Whirlpool Residential Gas Water Heater Installation Instructions And Use & Care Manual page 24

Replacing the Pilot/Thermopile Assembly
1. Remove the manifold assembly as directed previously.
2. Lift the retainer clip straight up from the back of
the manifold component block (using a flat-blade
screwdriver), then remove the manifold component
block from the manifold door (Figure 25).
Figure 25
Manifold Component
Block Assembly
White
Igniter
Wire
Wire
Manifold Component
Block
Pilot Tube
Manifold Door
3. Locate and remove the screws on the underside of the
burner, then remove the burner. IMPORTANT: DO NOT
remove the orifice. LP Cast Burner models DO NOT
require the burner to be removed. Remove the screw
securing the pilot assembly to the manifold.
NOTE: For cast burner models, remove the screw securing
the pilot assembly to the burner.
4. Using a 7/16" wrench, loosen the nut securing the pilot
tube to the pilot assembly.
NOTE: To prevent any bending of the pilot bracket, use
pliers to hold the pilot assembly bracket while loosening the
pilot nut.
Figure 26
Pilot/Thermopile Assembly
Igniter
Connector
White
Wire
5. Disconnect the red wire connected to the thermal switch,
then lift the pilot/thermopile assembly (including the igniter
wire) from the manifold assembly.
6. Pull the pilot tube from the pilot assembly (Figure 26).
IMPORTANT: Be careful not to bend or alter the position of
the pilot assembly components.
7. Using the old pilot/pilot tube assembly as a guide, bend
the new pilot tube to match the old one. Make only the
bends closest to the pilot before going to the next step.
8. Push the new pilot assembly connectors through the hole
in the manifold door (See Figure 25). Reconnect the pilot
tube and tighten the nut securing it to the pilot assembly.
IMPORTANT: Keep the pilot orifice in the pilot when
making the connection. DO NOT operate the water
heater without the pilot orifice installed. Reattach the pilot
assembly to the manifold. Cast burner models reattach the
pilot assembly to the burner.
9. Reattach the burner and secure with screws.
24
Burner and other
Thermopile
fittings not show
Connector
for clarity.
Retainer
Clip
Red
Wire
Thermopile
Pilot
Pilot/Thermopile
Assembly
Thermopile
Connector
Thermal
Switch
Connectors
Red
Wire
NOTE: See figure 24A for correct burner orientation.
10. Position the new thermopile wires through the top opening
of the manifold component block (Figure 25). Be sure the
igniter wire is positioned through the middle opening of
the manifold component block.
11. See "Replacing Manifold Assembly" Page 25.
Filter Installation and Cleaning
IMPORTANT: It is essential that the fi lter be installed properly.
If you encounter diffi culty installing the fi lter or have a question,
please call the Service & Warranty Department at 1-877-817-6750.
Filter Installation
1. Before attaching the filter, remove any dust, lint or debris
that may have accumulated in the installation area. It is
also recommended that a visual inspection of the flame-
trap be performed. Refer to the "External Inspection &
Cleaning of the Flame-trap" section.
2. Installation: Wrap the filter around the base of the water
heater. Cut to fit around a sensor if present. Trim excess
filter material with scissors but allow filter material to
overlap a few inches (Figure 27).
3. The filter should fit snugly against base of water heater
with no gaps. The filter must fit flush against the bottom of
the drain pan and/or floor. Hold the filter in place, stretch
the filter clip over the overlapped joint and hook in place
(Figure 27).
4. It is recommended that the filter be inspected every three
months and periodically clean as necessary.
Periodic Cleaning of the Filter
1. If periodic inspection of the filter shows a build-up on the filter,
it should be removed and cleaned.
2. The filter can then be vacuumed to remove the build-up.
3. The filter may need to be removed and washed using a
mild hand soap and water to remove any oily residue. After
washing allow to dry and then properly reinstall.
4. Before reinstalling the filter, a visual inspection of the flame-
trap is recommended. Refer to the "External Inspection &
Cleaning of the Flame-trap" section.
5. Follow Filter Installation instructions 2-3 to re-attach the filter.
Figure 27
Air Filter Assembly Installation:
If water heater has a "SENSOR",
the air filter must be trimmed
around the "SENSOR".
1 1 / "
8
(28 mm)
1 /
1
(38 mm)
Overlap
4"
(100 mm)
Fit around "SENSOR" (if present)
then wrap the Air Filter Assembly
around the bottom of the water
heater (Note: Clip on top edge).
*
DRAIN PAN SHOWN
REMOVED FOR CLARITY.
Trim excess material, making
sure there is enough to overlap
by 4 inches (100 mm).
Discard piece
after trimming.
"
2
Filter Clip end on the
Air Filter Assembly.
Attach Filter Clip as
shown holding the
Air Filter Assembly
in place.
*Flush Fit against bottom
of Drain Pan and/or Floor.