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Whirlpool Energy Smart Gas Water Heater Installation Instructions And Use & Care Manual

Energy smart 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.
Energy Smart Gas
Water Heater
with the Flame Lock
Safety System
Installation
Instructions and
Use & Care Guide
NATURAL GAS MODELS ONLY
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
6510374
W10100870
February 2006
1

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  Summary of Contents for Whirlpool Energy Smart Gas Water Heater

  • Page 1 http://waterheatertimer.org/How-to-troubleshoot-gas-water-heater.html Energy Smart Gas Water Heater ™ with the Flame Lock Safety System Installation WARNING: If the information in these instructions is not followed exactly, a fire Instructions and or explosion may result causing property damage, personal injury or death. Use &...
  • 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: Water Heater Safety

    INSTALLING YOUR GAS WATER HEATER Important Information About instructions, you should not proceed but have a qualified person perform the installation of this water heater. Massachusetts code requires this water heater to be This Water Heater installed in accordance with Massachusetts Plumbing and This gas water heater was manufactured to voluntary Fuel Gas Code 248 CMR Section 2.00 and 5.00.
  • Page 4: Location Requirements

    Location Requirements WARNING WARNING Carbon Monoxide Poisoning Hazard Do not install in a mobile home. Doing so can result in death or carbon monoxide poisoning. FLAMMABLES Flammable Vapors The Flame Lock™ Safety System is designed to reduce the risk of flammable vapor-related fires. The patented system protects your family by trapping the burning vapors within FIRE AND EXPLOSION HAZARD the water heater combustion chamber through the special...
  • Page 5: Clearances And Accessibility

    IMPORTANT: The water heater should be located in Figure 1 Air-moving an area where leakage of the tank or connections Devices 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

    Gas Supply 3. Install a ground joint union between the gas control valve/thermostat and the manual shut-off valve. This is to allow easy removal of the gas control valve/ WARNING thermostat. 4. Turn the gas supply on and check for leaks. Test all connections by brushing on an approved noncorrosive leak-detection solution.
  • 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 Length of Pipe, Feet Size, in.
  • Page 8: Unconfined Space

    Unconfined Space Figure 4 12” maximum Opening Locations- A water heater in an unconfined space uses indoor air for Confined Spaces 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 Closet footage (area) required for various BTUH inputs.
  • Page 9: All Air From Outdoors

    All Air from Outdoors Gable vent to outdoors Outdoor fresh air can be provided to a confined area either Install above directly or by the use of vertical and horizontal ducts. The insulation fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors.
  • Page 10: Vent Pipe System

    Vent Pipe System Vent Pipe Size This water heater uses a non-direct, single-pipe vent It is important that you follow the guidelines in these system to remove exhaust gases created by the burning of instructions for sizing a vent pipe system. If a transition to fossil fuels.
  • Page 11: Chimney Connection

    Chimney Connection Listed Lined Chimney IMPORTANT: Before connecting a vent to a chimney, make sure the chimney passageway is clear and free of 2 ft. minimum above any obstructions. The chimney must be cleaned if previously object within10 ft. used for venting solid fuel appliances or fireplaces. Also horizontally 3 ft.
  • Page 12: Water System Piping

    Water System Piping Figure 13 Water Piping Installation Piping Installation In a closed system use a thermal expansion tank Piping, fittings, and valves should be installed according to Cold Water the installation drawing (Figure 13). If the indoor installation Supply to Fixtures Hot Water area is subject to freezing temperatures, the water piping Outlet...
  • Page 13: Temperature And Pressure Relief Valve

    Closed System/Thermal Expansion Figure 15A Temperature and Pressure Periodic discharge of the temperature and pressure relief Relief Valve Installation Optional location valve may be due to thermal expansion in a closed water some models only supply system. The water utility supply meter may contain a check valve, backflow preventer or water pressure reducing valve.
  • Page 14: Special Applications

    • Pumps, valves, piping and fittings must be compatible Figure 15B with potable water. T&P Relief Valve Insulation • A properly installed flow control valve is required to pre- T&P Relief Valve Insulation vent thermosiphoning. Thermosiphoning is the result of a continuous flow of water through the air handler circuit during the off cycle.
  • Page 15: Installation Checklist

    Important Information About Installation Checklist Your Water Heater Water Heater Location □ This gas water heater was manufactured to voluntary Centrally located with the water piping system. Located safety standards to reduce the likelihood of a flammable as close to the gas piping and vent pipe system as vapor ignition incident.
  • Page 16: Operating Your Water Heater

    OPERATING YOUR WATER HEATER Lighting Instructions WARNING Read and understand these directions thoroughly before Explosion Hazard attempting to light or re-light the pilot. Make sure the viewport is not missing or damaged. (See Figure 23) Replace viewport if glass is Make sure the tank is completely filled with water before missing or damaged.
  • Page 17: Checking The Draft

    Checking the Draft Water Temperature Regulation WARNING WARNING Burn Hazard Do not touch vent. Doing so can result in burns. After successfully lighting the water heater, allow the unit to operate for 15 minutes and check the drafthood relief opening for proper draft. Make sure all other appliances in Water temperature over 125°F can cause Figure 17...
  • Page 18: Operating The Temperature Control System

    Operating the Temperature Control System NOTE: If the pilot lights, but will only stay lit with the knob Figure 19B Temperature Control System depressed in the pilot position, look for the following status light codes. STATUS LIGHT CODE 6 Second Solid Light followed by: 4 Flashes The unit will not relight because it detects an overheat failure.
  • Page 19: Operational Conditions

    Operational Conditions A high temperature limit switch or ECO (Energy Cut Off) in the tank is used to shut off the unit if the water temperature Condensation exceeds 180°F (83°C). The ECO is a single use switch and requires complete replacement of the entire gas control Moisture from the products of combustion condenses on valve/thermostat.
  • Page 20: Maintenance Of Your Water Heater

    MAINTENANCE OF YOUR WATER HEATER Draining and Flushing Temperature and Pressure Relief Valve 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 WARNING being shut down during freezing temperatures.
  • Page 21: Replacement Parts

    Replacement Parts Removing the Burner from the Manifold Assembly IMPORTANT: The following maintenance procedures are for the Flame Lock ™ Safety System components and Natural Gas Burner (Low Nox) should be performed by a qualified person. 1. Take off the burner by removing the two (2) screws Replacement parts may be ordered through your plumber located underneath the burner.
  • Page 22: Replacing The Pilot Assembly

    Replacing the Pilot Assembly External Inspection & Cleaning of the Flame-trap 1. Remove the manifold assembly as directed previously. 2. Remove the retainer clip from the back of the two Inspect the wrap around filter periodically to check for lint, piece wire connector and remove the two piece wire dust, or other debris that may have accumulated on it.
  • Page 23: Piezoelectric Igniter System

    Replacing the Manifold Assembly 9. Check for leaks by brushing on an approved noncorrosive leak detection solution. Bubbles forming indicate a leak. Correct any leak found. IMPORTANT: WARNING All leaks must be fixed immediately. 10. Replace the outer door. Figure 28A Combustion Chamber Flame-trap Bracket...
  • Page 24: Troubleshooting Charts

    Removing and Replacing the Gas Replacing the Gas Valve: To replace the gas control valve/thermostat, reassemble in Control Valve/Thermostat reverse order. IMPORTANT: This water heater has a resettable thermal switch installed. DO NOT attempt to disable IMPORTANT: The gas control valve/thermostat is a standard or modify this feature in any way.
  • Page 25 PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION HIGH OPERATION COSTS Thermostat set too high Set temperature dial to lower setting Sediment or lime in tank Drain/flush-provide water treatment if needed Water heater too small for job Install adequate heater Wrong piping connections Correct piping-dip tube must be in cold inlet Leaking faucets Repair faucets...
  • Page 26: Troubleshooting Charts

    PILOT LIGHT TROUBLESHOOTING CHART Section A: Pilot light will not light (new installation). Section C: Pilot light will not remain lit. Check for insufficient combustion air. Is the manual gas shut-off valve, Turn the manual gas shut-off valve to located in the supply line to the the on position and follow the lighting Are the combustion air supply and ventilation openings water heater, in the on position?
  • Page 27: 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 DRAFTHOOD REDUCER RING - SOME MODELS FLUE BAFFLE HEAT TRAP (COLD) - SOME MODELS HEAT TRAP (HOT) - SOME MODELS...
  • Page 28: Listed Parts Kits And Illustrations

    Item 17: Contains viewport Item 18: Contains replacement thermistors Item #18 WHIRLPOOL, FLAME LOCK & DESIGN, and FLAME LOCK are trademarks of Whirlpool, U.S.A. © 2006 Whirlpool Corporation. All rights reserved. Manufactured under license by American Water Heater Company, Tennessee.