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Troubleshooting Guide
Start Up Conditions
CONDENSATION THERMAL EXPANSION
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 tem-
peratures are lower.
When you use large amounts of hot water in a short time
and the refill water is very 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 produce a "sizzling" or
"frying" noise.
Excessive condensation can cause pilot outage due to water run-
ning down the title 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 initial start-up. This is due to burning off of oil
from metal parts, and will disappear in a short while.
Water supply systems may, because of such events as high line
pressure, frequent cut-oti;, the effects of water hammer among
others, have installed devices such as pressure reducing valves,
check valves, back flowpreventers, 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 (ther-
mal expansion) and closed systems do not allow for the expan-
sion 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 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 l i inches-14_inches _';Male
Expansion Tank Sizing Chart
Water Heater Capacity (Gallons)
Inlet*
Water
Expansion Pressure 30
Tank 40psi 2
Capacity 50psi 2
Needed 60psi 2
70psi 2
80psi 2
40
2
2
2
2
5
50 66
2 5
2 5
5
5 5
5 5
82
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 tank's air pressure must be adjusted to match that
pressure, but most not be higher than 80 psi.
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