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

Residential gas water heater with the flame lock safety system natural & l.p. gas models
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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.
Residential Gas
Water Heater
with the Flame Lock
Safety System
Installation
Instructions and
Use & Care Guide
NATURAL & L.P. GAS MODELS
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
318051-002
October 2010
1

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  Summary of Contents for Whirlpool Residential Gas Water Heater

  • Page 1 Residential 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 & Care Guide Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
  • 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 installed in accordance with Massachusetts Plumbing and Fuel Gas Code 248 CMR Section 2.00 and 5.00. This Water Heater A data plate identifying your water heater can be found next to the gas control valve/thermostat. When referring to your This gas water heater was manufactured to voluntary water heater, always have the information listed on the data safety standards to reduce the likelihood of a flammable...
  • Page 4: Location Requirements

    heater. Note: Not following these instructions and/or an WARNING inadequate air supply can cause the Flame Lock Safety ® System to disable the water heater. Please make required installation and venting/air supply changes prior to resetting the system (see “Combustion Air Supply and Ventilation” section).
  • Page 5: Clearances And Accessibility

    IMPORTANT: The water heater should be located Figure 1A Air-moving in 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 Figure 3 Gas Piping Manual Gas Shut-off Valve WARNING Ground Joint Union Check with local utility for minimum height 3” Minimum Explosion Hazard Drip Leg Gas Pressure Use a new CSA approved gas supply line. IMPORTANT: The gas supply pressure must not exceed the Install a shut-off valve.
  • Page 7: Combustion Air Supply And Ventilation

    BTU/HR. Combustion Air Supply and • beauty shops • photo processing labs Ventilation • buildings with indoor pools WARNING • water heaters installed in laundry, hobby, or craft rooms • water heaters installed near chemical storage areas Carbon Monoxide Hazard Combustion air must be free of acid-forming chemicals Water heater must be vented to outdoors.
  • 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 BTU/HR 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 BTU/HR 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 Size

    Figure 9 Draft hood Inst allation Alternative Sheet Metal Screws (four provided) Opening Location Draft hood Legs 1 sq. Inch Confined Legs Per 3000 BTU/HR Space Slot Slot Jacket top Install the draft hood with the four screws provided. Vent Pipe Size It is important that you follow the guidelines in these instructions for sizing a vent pipe system.
  • 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 7. After piping has been properly connected to the water heater, remove the aerator at the nearest hot water Piping Installation faucet. Open the hot water faucet and allow the tank to completely fill with water. To purge the lines of any ex- Piping, fittings, and valves should be installed according to cess air, keep the hot water faucet open for 3 minutes the installation drawing (Figure 13).
  • Page 13 Closed System/Thermal Expansion Please note the following: • The system should be installed only with piping that is WARNING 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: Temperature & Pressure Relief Valve

    Temperature and Pressure IMPORTANT: Only a new temperature and pressure relief valve should be used with your water heater. Do not use an Relief Valve old or existing valve as it may be damaged or not adequate for the working pressure of the new water heater. Do not WARNING place any valve between the relief valve and the tank.
  • Page 15: Special Applications

    Special Applications Some jurisdictions may require a backflow preventer in the incoming cold water line. This may cause the Combination Space Heating/Potable temperature and pressure relief valve on the water heater to discharge or weep due to expansion of the heated water. Water System A diaphragm-type expansion tank suitable for potable water will normally eliminate this weeping condition.
  • 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 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 missing Make sure the tank is completely filled with water before or damaged.
  • Page 18: Burner Flames

    L.P.G. (Bottled Propane) Models Burner Flames Inspect the burner flames through the viewport and Liquefi ed petroleum gas is over 50% heavier than air compare them to the drawings in Figure 18. A properly and in the occurrence of a leak in the system, the gas operating burner will settle at fl...
  • Page 19: Water Temperature Regulation

    Water Temperature Regulation IMPORTANT: Adjusting the thermostat past the 120°F bar on the temperature dial will increase the risk of scald injury. WARNING Hot water can produce first degree burns within: Table 4: Time for Time for 1st Water Permanent Burns Degree Burn Temperature °F 2nd &...
  • Page 20: Operating The Temperature Control System

    Operating the Temperature Control System Status Light Code Figure 19B: Status Codes Normal Flashes: List of status codes are shown • 0 Flashes Indicates Control Off/Pilot Out. at top of gas control valve/thermostat. • 1 Flash Indicates Normal Operation. • Continuous Light indicates the gas control valve/thermostat is shutting down.
  • Page 21: Operational Conditions

    Operational Conditions water heater if the water temperature exceeds 189°F (87°C) for 155°F models or 199°F (93°C) for 180°F models. See the data plate for your model. Condensation The Diagnostic Status Light will flash a code indicating Moisture from the products of combustion condenses on the an “Overheat Failure”...
  • Page 22: 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 WARNING during operation. The water heater should be drained if being shut down during freezing temperatures.
  • Page 23 Replacement Parts Removing the Burner from the Manifold Assembly IMPORTANT: The following maintenance procedures are for the Flame Lock Safety System components and should ® Natural Gas Burner (Low Nox) & L.P. Burner be performed by a qualified person. 1. Take off the burner by removing the two (2) screws lo- Replacement parts may be ordered through your plumber cated underneath the burner.
  • Page 24 Replacing the Pilot/Thermopile Assembly NOTE: See figure 24A for correct burner orientation. 10. Position the new thermopile wires through the top opening 1. Remove the manifold assembly as directed previously. of the manifold component block (Figure 25). Be sure the 2.
  • Page 25: Piezoelectric Igniter System

    Cleaning the Combustion Chamber and Check for leaks by brushing on an approved noncorrosive leak detection solution. Bubbles forming Flame-trap indicate a leak. Correct any leak found. IMPORTANT: All leaks must be fixed immediately. 1. Follow procedure outlined in “Removing the Manifold Replace the outer door.
  • Page 26: Troubleshooting Charts

    Removing and Replacing the Gas gas control valve/thermostat (counterclockwise.) Do not use pipe wrench or equivalent to grip body. Damage Control Valve/Thermostat may result, causing leaks. Do not insert any sharp objects into the inlet or outlet connections. Damage to IMPORTANT: The gas control valve/thermostat is a standard the gas control valve/thermostat may result.
  • Page 27 PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION PILOT WILL NOT LIGHT OR 11. Pilot line or orifice clogged 11. Clean, locate source and correct REMAIN LIT (continued) 12. Non-functioning thermopile 12. Replace thermopile 13. Air for combustion obstructed 13. See maintenance section for inspection and cleaning of flame trap 14.
  • Page 28 STATUS LIGHT CODE TROUBLESHOOTING CHART LED STATUS PROBLEM CORRECTIVE ACTION 0 FLASHES (LED NOT LIT) Pilot light is not lit. Not enough Follow the lighting instructions on the front of the power (millivolts) to keep it lit. water heater and record any diagnostic codes. See Diagnostic Status Light Code section.
  • Page 29: 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 water heater, in the on position? Are the combustion air supply and ventilation openings...
  • Page 30: 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 31: Listed Parts Kits And Illustrations

    Listed Parts Kits and Illustrations Item 12: Pilot assembly kit, which contains the pilot assembly, thermopile, and retainer clip (Natural Gas) Item 12: Pilot assembly kit, which contains the pilot assembly, thermopile, and retainer clip (L.P. Gas) Item 13: Burner (Natural Gas/L.P. Gas) Item 13: Burner (L.P.
  • Page 32 ® Registered trademark/TM Trademark of Whirlpool, U.S.A. © 2010 Whirlpool Corporation. All rights reserved. Manufactured under license by American Water Heater Company, Tennessee. Warranty provided by Manufacturer.