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Whirlpool 201553 Installation Instructions And Use & Care Manual

Ultra low nox gas water heater with the flame lock safety system
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WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electrical switch;
do not use any phone in your
building.
Immediately call your gas supplier
from a neighbor's phone. Follow
the gas supplier's instructions.
If you cannot reach your gas
supplier, call the fire department.
Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.
INSTALLER:
AFFIX THESE INSTRUCTIONS TO OR ADJACENT
TO THE WATER HEATER.
OWNER:
RETAIN THESE INSTRUCTIONS AND WARRANTY
FOR FUTURE REFERENCE. RETAIN THE ORIGINAL
RECEIPT AS PROOF OF PURCHASE.
®
Ultra Low Nox
Gas Water Heater
with the Flame Lock™
Safety System
Installation
Instructions and
Use & Care Guide
To obtain technical, warranty, or service assistance during or after
the installation of this water heater, visit our website at:
http://www.whirlpoolwaterheatersupport.com
or call toll free
1-877-817-6750
When calling for assistance, please have the following
information ready:
1.
Model number
2.
7 digit product number
3.
Serial number
4.
Date of installation
5.
Place of purchase
Table of Contents ......................................................
2
6510415
W10123251
March 2007
1

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  Summary of Contents for Whirlpool 201553

  • Page 1 WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS •...
  • Page 2: Table Of Contents

    WATER HEATER SAFETY Your safety and the safety of others are very important. We have provided many important safety messages in this manual and on your appliance. Always read and obey all safety messages. This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others.
  • Page 3: Installing Your Gas Water Heater

    INSTALLING YOUR GAS WATER HEATER Important Information About This Water Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation environments.
  • Page 4: Location Requirements

    WARNING Flammable Vapors FLAMMABLES FIRE AND EXPLOSION HAZARD Can result in serious injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Storage of or use of gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance can result in serious injury or death.
  • Page 5: Clearances And Accessibility

    IMPORTANT: The water heater should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower floors of the structure. Due to the normal corrosive action of the water, the tank will eventually leak after an extended period of time.
  • Page 6: Gas Supply

    WARNING Explosion Hazard Use a new CSA approved gas supply line. Install a shut-off valve. Do not connect a natural gas water heater to an L.P. gas supply. Do not connect an L.P. gas water heater to a natural gas supply. Failure to follow these instructions can result in death, explosion, or carbon monoxide poisoning.
  • Page 7: Combustion Air Supply And Ventilation

    Table 1 Natural Gas Pipe Capacity Table (Cu. Ft./Hr.) Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity of 0.60 (natural gas). Nominal Iron Pipe Size, in. 1-1/4 1050 1-1/2...
  • Page 8: Unconfined Space

    Unconfined Space A water heater in an unconfined space uses indoor air for combustion and requires at least 50 cubic feet for each 1,000 BTUH of the total input for all gas appliances. The table below shows a few examples of the minimum square footage (area) required for various BTUH inputs.
  • Page 9: All Air From Outdoors

    All Air from Outdoors Outdoor fresh air can be provided to a confined area either directly or by the use of vertical and horizontal ducts. The fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors. Attic or crawl spaces cannot be closed and must be properly ventilated to the outside.
  • Page 10: Vent Pipe Size

    Vent Pipe System This water heater uses a non-direct, single-pipe vent system to remove exhaust gases created by the burning of fossil fuels. Air for combustion is taken from the immediate water heater location or is ducted in from the outside (see “Combustion Air Supply and Ventilation”...
  • Page 11: Chimney Connection

    Chimney Connection IMPORTANT: Before connecting a vent to a chimney, make sure the chimney passageway is clear and free of obstructions. The chimney must be cleaned if previously used for venting solid fuel appliances or fireplaces. Also consult local and state codes for proper chimney sizing and application or, in the absence of local and state codes, the “National Fuel Gas Code”, ANSI Z223.1(NFPA 54)- latest edition.
  • Page 12: Water System Piping

    Piping, fittings, and valves should be installed according to the installation drawing (Figure 13). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation. Water supply pressure should not exceed 80% of the working pressure of the water heater.
  • Page 13 Please note the following: • The system should be installed only with piping that is suitable for potable (drinkable) water such as copper, CPVC, or polybutylene. This water heater must not be installed using iron piping or PVC water piping. •...
  • Page 14: Relief Valve

    Relief Valve WARNING Explosion Hazard If the temperature and pressure relief valve is dripping or leaking, have a qualified person replace it. Examples of a qualified person include: licensed plumbers, authorized gas company personnel, and authorized service personnel. Do not plug valve. Do not remove valve.
  • Page 15 Combination Space Heating/Potable Water System Some water heater models are equipped with inlet/outlet tappings for use with space heating applications. If this water heater is to be used to supply both space heating and domestic potable (drinking) water, the instructions listed below must be followed.
  • Page 16: Installation Checklist

    Important Information About This Water Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident. The new technology used in meeting these standards makes this product more sensitive to installation errors.
  • Page 17: Operating Your Water Heater

    OPERATING YOUR WATER HEATER Lighting Instructions Read and understand these directions thoroughly before attempting to light or re-light the pilot. Make sure the viewport is not missing or damaged. (See Figure 23) Make sure the tank is completely filled with water before lighting the pilot.
  • Page 18: Lighting Instructions

    This appliance has a pilot which is lighted by a piezoelectric igniter. When lighting the pilot, follow these instructions exactly. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.
  • Page 19: Burner Flames

    Burner Flames Inspect burner Figure 18 flames through Flame Characteristics viewport. Flames should be very small Correct flame soft blue with a blue haze and small amounts of yellow or orange at the edges. After several minutes of operation the burner screen may glow red.
  • Page 20: Operational Conditions

    Operational Conditions Condensation Moisture from the products of combustion condenses on the tank surface and the outside jacket of the water heater and forms drops of water which may fall onto the burner or other hot surfaces. This will produce a “sizzling” or “frying” noise.
  • Page 21: Maintenance Of Your Water Heater

    MAINTENANCE OF YOUR WATER HEATER Draining and Flushing It is recommended that the tank be drained and flushed every 6 months to remove sediment which may build up during operation. The water heater should be drained if being shut down during freezing temperatures. To drain the tank, perform the following steps: 1.
  • Page 22: Replacement Parts

    Replacement Parts IMPORTANT: The following maintenance procedures are for the Flame Lock™Safety System components and should be performed by a qualified person. Replacement parts may be ordered through your plumber or the local distributor. Parts will be shipped at prevailing prices and billed accordingly.
  • Page 23: Replacing The Thermocouple

    Replacing the Thermocouple 1. Remove the Burner Door Assembly as directed previously. 2. Remove the retainer clip from the back of the two piece wire connector and remove the two piece wire connector from the assembly (Figure 25). 3. Pull the thermocouple from the pilot assembly (Figure 29).
  • Page 24: Replacing The Burner Door Assembly

    Replacing the Burner Door Assembly WARNING Explosion Hazard Tighten both manifold door screws securely. Remove any fiberglass between gasket and combustion chamber. Replace viewport if glass is missing or damaged. Replace two piece wire connector if missing or removed. Replace door gasket if damaged. Failure to follow these instructions can result in death, explosion, or fire.
  • Page 25: Troubleshooting Chart

    Removing and Replacing the Gas Control Valve/Thermostat IMPORTANT: The gas control valve/thermostat is a standard valve with a right-hand thread thermocouple. Use only factory authorized replacement parts. Removing the Gas Valve: 1. Turn the gas control knob on the combination gas control valve/thermostat clockwise to the “OFF”...
  • Page 26 PROBLEM PILOT WILL NOT REMAIN LIT 1. 10. Pilot dirty HIGH OPERATION COSTS INSUFFICIENT HOT WATER 1. SLOW HOT WATER RECOVERY DRIP FROM RELIEF VALVE THERMOSTAT FAILS TO SHUT OFF COMBUSTION ODORS SMOKING AND CARBON FORMATION (SOOTING) CONDENSATION BURNER FLAME FLOATS AND LIFTS OFF PORTS FLAME BURNS AT ORIFICE PILOT FLAME TOO SMALL...
  • Page 27 PILOT LIGHT TROUBLESHOOTING CHART Section A: Pilot light will not light. Check the manual gas shut-off valve to Is the gas turned on? see if it is in the open position, if it is open then contact the gas utility company. While repeatedly depressing the igniter button, Have you bled all the air hold down the reset button until the pilot is lit and...
  • Page 28: Repair Parts Illustration

    REPAIR PARTS ILLUSTRATION When ordering repair parts always give the following information: 1. Model, serial, and product number 2. Type of gas 3. Item number 4. Parts description Repair Parts List Item Parts Description DRAFT HOOD REDUCER RING - SOME MODELS FLUE BAFFLE HEAT TRAP (COLD) - SOME MODELS HEAT TRAP (HOT) - SOME MODELS...
  • Page 29: Listed Parts Kits And Illustrations

    Item #19 Item #18 Alternate Igniter WHIRLPOOL, FLAME LOCK & DESIGN, and FLAME LOCK are trademarks of Whirlpool, U.S.A. © 2007 Whirlpool Corporation. All rights reserved. Manufactured under license by American Water Heater Company, Tennessee. Item #13 Item #17 Item #14...