Kenmore THE ECONOMIZER 153.332040 User manual

1PRINTEDINTHEU.S.A.0905 www.sears.com PART NO. 185249-000
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A
C3 Technology®Gas Water Heaters meet
the newANSI Z21.10.1 standard that deals
with the accidental or unintended ignition
of flammable vapors, such as those
emitted by gasoline.
Owner’s Manual
FORPOTABLEWATER HEATING ONLY.
NOTSUITABLEFORSPACE HEATING.
NOT FOR USE IN MOBILE HOMES.
MODELNO.
153.332040 40Gallon Nat
153.332050 50Gallon Nat
153.332060 40Gallon LP
153.332070 50Gallon LP For Your Safety
ANODORANTISADDEDTOTHEGASUSEDBYTHISWATERHEATER.
• Safety Instructions
• Installation
• Operation
• Care and Maintenance
• Troubleshooting
• Parts List
THE ECONOMIZER™ 6
GAS WATER HEATER
POWER VENTED GAS MODELS
WITH HOT SURFACE IGNITION
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y/o etiquetas en español puede obtenerlos llamando al
1-800-821-2017. NO TRATE DE INSTALAR O OPERAR ESTE
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resultarenlaMUERTEOGRAVESLESIONESCORPORALES.
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 injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very
important that the meaning of each safety message is understood by you and others who install, use or service this water heater.
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.
IMPORTANT DEFINITIONS
•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
offerservice andinspection ofappliances withinthe building.
© Sears, Roebuck and Co.

3
SAFETY PRECAUTIONS

4
SAFE INSTALLATION, USEAND SERVICE.................................................................................................................................... 2
SAFETY PRECAUTIONS ................................................................................................................................................................. 3
TABLE OF CONTENTS .................................................................................................................................................................... 4
CUSTOMER RESPONSIBILITIES................................................................................................................................................... 5
PRODUCT SPECIFICATIONS ......................................................................................................................................................... 5
MATERIALSAND BASICTOOLS NEEDED .................................................................................................................................... 6
TYPICALINSTALLATION.................................................................................................................................................................. 7
INSTALLATION INSTRUCTIONS .............................................................................................................................................. 8-21
Removing the Old Water Heater ............................................................................................................................................. 8
Facts to Consider About the Location .............................................................................................................................. 9-10
Insulation Blankets................................................................................................................................................................. 10
Combustion Air and Ventilation for Appliances Located in Unconfined Spaces ............................................................. 10
Combustion Air and Ventilation for Appliances Located in Confined Spaces ............................................................10-11
Water Piping...................................................................................................................................................................... 12-13
Temperature-Pressure Relief Valve ............................................................................................................................... 13-14
Gas Piping......................................................................................................................................................................... 14-15
Sediment Traps ...................................................................................................................................................................... 15
Filling the Water Heater ......................................................................................................................................................... 15
Blower Assembly Installation .......................................................................................................................................... 15-16
Vent Connections to Blower Assembly................................................................................................................................. 17
Venting and Installation ......................................................................................................................................................... 17
Condensation ......................................................................................................................................................................... 17
Maximum Vent Lengths.......................................................................................................................................................... 17
Venting ..................................................................................................................................................................................... 18
Vent Terminal Installation ................................................................................................................................................ 18-19
Vertical Vent Through Roof..................................................................................................................................................... 19
Vertical Vent Termination Restrictions.................................................................................................................................. 19
Vent Pipe Preparation ...................................................................................................................................................... 20-21
OPERATING INSTRUCTIONS................................................................................................................................................. 22-23
Lighting and Operating Label ............................................................................................................................................... 22
Temperature Regulation........................................................................................................................................................ 23
FORYOUR INFORMATION...................................................................................................................................................... 24-25
Start Up Conditions .......................................................................................................................................................... 24-25
Operational Conditions.......................................................................................................................................................... 25
SERVICEAND ADJUSTMENT ................................................................................................................................................. 25-27
Venting System Inspection .................................................................................................................................................... 25
Burner Operation and Inspection ................................................................................................................................... 25-26
Burner Cleaning ..................................................................................................................................................................... 26
Housekeeping ........................................................................................................................................................................ 26
Anode Rod Inspection............................................................................................................................................................ 26
Temperature-Pressure Relief Valve Operation ............................................................................................................. 26-27
Draining ................................................................................................................................................................................... 27
Drain Valve Washer Replacement........................................................................................................................................ 27
Service ..................................................................................................................................................................................... 27
LEAKAGE CHECKPOINTS ............................................................................................................................................................ 28
TROUBLESHOOTING GUIDELINES ...................................................................................................................................... 29-30
REPAIR PARTS LIST...................................................................................................................................................................... 31
WARRANTY..................................................................................................................................................................................... 32
TABLE OF CONTENTS

5
TANK RECOVERY MINIMUM
CAPACITY INPUT RATE GALS. VENT PIPE DIAMETER DIMENSIONS IN
MODEL IN GALS. TYPEOF RATE PERHOUR INCHES INCHES INCHES (mm) HEIGHT
NUMBER (LTRS) GAS (Btu/hr) @90°F RISE (mm) (mm) TOJACKET TOP
153.332040 40 (151) NATURAL 40,000 44 2 (51) 18 1/2 (470) 55 (1,397)
153.332050 50 (189) NATURAL 40,000 44 2 (51) 20 (508) 56 3/4 (1,441)
153.332060 40 (151) PROPANE 40,000 44 2 (51) 18 1/2 (470) 55 (1,397)
153.332070 50 (189) PROPANE 40,000 44 2 (51) 20 (508) 56 3/4 (1,441)
ThankYouforpurchasingaKenmore waterheater.Properlyinstalled
andmaintained,itshouldgive youyears oftrouble freeservice. Ifyou
should decide that you want the new water heater professionally
installedbySearscall1-800-4-MY-HOME®.Theywillarrangeforprompt,
qualityinstallation bySears authorizedcontractors.
AbbreviationsFoundInThis InstructionManual:
• CSA- CanadianStandardsAssociation
• ANSI-AmericanNationalStandardsInstitute
• NFPA-NationalFireProtectionAssociation
• ASME-AmericanSocietyofMechanicalEngineers
• GAMA-GasApplianceManufacturer’sAssociation
• UL- UnderwritersLaboratories Inc.
Thisgas-firedwaterheateris listedby UnderwritersLaboratories Inc.
underAmericanNationalStandard/CSAStandardforGasWaterHeaters
ANSIZ21.10.1 •CSA4.1(currentedition).
PREPARING FOR THE INSTALLATION
1. Read the“Safety Precautions” section,page 3ofthis manualfirst
andthenthe entiremanual carefully. Ifyoudon’t followthe safety
rules, the water heater will not operate properly. It could cause
DEATH,SERIOUSBODILYINJURYAND/ORPROPERTYDAMAGE.
Thismanualcontainsinstructionsfortheinstallation,operation,and
maintenanceofthe gas-firedwaterheater. Italsocontainswarnings
throughout the manual that you must read and be aware of. All
warningsandall instructionsare essentialtothe properoperation
ofthewaterheaterandyoursafety. Sincewecannot puteverything
on the first few pages, READ THE ENTIRE MANUAL BEFORE
ATTEMPTINGTOINSTALLOROPERATETHEWATERHEATER.
2. The installation must conform with these instructions and the local
code authority having jurisdiction. In the absence of local codes,
installationsshallcomplywiththeNationalFuelGasCodeANSIZ223.1/
NFPA54andtheNationalElectricalCode,NFPA70.Thesepublications
are available from The National Fire Protection Association, 1
BatterymarchPark,Quincy,MA02269.
3. The waterheater wheninstalled mustbegroundedinaccordance
withthelocalcodes,or inthe absenceof localcodes,the National
ElectricalCodeNFPA70.
4. If after reading this manual you have any questions or do not
understandany portionofthe instructions,callthe localgasutility or
theSears ServiceCenter.
5. Carefullyplan theplacewhereyou aregoingtoputthe waterheater.
Correct combustion,vent action,andvent pipeinstallationarevery
important in preventing death from possible carbon monoxide
poisoningand fires.
Examinethelocationtoensure thewater heatercomplies withthe
“FactstoConsiderAbouttheLocation”sectioninthismanual.
6. ForCaliforniainstallationthiswaterheatermustbebraced,anchored,
or strapped to avoid falling or moving during an earthquake. See
instructionsfor correctinstallationprocedures. Instructionsmaybe
obtained from California Office of theStateArchitect, 400 P Street,
Sacramento,CA95814.
7. Massachusetts Code requires this water heater to be installed in
accordancewithMassachusetts248-CMR2.00:StatePlumbingCode
and248-CMR5.00.
8. Complies withSCAQMDrule#1121 anddistrictshavingequivalent
NOxrequirements.
CUSTOMER RESPONSIBILITIES
PRODUCT SPECIFICATIONS

6
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 GAS
CONNECTOR WITH FITTINGS.
EXPANSIONTANKSFOR
THERMALEXPANSION
CONDITIONSAVAILABLE
IN 2 GALLONS
(7.6 LITERS) AND
5 GALLONS (18.9 LITERS)
CAPACITYTHROUGH
LOCAL SEARS STORE OR
SERVICE CENTER.
DRAINPANSAVAILABLE IN 20”
(508 mm) DIAMETER FOR
WATERHEATERSHAVING A
DIAMETER 18” (457 mm) OR
LESS, 24” (610mm) DIAMETER
FOR WATER HEATERSHAVING
A DIAMETER 22” (559 mm) OR
LESSAND AVAILABLE IN 28”
(711 mm) DIAMETER FOR
WATERHEATERSHAVING 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
GARDENHOSE 6 FOOTTAPE
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
EMERYCLOTH
MATERIALS AND BASIC TOOLS NEEDED

7
TYPICAL INSTALLATION
GET TO KNOW YOUR WATER HEATER - GAS MODELS
A Vent Pipe–Exhaust
B Vent Terminal
C Vent Adapter-Rubber Boot
D Blower Assembly
E Cold Water Inlet
F Inlet Water Shut-off Valve
G Union
H Inlet Dip Tube
J Anode**
FIGURE1.
K Hot Water Outlet
L Outlet Receptacle (115 VAC)
M Temperature-Pressure Relief Valve
N Flue
O Flue Baffle Assembly**
P Insulation
Q Control Harness
R Rating Plate
S Gas Supply
T Manual Gas Shut-off Valve
U Ground Joint Union
V Drip Leg (Sediment Trap)
W Drain Valve
X Gas Valve-Thermostat
Y Drain Pan
Z Air Intake Screen - Base Pan
AA Inner Door
BB Outer Door
CC HSI Burner Assembly
DD Air Intake Screen -
Blower Assembly
EE FV Sensor Assembly
NATURAL HOT SURFACE IGNITER& MAINBURNER
HOT
SURFACE
IGNITOR
SENSOR
PROPANE HOT SURFACEIGNITER& MAIN BURNER
TEMPERATURE INDICATORS
TEMPERATUREADJUSTMENTBUTTONS
HOT
SURFACE
IGNITOR
SENSOR
*CAUTION: 115 VAC IN CONTROL HARNESS
AND INSIDE OUTER DOOR
* ALL PIPING MATERIALS TO BE SUPPLIED BY CUSTOMERS.
** LOCATED UNDER THE BLOWER ASSEMBLY.
GAS MODELS
WITH HOT SURFACE IGNITION
& 2", 3" OR 4" PVC VENT CAPABILITY

8
1. Turn“OFF”thegassupplytothewater
heater.
If the main gas line Shut-off valve
servingallgasappliancesisused,also
shut“OFF” thegasateachappliance.
Leave all gas appliances shut “OFF”
until the water heater installation is
completed,see Figures2and3.
2. Turn “OFF” the water supply to the
water heater at the water shut off
valve or water meter. Some
installationsrequirethat thewater be
turned off to the entire house, see
Figures2 and4.
FIGURE2.
Removing the Old Water Heater
FIGURE3.
FIGURE4.
3. Check again to make sure the gas supply is “OFF” to the water
heater. Then disconnect the gas supply connection from the gas
controlvalve.
4. Attach ahosetothewater heaterdrain
valve and put the other end in a floor
drain or outdoors. Open the water
heaterdrain valve. Openanearby hot
water faucet which will relieve
pressureinthewater heaterand speed
draining.The waterpassing outof the
drainvalvemay beextremely hot. To
avoid being scalded, make sure all
connectionsaretightandthatthewater
flowis directedawayfrom anyperson,
seeFigures 2and 5. FIGURE5.
5. Disconnecttheventpipefromtheblower assemblywhere itconnects
tothewaterheater. Inmost installationsthe ventpipecanbeliftedoff
after any screw or other attached devices are removed. Make sure
existingvent complieswithmaximum andminimumvent lengthson
page17.
6. If youhave copperpiping tothewaterheater, thetwocopperwater
pipes can be cut with a hacksaw approximately four inches away
fromwhere theyconnect tothewaterheater,seeFigure6.Thiswill
avoidcutting offpipestoo short.Additionalcutscan bemade laterif
necessary. Disconnectthe temperature-pressurerelief valvedrain
line.Whenthewater heaterisdrained,disconnectthe hosefromthe
drainvalve.Closethedrainvalve.Thewaterheaterisnowcompletely
disconnectedand readyto beremoved.
FIGURE6.
If you have galvanized pipes to the water heater, loosen the two
galvanizedpipes witha pipewrench atthe unionin eachline. Also
disconnectthepiping remainingto thewaterheater, seeFigure 7.
These pieces should be saved since they may be needed when
reconnectingthenew waterheater. Disconnect thetemperature-
pressurereliefvalve drainline. When thewater heater isdrained,
disconnect the hose from the drain valve. Close the drain valve.
Thewaterheater isnow completelydisconnected andreadytobe
removed.Mineralbuildupor sedimentmayhaveaccumulatedin the
oldwater heater. Thiscauses thewater heaterto bemuch heavier
thannormal andthis residue,if spilledout, couldcausestaining.
FIGURE7.
INSTALLATION INSTRUCTIONS

9
FACTSTOCONSIDERABOUT THE LOCATION
Carefullychoose anindoorlocation forthenewwaterheater,because
the placement is a very important consideration for the safety of the
occupantsinthebuildingandforthemosteconomicaluseoftheappliance.
This water heater is not for use in manufactured (mobile) homes
or outdoor installation.
Whetherreplacing anold waterheater orputting thewater heaterin a
newlocation, thefollowingcritical pointsmustbeobserved:
1. Selecta locationindoorsasclose aspracticaltothevent terminalor
locationtowhichthewaterheaterventpipingisgoingtobeconnected,
andas centralizedwiththewaterpiping systemas possible.
2. Selected location must provide adequate clearances for servicing
andproper operationofthewaterheater.
Installationofthe waterheatermustbeaccomplishedin suchamanner
that if the tank or any connections should leak, the flow will not cause
damagetothe structure. Forthisreason,it isnotadvisabletoinstallthe
waterheater inanatticorupper floor. Whensuchlocationscannot be
avoided,asuitabledrainpanshouldbeinstalledunderthe waterheater.
Drainpansareavailableat yourlocalhardwarestore. Suchadrainpan
musthaveaminimumlengthandwidthofatleast2"(5.1cm)greaterthan
thewater heaterdimensions andmustbepipedto anadequate drain.
Thepanmust notrestrictcombustion airflow.
Water heater life depends upon water quality, water pressure and the
environment in which the water heater is installed. Water heaters are
sometimesinstalled inlocationswhereleakagemay resultin property
damage, even with the use of a drain pan piped to a drain. However,
unanticipateddamagecanbereducedorpreventedbyaleakdetectoror
watershut-offdeviceused inconjunctionwitha pipeddrainpan.These
devices are available from some plumbing supply wholesalers and
retailers,and detectandreacttoleakage invariousways:
• Sensorsmounted inthedrain panthattrigger analarmor turnoffthe
incomingwater tothewaterheaterwhen leakageisdetected.
• Sensorsmountedinthe drainpanthatturnoffthewatersupply tothe
entirehome whenwaterisdetectedin thedrainpan.
• Water supply shut-off devices that activate based on the water
pressure differential between the cold water and hot water pipes
connectedto thewaterheater.
• Devicesthat willturnoff thegassupply toagas waterheaterwhile at
thesame timeshutting offitswater supply.
INSTALLATIONSINAREASWHEREFLAMMABLELIQUIDS(VAPORS)
ARELIKELYTOBEPRESENTORSTORED(GARAGES,STORAGEAND
UTILITYAREAS,ETC.):Flammableliquids(suchasgasoline,solvents,
propane(LPor butane,etc.)andothersubstances(such asadhesives,
etc.)emitflammablevaporswhichcanbeignitedbyagaswaterheater’s
hotsurfaceigniterormainburner. Theresultingflashbackand firecan
causedeathorseriousburnstoanyoneinthe area.This waterheateris
equipped with a FV sensor for detecting the presence of flammable
vapors, see Figure 8. When the sensor detects those vapors, the unit
willshut downandnot operate.Shouldthis happen,pleaserefer tothe
troubleshootingguideonpages29-30. Eventhoughthis waterheateris
a flammable vapors ignition resistant water heater and is designed to
reduce the chances of flammable vapors being ignited, gasoline and
otherflammablesubstancesshouldneverbestoredorusedinthesame
vicinity or area containing a gas water heater or other open flame or
sparkproducingappliance.
FIGURE8.
Also, the water heater must be located and/or protected so it is not
subjecttophysical damagebyamovingvehicle.
Thiswaterheater mustnotbeinstalled directlyoncarpeting. Carpeting
mustbeprotectedbymetalorwoodpanelbeneaththeapplianceextending
beyondthefullwidth anddepthoftheappliancebyatleast3" (7.6cm)in
any direction, or if the appliance is installed in an alcove or closet, the
entirefloor mustbecovered bythepanel. Failure toheedthiswarning
mayresult inafirehazard.
Minimum clearances between the water heater and combustible
constructionare0inch atthesides andrear,5"(12.7 cm)fromthe front

10
and 12" (30.5 cm) from the top. (Standard clearance.) If clearances
statedontheheaterdifferfromstandardclearances,installwaterheater
accordingto clearancesstatedontheheater.
Adequateclearance forservicingthisapplianceshould beconsidered
beforeinstallation,suchaschangingtheanodes,etc.
A minimum clearance of 5" (12.7 cm) must be allowed for access to
replaceablepartssuchasthethermostats,drain valveandrelief valve.
Wheninstallingtheheater,considerationmustbegiventoproperlocation.
Locationselected shouldbe asclosetothewall aspracticable andas
centralizedwith thewaterpipingsystemas possible.
FIGURE9.
Agaswaterheater cannotoperateproperlywithoutthe correctamount
ofairforcombustion. Donotinstallin aconfinedarea suchasa closet,
unless you provide air as shown in the “Facts to ConsiderAbout the
Location” section. Never obstruct the flow of ventilation air. If you
haveanydoubtsor questionsat all,callyour gassupplier. Failureto
provide the proper amount of combustion air can result in a fire or
explosionand causedeath,seriousbodilyinjury, orpropertydamage.
FIGURE10.
Ifthiswater heaterwillbeusedinbeauty shops,barbershops,cleaning
establishments,or self-servicelaundrieswith drycleaning equipment,
it is imperative that the water heater or water heaters be installed so
thatcombustion andventilationairbetaken fromoutside theseareas.
Propellants of aerosol sprays and volatile compounds, (cleaners,
chlorinebased chemicals,refrigerants,etc.) inadditiontobeinghighly
flammableinmanycases,willalsoreact toformcorrosive hydrochloric
acid when exposed to the combustion products of the water heater.
Theresultscan behazardous, andalso causeproductfailure.
INSULATIONBLANKETS
Insulationblankets areavailable tothe generalpublicforexternaluse
ongaswater heatersbut are notnecessary withKenmoreproducts.
Thepurposeofaninsulationblanketistoreducethestandbyheatloss
encounteredwithstorage tankheaters. Your Kenmorewater heater
meets or exceeds the NationalAppliance Energy ConservationAct
standards with respect to insulation and standby loss requirements,
makinganinsulationblanketunnecessary.
Should you choose to apply an insulation blanket to this heater, you
should follow these instructions (For identification of components
mentioned below, see Figure 1). Failure to follow these instructions
can restrict the air flow required for proper combustion, potentially
resultingin fire,asphyxiation, seriouspersonalinjuryordeath.
•Do not apply insulation to the top of the water heater, as this will
interfere with safe operation of the blower assembly.
•Do not cover the outer door, thermostator temperature & pressure
reliefvalve.
•Do not allow insulation to come within 2" (5.1 cm) of the floor to
preventblockageof combustionair flowto theburner.
•Do not cover the instruction manual. Keep it on the side of the
water heater or nearby for future reference.
•Do obtain new warning and instruction labels from Sears
forplacement onthe blanketdirectly overthe existinglabels.
•Do inspect the insulation blanket frequently to make certain it
doesnotsag, therebyobstructing combustionair flow.
COMBUSTIONAIRAND VENTILATION FOR
APPLIANCESLOCATED IN UNCONFINED SPACES
UNCONFINED SPACE is space whose volume is not less than
50cubicfeet per1,000 Btuper hour(4.8cubic metersper kW)ofthe
aggregateinput ratingofall appliancesinstalledinthatspace. Rooms
communicating directly with the space in which the appliances are
installed,through openingsnotfurnished withdoors, areconsidereda
partofthe unconfinedspace.
Inunconfinedspacesinbuildings,infiltrationmaybeadequatetoprovide
airforcombustion,ventilationand dilutionof fluegases. However, in
buildingsof tightconstruction (forexample, weatherstripping,heavily
insulated,caulked,vapor barrier, etc.), additionalair mayneedto be
providedusingthemethodsdescribedin“CombustionAirandVentilation
forAppliances LocatedinConfinedSpaces.”
COMBUSTIONAIRAND VENTILATION FOR
APPLIANCESLOCATED IN CONFINED SPACES
CONFINEDSPACEisaspacewhosevolumeis lessthan50cubicfeet
per 1,000 Btu per hour (4.8 cubic meters per kW) of the aggregate
inputrating ofall appliancesinstalled inthatspace.