Kenmore 153 50-Gallon Electric Water Heater User Manual

Kenmore 153 50-Gallon Electric Water Heater

INTRODUCTION

Thank You for purchasing a Sears water heater. Properly installed and maintained, it should give you years of trouble-free service. it is strongly suggested that this new water heater be professionally installed, contact the local Sears Service Center or any Sears store. They will arrange for prompt, quality
installation by Sears authorized contractors.

Abbreviations Found In This Instruction Manual:

• UL – Underwriters Laboratories Inc.
• NEC – National Electrical Code
• ANSI -American National Standards Institute

Read the “General Safety” 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 installing, operating, and maintaining this electric water heater. It also contains warnings throughout 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 THIS ENTIRE MANUAL BEFORE ATTEMPTING. TO INSTALL OR OPERATE THE WATER HEATER. The installation must conform with the instructions in this manual; electric company rules; and Local Codes, or in the absence of Local Codes, with the current edition of the NEC – National Electrical Code, NFPA 70. This publication is available from your local government or public library or
electric company or by writing Underwriters Laboratories Inc., 333 Pfingsten Road, Northbrook, IL 60062. If after reading this manual you have any questions or do not understand any portion of the instructions, call Sears Service Center.

Carefully plan the place where you are going to put the water heater. Correct electrical wiring and connections are very important in preventing death from possible electrical shock and fires. Examine the location to ensure the water heater complies with the “Facts to Consider About the Location” section.
This water heater must be braced, anchored, or strapped for California installation 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, 400 P Street, Sacramento, CA 95814. Massachusetts Code requires this water heater to be installed following Massachusetts 248-CMR 2.00; State Plumbing Code and 248-CMR 5.00. In the Commonwealth of Massachusetts, this product must be installed by a licensed plumber or gasfitter.

PRODUCT SPECIFICATION

*Wiring size based on standard 60°C copper wire. If the distance from the fuse box to the water heater is more than 90 feet, refer to your local electrical code.

MATERIAL 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.

Basic Tools

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

Additional Tools Needed When Sweat Soldering

Removing the Old Water Heater

1. Turn “OFF” electrical supply to the water heater.
2. Turn “OFF” the water supply to the water heater at the water shut-off valve or water meter.
3. Attach a hose to the water heater drain valve and put the other end in a floor drain or outdoors. Open the water 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.
4. Check again to make sure the electrical supply is turned “OFF” to the water heater. Then unplug the water heater (cord set) or disconnect the electrical supply connection from the water heater junction box.
   
   1. 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. This will avoid cutting off the 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.
   2. If you have a galvanized pipe 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. 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.

Facts to Consider About the Location

You should carefully choose an indoor location for the new water heater because 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 intended for outdoor installation. Whether replacing an old water heater or putting the water heater in a new location, the following critical points must be
observed. The location selected should be indoors as close to and as centralized with the water piping system as possible. This water heater, as well as all water heaters, will eventually leak. Do not install without adequate drainage provisions so water flow will not cause damage.

WATER HEATERS EVENTUALLY LEAK: Installation of the water heater must be accomplished in such a manner that if the tank or any connections should leak, the flow of water will not cause damage to the structure. When such locations cannot be avoided, a suitable drain pan should be installed under the
water heater. Drain pans are available at your local Sears stores. Such drain pans must be piped to an adequate drain. 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 drain pan piped to a drain. However, unanticipated damage can be reduced or prevented by a leak detector or water shutoff a device used in conjunction with a piped 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 drain pan that trigger an alarm or turn off the incoming water to the water heater when leakage is detected.
• Sensors mounted in the drain pan that turn offthe water supply to the entire home when water is detected in the 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.

INSTALLATION IN RESIDENTIAL GARAGES: The water heater must be located and/or protected so it is not subject to physical damage by a moving vehicle.

• The location selection must provide adequate clearances for servicing and proper operation of the water heater.

Insulation Blankets

Insulation blankets are available to the general public for external use on electric water heaters but are not necessary with this product. The purpose of an insulation blanket is to reduce the standby heat loss encountered with storage tank heaters. Your water heater meets or exceeds the National Appliance Energy Conversation Act standards with respect to insulation and standby loss requirements, making an insulation blanket unnecessary. Should you choose to apply an insulation blanket to this heater, you should follow these instructions below. Failure to follow these instructions can result in fire, serious personal injury, or death.

• Do not cover the temperature and pressure relief (T & P) valve with an insulation blanket.
• 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 for placement on the blanket directly over the existing labels.

Facts to Consider About the Convertible Lower Element

The Upper Element (if a double element model) is a conventional 3800 watt element which only operates at its rated wattage on 240 volts. (See rating plate on the water heater). The Lower Element of the water heater can be converted from operation at 3800 watts to 5500 watts on a 240 volt system.
Read and follow water heater warnings and instructions. If after reading these instructions in this manual, you do not understand any portion, call Sears Service Center.

HOTTER WATER CAN SCALD: Water heaters are intended to produce hot water. Water heated to a temperature which will satisfy 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 manufacturers instructions for installation of the valves. Before changing the factory setting on the thermostat, read the “Temperature Regulation” section in this manual.

Figure 8 shows the attachment of the water piping to the water heater. The water heater is equipped with 3/4″ water connections. If a water heater is installed in a closed water supply system; such as one having a back-flow preventer, check valve, water meter with a check valve, etc.., in the cold water supply; means
must be provided to control thermal expansion. Contact the local utility or Sears Service Center on how to control this situation.

NOTE: If using copper tubing, solder tubing to an adapter before attaching the adapter to the water inlet connection. Do not solder the water supply lines directly to the cold water inlet. It will harm the dip tube and damage the tank.

NOTE: To protect against untimely corrosion of hot and cold water fittings, it is strongly recommended that dielectric unions or couplings be installed on this water heater when connected to copper pipe.

1. Look at the top cover of the water heater. The hot 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″ threaded nipple. Using flexible connectors, connect the hot water pipe to the hot water outlet of the water heater.
2. Look at the top cover 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″ threaded nipple. Using flexible connectors, connect the cold water pipe to the cold water inlet of the water heater.

NOTE: Your water heater is 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.

T & P Valve and Pipe insulation

Remove insulation for T & P valve and pipe connections from carton. 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.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

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 of materials as meeting the requirements for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA 4.4, 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 = 1,035 kPa) and a discharge capacity not less than the water heater input rate as shown on the model rating plate. (For electric heaters, watts x 3.412 equals Btu/hr input rate) 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. 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.

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 at an adequate drain.
• Shall not have any valve between the relief valve and tank.

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.

NOTE: Whether or not the element conversion is made the model rating plate must be marked. Using a hard point ink pen, check the appropriate block within the model rating plate, which is located adjacent to the lower access panel.

Necessary element conversion parts are located in a small bag contained within the electrical junction box on top of the water heater.

1. Before beginning the conversion turn “OFF” electric power supply to the water heater.
2. The convertible element is located behind the lower access panel of the water heater. Remove the two screws securing the access panel, and remove panel.
3. Remove the insulation cap with handle to expose the terminal cover.
4. Lower Element: Lift out the tab as shown to unclip the terminal cover from the thermostat. The terminal cover can now be removed from the thermostat.
5. Remove the screws from terminal 2 of the element, and move the looped end of the wire aside.
6. The buss bar is labeled 5500 W. Place the buss bar over terminals 2 and 3 with the 5500 W visible. Install the extra screw provided into terminal 3
7. The wire removed from terminal 2 has a looped end. It must remain looped and now be placed (as shown) on top of the buss bar, over the opening of terminal 2, and secured using the remaining screw.
8. Tighten terminal s2 and 3 to ensure proper electrical connection Failure to tighten terminal screws can cause a fire which can result in DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.
9. Replace terminal cover on thermostat making sure that the locking tabs on the terminal cover are in place.Make sure the thermostat is flush against the tank, the terminal cover is in place, and the insulation is replaced. Failure to do so can result in DEATH, SERIOUS BODILY INJURY, OR
   PROPERTY DAMAGE.
10. Replace the insulation cap with handle so that it completely covers the thermostat and element.
11. Replace the access pane
12. Complete wiring to the water heater, or if completed, turn “ON” electric power to the water heater after filling the tank with water

Never use this water heater unless it is completely full of water. To prevent damage to the tank and heating element, the tank must be filled with water. Water must flow from the hot water faucet before turning “ON” power.

Wiring

You must provide all wiring of the proper size outside of the water heater. You must obey local codes and electric company requirements when you install this wiring. If you are not familiar with electric codes and practices, or if you have any doubt, even the slightest doubt, in your ability to connect the wiring to this water heater, obtain the service of a competent electrician. Contact your Sears salesperson to arrange for a professional electrician.

WATER HEATERS EQUIPPED FOR ONE VOLTAGE ONLY: This water heater is equipped for one type voltage only. Check the rating plate near the bottom access panel for the correct voltage. DO NOT use this water heater with any voltage other than the one shown on the model rating plate. Failure to use the correct voltage can cause problems which can result in DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE. If you have any questions or doubts consult your electric company.

If wiring from your fuse box or circuit breaker box was aluminum for your old water heater, replace it with copper wire. If you wish to reuse the existing aluminum wire, have the connection at the water heater made by a competent electrician. Contact your Sears salesperson to arrange for a professional electrician.

1. Provide a way to easily shut off the electric power when working on the water heater. This could be with a circuit breaker or fuse block in the entrance box or a separate disconnect switch.
2. Install and connect a circuit directly from the main fuse or circuit breaker box. This circuit must be the right size and have its own fuse or circuit breaker. Refer to the chart in the “Product Specifications” section for the correct size wire and fuse or circuit breaker.
3. If metal conduit is used for the grounding conductor:
   1. The grounding electrode conductor shall be of copper, aluminum, or copperclad aluminum. The material shall be of one continuous length without a splice or joint.
   2. Rigid metal conduit, intermediate metal conduit, or electrical metallic tubing may be used for the grounding means if conduit or tubing is terminated in fittings approved for grounding.
   3. Flexible metal conduit or flexible metallic tubing shall be permitted for grounding if all the following conditions are met:
      1. The length in any ground return path does not exceed 6 feet.
      2. The circuit conductors contained therein are protected by overcurrent devices rated at 20 amperes or less.
      3. The conduit or tubing is terminated in fittings approved for grounding.For complete grounding details and all allowable exceptions, refer to the current edition of the NEC – National Electrical Code NFPA70.
4. A standard 1/2″ conduit opening has been made in the water heater junction box for the conduit connection.
5. WiringDiagram(ssee”Wiring Diagrams” section) have been supplied showing the two most common types of connections between the water heater and the power supply. You can easily see which type connection you have by removing the junction box cover on top of the water heater.
   • Two Wire Connection Diagrams: is the most common requiring you to simply connect red to red, black to black, and the ground wire to the green ground screw in the junction box of the water heater.
   • Three Wire Connection Diagram: is used when you are connecting the water heater to a power supply that has a “Time Clock” or “Off Peak” meter. To make these connections refer to block 1 or 2 in this wiring diagram for the type of system you have.
     NOTE: If you have purchased a three wire connection water heater but you are not on a “Time Clock” or “Off Peak” meter and have a standard two wire connection power supply,
     simply follow the connection diagram in block 3 of the three wire connection diagram.
6. Use wire nuts and connect the power supply wiring to the wires inside the water heater’s junction box.
7. The water heater must be electrically “grounded” by the installer. A green ground screw has been provided on the water heater’s junction box. Connect ground wire to this location.
8. Replace the wiring junction cover using the screw provided

TROUBLESHOOTING

THERMAL EXPANSION

Water supply systems may, because of such events as high line pressure, frequent cut-offs, the effects of water hammer among others, 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. 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.

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

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.

NOT ENOUGH OR NO HOT WATER

1. In a new installation, the water heater may not be properly connected. Make sure the cold water supply valve is open. Review and check piping installation. Make sure that the cold water line is connected to the cold water inlet to the water heater and the hot water line to the hot water outlet
   on the water heater.
2. Make sure the electrical supply to your water heater is “ON”.
3. Check for loose or blown fuses in your water heater circuit. Circuit breakers weaken with age and may not handle their rated load and should be replaced.
4. Make certain the disconnect switch, if used, is in the “ON” position.
5. Check to see the electric service to your house has not been interrupted. If this is the case, contact the electric company.
6. Is the thermostat set to the desired temperature? See “Temperature Regulation” section.
7. If you had experienced very hot water and now no hot water, the problem may be due to the high temperature shut off system. See “High Temperature Shut Off System” in the “Troubleshooting” section.
8. During very cold weather, the incoming water will also be colder and it will require a longer time to become heated. 

    

9. The hot water usage may exceed the capacity of the water heater. If so, wait for water heater to recover after abnormal demand. Also examine pipes and faucets for possible water leaks. 
10. If you can not determine the problem, then call the Sears Service Department.WATERS TOO HOT: Adjust the thermostat to a lower setting. See the “Temperature Regulation” section.

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Kenmore 153 50-Gallon Electric Water Heater-FAQs