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.

Breathing Hazard - Carbon Monoxide Gas

Install vent system in accordance with codes.

Do not operate water heater if flood damaged

Heater should not be installed for High Altitude operation above 10,100 feet (3,078 m).

Do not operate if soot buildup.

Do not obstruct water heater air intake with insulating jacket.

Do not place chemical vapor emitting products near water heater.

Gas and carbon monoxide detectors are available.

Breathing carbon monoxide can cause brain damage or death. Always read and understand instruction manual.

Master Protection Agreements

Congratulations on making a smart purchase. Your new Kenmore?? product is designed and manufactured for years of dependable operation. But like all products, it may require preventive maintenance or repair from time to time. That???s when having a Master Protection Agreement can save you money and aggravation.

The Master Protection Agreement also helps extend the life of your new product. Here???s what the Agreement* includes:

???Parts and labor needed to help keep products operating properly under normal use, not just defects. Our coverage goes well beyond the product warranty. No deductibles, no functional failure excluded from coverage??? real protection.

???Expert service by a force of more than 10,000 authorized Sears service technicians, which means someone you can trust will be working on your product.

???Unlimited service calls and nationwide service, as often as you want us, whenever you want us.

??????No-lemon??? guarantee ??? replacement of your covered product if four or more product failures occur within twelve months.

???Product replacement if your covered product can???t be fixed.

???Annual Preventive Maintenance Check at your request ??? no extra charge.

???Fast help by phone ??? we call it Rapid Resolution ??? phone support from a Sears representative on all products. Think of us as a ???talking owner???s manual.???

???Power surge protection against electrical damage due to power fluctuations.

???$250 Food Loss Protection annually for any food spoilage

???Rental reimbursement if repair of your covered product takes longer than promised.

???10% discount off the regular price of any non-covered repair service and related installed parts.

Once you purchase the Agreement, a simple phone call is all that it takes for you to schedule service. You can call anytime day or night, or schedule a service appointment online.

The Master Protection Agreement is a risk free purchase. If you cancel for any reason during the product warranty period, we will provide a full refund. Or, a prorated refund anytime after the product warranty period expires. Purchase your Master Protection Agreement today!

Some limitations and exclusions apply. For prices and additional information in the U.S.A. call 1-800-827-6655.

* Coverage in Canada varies on some items. For full details, call Sears Canada at 1-800-361-6665.

Sears Installation Service

For Sears professional installation of home appliances, garage door openers, water heaters, and other major home items, in the U.S.A. or Canada call 1-800-4-MY-HOME??.

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 gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a ???ammable vapor ignition incident. New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation environments. Please review the Installation Checklist section and make any required installation upgrades or changes.

This manual contains instructions for the installation, operation, and maintenance of the gas-???red water heater. It also contains warnings through out the manual that you must read and be aware of. All warnings and all instructions are essential to the proper operation of the water heater and your safety. Since we cannot put everything on the ???rst few pages, READ THE ENTIRE MANUAL

BEFORE ATTEMPTING TO INSTALL OR OPERATE THE WATER

HEATER.

???The installation must conform with these instructions and the local code authority having jurisdiction. In the absence of local codes, installations shall comply with the following:

In the United States: The National Fuel Gas Code ANSI Z223.1/ NFPA 54. This publication is available from the Canadian Standards Association, 8501 East Pleasant Valley Rd, Cleveland Ohio 44131, or The National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.

???If 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 ???res. See Figure 1.

???Examine the location to ensure the water heater complies with the Installation 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 Of???ce of the State Architect, 1102 Q Street, Suite 5100, Sacramento, CA 95811. Instructions can also be downloaded to your computer at www.dsa.dgs.ca.gov/Pubs.

???Massachusetts Code requires this water heater to be installed in accordance with Massachusetts 248-CMR 2.00: State Plumbing Code and 248-CMR 5.00.

???Complies with 40 Ng/J NOx requirements of Texas and most California AQM Districts.

WARNING

Excessive Weight Hazard

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, or the data label from either the outside of the water heater or on the inside of water heater panels.

???Remove exterior packaging and place installation components aside.

???Inspect all parts for damage prior to installation and start-up.

???Completely read all instructions before attempting to assemble and install this product.

???After installation, dispose of/recycle all packaging materials.

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??? (19.05 mm) COPPER PLUMBING AND FLEXIBLE

GAS CONNECTOR WITH FITTINGS.

METAL DRAIN PANS AVAILABLE IN 20??? (508 mm) DIAMETER

FOR WATER HEATERS HAVING A DIAMETER 18??? (457 mm) OR LESS, 24??? (610mm) DIAMETER

FOR WATER HEATERS HAVING A DIAMETER 22??? (559 mm) OR LESS AND AVAILABLE IN 28??? (711 mm)

DIAMETER FOR WATER HEATERS HAVING A DIAMETER 26??? (660 mm)

OR LESS.

BASIC TOOLS

You may or may not need all these tools, depending on your type of installation. These tools can be purchased at your local Sears Store.

ADDITIONAL TOOLS NEEDED

WHEN SWEAT SOLDERING

???Pipe Wrenches (2) 14??? (356 mm)

???Screwdriver

???Tin Snips

???6??? (1.82 m) Tape or Folding Ruler

???Garden Hose

???Drill

???Pipe Dope or Te???on Tape

SLOT-HEAD SCREWDRIVER

PHILLIPS SCREWDRIVER

ROLL OF TEFLON

TAPE (USE ONLY ON

WATER CONNECTIONS)

DRILL

TIN SNIPS

PIPE DOPE

(SQUEEZE TUBE)

USE FOR WATER AND GAS

CONNECTIONS

BY LOCAL CODES.

* ALL PIPING MATERIALS

TO BE SUPPLIED BY

CUSTOMERS.

(S) GAS CONTROL VALVE/THERMOSTAT

???

???

Installation area free of corrosive elements and flammable materials.

Centrally located with the water piping system (For new installations). Located as close to the gas piping, vent pipe system and 120VAC outlet as possible.

???

???

Located indoors and in a vertical position. Protected from freezing temperatures.

Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor.

???

???

Provisions made to protect the area from water damage. Metal drain pan installed and piped to an adequate drain.

Sufficient room to service the water heater. See Clearances and Accessibility section of this manual.

???

???

Water heater not located near an air moving device.

Is the installed environment dirty (excessive amounts of lint, dirt, dust, etc.)? If so, the air intake chamber louvers located on the side of the water heater will need to be cleaned periodically. Refer to the maintenance section of your water heater???s manual for information on cleaning the ???Air Intake Chamber Screen???.

6 1

MANUAL GAS

SHUT-OFF VALVE

GROUND

JOINT

UNION

CHECK WITH

LOCAL UTILITY

5 2

DISCHARGE PIPE

(DO NOT CAP

OR PLUG)

4.Attach a hose to the water heater drain valve and put the other end in a ???oor drain or outdoors. (See Figures 2 and 5.) Open the water heater drain valve.

FIGURE 5.

FOR MINIMUM HEIGHT

DRIP LEG

FIGURE 2.

1.Turn ???OFF??? the gas supply to the water heater.

If the main gas line shutoff valve serving all gas appliances is used, also shut ???OFF??? the gas at each appliance. Leave all gas appliances

and 4.

3.Check again to make sure the gas supply is ???OFF??? to the water heater. Then disconnect the gas supply connection from the gas control valve.

6.If you have copper piping to the water heater, the two copper water pipes can be cut with a hacksaw approximately four inches away from where they connect to the water heater. See Figure 6. This will avoid cutting off pipes too short. Additional cuts can be made later if necessary. Disconnect the temperature-pressure relief valve drain line. When the water heater is drained, disconnect the hose from the drain valve. Close the drain valve. The water heater is now completely disconnected and ready to be removed.

FIGURE 6.

If you have galvanized pipes to the water heater, loosen the two galvanized pipes with a pipe wrench at the union in each line. Also disconnect the piping remaining to the water heater. See Figure 7. These pieces should be saved since they may be needed when reconnecting the new water heater. Disconnect the temperature-pressure relief valve drain line. When the water heater is drained, disconnect the hose from the drain valve. Close the drain valve. The water heater is now completely disconnected and ready to be removed. Mineral buildup or sediment may have accumulated in the old water heater. This causes the water heater to be much heavier than normal and this residue, if spilled out, could cause staining.

Location Requirements

WARNING

Carbon Monoxide Poisoning Hazard

Do not install in a mobile home.

Doing so can result in carbon monoxide poisoning and death.

The FVIR System is designed to reduce the risk of flammable vapor-related fires. Flammable liquids (such as gasoline, solvents, propane, etc,) emit flammable vapors which can be ignited by a gas water heater???s hot surface igniter or main burner. The resulting flashback and fire can cause death or serious burns to anyone in the area.

FIGURE 8.

FV Sensor

This heater is equipped with a FV sensor for detecting the presence of flammable vapors. When the sensor detects those vapors, the unit will shut down and not operate. Should this happen, please refer to the troubleshooting guide on pages 38-40 (numbers 9,11,12). Even though this water heater is a flammable vapors ignition resistant water heater and is designed to reduce the chances of flammable vapors being ignited, gasoline and other flammable substances should never be stored or used in the same vicinity or area containing a gas water heater or other open flame or spark producing appliance.

WARNING

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 vicinity of this or any other appliance can result in serious injury or death.

Read and follow water heater warnings and instructions

Do not use or store flammable products such as gasoline, solvents, or adhesives in the same room or area near the water heater. If such flammables must be used, all gas burning appliances in the vicinity must be shut off and their pilot lights extinguished. Open the doors and windows for ventilation while flammable substances are in use.

If flammable liquids or vapors have spilled or leaked in the 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

Fire or Explosion Hazard

???Read instruction manual before installing, using or servicing water heater.

???Improper use may result in fire or explosion.

???Maintain required clearances to combustibles.

Keep combustibles such as boxes, magazines, clothes, etc. away from the water heater area.

Site Location

???Select a location near the center of the water piping system. The water heater must be installed indoors and in a vertical position on a level surface. DO NOT install in bathrooms, bedrooms, or any occupied room normally kept closed.

???Locate the water heater as close to the chimney or gas vent as practical. Consider the vent system piping and combus- tion air supply requirements when selecting the water heater location. The venting system must be able to run from the water heater to termination with minimal length and elbows.

???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.

???The water heater should be located in an area not subject to freezing temperatures. Water heaters located in unconditioned spaces (i.e., attics, basements, etc.) may require insulation of the water piping and drain piping to protect against freezing. The drain and controls must be easily accessible for operation and service. Maintain proper clearances as specified on the water heater.

???Do not locate the water heater near an air-moving device. The operation of air-moving devices such as exhaust fans, ventilation systems, clothes dryers, fireplaces, etc., can af- fect the proper operation of the water heater. Special atten- tion must be given to conditions these devices may create.

Flow reversal of flue gases may cause an increase of carbon monoxide inside of the dwelling (Figure 10).

???The water heater is to be located as close as possible to a 120VAC outlet. NOTE: all electrical wiring should be in accordance to the NEC and all local/state electrical codes (extension cord is not allowed).

NOTE: This water heater must be installed according to all local and state codes or, in the absence of local and state codes, the ???National Fuel Gas Code???, ANSI Z223.1(NFPA 54)-current edition and the ???National Electrical Code???, ANSI/NFPS 70 current edition.

IMPORTANT: The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure. Due to the normal corrosive action of water, the tank will eventually leak after an extended period of time. Also any external plumbing leak, including those from improper installation, may cause early failure of the tank due to corrosion if not repaired. If the homeowner is uncomfortable with making the repair a qualified technician should be contacted. A suitable metal drain pan should be installed under the water heater as shown below, to help protect the property from damage which may occur from condensate formation or leaks in the piping connections or tank. The pan must limit the water level

to a maximum depth of 1-3/4??? and be two inches wider than the heater and piped to an adequate drain. Locate the water heater near a suitable indoor drain. Outside drains are subject to freezing temperatures which can obstruct the drain line. The piping should be at least 3/4??? ID and pitched for proper drainage.

FIGURE 9.

Pipe to an adequate drain

Water heater life depends upon water quality, water usage, water temperature and the environment in which the water heater is installed. Water heaters are sometimes installed in locations where leakage may result in property damage, even with the use of a metal drain pan piped to a drain. However, unanticipated damage can be reduced or prevented by a leak detector or water shut-off device used in conjunction with a piped metal drain

pan. These devices are available from some plumbing supply wholesalers and retailers, and detect and react to leakage in various ways:

???Sensors mounted in the metal drain pan that trigger an alarm or turn off the incoming water to the water heater when water is detected.

FIGURE 10.

Clearances and Accessibility

NOTE: Minimum clearances from combustible materials are stated on the label on the front of the heater adjacent to the gas control valve/thermostat of the water heater.

The water heater is certified for installation on a combustible floor.

???IMPORTANT: If installing over carpeting, the carpeting must be protected by a metal or wood panel beneath the water heater. The protective panel must extend beyond the full width and depth of the water heater by at least five inches (127mm) in any direction; or if in an alcove or closet installa- tion, the entire floor must be covered by the panel.

???Figure 11 may be used as a reference guide to locate the specific clearance locations. A minimum of 5 inches of front clearance should be provided for inspection and service.

0??? min. Back

0??? min. Sides

0??? min. Air Inlet Chamber

5??? min.

Front

Top View

???Sensors mounted in the metal drain pan that turn off the water supply to the entire home when water is detected in the metal drain pan.

???Water supply shut-off devices that activate based on the water pressure differential between the cold water and hot water pipes connected to the water heater.

???Devices that will turn off the gas supply to a gas water heater while at the same time shutting off its water supply.

Minimum Clearance Locations

FIGURE 11.

High Altitude Installation

This water heater should not be installed for operation at elevations above 10,100 ft. (3,078 m).

14

WARNING

Explosion Hazard

Manual Gas

Shut-Off Valve

Ground Joint Union

Install a readily acces- sible manual shut-off valve in the gas supply line as recommended by the local utility.

Check with local utility for minimum height.

3??? Minimum

Drip Leg

Discharge Pipe (Do Not plug or cap)

6??? Max. Air Gap

Suitable Drain

Gas Requirements

IMPORTANT: Read the rating plate to be sure the water heater is made for the type of gas you will be using in your home. This information will be found on the rating plate located near the gas control valve/thermostat. If the information does not agree with the type of gas available, do not install or light. Call your dealer.

NOTE: An odorant is added by the gas supplier to the gas used by this water heater. This odorant may fade over an extended period of time. Do not depend upon this odorant as an indication

of leaking gas.

Gas Piping

The gas piping must be installed according to all local and state codes or, in the absence of local and state codes, the ???National Fuel Gas Code???, ANSI Z223.1(NFPA 54)-current edition.

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 gases (See Figure 12.)

1.Install a readily accessible manual shut-off valve in the gas supply line as recommended by the local utility. Know the location of this valve and how to turn off the gas to this unit.

2.Install a drip leg (if not already incorporated as part of the water heater) as shown. The drip leg must be no less than three inches long for the accumulation of dirt, foreign material, and water droplets.

3.Install a ground joint union between the gas control valve/ thermostat and the manual shut-off valve. This is to allow easy removal of the gas control valve/ thermostat.

4.Turn the gas supply on and check for leaks. Test all connections by brushing on an approved noncorrosive leak- detection solution. Bubbles will show a leak. Correct any leak found.

FIGURE 12.

Gas Pressure

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.

???If a gas leak is detected, follow the ???What to do if you smell gas??? instructions on the cover of this manual.

IMPORTANT: The gas supply pressure must not exceed the maximum supply pressure as stated on the water heater???s rating plate. The

minimum supply pressure is for the purpose of input adjustment.

Gas Pressure Testing

IMPORTANT: This water heater and its gas connection must be leak tested before placing the appliance in operation.

???If the code requires the gas lines to be tested at a pressure exceeding 14??? W.C., the water heater and its manual shut-off valve must be disconnected from the gas supply piping system and the line capped.

???If the gas lines are to be tested at a pressure less than 14??? W.C., the water heater must be isolated from the gas supply piping system by closing its manual shut-off valve.

NOTE: Air may be present in the gas lines and could prevent the burner from lighting on initial start-up. The gas lines should be purged of air by a qualified technician after installation of the gas piping system. While purging the gas piping system of air, insure that the fuel is not spilled in the area of the water heater installation, or any source of ignition (NOTE: spilled fuel may trip the FV Sensor preventing heater from starting). 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.

Gas Pipe Capacity Table

WARNING

Explosion Hazard

???Use a new CSA approved gas supply line.

???Install a shut-off valve.

???Do not connect a natural gas water heater to an L.P. gas supply.

???Do not connect an L.P. gas water heater to a natural gas supply.

???Failure to follow these instructions can result in death, explosion, or carbon monoxide poisoning.

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.

???If a gas leak is detected, follow the ???What to do if you smell gas??? instructions on the cover of this manual.

WARNING

Carbon Monoxide Warning

Water heater must be vented to outdoors.

Vent must be installed by a qualified technician using the installation instructions.

Examples of a qualified technican include: gas technicians, authorized gas company personel, and authorized service persons.

Failure to so do can result in death or carbon monoxide poisoning.

IMPORTANT: Air for combustion and ventilation must not come from a corrosive atmosphere. Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage.

The following types of installation (not limited to the following) will require outdoor air for combustion due to chemical exposure and may reduce but not eliminate the presence of corrosive chemicals in the air:

???beauty shops

???photo processing labs

???buildings with indoor pools

???water heaters installed in laundry, hobby, or craft rooms

???water heaters installed near chemical storage areas

Combustion air must be free of acid-forming chemicals such as sulfur, fluorine, and chlorine. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, air fresheners, paint, and varnish removers, refrigerants, and many other commercial and household products. When burned, vapors from these products form highly corrosive acid compounds. These products should not be stored or used near the water heater or air inlet.

Combustion and ventilation air requirements are determined by the location of the water heater. The water heater may be located in either an open (unconfined) area or in a confined area or small enclosure such as a closet or small room. Confined spaces are areas with less than 50 cubic feet for each 1,000 BTUH of the total input for all gas-using appliances.

Unconfined Space

A water heater in an unconfined space uses indoor air for combustion and requires at least 50 cubic feet for each 1,000 BTUH of the total input for all gas appliances. The table below shows a few examples of the minimum square footage (area) required for various BTUH inputs.

TABLE 3

IMPORTANT:

???The area must be open and be able to provide the proper air requirements to the water heater. Areas that are being used for storage or contain large objects may not be suitable for water heater installation.

???Water heaters installed in open spaces in buildings with un- usually tight construction may still require outdoor air to func- tion properly. In this situation, outside air openings should be sized the same as for a confined space.

???Modern home construction usually requires supplying out- side air into the water heater area.

Confined Space

For the correct and proper operation of this water heater, ample air must be supplied for the combustion, ventilation, and dilution of flue gases. Small enclosures and confined areas must have two permanent openings so that sufficient fresh air can be drawn from outside of the enclosure. One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure as shown in Figure 13.

The size of each opening (free area) is determined by the total BTUH input of all gas utilization equipment (i.e., water heaters, furnaces, clothes dryers, etc.) and the method by which the air is provided. The BTUH input can be found on the water heater rating plate. Additional air can be provided by two methods:

1.All air from inside the building.

2.All air from outdoors.

12??? Max.

free area of the opening to which they connect. The minimum dimension of rectangular air ducts cannot be less than three inches.

Permanent openings to the outside or additional rooms within the building

The size of each of the two openings is determined by the method in which the air is to be provided. Refer to Table 4 to calculate the minimum free area for each opening. Figures 15, 16, 17 and 18 are typical examples of each method.

Louvers and Grilles

In calculating free area for ventilation and combustion air supply openings, consideration must be given to the blocking effect

of protection louvers, grilles, and screens. These devices can reduce airflow, which in turn may require larger openings to achieve the required minimum free area. Screens must not be smaller than 1/4??? mesh. If the free area through a particular

FIGURE 13.

All Air from the Building

When additional air is to be provided to the confined area from additional room(s) within the building, the total volume of the room(s) must be of sufficient size to properly provide the necessary amount of fresh air to the water heater and other gas utilization equipment in the area. If you are unsure that the structure meets this requirement, contact your local gas utility company or other qualified agency for a safety inspection. Each of the two openings shall have a minimum free area of 1 square inch per 1,000 BTUH of the total input rating of all gas utilization equipment in the confined area, but not less than 100 square inches (Figure 14).

Confined

Space

Permanent

Openings

1 Square inch/1000

BTUH (min. 100 sq. in.)

FIGURE 14.

All Air from Outdoors

Outdoor fresh air can be provided to a confined area either directly or by the use of vertical and horizontal ducts. The fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors. Attic or crawl spaces cannot be closed and must be properly ventilated to the outside.

Ductwork must be of the same cross-sectional area as the

design of louver or grille is known, it should be used in calculating the specified free area of the opening. If the design and free area are not known, it can be assumed that most wood louvers will allow 20 - 25% of free area while metal louvers and grilles will allow 60 - 75% of free area.

Louvers and grilles must be locked open or interconnected with the equipment so that they are opened automatically during equipment operation.

Keep louvers and grilles clean and free of debris or other obstructions.

TABLE 4

Minimum Free Area of Permanent Openings for Ventilation and Combustion Air Supply - All Air from Outdoors Only.

Based on total BTUH input rating for all utilizing equipment within the con???ned space.

Example: A water heater with an input rating of 50,000 BTUH using horizontal ducts would require each opening to have a minimum free area of 25 square inches.

Minimum free area = 50,000 BTUH x 1 sq. in. / 2000 BTUH = 25 sq. in.

*These openings connect directly with the outdoors through a venti- lated attic, a ventilated crawl space, or through an outside wall.

Consult the local codes of your area for specific ventilation and combustion air requirements.

All Air From Outdoors: Inlet Air From Ventilated Crawl Space/Outlet Air To Ventilated Attic

FIGURE 15.

Alternative

Opening

Location

Confined

Space

1 sq. in. per

3000 BTUH

All Air From Outdoors - Using A Single Permanent Opening

FIGURE 18.

Vent Pipe System

This water heater uses a non-direct, single-pipe vent system to remove exhaust gases created by the burning of fossil fuels. Air

Confined

Space

Gable Vent to Outdoors

Install Above

Outlet Air to the Attic 1 sq. in. per 4000 BTUH

Inlet Air Duct 1 sq. in. per 4000 BTUH

for combustion is taken from the immediate water heater location or is ducted in from the outside (see ???Combustion Air Supply and Ventilation???).

This water heater must be properly vented for the removal of exhaust gases to the outside atmosphere. Correct installation of the vent pipe system is mandatory for the proper and efficient operation of this water heater and is an important factor in the life of the unit.

The vent pipe must be installed according to all local and state codes or, in the absence of local and state codes, the ???National Fuel Gas Code???, ANSI Z223.1(NFPA 54)-current edition. The vent pipe installation must not be obstructed so as to prevent the removal of exhaust gases to the outside atmosphere.

12??? Max.

All Air from Outdoors Through Ventilated Attic

FIGURE 16.

1 sq. in. per

2000 BTUH

Outdoor

Air Ducts

Inlet

1 sq. in. per

2000 BTUH

All Air From Outdoors Using Horizontal Ducts

FIGURE 17.

IMPORTANT: The use of vent dampers is not recommended by the manufacturer of this water heater. Although some vent dampers are certified by CSA International, this certification applies to the vent damper device only and does not mean they are certified for use on this water heater.

U.L. recognized fuel gas and carbon monoxide (CO) detectors are recommended in all applications and should be installed 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.

Draft Hood Installation

FIGURE 19.

19

40 Gal. Water Heater: Align the reducer flue over top of baffle as

shown in Figure 19 (NOTE: reducer flue must be installed on 40 gal. water heater above elevation 5,400 Ft. (1,646 m) from sea level).

40 & 50 Gal. Water Heaters: Align the legs of the draft hood with the slots provided. Insert the legs and secure the draft hood to the water heater???s top with the four screws provided as shown

in Figure 19. Do not alter the draft hood in any way. If you are replacing an existing water heater, be sure to use the draft hood supplied with this water heater.

Vent Pipe Size

It is important that you follow the guidelines in these instructions for sizing a vent pipe system. If a transition to a larger vent size is required, the vent transition connection must be made at the draft hood outlet.

Vent Connectors

1.Type B, Double wall, U.L. Listed Vent Pipe.

2.Single wall Vent Pipe.

Maintain the manufacturer???s specified minimum clearance from combustible materials when using type B double wall vent pipe.

Vent connectors made of type B, double wall vent pipe material may pass through walls or partitions constructed of combustible material if the minimum listed clearance is maintained.

Maintain a six inch minimum clearance from all combustible materials when using single wall vent pipe.

IMPORTANT: Single wall vent pipe cannot be used for water heaters located in attics and may not pass through attic spaces, crawl spaces or any confined or inaccessible location. A single wall metal vent connector cannot pass through any interior wall.

When installing a vent connector, please note the following (See Figures 20-22):

???Install the vent connector avoiding unnecessary bends, which create resistance to the flow of vent gases.

???Install without dips or sags with an upward slope of at least 1/4-inch per foot.

???Joints must be fastened by sheet metal screws or other approved means. It must be supported to maintain clearances and prevent separation of joints and damage.

???The length of the vent connector cannot exceed 75% of the vertical vent height.

???The vent connector must be accessible for cleaning, inspection, and replacement.

???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.

IMPORTANT: Existing vent systems must be inspected for obstructions, corrosion, and proper installation.

Chimney Connection

IMPORTANT: Before connecting a vent to a chimney, make sure the chimney passageway is clear and free of obstructions. The chimney must be cleaned if previously used for venting solid fuel appliances or fireplaces. Also consult local and state codes for proper chimney sizing and application or, in the absence

of local and state codes, the ???National Fuel Gas Code???, ANSI

Z223.1(NFPA 54)-current edition.

???The connector must be installed above the extreme bottom of the chimney to prevent potentially blocking the flue gases.

???The connector must be firmly attached and sealed to prevent it from falling out.

???To aid in removing the connector, a thimble or slip joint may be used.

???The connector must not extend beyond the inner edge of the chimney as it may restrict the space between it and the opposite wall of the chimney (Figure 20).

Chimney Termination Vent System

FIGURE 20.

Do not terminate the vent connector in a chimney that has not been certified for this purpose. Some local codes may prohibit the termination of vent connectors in a masonry chimney.

Vertical Exhaust Gas Vent

Vertical exhaust gas vents must be installed with U.L. listed type B vent pipe according to the vent manufacturer???s instructions and the terms of its listing.

It must be connected to the water heater???s draft hood by a listed vent connector or by directly originating at the draft hood opening.

Vertical gas vents must terminate with a listed cap or other roof assembly and be installed according to their manufacturer???s instructions.

Gas vents must be supported to prevent damage, joint separation, and maintain clearances to combustible materials (Figures 21 and 22).

IMPORTANT: This gas vent must be terminated in a vertical position to facilitate the removal of the burnt gases.

An unused chimney flue or masonry enclosure may be used as a passageway for the installation of a gas vent (Figure 22).

Common (combined) venting is allowable with vertical type B vent systems and lined masonry chimneys as long as proper draft for the water heater is established under all conditions of operation. CAUTION: DO NOT common vent this water heater with any power vented appliance.

Figures 20-22 are examples of vent pipe system installations and may or may not be typical for your specific application. Consult the ???National Fuel Gas Code???, NFPA 54, ANSI Z223.1-current edition and the guidelines set forth by prevailing local codes.

Venting Gas Vent System With Type B Double Wall Vent Pipe.

Venting Through Chimney With Type B Double Wall Vent Pipe.

FIGURE 22.

*Maintain vent pipe clearance requirements to local, state and/or the ???National Fuel Gas Code???, ANSI Z223.1(NFPA 54)-current edition.

**NFPA 211, Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances states that these chimneys are intended to be installed in accordance with the installation instructions provided with each chimney support assembly. Minimum air space clearance to combustible materials should be maintained as marked on the chimney sections.

WATER SYSTEM PIPING

Piping Installation

Piping, fittings, and valves should be installed according to the installation drawing (Figure 23). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation.

The water supply pressure should not exceed 80 psi. If this occurs, a pressure reducing valve with a bypass should be installed in the cold water inlet line. This should be placed on the supply to the entire house in order to maintain equal hot and cold water pressures.

IMPORTANT: Heat cannot be applied to the water fittings on the heater as they may contain nonmetallic parts. If solder connections are used, solder the pipe to the adapter before attaching the adapter to the hot and cold water fittings.

IMPORTANT: Always use a good grade of joint compound and be certain that all fittings are drawn up tight.

1.Install the water piping and fittings as shown in Figure 23. Connect the cold water supply (3/4??? NPT) to the cold water inlet fitting. Connect the hot water piping (3/4??? NPT) to the hot water outlet fitting.

IMPORTANT: Some models may contain energy saving heat traps to prevent the circulation of hot water within the pipes. Do not remove the inserts within the heat traps.

2.The installation of unions in both the hot and cold water supply lines is recommended for ease of removing the water heater for service or replacement.

3.The manufacturer of this water heater recommends installing a mixing valve or an anti-scald device in the domestic hot water line as shown in Figure 24. These valves reduce the point-of-use temperature of the water by mixing cold and hot water and are readily available for use.

4.If installing the water heater in a closed water system, install an expansion tank in the cold water line as specified under Closed System/Thermal Expansion.

5.Install a shut-off valve in the cold water inlet line. It should be located close to the water heater and be easily accessible. Know the location of this valve and how to shut off the water to the heater.

6.A temperature and pressure relief valve must be installed in the opening marked ???Temperature and Pressure (T & P) Relief Valve??? on the water heater. A discharge line must be added to the opening of the T&P Relief Valve. Follow the instructions under Temperature and Pressure Relief Valve.

7.After piping has been properly connected to the water heater, remove the aerator at the nearest hot water faucet. Open the hot water faucet and allow the tank to completely fill with water. To purge the lines of any excess air, keep the hot water faucet open for 3 minutes after a constant flow of water is obtained. Close the faucet and check all connections for leaks.

FIGURE 23.

Mixed Water

To Fixtures

Unmixed

Hot Water

Cold Water

Inlet

Hot Water

Outlet

Mixing Valve

(Set To 1200 F)

Follow The Mixing Valve

Manufacturer???s Instructions

FIGURE 24.

Please note the following:

???The system should be installed only with piping that is suitable for potable (drinkable) water such as copper, CPVC, or polybutylene. This water heater must not be installed using iron piping or PVC water piping.

???Use only pumps, valves, or fittings that are compatible with potable water.

???It is recommend that only full flow ball or gate valves are used in water piping installations. The use of valves that may cause excessive restriction to water flow is not recommended.

???Use only 95/5 tin-antimony or other equivalent solder. Any lead based solder must not be used.

???Piping that has been treated with chromates, boiler seal, or other chemicals must not be used.

???Chemicals that may contaminate the potable water supply must not be added to the piping system.

Closed System/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. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent temperature-pressure relief valve operation: water discharged from the valve due to excessive pressure build up. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This condition is not covered under the limited warranty.

A properly-sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion. Contact a plumbing service agency or your retail supplier regarding the installation of a thermal expansion tank.

Temperature and Pressure Relief Valve

Explosion Hazard

??? Temperature-pressure relief valve must comply with ANSI Z21.22-CSA 4.4 and ASME code.

??? Properly sized temperature- pressure relief valve must be installed in opening provided.

??? Can result in overheating and excessive tank pressure.

??? Can cause serious injury or death.

Temperature and

Pressure Relief Valve

(T&P)

Discharge line 3/4??? Min.

Do not cap or plug.

Metal Drain Pan

6??? Max.

Drain

FIGURE 25.

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. The function of the temperature and pressure relief valve is to discharge water in large quantities in the event of excessive temperature or pressure developing in the water heater. The valve???s relief pressure must not exceed the working pressure of the water heater as stated on the rating plate.

IMPORTANT: Only a new temperature and pressure relief valve should be used with your water heater. Do not use an old or existing valve as it may be damaged or not adequate for the working pressure of the new water heater. Do not place any valve between the relief valve and the tank.

The Temperature & Pressure Relief Valve:

???Must not be in contact with any electrical part.

???Must be connected to an adequate discharge line.

???Must not be rated higher than the working pressure shown on the rating plate of the water heater.

The Discharge Line:

???Must not be smaller than the pipe size of the relief valve or have any reducing coupling installed in the discharge line.

???Must not be capped, blocked, plugged or contain any valve between the relief valve and the end of the discharge line.

???Must terminate a maximum of six inches above a floor drain or external to the building. In cold climates, it is recommend- ed that the discharge pipe be terminated at an adequate drain inside the building.

???Must be capable of withstanding 250??F (121??C) without dis- tortion.

???Must be installed to allow complete drainage of both the valve and discharge line.

4.Locate the hot water (outlet) & cold water (inlet) pipes to the water heater.

5.Locate the slit running the length of a section of pipe insulation.

6.Spread the slit open and slip the insulation over the cold water (inlet) pipe. Apply gentle pressure along the length of the insulation to ensure it is fully seated around the pipe. Also ensure that the base of insulation is flush with the water heater. Once seated, secure the insulation with duct tape, electrical tape, or equivalent.

7.Repeat steps 5 through 6 for the hot water (outlet) pipe.

8.Add additional sections of pipe insulation as needed.

Electrical Connections

IMPORTANT: Do not use an extension cord to connect the water heater to an electrical outlet.

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.

???Unit is to connect to a 120VAC electrical supply outlet (extension cord is not allowed).

WARNING

Electric Shock Hazard

Disconnect power before servicing.

Replace all parts and panels before operating.

Failure to do so can result in death or electrical shock.

???The water heater and the outlet are properly grounded.

???Installed in accordance with prevailing provisions of local codes, or in the absence of such, National Electric Code, ANSI/NFPS 70 current edition.

Completely fill the tank with water and check all connections for leaks. Open the nearest hot water faucet and let it run for three (3) minutes to purge the water lines of air and sediment and to ensure complete filling of the tank. The electrical power may then be turned on. Verify proper operation after servicing.

Solar Installation

If this water heater is used as a solar storage heater or as a backup for the solar system, the water supply temperatures to the water heater tank may be in excess of 120??F. A mixing valve or other temperature limiting valve must be installed in the water supply line to limit the supply temperature to 120??F.

NOTE: Solar water heating systems can often supply water with temperatures exceeding 180??F and may result in water heater malfunction.

Operating Instructions

Read and understand these directions thoroughly before attempting to operate the water heater. Make sure the view port is not missing or damaged (See Figure 36). Make sure the tank is completely filled with water before operating the water heater. The gas control valve/thermostat has a ???On/Off Switch??? and needs to be turned on before water heater is operational. Check the label on the front of heater 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 label. If you have any questions or doubts, consult your gas supplier or gas utility company.

WARNING

Explosion Hazard

Replace view port if glass is missing or damaged.

Failure to do so can result in death, explosion or fire.

ON

ON/OFF

SWITCH

"GAS CONTROL"

1.STOP! Read the safety information

above on the label.

2.Turn on all electrical power to the appliance.

3.Set the ON/OFF switch on the gas control to the "ON" position.

4.Set the Electronic Display to the lowest setting by first pressing the COOLER and HOTTER buttons together and holding for 1 second. Then press the COOLER button to the lowest setting.

5.Set the ON/OFF switch on the gas control to the "OFF" position.

6.This appliance is equipped with a device which automatically lights the burner.

DO NOT TRY TO LIGHT THE BURNER BY HAND.

the safety information above on this label. If you don't smell gas, go to the next step.

"ELECTRONIC DISPLAY"

8.Set the ON/OFF switch on the gas control to the "ON" postition.

9.Set the Electronic Display to the desired setting by first pressing the COOLER and HOTTER but- tons together and holding for 1 second. Then press the HOTTER button until the desired setting is reached.

DANGER: Hotter water increases the risk scald injury. Consult the instruction manual before changing temperature.

10.If the appliance will not operate, follow the instruc- tions "TO TURN OFF GAS TO APPLIANCE" and call your technician or gas supplier.

WARNING: TURN OFF ALL

ELECTRIC POWER BEFORE SERVICING.

1. Set the Electronic Display to the lowest setting by first pressing the COOLER and HOTTER but- tons together and holding for 1 second. Then press the COOLER button to the lowest setting.

2.Set the ON/OFF switch on the gas control to the "OFF" postition.

3.Turn off all electrical power to the appliance if service is to be performed.

Water Heater Operation

Figure 29 below shows the water heater???s sequence of operation when a call for heat is initiated. The ignition control module will attempt to light the burner three times. If the ignition control does not detect ignition it will enter lockout mode, indicated by display flashing status code (see status code 3 page 38 and/or status code 8 page 39).

Checking the Draft

WARNING

Burn Hazard

Do not touch vent.

Doing so can result in burns.

SEQUENCE OF OPERATION

After successfully lighting the water heater, allow the unit to operate for 15 minutes and check the draft hood relief opening for proper draft (Figure 30). Make sure all other appliances in the area are operating and all doors/windows are closed when

Call for heat indicated by flashing of display screen status codes.

Gas valve/thermostat will open for 4 second trial for ignition and fan will turn on.

performing the draft test. Pass a match flame or smoke around the relief opening of the draft hood. A steady flame or smoke drawn into the opening indicates proper draft.

Gas valve/thermostat will do a relay check (relay clicks will be heard).

Display will show temperature set point during call for heat.

Draft Blower is energized.

System will verify pressure switch operation and start a 5 second pre-purge, then air intake fan will turn off.

Ignitor will start a 12 second warm up period. ???IGN??? will show on display.

Main burner flame is detected by flame sense rod. Air intake fan and main burner will continue to operate until water temperature inside the tank reaches temperature set point.

Gas valve/thermostat is de- energized and air intake fan continues for a post purge time of approximately 5 seconds.

Water heater returns to standby mode.

Flue Products Vented

to Ouside of Building

Dilution Air

Draft Hood

Dilution Air

(Relief Opening)

Dilution Air

Match

Air is drawn in for combustion. Keep area clean and free from combustibles and flammable vapors.

Burner Flames

Inspect the burner flames through the viewport and compare them to the drawings in Figure 31. A properly operating burner should produce a soft blue flame. Blue tips with yellow inner cones are satisfactory. The tips of the flame may have a slight yellow tint. The flame should not be all yellow or have a sharp blue-orange color. Contaminated air may cause an orange colored flame. Contact a qualified technician if the flame is not satisfactory.

FIGURE 31.

Emergency Shut Down

IMPORTANT: Should overheating occur or the gas supply fails to shut off, turn off the heater???s manual gas control valve and the electrical power. Call a qualified technician.

Water Temperature Regulation

Water temperature over 125??F (52??C) can cause servere burns instantly resulting in severe injury or death.

Children, the elderly, and the physically or mentally disabled are at highest risk for scald injury.

Feel water before bathing or showering.

Temperature limiting valves are available.

Read instruction manual for safe temperature setting.

Due to the nature of the typical gas water heater, the water temperature in certain situations may vary up to 30??F (16.7 ??C) higher or lower at the point of use such as, bathtubs, 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 using the lowest possible temperature setting that satisfies your hot water needs, a means such as a mixing valve,

should be used at the hot water taps used by these people or at the water heater. Mixing valves are available at plumbing supply or hardware stores, see Figure 24. Follow manufacturer???s instructions for installation of the valves. Before changing the factory setting on the thermostat see Table 5 and Figure 32. Using the lowest hot water temperature that meets your needs will also provide the most energy efficient operation of the water heater. Never allow small children to use a hot water tap, or to draw their own bath water. Never leave a child or handicapped person unattended in a bathtub or shower.

NOTE: A water temperature range of 120??F-140??F (49??C-60??C) is recommended by most dishwasher manufacturers.

The thermostat of this water heater has been factory set at its lowest position. It is adjustable and must be reset to the desired temperature setting to reduce the risk of scald injury. The electronic control display temperature should be set at approximately 120??F (49??C) and this is the preferred starting point, see Table 5. Some states have a requirement for a lower

setting. If you need hotter water, follow directions for temperature adjustment, but beware of the warnings in this section.

(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978)

TABLE 5

Pressing the ???COOLER???button decreases temperature and pressing the ???HOTTER???button increases the temperature.

To avoid any unintentional changes in water temperature settings, the control has a tamper resistant feature for changing the temperature setting. To change the temperature setting follow these instructions:

1.???Unlock??? the temperature indicators by holding down both ???COOLER??? and ???HOTTER??? temperature adjustment buttons at the same time for one second (See Figure 32). The dis- play will light up. The display will only remain on for 30 sec- onds if no further buttons are pressed. After 30 seconds the control will go back to ???Lock??? mode (???Lock??? mode indicates a temperature setting is locked into the control memory).

2.Release both of the temperature adjustment buttons.

A.To decrease the temperature press and release the ???COOLER???button until the desired setting is reached.

B.To increase the temperature press and release the ???HOTTER???button until the desired setting is reached.

NOTE: Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve to the appliance.

NOTE: During low demand periods when hot water is not being used, a lower thermostat setting will reduce energy losses and

may satisfy your normal hot water needs. If hot water use is expected to be more than normal, a higher thermostat setting may be required to meet the increased demand. When leaving your home for extended periods (vacations, etc.) Set the electronic control display temperature ???COOLER???button to its lowest setting. This will maintain the water at low temperatures with minimum energy losses and prevent the tank from freezing during cold weather.

Gas Control Valve/Thermostat Settings

HOTTER COOLER

Electronic Control Display

FIGURE 32.

Powered Anode Operation

To protect the glass-lined water tank from corrosion through electrolysis, this water heater is equipped with a non sacrificial powered anode rod. The powered anode rod is non sacrificial and should not need to be replaced unless damaged.

If the powered anode rod has been damaged then the powered anode rod should be removed from the water heater tank and replaced. IMPORTANT: If the damaged powered anode rod has not been replaced but has been removed permanently, this will void any warranties.

FIGURE 33.

NOTE: Whether re-installing or replacing the powered anode rod, check for any leaks and immediately correct if found.

To replace the powered anode rod:

1.Set the gas control valve/thermostat to its lowest setting by pressing the ???COOLER??? and ???HOTTER??? buttons together at the same time holding for 1 second. Then press the ???COOLER??? button to the lowest setting (Figure 32).

2.Turn gas control switch to the ???OFF??? position (located right side of the gas control valve/thermostat (Figure 28), and turn off the gas supply to the unit.

3.Disconnect the electric connection by unplugging the water heater from the wall outlet.

4.Shut off the incoming water supply to the water heater and open a nearby hot water faucet to depressurize the water tank.

5.Remove the manifold cover outer door and connect a hose to the drain valve and terminate it to adequate drain or to the exterior of the building. Open the drain valve and allow at least 5 gallons of water from the tank to drain. Close drain and remove hose.

6.Unplug the electrical connection on top of the powered anode by pulling the wire connector up and off of the powered anode rod electrical connector (Figure 33).

7.Remove the powered anode rod by using a ratchet and a 1-1/16??? socket turning counterclockwise (Figure 33) (Note: Figure 33 is shown exploded). If the socket used is short well you may have to remove the top male connector first before removing the powered anode rod.

8.Use Teflon?? tape or an approved pipe sealant on threads of the new powered anode rod.

9.Prior to installing, it will be necessary to use pliers to bend up approximately 90?? the electrical male connector on the top of the powered anode rod. The electrical connector should be bent upward in order to allow the 1-1/16??? deep well socket to pass over the connector. Note: if using a short well socket the male connector must first be removed (Figure 33 is shown exploded for clarity).

10.Place the powered anode rod in the spud (top of the tank) and turn clockwise until the threads are hand tight. Using a ratchet and 1-1/16??? socket tighten down water tight (Torque should be between 65 to 120 foot pounds).

11.Open a nearby hot water faucet to purge air from the water line. Fill water heater tank completely (Note: To assure the water heater tank is full, keep the hot water faucet open for 3 minutes after a constant flow of water is obtained).

12.After turning off the hot water faucet, check for water leaks around powered anode rod and immediately correct any if found.

13.Upon determining there???s no water leak at the newly installed powered anode rod, reconnect the electrical plug connector to the top of the anode male terminal.

14.Plug the electric transformer in the wall outlet and turn the gas supply back on to the gas control valve/thermostat.

15.Turn the gas control switch to the ???ON??? position (located on the side of the gas control valve/thermostat (Figure 28).

16.To restart the water heater, follow the directions on the ???Lighting and Operating Instructions??? label located on the front of the water heater near the gas control valve/ thermostat (Figure 28).

17.Upon verifying proper operation of the water heater, replace the manifold cover outer door.

TEFLON?? is a registered trademark of E.I. Du Pont De Nemours and Company

Draining and Flushing

It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during operation. The water heater should be drained if being shut down during freezing temperatures. To drain the tank, perform the following steps:

1.Turn off the gas to the water heater at the manual gas shut- off valve and turn off the electrical power to the gas control/ thermostat valve.

2.Open a nearby hot water faucet until the water is not longer hot.

3.Close the cold water inlet valve.

4.Connect a hose to the drain valve and terminate it to an adequate drain or external to the building.

5.Open the water heater drain valve and allow all the water to drain from the tank. Flush the tank with water as needed to remove sediment.

6.Close the drain valve, refill the tank, and restart the heater as directed in this manual.

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.

Routine Preventive Maintenance

At least annually, a visual inspection should be made of the venting and air supply system, piping systems, and main burner. Check the water heater for the following:

???Obstructions, damage, or deterioration in the venting system. Make sure the ventilation and combustion air supplies are not obstructed.

???Clean any dust or debris from the screen of the air intake chamber.

Temperature and Pressure Relief Valve

Explosion Harzard

??? Temperature-pressure relief valve must comply with ANSI Z21.22-CSA 4.4 and ASME code.

??? Properly sized temperature- pressure relief valve must be installed in opening provided.

??? Can result in overheating and excessive tank pressure.

??? Can cause serious injury or death.

Manually operate the temperature and pressure relief valve at least once a year to make sure it is working properly. To prevent water damage, the valve must be properly connected to a discharge line which terminates at an adequate drain. Standing clear of the outlet (discharged water may be hot), slowly lift

and release the lever handle on the temperature and pressure relief valve to allow the valve to operate freely and return to its closed position. See Figure 34. If the valve fails to completely reset and continues to release water, immediately shut off the electrial power, manual gas control valve and the cold water

inlet valve and call a qualified technician. Contact Sears Service 1-800-4-MY-HOME?? (www.sears.com).

TEMPERATURE AND PRESSURE

RELIEF VALVE

MANUAL RELIEF

VALVE

DISCHARGE LINE TO DRAIN

FIGURE 34.

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.parts description

See ???Parts Order List??? section for a list of available repair parts.

Removing the Manifold/Burner Assembly

1.Turn off the gas supply to the water heater at the manual gas shut-off valve. This valve is typically located beside the water heater. Note the position of the shut-off valve in the open/on position then proceed to turn it off (Figure 12).

2.Disconnect power supply to the heater.

3.Remove the outer door. Remove the 2 screw securing the manifold door assembly to the skirt.

4.Disconnect all wiring connectors from the gas control valve/ thermostat (Figure 35). Disconnect the manifold tube at the gas control valve/thermostat.

5.Grasp the manifold tube and push down slightly to free the manifold from the gas control valve/thermostat.

6.Carefully remove the manifold assembly from the burner com- partment. NOTE: Be sure not to damage internal parts (Figure 39).

7.Check the burner to see if it is dirty or clogged. The burner may be cleaned with soap and hot water.

Gas Control Valve/

Thermostat

FIGURE 35.

Removing the Burner from the Manifold/ Burner Assembly

Natural Gas Burner

1.Take off the burner by removing the two (2) screws located underneath the burner.

2.Check the burner to see if it is dirty or clogged. The burner may be cleaned with soap and hot water (Figure 36).

Screws

Igniter/Flame

Sense Connector

Burner

(Bottom View)

FIGURE 36.

Replacing the Flame Sense/Hot Surface igniter Assembly

1.Remove the manifold/burner assembly. See Removing the Manifold/Burner Assembly.

2.Lift the retainer clip straight up from the back of the manifold component block (using a flat-blade screwdriver), then remove the manifold component block from the manifold door (Figure 37.)

3.Remove and keep the screw securing the flame sense/hot surface igniter assembly (Figure 37)

4.Remove and discard the old flame sense/hot surface igniter assembly.

5.Route the new flame sense/hot surface igniter connector wire through manifold/burner door opening as shown in figure 37. Secure assembly to bracket using screw removed earlier.

6.Reposition the manifold component block in the mani-fold door opening and secure it with the retainer clip.

7.See Replacing the Manifold/Burner Assembly.

External Inspection & Cleaning of the

Air Intake Chamber Screen

1.At least twice annually inspect the air intake chamber screen (Figure 38) for any dust or debris that may have accumulated on the louvers. NOTE: If the water heater is located in an area that is subjected to lint and dirt, it may be necessary to check the air intake chamber screen

more frequently.

2. Use a vacuum cleaner with a hose attachment to remove any dust or debris that may have accumulated on the screen.

Air Intake Chamber

Screen

FIGURE 38.

Cleaning the Combustion Chamber and Air

Diverter Assembly

1.Follow procedure outlined in ???Removing the Manifold/Burner Assembly???.

2.Use a vacuum cleaner/shop vac to remove all loose debris in the combustion chamber (Figure 39). Use compressed air to clear any dust or debris that may have accumulated on the air diverter assembly.

3.Reassemble following the procedure under ???Replacing the Manifold/Burner Assembly???

Replacing the Manifold/Burner Assembly

WARNING

Explosion Hazard

???Remove any fiberglass between gasket and combustion chamber.

???Replace viewport if glass is missing or damaged.

???Replace two piece wire connector if missing or removed.

???Replace door gasket if damaged.

???Tighten both manifold door screws securely.

???Failure to follow these instructions can result in death, explosion, or fire.

1.Check the door gasket for damage or imbedded debris prior to installation.

2.Inspect the view port for damage and replace as required.

3.Insert the manifold/burner assembly into the burner compartment making sure that the tip of the manifold tube engages in the slot of the bracket inside the combustion chamber (Figure 40).

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. IMPORTANT: Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber.

6.During the following procedure, do not cross-thread or apply any thread sealant to any of the fittings listed below. First, reconnect the manifold tubing to the gas control valve/ thermostat.

7.Reconnect the flame sense/hot surface igniter wire to the gas control valve/thermostat (Figure 35).

8.Turn gas supply on and refer to the Lighting Instructions.

9.With the burner lit, check the gas control valve/thermostat supply line, two piece wire connector, and manifold tube connections for leaks. Check for leaks by brushing on an approved noncorrosive leak detection solution. IMPORTANT:

Do Not splash solution onto the electrical connections.

Bubbles forming indicate a leak. Correct any leak found. All leaks must be fixed immediately.

10. Replace the outer door (see item K page 10).

Removing and Replacing the Gas Control

Valve/Thermostat

IMPORTANT: Use only factory authorized replacement parts.

Removing the Gas Control Valve/Thermostat:

1.Set the gas control valve/thermostat to its lowest setting by first depressing the COOLERand HOTTER buttons together and hold for 1 second. Then press the COOLER button until the VAC indicator light appears (Figure 32).

2.Unplug the water heater from the wall outlet.

3.Turn off the gas supply to the water heater at the manual gas shut-off valve. This valve is typically located beside the water heater. Note the position of the shut-off valve in the open/on position then proceed to turn it off (Figure 12).

4.Drain the water heater. Refer to the section of ???Draining and Flushing??? section and follow the procedure.

5.Disconnect the the flame sense/hot surface igniter wire, power supply transformer, pressure switch/fan and display connector wires from the thermostat (Figure 35). Disconnect the manifould tube at the thermostat (Figure 35).

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.To remove the gas control valve/thermostat, thread a correctly sized pipe into the inlet and use it to turn the gas control valve/ thermostat (counterclockwise.) Do not use pipe wrench or equivalent to grip body. Damage may result, causing leaks. Do not insert any sharp objects into the inlet or outlet connections. Damage to the gas control valve/thermostat may result.

Replacing the Gas Valve:

1.To replace the gas control valve/thermostat, reassemble in reverse order. When replacing the gas control valve/ thermostat, thread a correctly sized pipe into the inlet and use it to turn the gas valve (clockwise.) DO NOT OVER TIGHTEN or damage may result. NOTE: Use an approved TEFLON?? tape or pipe compound only on the threaded section of the gas control valve/thermostat that screws into the tank.

2.Reconnect the gas piping to the gas control valve/ thermostat. NOTE: Use an approved Teflon tape or pipe compound on the gas piping connections.

3.Reconnect the manifold tube, flame sense/hot surface igniter wire, power supply transformer, pressure switch/fan and display connector wires (Figure 35).

4.Fill the tank completely with water. NOTE: To purge the lines of any excess air, keep the hot water faucet open for 3 minutes after a constant flow of water is obtained.

5.Turn on the gas supply and test the gas supply connections by brushing on an approved noncorrosive leak detection solution. IMPORTANT: Do Not splash solution onto the electrical connections. Bubbles forming indicate a leak. Correct any leak found.

6.Check the operation of the burner by following the lighting instructions on the front of the water heater. With the burner lit, check the gas control valve/thermostat supply line, manifold tube connections for leaks.

7.Verify proper operation and then replace the outer door.

TEFLON?? is a registered trademark of E.I. Du Pont De Nemours and Company

As water is heated, it expands (thermal expansion). In a closed system, the volume of water will grow. As the volume of water grows, there will be a corresponding increase in water pressure due to thermal expansion. Thermal expansion can cause premature tank failure (leakage). This type of failure is not covered under the limited warranty. Thermal expansion can also cause intermittent temperature-pressure relief valve operation: water discharged from the valve due to excessive pressure build up. The temperature-pressure relief valve is not intended for the constant relief of thermal expansion. This condition is not covered under the limited warranty.

A properly sized thermal expansion tank should be installed on all closed systems to control the harmful effects of thermal expansion. Thermal expansion tanks are available from Sears stores and through the Sears Service Centers. Contact the local plumbing inspector, water supplier and/or the Sears Service Center for assistance in controlling these situations. See Figure 41.

Thermal Expansion Tank Specifications

TABLE 6

Expansion Tank Sizing Chart

TABLE 7

*Highest recorded inlet water pressure in a 24 hour period or regulated water pressure.

FIGURE 41.

Strange Sounds

Possible noises due to expansion and contraction of some metal parts during periods of heat-up and cool-down do not represent harmful or dangerous conditions.

Condensation causes sizzling and popping within the burner area during heating and cooling periods and should be considered normal. See ???Condensation??? section.

Draft Hood Operation

Check draft hood operation by performing a worst case depressurization of the building. With all doors and windows closed, and with all air handling equipment and exhaust fans operating such as furnaces, clothes dryers, range hoods and bathroom fans, a match flame should still be drawn into the draft hood of the water heater with its burner firing. If the flame is not

drawn toward the draft hood, shut off water heater and make necessary air supply changes to correct.

Condensation

Whenever the water heater is filled with cold water, some condensate will form while the burner is on. A water heater may appear to be leaking when in fact the water is condensation. This usually happens when:

???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.

???Large amounts of hot water are used in a short time and the refill water in the tank is very cold.

Moisture from the products of combustion condense on the cooler tank surfaces and form drops of water which may fall onto the burner or other hot surfaces to produce a ???sizzling??? or ???frying??? noise.

Because of the suddenness and amount of water, condensation water may be diagnosed as a ???tank leak???. After the water in the tank warms up (about 1-2 hours), the condition should disappear.

Do not assume the water heater is leaking until there has been enough time for the water in the tank to warm up.

An undersized water heater will cause more condensation. The water heater must be sized properly to meet the family???s

demands for hot water including dishwashers, washing machines and shower heads.

Excessive condensation may be noticed during the winter and early spring months when incoming water temperatures are at their lowest.

Good venting is essential for a gas fired water heater to operate properly as well as to carry away products of combustion and water vapor.

Smoke Odor

It is not uncommon to experience a small amount of smoke and odor during the initial start-up. This is due to burning off of oil from metal parts, and will disappear in a short while.

Operational Conditions

???AIR??? In Hot Water Faucets

HYDROGEN GAS: Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally two weeks or more). Hydrogen gas is extremely ???ammable and explosive. To prevent the possibility of injury under these conditions, we recommend the hot water faucet, located farthest away, be opened for several minutes before any electrical appliances which are connected to the hot water system are used (such as a dishwasher or washing machine). If hydrogen gas is present, there will probably be an unusual sound similar to air escaping through the pipe as the hot water faucet is opened. There must be no smoking or open ???ame near the faucet at the time it is open.

Do not remove the anode, leaving the tank unprotected. By doing so, all warranty on the water heater tank is voided.

Safety Shut-off and Thermal Switch

This water heater is designed to automatically shut-off in the event of the following:

1.The burner flame is extinguished for any reason.

2.The water temperature exceeds 195??F (91??C).

3.Excessive build up of dust on the louvers of the air intake chamber. See Maintenance of your Water Heater Section.

This unit is also equipped with a flammable vapor sensor (FV Sensor), designed to shut off the gas supply in the event the water heater has been exposed to flammable vapors (e.g., spilled gasoline). NOTE: If the FV-Sense senses the presence of ???ammable vapors a special FV-Sense reset sequence is required to be input into the Electronic Control Display in order to restore operation of the water heater.

A high temperature limit switch or ECO (Energy Cut Off) in the tank is used to shut off the unit if the water temperature exceeds 195??F (91??C). The ECO is a single-use switch, which, if activated, requires complete replacement of the entire gas control valve/thermostat. If the ECO should activate, the water heater cannot be used until the gas control valve/thermostat is replaced by a qualified technician. Contact Sears Service 1-800-4-MY-HOME?? (www.sears.com).

Service

Before calling for repair service, please read the Troubleshooting Guide in this manual. If a condition persists or you are uncertain about the operation of the water heater, let the Sears Service Center check it out. Contact Sears Service 1-800-4-MY-HOME?? (1-800-469-4663).

Leakage Checkpoints

B.*Condensation may be seen on pipes in humid weather or pipe connections may be leaking.

C.*The anode rod fitting may be leaking.

D.Small amounts of water from temperature-pressure relief valve may be due to thermal expansion or high water pressure in your area.

E.*The temperature-pressure relief valve may be leaking at the tank fitting.

F.Water from a drain valve may be due to the valve being slightly opened.

G.*The drain valve may be leaking at the tank fitting.

H.Combustion products contain water vapor which can condense on the cooler surfaces of the tank. Droplets form and drip onto the burner or run on the floor. This is common at the time of start-up after installation and when incoming water is cold.

I.Water in the water heater bottom or on the floor may be from condensation, loose connections, or the relief valve. DO NOT replace the water heater until a full inspection of all possible water sources is made and necessary corrective steps taken.

Leakage from other appliances, water lines, or ground seepage should also be checked.

*To check where threaded portion enters tank, insert cotton swab between jacket opening and fitting. If cotton is wet, follow draining instructions in the ???Draining and Flushing??? section and then remove fitting. Put pipe dope or teflon tape on the threads and replace. When you are finished, follow the steps in ???Filling the Water Heater??? in the Installation Instructions earlier in this manual.

Teflon?? is a registered trademark of E.I. Du Pont De Numours and Company.

Pressurized Combustion Chamber System

Operational Checklist

1.Manifold gasket properly sealed.

2.Viewport not damaged or cracked.

3.Combustion chamber free of debris and undamaged.

4.Manifold component block properly installed.

5.No leaks at manifold connection.

6.Manifold door screws securely tightened.

Now that you have purchased your gas water heater, should a need ever exist for repair parts or service, simply contact any Sears Service Center or call 1-800-4-MY-HOME?? (1-800-469-4663). Be sure to provide all pertinent facts when you call or visit.

WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE

FOLLOWING INFORMATION:

THIS IS A REPAIR PARTS LIST, NOT A PACKING LIST.

1-800-827-6655 (U.S.A.)

Para pedir servicio de reparaci??n a domicilio, y para ordenar piezas:

1-888-SU-HOGAR??

(1-888-784-6427) www.sears.com

1-800-361-6665 (Canada)

Au Canada pour service en fran??ais:

1-800-LE-FOYERMC

(1-800-533-6937) www.sears.ca