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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 leaklngwhen 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 isproduced 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 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 machir_es
and shower heads.
Excessive condensation may be noticed during the winter and
early spring months when incoming water temperatures are at
their lowest.
Good vendng is essential for a gas fired water heater to operate
properly as well as to carry away products of combustiohand
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 suppl,_, systems may, because of high line pressure, fre-
quent cut-orrs, 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 dosed. As water is heated, it expands (thermal expan-
sion) and closed systems do not allow for the expansion of fieat-
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 excess pressure. The tempera-
ture-pressure relief valve is not intended for the constant
relief of thermal e_tpansion. This is an unacceptable condition
and must be corrected.
It is recommended that any devicesinstalledwhich could create
a closedsystem have a by-passand/or the system havean expan-
sion tank to relievethe 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
assistancein 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
Water Heater Capacity (Gallons)
Inlet*
Water
Pressure
40psi
50psi
60psi
70psi
80psi
Expansion 30 40 50 66 82
Tank 2 2 2 5 5
Capacity 2 2 2 5 5
Needed 2 2 5 5 5
2 2 5 5 5
2 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 ac_justed to match that
pressure, but must not be higher than 80 psi.
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