked and/or replaced more often than an anode rod that appears to be intact. Replacement of a depleted anode rod can extend the life of your water heater. Inspection should be conducted by calling the Sears Service Center for an authorized contractor. At a minimum, the anode(s) should be checked annually after the warranty period.
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 IMPORTANT: The following maintenance procedures are for the FVIR System components and should be performed by a qualified technician. Replacement parts may be ordered from Sears Parts and Service Centers or by calling 1-800-4-MY-HOME (1-800-469-4663). When ordering replacement parts, always have the following information ready: 1. model, serial, and product number 2. type of gas 3. item number 4.
Igniter Wire Pilot/Igniter-Flame Sensor Assembly Pilot Tube Cleaning the Combustion Chamber and Flame-arrestor Retainer Clip 1. Follow procedure outlined in “Removing the Manifold/ Burner Assembly.” 2. Use a vacuum cleaner/shop vac to remove all loose debris in the combustion chamber (Figure 40). Use compressed air to clear any dust or debris that may have accumulated in the flame-arrestor. FLAME ARRESTOR COMBUSTION CHAMBER Manifold Component Block Manifold Door DOOR GASKET FIGURE 37. 4.
4. Inspect the door gasket and make sure there is no fiberglass insulation between the gasket and the combustion chamber. 5. Replace the two screws, which secure the manifold/ burner assembly door to the combustion chamber and tighten securely. Once the manifold/burner assembly door is tightened, visually inspect the door gasket between the manifold/burner assembly door and the combustion chamber for spaces or gaps that would prevent a seal.
5. Disconnect the wire harness, flammable vapor sensor wires, and igniter wire from the gas control valve/thermostat. Disconnect pilot tube (7/16” wrench) and manifold tube (3/4” wrench) at the gas control valve/thermostat (Figure 34). NOTE: L.P. Gas systems use reverse (left-hand) threads on the manifold tube 6. Refer to “Gas Piping” section (Figure 12) and disconnect the ground joint union in the gas piping. Disconnect the remaining pipe from the gas control valve/thermostat. 7.
TROUBLESHOOTING GUIDE Start Up Conditions 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. 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 Whenever the water heater is filled with cold water, some condensate will form while the burner is on. A water heater may appear to be leaking when in fact the water is condensation. This usually happens when: • A new water heater is filled with cold water for the first time. • Burning gas produces water vapor In water heaters, particularly high efficiency models where flue temperatures are lower.
IMPORTANT: If the flammable vapor sensor activates a qualified technician must be contacted. Reference Seven Flash Error code in the “Status Light Troubleshooting Flowchart Section.” This unit is also equipped with a thermal switch designed to shut off the gas control valve/thermostat in the event the water heater has poor combustion caused by a blocked vent or insufficient combustion air. If the switch opens: 1. Check the flame-arrestor for signs of high temperature (blue or black discoloration).
TROUBLESHOOTING CHART PROBLEM BURNER WILL NOT IGNITE POSSIBLE CAUSE(S) CORRECTIVE ACTION 1. Pilot will not light 1. 2. 3. 4. 5. 6. 7. 8. 9. Thermostat set too low No gas Dirt in the gas lines Pilot line clogged Main burner line clogged Non-functioning thermostat Heater installed in a confined area Flue Damper not functioning 2. 3. 4. 5. 6. 7. 8. 9. See PILOT WILL NOT LIGHT OR REMAIN LIT Turn temp.
TROUBLESHOOTING CHART (CONTINUED) PROBLEM SLOW HOT WATER RECOVERY POSSIBLE CAUSE(S) CORRECTIVE ACTION 1. Insufficient secondary air 1. 2. 3. 4. 5. 6. 7. Flue clogged Low gas pressure Improper calibration Thermostat set too low Water heater too small Wrong piping connections 2. 3. 4. 5. 6. 7. 8. Wasted hot water 8. 1. Excessive water pressure 1. 2. 3. Heater stacking Closed water system 2. 3.
STATUS LIGHT TROUBLESHOOTING FLOWCHART Status Light Code LED FLASH SEQUENCE CONTROL STATUS Short flash once every four second IDLE (No call for heat, no fault conditions) “Heartbeat”, alternates bright/dim Call for Heat (No fault conditions) One Flash, three second pause Low Flame Signal (control continues to operate) Two Flash, three second pause End Switch Failed Closed CORRECTIVE ACTION Turn the power switch on the gas control valve to the “OFF” position and unplug the power cord from the pow
STATUS LIGHT TROUBLESHOOTING FLOWCHART LED FLASH SEQUENCE Six-Two Flash, three second pause CONTROL STATUS CORRECTIVE ACTION Soft Lockout* - Recycle Limit - Flame Lost - Turn the power switch on the gas control valve to the “OFF” position and unplug the power cord from the power outlet. END Switch Fails Six-Three Flash, three second pause Soft Lockout* - Recycle Limit - Flame Lost 1.
SEQUENCE OF OPERATION CHART Apply Power to Appliance. Is there a Call for Heat. Y Is Damper Closed? N Will not attempt to light. 2 flash error code. See Corrective Action Table on pages 40-41. N Gas Valve attempts to open damper for 30 seconds, displays 3 flash error code, and then waits 2 mintues before attempting to open damper again. See Corrective Action Table pages 40-41. N Will not light. 8-4 flash error code. See Corrective Action Table on pages 40-41. Damper Energizes.
PARTS ORDER LIST 5 16 KENMORE FLUE DAMPER GAS WATER HEATER 1 MODEL NUMBERS 153.337021 40 Gallon Tall (Natural) 153.337041 50 Gallon Tall (Natural) 11 8 3 14 4 13 17 7 18 2 12 15 10 6 Model Numbers Key No.
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