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

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.
Do not try to light any appliance.
Do not touch any electrical switch;
do not use any phone in your
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.
Residential Gas
Water Heater
with the Flame Lock
Safety System
Instructions and
Use & Care Guide
(Flammable Vapor Ignition Resistant)
To obtain technical, warranty, or service assistance during or after
the installation of this water heater, visit our website at:
or call toll free
When calling for assistance, please have the following
information ready:
Model number
7 digit product number
Serial number
Date of installation
Place of purchase
Table of Contents ......................................................
September 2010



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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 and instructions is not followed exactly, a fire or explosion may result causing property Use & Care Guide damage, personal injury or death. Do not store or use gasoline or other (Flammable Vapor Ignition Resistant) flammable vapors and liquids in the...
  • 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

    ignition resistant water heater and is designed to reduce WARNING the chances of flammable vapors being ignited, gasoline and other flammable substances should never be stored or used in the same vicinity or area containing a gas water heater or other open flame or spark producing appliance. In the event the FVIR system does not prevent the ignition of flammable vapors, the Flame Lock Safety System is...
  • Page 5: Clearances And Accessibility

    • Locate the water heater near the existing gas piping. conditions these devices may create. Flow reversal of If installing a new gas line, locate the water heater to flue gases may cause an increase of carbon monoxide inside of the dwelling. minimize the pipe length and elbows.
  • Page 6: Gas Supply

    Gas Supply Figure 4 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 6 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 12 Draft hood Inst allation Draft hood Alternative Opening Location Flue Damper 1 sq. Inch Confined Per 3000 BTU/HR Space Draft hood Leg Tips* * Twist or bend the leg tips to secure the draft hood to the flue damper Vent Pipe Size Figure 11 It is important that you follow the guidelines in these...
  • Page 11: Chimney Connection

    Chimney Connection Listed Lined Figure 13 Chimney Termination Chimney IMPORTANT: Before connecting a vent to a chimney, Vent System 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.
  • 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 16).
  • 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: 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 16: Operating Your Water Heater

    OPERATING YOUR WATER HEATER Lighting Instructions WARNING Read and understand these directions thoroughly before Explosion Hazard attempting to start or re-start the water heater. Make sure the viewport is not missing or damaged. (See Figure 28) Replace viewport if glass is missing Make sure the tank is completely filled with water before or damaged.
  • Page 17: 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 21. A properly and in the occurrence of a leak in the system, the gas operating burner should produce a soft blue flame.
  • Page 18: 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 5: Time for Time for 1st Water Permanent Burns Degree Burn Temperature °F 2nd &...
  • Page 19: Electrical Connections

    Electrical Connections WARNING Before plugging in the water heater, always make sure: • The Voltage and frequency correspond to that specified on the water heater. • The electrical outlet has the proper overload fuse or breaker protection. • Water heater to be located within 6 feet of 120VAC outlet. •...
  • Page 20: Operating The Temperature Control System

    Operating the Temperature Control System Water Temperature Adjustment Figure 24: Status Codes The water temperature can be adjusted from 70°F to 160°F. Status Turn the Gas Control/Temperature Knob to the desired Light setting/temperature. STATUS Operating Modes and Settings • Standard Mode - The controller adjusts the water heater to maintain the temperature set by the user.
  • Page 21: Operational Conditions

    Operational Conditions A temperature limit switch or ECO (Energy Cut Off) sensor located in the gas control valve\thermostat, is used to shut off the water heater if the water temperature exceeds 189°F (87°C). 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 NOTE: To prevent any bending of the pilot bracket, use (see Figure 32). NOTE: Depending on the size of your pliers to hold the pilot assembly bracket while loosening water heater, the filter may have some excess material. the pilot nut. This may be trimmed away.
  • Page 25: Igniter System

    Replacing the Manifold Assembly 8. Reconnect the igniter wire to the gas control valve/ thermostat. WARNING 9. Turn the gas supply on and check for leaks. Test the water heater by brushing on an approved noncorrosive leak detection solution. Bubbles forming indicate a leak. Correct any leak found.
  • Page 26: Troubleshooting Charts

    Removing and Replacing the Gas objects into the inlet or outlet connections. Damage to the gas control valve/thermostat may result. Control Valve/Thermostat Gas Control Valve/Thermostat: To replace the gas control valve/thermostat, reassemble IMPORTANT: The gas control valve/thermostat is a standard in reverse order.
  • Page 27 PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION BURNER FLAME YELLOW- Insufficient secondary air Provide ventilation to water heater LAZY Low gas pressure Check with gas utility company Flue clogged Clean, locate source and correct Flue damper partially open Cycle gas control valve/thermostat OFF then ON.
  • Page 28 STATUS LIGHT CODE TROUBLESHOOTING TABLE Status Light Code LED FLASH CONTROL STATUS CORRECTIVE ACTION SEQUENCE Short flash once every four second IDLE (No call for heat, no fault conditions) “Heartbeat”, alternates bright/dim Call for Heat (No fault conditions) One Flash, three second pause Low Flame Signal (control continues to oper- Turn the power switch on the gas control valve to the “OFF”...
  • Page 29 STATUS LIGHT CODE TROUBLESHOOTING TABLE Status Light Code LED FLASH CONTROL STATUS CORRECTIVE ACTION SEQUENCE Six-Two Flash, three second pause Soft Lockout - Recycle Limit - Flame Lost - Turn the power switch on the gas control valve to the “OFF” position and unplug the power cord from the power outlet.
  • Page 30: Sequence Of Operation Chart

    SEQUENCE OF OPERATION CHART Apply Power to Appliance. Is there a Call for Heat. Will not attempt to light 2 flash error code. See Is Damper Corrective Action Table Closed? on page 28. Damper Energizes. Gas Valve attempts to open damper for 30 seconds, then waits 2 mintues.
  • Page 31: 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 FLUE DAMPER FLUE BAFFLE HEAT TRAP (COLD) - SOME MODELS HEAT TRAP (HOT) - SOME MODELS COLD WATER DIP TUBE...
  • Page 32: Listed Parts Kits And Illustrations

    Listed Parts Kits and Illustrations Item 12A: Pilot/Igniter-Flame Sensor assembly kit, which contains the pilot, igniter-flame sensor, and retainer clip (Natural Gas) Item 12B: Pilot/Igniter-Flame Sensor assembly kit, which contains the pilot, igniter-flame sensor, and retainer clip (L.P. Gas) Item 13A: Burner (Natural Gas/L.P. Gas) Item 13B: Burner (L.P.