Kenmore POWER MISER 153.33066 User manual

1
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A
This water heater meets the new ANSI Z21.10.1
standard that deals with the accidental or
unintended ignition of flammable vapors, such
as those emitted by gasoline.
Owner’s Manual
FOR POTABLE WATER HEATING ONLY.
NOT SUITABLE FOR SPACE HEATING.
NOT FOR USE IN MOBILE HOMES.
MODEL NO.
153.330660 40 Gallon
For Your Safety
AN ODORANT IS ADDED TO THE GAS USED BY THIS WATER HEATER.
• Safety Instructions
• Installation
• Operation
• Care and Maintenance
• Troubleshooting
• Parts List
POWER MISER™ 6
ULTRA LOW NOx
GAS WATER HEATER
www.sears.com
PRINTED IN THE U.S.A 0609 PART NO. 315428-001
Si no puede leer o entender el inglés y necesita el manual de
instrucciones en español, puede solicitarlo al 1-800-821-2017. NO
TRATE DE INSTALAR U OPERAR ESTE CALENTADOR DE AGUA
SI NO ENTIENDE LAS INSTRUCCIONES. No hacer caso de esta
advertencia podría originar lesiones graves o mortales.
ADVERTENCIA

2
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 hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that
the meaning of each safety message is understood by you and others who install, use or service this water heater.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message and
how to avoid the risk of injury.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of
substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires
businesses to warn of potential exposure to such substances.
WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other
reproductive harm.
This appliance can cause low-level exposure to some of the substances included in the Act.
IMPORTANT DEFINITIONS
• Qualified Installer: A qualified installer must have ability equivalent to a licensed tradesman in the fields of plumbing.
air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas
Code as it relates to the installation of gas fired water heaters. The qualified installer must also be familiar with the
design features and use of flammable vapor ignition resistant water heaters, and have a thorough understanding of this
instruction manual.
• Service Agency: A service agency also must have ability equivalent to a licensed tradesman in the fields plumbing
air supply, venting and gas supply, including a thorough understanding of the requirements of the National Fuel Gas
Code as it relates to the installation of gas fired water heaters. The service agency must also have a thorough
understanding of the instruction manual, and be able to perform repairs strictly in accordance with the service guidelines
provided by the manufacturer.
• Gas Supplier: The natural gas or propane utility or service who supplies gas for utilization by the gas burning
appliances within this application. The gas supplier typically has responsibility for the inspection and code approval of
gas piping up to and including the natural gas meter or propane storage tank of a building. Many gas suppliers also
offer service and inspection of appliances within the building.
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER
WARNING
CAUTION
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or injury.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in death or injury.
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result
in minor or moderate injury.
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result
in property damage.
CAUTION
© Sears, Roebuck and Co.

3
SAFETY PRECAUTIONS

4
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE...................................................................................................................... 2
SAFETY PRECAUTIONS.............................................................................................................................. 3
TABLE OF CONTENTS................................................................................................................................. 4
CUSTOMER RESPONSIBILITIES......................................................................................................................................... 5
PRODUCT SPECIFICATIONS ................................................................................................................................................ 5
MATERIALS AND BASIC TOOLS NEEDED....................................................................................................................... 6
Materials Needed .....................................................................................................................................................6
Basic Tools................................................................................................................................................................6
TYPICAL INSTALLATION.......................................................................................................................................................... 7
INSTALLATION INSTRUCTIONS...................................................................................................................................... 8-17
Removing the Old Water Heater...............................................................................................................................8
Facts to Consider About the Location..................................................................................................................9-10
Insulation Blankets .................................................................................................................................................10
Combustion Air and Ventilation Appliances in Unconfined Spaces ........................................................................ 11
Combustion Air and Ventilation Appliancesin Confined Spaces ........................................................................11-12
Water Piping ......................................................................................................................................................12-13
T & P Valve and Pipe Insulation ........................................................................................................................13-14
Temperature Pressure Relief Valve ...................................................................................................................13-14
Filling the Water Heater ..........................................................................................................................................15
Venting...............................................................................................................................................................15-16
Gas Piping .........................................................................................................................................................16-17
Sediment Trap ........................................................................................................................................................17
OPERATING INSTRUCTIONS......................................................................................................................................... 18-19
Lighting & Operating Label .....................................................................................................................................18
Temperature Regulation .........................................................................................................................................19
SERVICE AND ADJUSTMENT ........................................................................................................................................ 20-22
Tank (Sediment) Cleaning ......................................................................................................................................20
Venting System Inspection .....................................................................................................................................20
Burner Inspection ...................................................................................................................................................20
Removing the Burner Door Assembly ....................................................................................................................21
Ultra Low NOx Natural Gas Burner ........................................................................................................................21
Replacing the Pilot Assembly .................................................................................................................................21
Replacing the Thermocouple..................................................................................................................................22
External Inspection & Cleaning of the Flame Arrestor............................................................................................22
Cleaning the Combustion Chamber and Flame Arrestor........................................................................................22
Replacing the Burner Door Assembly.....................................................................................................................23
Piezoelectric Igniter System ...................................................................................................................................23
Testing the Igniter System ......................................................................................................................................23
Removing and Replacing the Gas Control Valve/Thermostat ................................................................................24
Housekeeping.........................................................................................................................................................24
Anode Rod Inspection ............................................................................................................................................24
Temperature-Pressure Relief Valve Operation .......................................................................................................25
Draining ..................................................................................................................................................................25
Drain Valve Washer Replacement..........................................................................................................................25
Service....................................................................................................................................................................25
TROUBLESHOOTING GUIDE ........................................................................................................................................ 26-30
Start Up Conditions ...........................................................................................................................................26-27
Thermal Expansion ...........................................................................................................................................26
Strange Sounds ................................................................................................................................................26
Draft Hood Operation ........................................................................................................................................26
Condensation ....................................................................................................................................................27
Smoke/Odor ......................................................................................................................................................27
Operational Conditions ...........................................................................................................................................27
Smelly Odor ......................................................................................................................................................27
Air in Hot Water Faucets ...................................................................................................................................27
High Temperature Shut-Off System ..................................................................................................................27
Troubleshooting Items .......................................................................................................................................28-30
PARTS ORDER LIST................................................................................................................................................................ 31
WARRANTY................................................................................................................................................................................. 32

5
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
• This gas-fired water heater is design certified by CSA
INTERNATIONAL under American National Standard/CSA
Standard for Gas Water Heaters ANSI Z21.10.1 • CSA 4.1
(current edition).
• Read the “Safety Precautions” section, page 3 of this manual
first and then the entire manual carefully. If you don’t follow
the safety rules, the water heater will not operate properly. It
could cause DEATH, SERIOUS BODILY INJURY AND/OR
PROPERTY DAMAGE.
This manual contains instructions for the installation, operation,
and maintenance of the gas-fired 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 first 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 current
edition of 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 fires. See
figure 1.
Examine the location to ensure the water heater complies
with the Facts to Consider About the Location 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 the California Office of the
State Architect, 1102 Q Street, Suite 5100, Sacramento, CA
95811. Instructions can also be downloaded to your computer
at WWW.dsa.dgs.ca.gov/Pubs.
• Complies with 10 ng/J SCAQMD rule #1121 and districts
having equivalent NOx requirements.
CUSTOMER RESPONSIBILITIES
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
INCHES
(mm)
DIAMETER
INCHES
(mm)
DIMENSIONS IN
INCHES (mm)
HEIGHT TO
JACKET TOP
153.330660 40 (151) NATURAL 40,000 41.0 3 (76) OR 4 (102)
20 (508) 58 3/8 (1,483)

6
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.
WATER HEATER INSTALLATION KIT WITH
FLEXIBLE CONNECTORS FOR 3/4”
(19.05 mm) OR 1/2” (12.7 mm) THREADED OR
COPPER PLUMBING AND FLEXIBLE WATER
HEATER GAS CONNECTOR WITH FITTINGS.
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.
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.
• Pipe Wrenches (2) 14” (356 mm)
• Screwdriver
• Tin Snips
• 6’ (1.82 m) Tape or Folding Ruler
• Garden Hose
• Drill
• Pipe Dope or Teflon Tape
Additional Tools Needed
When Sweat Soldering
• Tubing Cutters or Hacksaw
• Propane Tank
• Soft Solder
• Solder Flux
• Emery Cloth
• Wire Brushes
SLOT-HEAD SCREWDRIVER
PHILLIPS SCREWDRIVER
TIN SNIPS
PIPE WRENCH
PIPE DOPE
(SQUEEZE TUBE)
USE FOR WATER AND GAS
CONNECTIONS
DRILL
GARDEN HOSE 6 FOOT TAPE
ROLL OF TEFLON
TAPE (USE ONLY ON
WATER CONNECTIONS)
HACKSAW
3/4” (19 mm) WIRE BRUSH
1/2” (13 mm) WIRE BRUSH
SOLDER
FLUX
ROLL OF LEAD-FREE
SOFT SOLDER
TUBING CUTTER
PROPANE
TORCH
ROLL OF
EMERY CLOTH

7
A
B
C
D
E
F
G
H
I
J
X
W
V
U
T
Y
Q
P
F
M
NO
S
KL
R
6” MAXIMUM
AIR GAP
DISCHARGE PIPE
(Do not cap or plug)
VACUUM RELIEF
VALVE
*INSTALL PER
LOCAL CODES
INSTALL THERMAL EXPANSION
TANK OR DEVICE IF WATER
HEATER IS INSTALLED IN A
CLOSED WATER SYSTEM
TYPICAL INSTALLATION
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A Vent Pipe
B Drafthood
C Anode
D Hot Water Outlet
E Outlet
F Flexible Water Connections
G Gas Supply
H Manual Gas Shut-off Valve
I Ground Joint Union
* INSTALL IN ACCORDANCE
WITH LOCAL CODES.
* DRIP LEG AS REQUIRED
BY LOCAL CODES.
FIGURE 1.
J Drip Leg (Sediment Trap)
K Inner Door
L Outer door
M Union
N Inlet Water Shut-off Valve
O Cold Water Inlet
P Inlet Dip Tube
Q Temperature-Pressure Relief Valve
R Rating Plate
S Flue Baffle
T Gas Control Valve/Thermostat
U Drain Valve
V Pilot and Main Burner
W Flue
X Metal Drain Pan
Y Piezo Igniter
* ALL PIPING MATERIALS TO BE
SUPPLIED BY CUSTOMERS.
TO VENT TERMINATION
ON ROOF
GAS CONTROL KNOB
(T) GAS CONTROL VALVE/
THERMOSTAT
WATER TEMPERATURE
(ADJUSTING DIAL)
TOP VIEW
“OFF”
POSITION
“PILOT”
POSITION
“ON”
POSITION
(V) PILOT & MAIN BURNER
PILOT TUBING
THERMOCOUPLE
PILOT BURNER
IGNITER ROD
BURNER
TUBE
MAIN BURNER

8
INSTALLATION INSTRUCTIONS
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
shut “OFF” until the water heater
installation is completed, see
Figures 2 and 3.
2. Turn “OFF” the water supply to
the water heater at the water shut
off valve or water meter. Some
installations require that the water
be turned off to the entire house,
see Figures 2 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.
FIGURE 2.
Removing the Old Water Heater
FIGURE 3.
FIGURE 4.
4. Attach a hose to the water heater
drain valve and put the other end in
a floor drain or outdoors. Open the
water heater drain valve. Open a
nearby hot water faucet which will
relieve pressure in the water heater
and speed draining. The water
passing out of the drain valve may
be extremely hot. To avoid being
scalded, make sure all connections
are tight and that the water flow is
directed away from any person, see
Figures 2 and 5.
5. Disconnect the vent pipe from the draft hood where it connects
to the water heater. In most installations the vent pipe can
be lifted off after any screw or other attached devices are
removed. Dispose of the draft hood. The new water heater
has a draft hood which must be used for proper operation.
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.
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.
FIGURE 5.
1
2
3
4
5
6
FIGURE 6.
FIGURE 7.

9
Facts to Consider About
the Location
Carefully choose an indoor location for the new water heater.
The placement is a very important consideration for the safety
of the occupants in the building and for the most economical
use of the appliance. This water heater is not for use in
manufactured (mobile) homes or outdoor installation.
Whether replacing an old water heater or putting the water
heater in a new location, the following critical points must be
observed:
• Select a location indoors as close as practical to the gas
vent or chimney to which the water heater vent is going to be
connected, and as centralized with the water piping system
as possible.
• Selected location must provide adequate clearances for
servicing and proper operation of the water heater.
Installation of the water heater must be accomplished in such a
manner that if the tank or any connections should leak, the flow
will not cause damage to the structure. For this reason, it is not
advisable to install the water heater in an attic or upper floor. When
such locations cannot be avoided, a suitable metal drain pan should
be installed under the water heater. Metal drain pans are available
at your local Sears or hardware store. Such a drain pan must have
a minimum length and width of at least 2 inches (51 mm) greater
than the water heater dimensions and must be piped to an adequate
drain. The pan must not restrict combustion air flow.
Water heater life depends upon water quality, water pressure
and the environment in which the water heater is installed. Water
heaters are sometimes installed in locations where leakage may
result in property damage, even with the use of a metal drain
pan piped to a drain. 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 leakage
is detected.
• 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.
INSTALLATIONS IN AREAS WHERE FLAMMABLE LIQUIDS
(VAPORS) ARE LIKELY TO BE PRESENT OR STORED
(GARAGES, STORAGEAND UTILITYAREAS, ETC.): Flammable
liquids (such as gasoline, solvents, propane [LP or butane, etc.]
and other substances such as adhesives, etc.) emit flammable
vapors which can be ignited by a gas water heater’s pilot light or
main burner. The resulting flashback and fire can cause death
or serious burns to anyone in the area. Even though this water
heater is a flammable vapor 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.
Also, the water heater must be located and/or protected so it is
not subject to physical damage by a moving vehicle.
This water heater must not be installed directly on carpeting.
Carpeting must be protected by metal or wood panel beneath
the appliance extending beyond the full width and depth of the
appliance by at least 3 inches (76.2mm) in any direction, or if
the appliance is installed in an alcove or closet, the entire floor
must be covered by the panel. Failure to heed this warning may
result in a fire hazard.

10
If this water heater will be used in beauty shops, barber shops,
cleaning establishments, or self-service laundries with dry
cleaning equipment, it is imperative that the water heater or
water heaters be installed so that combustion and ventilation
air be taken directly from outdoors (direct vent).
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorine based chemicals, refrigerants, etc.) in addition to being
highly flammable in many cases, will also change to corrosive
hydrochloric acid when exposed to the combustion products of
the water heater. The results can be hazardous, and also cause
product failure.
Insulation Blankets
Insulation blankets available to the general public for external
use on gas water heaters are not necessary with Kenmore
products. The purpose of an insulation blanket is to reduce the
standby heat loss encountered with storage tank heaters. Your
Kenmore water heater meets or exceeds the National Appliance
Energy Conservation Act standards with respect to insulation
and standby loss requirements, making an insulation blanket
unnecessary.
Minimum clearances between the water heater and combustible
surfaces are 0 inch at the sides and rear, 4 inches (102 mm)
at the front, and 6 inches (153 mm) from the vent pipe, see
Figure 8. Clearance from the top of the jacket is 8 inches (203
mm) on most models. Note that a lesser dimension may be
allowed on some models, refer to the label attached adjacent
to the gas control valve on the water heater.
FIGURE 8.
FIGURE 9.
A gas water heater cannot operate properly without the correct
amount of air for combustion, see Figure 9. Do not install in a
confined area such as a closet, unless you provide air as shown
in the Locating The New Water Heater section. Never obstruct
the flow of ventilation air. If you have any doubts or questions at
all, call your gas supplier. Failure to provide the proper amount of
combustion air can result in a fire or explosion and cause death,
serious bodily injury, or property damage.
WARNING
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.
• Do not apply insulation to the top of the water heater, as this
will interfere with safe operation of the draft hood.
• Do not cover the outer door, thermostat or temperature &
pressure relief valve.
• Do not allow insulation to come within 2” (50.8 mm) of the floor
to prevent blockage of combustion air flow to the burner.
• Do not cover the instruction manual. Keep it on the side of
the water heater or nearby for future reference.

11
• Do obtain new warning and instruction labels from Sears for
placement on the blanket directly over the existing labels.
• Do inspect the insulation blanket frequently to make certain
it does not sag, thereby obstructing combustion air flow.
Combustion Air and Ventilation for
Appliances Located in Unconfined Spaces
UNCONFINED SPACE is space whose volume is not less than
50 cubic feet per 1,000 Btu per hour (4.8 m3per kW) of the
aggregate input rating of all appliances installed in that space.
Rooms communicating directly with the space in which the
appliances are installed, through openings not furnished with
doors, are considered a part of the unconfined space.
In unconfined spaces in buildings, infiltration may be adequate
to provide air for combustion, ventilation and dilution of flue
gases. However, in buildings of tight construction (for example,
weather stripping, heavily insulated, caulked, vapor barrier,
etc.), additional air may need to be provided using the methods
described in Combustion Air and Ventilation for Appliances
Located in Confined Spaces.
Combustion Air and Ventilation for
Appliances Located in Confined Spaces
CONFINED SPACE is a space whose volume is less than
50 cubic feet per 1,000 Btu per hour (4.8 m3per kW) of the
aggregate input rating of all appliances installed in that space.
A. ALL AIR FROM INSIDE BUILDINGS:
(See Figure 9 on page 10 and Figure 10 below)
The confined space shall be provided with two permanent
openings communicating directly with an additional room(s) of
sufficient volume so that the combined volume of all spaces
meets the criteria for an unconfined space. The total input of all
gas utilization equipment installed in the combined space shall
be considered in making this determination. Each opening shall
have a minimum free area of one square inch per 1,000 Btu per
hour (22 cm2/kW) of the total input rating of all gas utilization
equipment in the confined space, but not less than 100 square
inches (645 cm2). One opening shall commence within 12 inches
(30 cm) of the top and one commencing within 12 inches (30
cm) of the bottom of the enclosures.
The confined space shall be provided with two permanent
openings, one commencing within 12 inches (30 cm) of the top
and one commencing within 12 inches (30 cm) from the bottom
of the enclosure. The openings shall communicate directly, or
by ducts, with the outdoors or spaces (crawl or attic) that freely
communicate with the outdoors.
FIGURE 11.
• When directly communicating with the outdoors, each opening
shall have a minimum free area of 1 square inch per 4,000 Btu
per hour (5.5 cm2/kW) of total input rating of all equipment in
the enclosure. See Figure 11.
• When communicating with the outdoors through vertical
ducts, each opening shall have a minimum free area of
1 square inch per 4,000 BTU per hour (5.5 cm2/kW) of
total input rating of all equipment in the enclosure. See
Figure 12.
FIGURE 10.
FIGURE 12.
• When communicating with the outdoors through horizontal
ducts, each opening shall have a minimum free area of
1 square inch per 2,000 BTU per hour (11 cm2/kW) of
total input rating of all equipment in the enclosure. See
Figure 13.
• When ducts are used, they shall be of the same cross-
sectional area as the free area of the openings to which
they connect. The minimum short side dimension of
rectangular air ducts shall not be less than 3 inches
(76.2 mm). See Figure 13.
B. ALL AIR FROM OUTDOORS: (See Figures 9, 11,12,13 and 13A)

12
Water Piping
FIGURE 13.
• Alternatively a single permanent opening may be used when
communicating directly with the outdoors, or with spaces that
freely communicate with the outdoors. The opening shall
have a minimum free area of 1 square inch per 3,000 BTU
per hour (8.3 cm²/kW) of total input rating of all equipment in
the enclosure. See Figure 13A.
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, cleaning 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 14. Valves
for reducing point of use temperature by mixing cold and hot
water are also available. Follow manufacturer’s instructions
for installation of the valves. Before changing the factory
setting on the thermostat, read the Temperature Regulation
section in this manual.
FIGURE 14.
• Louvers and Grilles: In calculating free area, consideration
shall be given to the blocking effect of louvers, grilles or
screens protecting openings. Screens used shall not be
smaller than 1/4 inch (6.4 mm) mesh. If the free area through
a design of louver or grille is known, it should be used in
calculating the size opening required to provide the free area
specified. If the design and free area is not known, it may be
assumed that wood louvers will be 20-25 percent free area
and metal louvers and grilles will have 60-75 percent free
area. Louvers and grilles shall be fixed in the open position
or interlocked with the equipment so that they are opened
automatically during equipment operation.
• Special Conditions Created by Mechanical Exhausting or
Fireplaces: operation of exhaust fans, ventilation systems,
clothes dryers or fireplaces may create conditions requiring
special attention to avoid unsatisfactory operation of installed
gas utilization equipment.
FIGURE 13A.

13
This water heater shall not be connected to any heating
systems or component(s) used with a non-potable water heating
appliance.
All piping components connected to this unit for space heating
applications shall be suitable for use with potable water.
Toxic chemicals, such as those used for boiler treatment shall
not be introduced into this system.
Water supply systems may, because of such events as high line
pressure, frequent cut-offs or the effects of water hammer, have
installed devices such as pressure reducing valves, check valves,
back flow preventers, etc. to control these types of problems.
When these devices are not equipped with an internal by-pass,
and no other measures are taken, the devices cause the water
system to be closed. As water is heated, it expands (thermal
expansion) and closed systems do not allow for the expansion
of heated water.
The water within the water heater tank expands as it is heated
and increases the pressure of the water system. If the relieving
point of the water heater’s temperature-pressure relief valve
is reached, the valve will relieve the excess pressure. The
temperature-pressure relief valve is not intended for the
constant relief of thermal expansion. This is an unacceptable
condition and must be corrected. It is recommended that any
devices installed which could create a closed system have a
by-pass and/or the system have an expansion tank to relieve the
pressure built by thermal expansion in the water system. Refer
to the Thermal Expansion section under Troubleshooting Guide
or contact local plumbing authority or local Sears Service Center
on how to control this situation.
NOTE: To protect against untimely corrosion of hot and cold
water fittings, it is strongly recommended that di-electric
unions or couplings be installed on this water heater when
connected to copper pipe.
Figure 15 shows the typical attachment of the water piping to
the water heater. The water heater is equipped with 3/4” NPT
water connections.
NOTE: If using copper tubing, solder tubing to an adapter
before attaching the adapter to the cold water inlet
connection. Do not solder the cold water supply line directly
to the cold water inlet. It will harm the dip tube and damage
the tank.
• Look at the top cover of the water heater. The water outlet is
marked “HOT”. Put two or three turns of Teflon tape around the
threaded end of the threaded-to-sweat coupling and around
both ends of the 3/4” NPT threaded nipple. Using flexible
connectors, connect the hot water pipe to the hot water outlet
on the water heater.
TEFLON®is a registered trademark of E.I. Du Pont De Nemours and Company.
• Look at the top of the water heater. The cold water inlet is
marked “COLD”. Put two or three turns of Teflon tape around
the threaded end of the threaded-to-sweat coupling and
around both ends of the 3/4” NPT threaded nipple. Using
flexible connectors, connect the cold water pipe to the cold
water inlet of the water heater.
NOTE: This water heater is super insulated to minimize
heat loss from the tank. Further reduction in heat loss
can be accomplished by insulating the hot water lines
from the water heater.
INSTALLATION COMPLETED USING
INSTALLATION KIT
T & P Valve and Pipe Insulation
Remove insulation for T & P valve and pipe connections from
carton.
FIGURE 15A.
Fit pipe insulation over the incoming cold water line and the hot
water line. Make sure that the insulation is against the top cover
of the heater.
FLOOR DRAIN
DISCHARGE PIPE
(Do not cap or plug)
TEMPERATURE-
PRESSURE
RELIEF VALVE
3/4” THREADED
COUPLING
THREADED TO
SWEAT COUPLING
SHUTOFF
VALVE
FLEXIBLE
WATER
CONNECTORS
3/4” THREADED
COUPLING
THREADED TO
SWEAT COUPLING
DRAFT HOOD
HOT WATER
OUTLET
COLD WATER
INLET
6” MAXIMUM
AIR GAP
FIGURE 15.

14
Fit T & P valve insulation over valve. Make sure that the insulation
does not interfere with the lever of the T & P valve.
Secure all insulation using tape.
Temperature-Pressure Relief Valve
The Discharge Pipe:
• Shall not be smaller in size than the outlet pipe size of the
valve, or have any reducing couplings or other restrictions.
• Shall not be plugged or blocked.
• Shall be of material listed for hot water distribution.
• Shall be installed so as to allow complete drainage of both the
temperature-pressure relief valve, and the discharge pipe.
• Shall terminate a maximum of six inches above a floor drain
or external to the building. In cold climates, it is recommended
that the discharge pipe be terminated at an adequate drain
inside the building.
• Shall terminate at an adequate drain.
• Shall not have any valve between the relief valve and tank.
FLOOR DRAIN
DISCHARGE PIPE
(Do not cap or plug)
TEMPERATURE - PRESSURE
RELIEF VALVE
(OPTIONAL TOP T&P RELIEF
VALVE NOT SHOWN)
SHUTOFF
VALVE
DRAFT HOOD
HOT WATER
OUTLET
COLD WATER
INLET
DRAIN VALVE
HOT COLD
6” MAXIMUM
AIR GAP
FIGURE 16.
This heater is provided with a properly certified combination
temperature - pressure relief valve by the manufacturer.
The valve is certified by a nationally recognized testing laboratory
that maintains periodic inspection of production of listed
equipment as meeting the requirements for Relief Valves for Hot
Water Supply Systems, ANSI Z21.22 and the code requirements
of ASME.
If replaced, the valve must meet the requirements of local codes,
but not less than a combination temperature and pressure relief
valve certified as indicated in the above paragraph.
The valve must be marked with a maximum set pressure not to
exceed the marked hydrostatic working pressure of the water
heater (150 psi = 1,035kPa) and a discharge capacity not less
than the water heater input rate as shown on the model rating
plate.
For safe operation of the water heater, the relief valve must not
be removed from its designated opening nor plugged.
The temperature-pressure relief valve must be installed directly
into the fitting of the water heater designed for the relief valve.
Position the valve downward and provide tubing so that any
discharge will exit only within 6 inches (153 mm) above, or
at any distance below the structural floor, see Figure 16. Be
certain that no contact is made with any live electrical part.
The discharge opening must not be blocked or reduced in
size under any circumstances. Excessive length, over 30 feet
(9.14 m), or use of more than four elbows can cause restriction
and reduce the discharge capacity of the valve.
No valve or other obstruction is to be placed between the relief
valve and the tank. Do not connect tubing directly to discharge
drain unless a 6 inch air gap is provided. To prevent bodily
injury, hazard to life, or property damage, the relief valve must
be allowed to discharge water in quantities should circumstances
demand. If the discharge pipe is not connected to a drain or other
suitable means, the water flow may cause property damage.

15
The temperature-pressure relief valve must be manually operated
at least once a year. Caution should be taken to ensure that
(1) no one is in front of or around the outlet of the temperature-
pressure relief valve discharge line, and (2) the water manually
discharged will not cause any bodily injury or property damage
because the water may be extremely hot.
If after manually operating the valve, it fails to completely reset
and continues to release water, immediately close the cold water
inlet to the water heater, follow the draining instructions, and
replace the temperature-pressure relief valve with a new one.
Filling the Water Heater
Never use this water heater unless it is completely full of water.
To prevent damage to the tank, the tank must be filled with water.
Water must flow from the hot water faucet before turning “ON”
gas to the water heater.
To fill the water heater with water:
• Close the water heater drain valve by inserting a flat head
screwdriver in the slot on the stem and turn to the right
(clockwise). The drain valve is on the lower front of the water
heater.
• Open the cold water supply valve to the water heater.
NOTE: The cold water supply valve must be left open
when the water heater is in use.
• To insure complete filling of the tank, allow air to exit by
opening the nearest hot water faucet. Allow water to run until
a constant flow is obtained. This will let air out of the water
heater and the piping.
• Check all water piping and connections for leaks. Repair as
needed.
Venting
VENT DAMPERS - Any vent damper, whether it is operated
thermally or otherwise must be removed if its use inhibits proper
drafting of the water heater.
Thermally Operated Vent Dampers: Gas-fired water heaters
having thermal efficiency in excess of 80% may produce a
relatively low flue gas temperature. Such temperatures may
not be high enough to properly open thermally operated vent
dampers. This would cause spillage of the flue gases and may
cause carbon monoxide poisoning.
Vent dampers must bear evidence of certification as complying
with the current edition of the American National Standard
ANSI Z21.68 (ANSI Z21.66 & 67, respectively, cover electrically
and mechanically actuated vent dampers). Before installation
of any vent damper, consult your local Sears Service Center or
the local gas supplier for further information.
To insure proper venting of this gas-fired water heater, the correct
vent pipe diameter must be utilized. Any additions or deletions
of other gas appliances on a common vent with this water
heater may adversely affect the operation of the water heater.
Consult your gas supplier if any such changes are planned.
For replacement heater installations where pre-existing venting
is used, the venting must be inspected for obstructions and if
deterioration is present, it must be replaced.
For proper venting in certain installations, a larger diameter vent
pipe may be necessary. Consult your local Sears Service Center
or gas supplier to aid you in determining the proper venting for
your water heater from the vent tables in the current edition of
the National Fuel Gas Code ANSI Z223.1/NFPA 54.
Periodically check the venting system for signs of obstruction or
deterioration and replace if needed.
The combustion and ventilation air flow must not be
obstructed.
The water heater with draft hood installed must be connected
to a chimney or listed vent pipe system, which terminates to the
outdoors. Never operate the water heater unless it is vented
to the outdoors and has adequate air supply to avoid risks of
improper operation, explosion or asphyxiation.
• For proper draft hood attachment, the draft hood legs may
be angled slightly inward.
• Place the draft hood legs in the receiving holes on the top
of the water heater. The legs will snap in the holes to give a
tight fit. Secure the legs to top with sheet metal screws. See
Figure 17.
• Place the vent pipe over the draft hood. With the vent pipe
in position, drill a small hole through both the vent pipe and
draft hood. Secure them together with a sheet metal screw.
Obstructed or deteriorated vent systems may present serious
health risk or asphyxiation.

16
The vent pipe from the water heater must be no less than the
diameter of the draft hood outlet on the water heater and must
slope upward at least 1/4 inch per linear foot (21 mm per meter).
See Figure 18.
FIGURE 17.
FIGURE 18.
All vent gases must be completely vented to the outdoors of the
structure (dwelling). Install only the draft hood provided with the
new water heater and no other draft hood.
Vent pipes must be secured at each joint with sheet metal
screws.
There must be a minimum of 6 inches (153 mm) clearance
between single wall vent pipe and any combustible material.
Fill and seal any clearance between single wall vent pipe
and combustible material with mortar mix, cement, or other
noncombustible substance. For other than single wall, follow
vent pipe manufacturer’s clearance specifications. To insure a
tight fit of the vent pipe in a brick chimney, seal around the vent
pipe with mortar mix cement.
Failure to have required clearances between vent piping and
combustible material will result in a fire hazard.
Be sure vent pipe is properly connected to prevent escape of
dangerous flue gases which could cause deadly asphyxiation.
Chemical vapor corrosion of the flue and vent system may occur
if air for combustion contains certain chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants, swimming pool chemicals, calcium and sodium
chloride, waxes, bleach and process chemicals are typical
compounds which are potentially corrosive.
Gas Piping
Make sure the gas supplied is the same type listed on the
model rating plate. The inlet gas pressure must not exceed
14 inch water column (3.5kPa) for natural and propane gas (L.P.)
gas. The minimum inlet gas pressure listed on the rating plate
is for the purpose of input adjustment. If the gas control valve
is subjected to pressures exceeding 1/2 pound per square inch
(3.5kPa), the damage to the gas control valve could result in a
fire or explosion from leaking gas.
If the main gas line shutoff serving all gas appliances is used, also
turn “OFF” the gas at each appliance. Leave all gas appliances
shut “OFF” until the water heater installation is complete.
A gas line of sufficient size must be run to the water heater.
Consult the current edition of National Fuel Gas Code ANSI
Z223.1/NFPA 54 and your gas supplier concerning pipe size.
There must be:
• A readily accessible manual shut off valve in the gas supply
line serving the water heater.
• A drip leg (sediment trap) ahead of the gas control valve to
help prevent dirt and foreign materials from entering the gas
control valve.
• A flexible gas connector or a ground joint union between the
shut off valve and control valve to permit servicing of the
unit.
Be sure to check all the gas piping for leaks before lighting the
water heater. Use a soapy water solution, not a match or open
flame. Rinse off soapy solution and wipe dry.
The minimum inlet gas pressure shown on the rating plate is that
which will permit firing at the rated input.

17
Water heaters covered in this manual have been tested and
approved for installation at elevations up to 2,000 feet (610
m) above sea level. For installation above 2,000 feet (610 m),
the water heater’s Btu input should be reduced at the rate of
4 percent for each 1,000 feet (305 m) above sea level which
requires replacement of the burner orifice in accordance with the
National Fuel Gas Code ANSI Z223.1/NFPA 54. Contact your
local gas supplier for further information.
Failure to replace the standard orifice with the proper high
altitude orifice when installed at elevations above 2,000 feet
(610 m) could result in improper and inefficient operation of the
appliance, producing carbon monoxide gas in excess of the safe
limits. This could result in serious injury or death. Contact your
local gas supplier for any specific changes that may be required
in your area.
Use pipe joint compound or Teflon tape marked as being resistant
to the action of petroleum (Propane [L.P.]) gases.
The appliance and its gas connection must be leak tested before
placing the appliance in operation.
The appliance and its individual shutoff valve shall be
disconnected from the gas supply piping system during any
pressure testing of that system at test pressures in excess of
1/2 pound per square inch (3.5 kPa). It shall be isolated from
the gas supply piping system by closing its individual manual
shutoff valve during any pressure testing of the gas supply piping
system at test pressures equal to or less than 1/2 pound per
square inch (3.5 kPa).
Connecting the gas piping to the gas control valve of the water
heater can be accomplished by either of the two methods shown
in Figures 19 and 20.
TEFLON®is a registered trademark of E.I. Du Pont De Nemours and Company.
Sediment Traps
Contaminants in the gas lines may cause improper operation
of the gas control valve that may result in fire or explosion.
Before attaching the gas line be sure that all gas pipe is clean
on the inside. To trap any dirt or foreign material in the gas
supply line, a drip leg (sometimes called a sediment trap) must
be incorporated in the piping. The drip leg must be readily
accessible. Install in accordance with the Gas Piping section.
Refer to the current edition of the National Fuel Gas Code,
ANSI Z223.1/NFPA 54.
A sediment trap shall be installed as close to the inlet of the water
heater as practical at the time of water heater installation. The
sediment trap shall be either a tee fitting with a capped nipple
in the bottom outlet or other device recognized as an effective
sediment trap. If a tee fitting is used, it shall be installed in
conformance with one of the methods of installation, shown in
Figures 19 and 20.
GAS CONTROL
VALVE
GROUND JOINT
UNION
(OPTIONAL)
3” MIN.
(76.2 mm)
DRIP LEG
(SEDIMENT TRAP)
FIGURE 19. GAS PIPING WITH FLEXIBLE CONNECTOR.
GAS CONTROL
VALVE
GROUND JOINT
UNION
(OPTIONAL)
3” MIN.
(76.2 mm)
DRIP LEG
(SEDIMENT TRAP)
BLACK PIPE
FIGURE 20. GAS PIPING WITH ALL
BLACK IRON PIPE TO GAS CONTROL.

18
OPERATING INSTRUCTIONS

19
Temperature Regulation
Due to the nature of the typical gas water heater, the water
temperature in certain situations may vary up to 30F° (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. Follow manufacturer’s instructions
for installation of the valves. Before changing the factory setting
on the thermostat See Figures 21 and 22.
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 for energy efficient operation at the minimum
water temperature setting that meets your hot water needs. To
reduce the risk of scald injury, 120°F (49°C) is preferred starting
point. Some states have a requirement for a lower setting.
Align the index bar on the thermostat with the desired water
temperature as shown in Figure 21.
Turn the water temperature dial clockwise ( ) to increase
the temperature, or counterclockwise ( ) to decrease the
temperature.
Should overheating occur or the gas supply fail to shut off, turn
off the manual gas control valve to the appliance.
C
A
U
T
I
O
N
W
A
T
E
R
I
N
C
R
E
A
S
E
S
H
O
T
T
E
R
T
H
E
R
I
S
K
O
F
S
C
A
L
D
I
N
J
U
R
Y
V
A
C
A
T
I
O
N
W
A
R
M
H
O
T
120°F
Bar
130°F
Bar
Reset
Button
Gas Control Knob
Dial Stop
Index
Bars
Temperature Dial
Robertshaw Gas Valve
140°F
Bar
150°F
Bar
160°F
Bar
FIGURE 21.
Temperature
Settings
Time to Produce 2nd & 3rd
Degree Burns on Adult Skin
160°F (71°C) About 1/2 second
150°F (66°C) About 1-1/2 seconds
140°F (60°C) Less than 5 seconds
130°F (54°C) About 30 seconds
120°F (49°C) More than 5 minutes
80°F (27°C) - - - - - - - - - - - - - - - -
FIGURE 22.

20
Tank (Sediment) Cleaning
Sediment build-up on the tank bottom may create varying
amount of noise and if left in the tank will cause permanent
tank failure. In some water areas, you may not be able to drain
all sediment deposits by simply draining the tank. In these
cases Mag-Erad (part no. 23600) can be used to help remove
the sediment deposits. This may be ordered from the Sears
Service Center. For ordering, refer to the Parts Order List
section.
Vent System Inspection
At least once a year a visual inspection should be made of the
venting system. You should look for:
• Obstructions which could cause improper venting. The
combustion and ventilation air flow must not be obstructed.
• Damage or deterioration which could cause improper venting
or leakage of combustion products.
• Rusted flakes around top of water heater.
Be sure the vent piping is properly connected to prevent
escape of dangerous flue gasses which could cause deadly
asphyxiation.
Obstructions and deteriorated vent systems may present serious
health risk or asphyxiation.
Chemical vapor corrosion of the flue and vent system may occur
if air for combustion contains certain chemical vapors. Spray can
propellants, cleaning solvents, refrigerator and air conditioner
refrigerants, swimming pool chemicals, calcium and sodium
chloride, waxes, bleach and process chemicals are typical
compounds which are potentially corrosive.
If when inspecting the vent system you find sooting or
deterioration, something is wrong. Call the local gas supplier to
correct the problem and clean or replace the flue and venting
before resuming operation of the water heater.
Burner Inspection
Flood damage to a water heater may not be readily visible or
immediately detectable. However, over a period of time a flooded
water heater will create dangerous conditions which can cause
DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.
Contact a Sears Service Center to replace a flooded water
heater. Do not attempt to repair the unit! It must be replaced!
At least once a year a visual inspection should be made of the
main burner. See Figure 23.
CORRECT FLAME
SOFT BLUE
FIGURE 23.
Inspect burner flames through viewport. Flames should be very
small with a blue haze and small amounts of yellow or orange at
the edges. After several minutes of operation the burner screen
may glow red. If large flames are observed at anytime shut-off
unit and contact a Sears Service Center.
SERVICE AND ADJUSTMENT