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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 leakingwhen 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 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 disap-
pear.
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 sizedproperly 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 initial start-up. This is due to burning off of oil
from metal parts, and will disappear in a short while.
THERMAL EXPANSION
Water suppl_ systems may, because of high line pressure, fre-
quent cut-otis, 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 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
refi_ 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.
STRANGE SOUNDS
Possible noises due to expansion and contraction of some metal
_arts during periods of heat-up and cool-down do not represent
armful or dangerous conditions.
Condensation causes sizzling and popping with the burner area
during heating and coofin_ periods and should be considered
normal. See Condensation section.
AWARNING
HOTTERWATERCAN SCALD:Water heatersareintendedto
,reducehot water.Water heatedto a temperaturewhichwill
satisfyclotheswashing,dishwashing,andothersanitizingneeds
canscaldandpermanentlyinjureyouuponcontact.Somepeo-
dearemorelikelyto bepermanentlyinju_l byhotwater than
other_Theseindudetheelderly,children,the infirm,or physical-
ly/mant_dlyhandicapped.Ifanyoneusinghotwaterinyourhome
Etsintooneofthesegroupsor ifthereisalocalcodeor statelaw
requiringacertaintomperatore wateratthe hotwater_ then
_u musttakespecialprecautions.Inadditionto usingthe lowest
x_ssibietemperaturesettingthatsatisfiesyourhotwater needs,
a meanssuchasa mixingvalve,shouldbe usedat the hotwater
tapsusedby thesepeopleor at the waterheater.Mixingvalves
areavailableat plumbingsupplyor hardwarestore_Followman-
ufacturersinstructionsfor installationof the valves.Before
changingthe factory setting on the thermostat, read the
'TemperatureRegulation"sectioninthismanual.
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