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Troubleshooting Guide
Start Up Conditions
CONDENSATION
Whenever the water heater is filled with cold water, a certain
amount of condensation will form while the burner is on. A
water heater may appear to be leakin_when in fact the water is
condensation. This usually happens wnen:
• When a new water heater is filled with cold water for the
first time.
• When gas burns and water vapor is produced in water
heaters, particularly high efficiency models where flue tem-
peratures arelower.
When you use large amounts of hot water, in ashort time
and the refill water Isvery cold.
Moisture from the products of combustion condense on the
cooler tank surfaces and form drops of water ".which may fall
onto the burner or other hot surfaces to produde a "sizzling" or
"frying" noise.
Excessive condensation can cause pilot outage due to water run-
ning down the flue tube onto the main burner and putting out
the pilot.
Because of the suddenness and amount of water, condensation
water may be diagnosed as a "tank leak". After the water in the
tank warms up (about 1-2 hours), the condition should
disappear.
Do not assume the water heater is leaking until there has been
enough time for the water in the tank to warm up.
An undersized water heater will cause more condensation. The
water heater must be sized properly to meet the family's
demands for hot water including dishwashers, washing machines
and shower heads.
Excessive condensation may be noticed during the winter and
early spring months when incoming water temperatures are at
their lowest.
Good venting is essential for a gas fired water heater to operate
properly as well as to carry away products of combustion and
water vapor.
SMOKE/ODOR
It is not uncommon to experience a small amount of smoke and
odor during the initi_ start-up. This is due to burning offof oil
from metal parts, and will disappear in ashort while.
THERMAL EXPANSION
Water supply systems may, because of high line pressure, fre-
quent cut-offs, the effects of water hammer and 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 sys-
tem to be closed. As water is heated, it expands (thermal expan-
sion) and closed systems do not allow for the expansion of heat-
ed 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 remperature-pressure relief valve is
reached, the valve will relieve the excess pressure. The tempera-
ture-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 expan-
sion tank to relieve the pressure built by thermal expansion in
the water system. Expansion tanks are available for ordering
through the Sears Service Center. Contact the local plumbing
inspector, water supplier, and/or the Sears Service Center for
assistance in controlling these situations.
Thermal Expansion Tank Specifications
Model
Number
Tank Capacity
In Gallons
2
5
153.331020
153.331050
Expansion Tank Sizing Chart
Water Heater Capacity (Gallons)
Dimensions in Inches I Pipe Fitting
Diameter Length : On Tank
8 inches 12_ inches] _" Male
i
llinches 14_inehes _"Male
AWARNING
HOTTERWATERCAN SCALD:Water heatersareintendedto
producehotwater.Water heatedto a temperaturewhichwill
satisfyclotheswashing,dishwashing,and othersanitizingneeds
canscaldandpermanentlyinjureyouuponcontact.Somepeo-
plearemorelikelyto bepermanentJyinjuredbyhotwaterthan
others,Theseincludetheelderly,children,the infirm,orphysicab
lylmentally handicapped.Ifanyoneusinghotwaterinyourhome
fitsintooneofthesegroupsor ifthere isalocalcodeorstatelaw
requiringa certaintemperaturewaterat thehotwaterta_ then
you musttakespecialprecautions.Inadditionto usingthe lowest
mssibletemperature settingthat satisfiesyourhotwater needs,
a meanssuchasa mixingvalve,shouldbeusedat the hotwater
tapsusedbythese people or at thewaterheater.Mixingvalves
areavailableat plumbingsupplyor hardwarestores.Followman-
ufacturersinstructionsfor installationof the valves.Before
changingthe factory setting on the thermostat, read the
'*l"emperotureRegulation"sectioninthis manual.
Expansion
Tank
Capacity
Needed
Inlet*
Water
Pressure 30 I 40 50
40psi 2 2 2
50psi 2 2 2
60psi 2 2 5
70psi 2 2 5
80psi 2 5 5
i 66 82
5 5
5 5
5 5
5 5
5 5
*Highest recorded inlet water pressure in a 24 hour period or
regulated water pressure.
NOTE: Expansion tanks are pre-charged with a 40 psi air
charge. If the inlet water pressure is higher than 40 psi, the
expansion tanks air pressure must be adjusted to match that
pressure, but must not be higher than 80 psi.
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