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Troubleshooting Guide
Start Up Conditions
CONDENSATION
SMOKE/ODOR
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 leaking when in fact the water is
condensation. This usually happens when:
• 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 ten>
peratures are lower.
• When you use large amounts of hot water in a short time
and the refill water is very cold.
Moisture front the products of combustion condense on the
cooler tank surfaces and form drops of water which may fall
onto the burner or other hot surfaces to produce a "sizzling" or
"frying" noise.
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 he 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.
It is not uncommon to experience a small amount of smoke and
odor during the inltia[ start-up. This is due to burning off ofoil
from metal parts, and wilt disappear in a short while.
THERMAL EXPANSION
Water supply systems may, because of high line pressttre, fie-
quent cut-offs, the eft_cts 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 (thernta[ 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 temperature-pressure relief valve is
reached, the valve will relieve the excesspressure. The tempera-
ture_ressure relief valve is not intended for the constant
relier of thermal expansion. This is an unacceptable condition
and must be corrected.
It is recommended that any devices insta ed wh ch 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 Tank Capacity Dimensions in Inches Pipe Fitting
Number In Gallons Diameter Length On Tank
153.331020 2 8 inches '12_ inches _" Male
153.331050 5 11 inches '14_ inches _,"Male
Expansion Tank Sizing Chart
Inlet* Water Heater Capacity (Gallons)
Water
Expansion Pressure 30 40 50 66 82
Tank 40psi 2 2 2 5 5
Capacity 50psi 2 2 ' 2 5 5
Needed 60psl 2 2 5 5 5
70psi 2 2 5 5 5
80psi 2 5 5 5 5
AWARNING
HOTTERWATERCAN SCALD:Water heatersareintendedto
producehot water.Water heatedto a temperaturewhichwill
satisfyclotheswashing,dishwashing,andothersanitizingneeds
canscaldandpermanentlyinjureyouuponcontact.Somepeo-
plearemore likelyto bepermanentlyinjuredbyhotwaterthan
others.Theseincludetheelderly,children,theinfirm,orphysical-
lylmeotallyhandicapped.Ifanyoneusinghotwaterinyour home
fitsintooneoftbesegroupsor ifthereisa localcodeor statelaw
requiringacertaintemperaturewaterat thehotwatertap,then
youmusttakespecialprecautions.Inadditionto usingthelowest
possibletemperaturesettingthat satisfiesyourhotwaterneeds,
a meanssuchasa mixingvalve,shouldbeusedat the hotwater
tapsusedbythesepeopleor at the waterheater.Mixingvalves
areavailableat plumbingsupplyor hardwarestores.Followman-
ufacturersinstructionsfor installationof the valves.Before
changingthe factory setting on the thermostat, read the
"TemperatureRegulation"sectioninthis manual.
*Highest recorded inlet water pressure in a 24 hour period or
regulated water presstne.
NOTE: Expansion tanks are pro-charged with a 40 psi air
charge. If the inlet water pressure is higher than 40 psi, the
expansion tank's air pressure must be adjusted to match that
pressure, but must not be higher than 80 psi.
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