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

Text of Whirlpool Energy Smart Gas Water Heater User Guide:

• Whirlpool Energy Smart Gas Water Heater, 19 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. NOTE: This condensation is normal and should not be confused with a leaking tank. Condensation may increase or decrease at different times of the year. High efficient energy saver water heaters will produce larger amounts of condensation on initial start-up or when a large amount of hot water is being used. NOTE: Do

• Whirlpool Energy Smart Gas Water Heater, 25 PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION HIGH OPERATION COSTS 1. Thermostat set too high 2. Sediment or lime in tank 3. Water heater too small for job 4. Wrong piping connections 5. Leaking faucets 6. Gas leaks 7. Wasted hot water 8. Long runs of exposed piping 9. Hot water piping in exposed wall 1. Set temperature dial to lower setting 2. Drain/flush-provide water treatment if needed 3. Install adequate heater 4. Correct piping-dip tube must be in cold inlet 5. Repair faucets 6. Check with u

• Whirlpool Energy Smart Gas Water Heater, 27 REPAIR PARTS ILLUSTRATION 1 2 3 4 8 5 10 11 9 7 6 Item No. Parts Description 1 DRAFTHOOD 2 REDUCER RING - SOME MODELS 3 FLUE BAFFLE 4 HEAT TRAP (COLD) - SOME MODELS 5 HEAT TRAP (HOT) - SOME MODELS 6 COLD WATER DIP TUBE 7 ANODE ROD 8 TEMPERATURE & PRESSURE RELIEF VALVE (LOCATED TOP OR SIDE) 9 DRAIN VALVE 10 GAS CONTROL VALVE/THERMOSTAT (with wire leads) 11 OUTER DOOR 12* PILOT ASSEMBLY KIT (Natural Gas) 13 BURNER (Natural Gas/Low Nox) 14* MANIFOLD DOOR ASSEMBLY (Natural Gas/Low Nox) 15* TWO PIECE W

• Whirlpool Energy Smart Gas Water Heater, 15 Installation Checklist Water Heater Location □ Centrally located with the water piping system. Located as close to the gas piping and vent pipe system as possible. □ Located indoors and in a vertical position. Protected from freezing temperatures. □ Proper clearances from combustible surfaces maintained and not installed directly on a carpeted floor. □ Provisions made to protect the area from water damage. Drain pan installed and piped to an adequate drain. □ Installation area free of

• Whirlpool Energy Smart Gas Water Heater, 13 Closed System/Thermal Expansion Periodic discharge of the temperature and pressure relief valve may be due to thermal expansion in a closed water supply system. The water utility supply meter may contain a check valve, backflow preventer or water pressure reducing valve. This will create a closed water system. During the heating cycle of the water heater, the water expands causing pressure inside the water heater to increase. This may cause the temperature and pressure relief valve to discharge small quantities of hot water. To prevent this, it is recommended that a diaphragm-type expansion tank (suitable for potable wate

• Whirlpool Energy Smart Gas Water Heater, 12 Water System Piping Piping Installation 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. The working pressure is stated on the water heater’s data plate. If this occurs, a pressure limiting valve with a bypass may need to be installed in the cold water inlet line. This should be placed on the supply to the entire house in order

• Whirlpool Energy Smart Gas Water Heater, 28 Listed Parts Kits and Illustrations Item 12: Pilot assembly kit, which contains the pilot assembly, thermopile, and retainer clip (Natural Gas) Item 13: Burner (Natural Gas/Low Nox) Item 14: Manifold door assembly which contains the manifold tube, gasket, door, pilot tube, thermopile, two piece wire connector with retainer clip, thermal switch, and pilot assembly. (Natural Gas/Low Nox) Item 15: Contains two piece wire connector and retainer clip Item 16: Contains manifold door gasket Item 17: Contains viewport Item 18: Contains replacement thermistors Item #18 WHIRLPOOL, FLAME LOCK

• Whirlpool Energy Smart Gas Water Heater, 22 Replacing the Pilot Assembly 1. Remove the manifold 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 manifold door (Figure 25). 3. Locate and remove the screws on the underside of the burner. Remove the screw securing the pilot assembly to the manifold. 4. Using a 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. 5. Pull the pilot tube from the pilot assembly (Figure 26)

• Whirlpool Energy Smart Gas Water Heater, 11 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. • The connector must be installed above the extreme bottom of the chimney to prevent potentially blocking the flue gases. • The connector must be firmly attached and sealed to prevent it from falling out. • To aid in removing the connector, a thimble

• Whirlpool Energy Smart Gas Water Heater, 20 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. Turn off the gas to the water heater at the manual gas shut-off valve. 2. Close the cold water inlet valve. 3. Open a nearby hot water faucet. 4. Connect a hose to the drain valve

• 14 Figure 16 Typical Tempering Valve Installation Combination Space Heating/Potable Water Heating System Drain Pan Drain Unions Tempering Valve Coil Air Handler Shut-off Valve To Air Handler Massachusetts code does not allow this type of installation. Pump Flow Control Valve In Out Domestic Hot Water Out Cold Water Inlet Hot Water Out Solar Installation If this water heater

• Whirlpool Energy Smart Gas Water Heater, 17 Checking the Draft 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 the area are operating and all doors are closed when performing the draft test. Pass a match flame around the relief opening of the drafthood. A steady flame drawn into the opening indicates proper draft. If the flame flutters or is blown out, combustion products are escaping from the relief opening. If this occurs, do not operate the water h

• Whirlpool Energy Smart Gas Water Heater, 6 Gas Supply Gas Requirements IMPORTANT: Read the data plate to be sure the water heater is made for the type of gas you will be using in your home. This information will be found on the data plate located near the gas control valve/thermostat. If the information does not agree with the type of gas available, do not install or light. Call your dealer. NOTE: An odorant is added by the gas supplier to the gas used by this water heater. This odorant may fade over an extended period of time. Do not depend upon this odorant as an indicati

• 1 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�

• Whirlpool Energy Smart Gas Water Heater, 8 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. 30,000 45,000 60,000 75,000 90,000 105,000 120,000 135,000 188 281 375 469 563 657 750 844 9x21 14x20 15x25 15x31 20x28 20x33 25x30 28x30 Typical Room with 8' Ceiling Minimum Square Feet with 8' Ceiling BTUH Input Table 2 IMPORTANT: • The area must be op

• Whirlpool Energy Smart Gas Water Heater, 9 Direct to outdoors Vertical ducts Horizontal ducts Figure 6 Figure 7 Figure 8 Table 3 Minimum Free Area of Permanent Openings for Ventilation and Combustion Air Supply - All Air from Outdoors Only. Based on the total BTUH input rating for all gas utilizing equipment within the confined space. Opening Source 1 Square inch per 4000 BTUH 1 Square inch per 4000 BTUH 1 Square inch per 2000 BTUH Minimum Free Area Per Opening (sq. in.) Reference Drawing Example: A water heater with an input rate of 50,000 BTUH using horizontal ducts would require each opening to have a m

• Whirlpool Energy Smart Gas Water Heater, 4 Location Requirements 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 the water heater combustion chamber through the special flame-trap. The burning vapors literally “burn themselves out” without escaping back into the room. In the event of a flammable vapor incident, the Flame Lock™ Safety System shuts off the gas supply to the water heater’s burner and pilot, preventing re-ignition of any remaining flammable vapors in the area. This will disa

• Whirlpool Energy Smart Gas Water Heater, 21 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. When ordering replacement parts, always have the following information ready: 1. model, serial, and product number 2. type of gas 3. item number 4. parts description See pages 27-28 for a list of available repair parts. Rem

• 5 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. Also any external plumbing leak, including those from improper installation

• 26 Thermal Switch Thermal Switch Location PILOT LIGHT TROUBLESHOOTING CHART Have you bled all the air from the pilot tube and gas supply line? NO While repeatedly depressing the igniter button, push in and hold the gas control/ temperature knob until the pilot is lit and maintains a stable flame, (status light will blink) then release the gas control/ temperature knob. Se

• Whirlpool Energy Smart Gas Water Heater, 3 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 fl ammable vapor ignition incident. New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation environments. Please review the Installation Checklist found at the end of the installation instructions section and make any required installation upgrades or changes. Consumer I

• Whirlpool Energy Smart Gas Water Heater, 10 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”). This water heater must be properly vented for the removal of exhaust gases to the outside atmosphere. Correct installation of the vent pipe system is mandatory for the proper and efficient operation of this water heater and is an important factor in the life of the unit. The vent pipe must be installed according to all local and state codes

• Whirlpool Energy Smart Gas Water Heater, 7 Nominal Iron Pipe Length of Pipe, Feet Size, in. 1/2 3/4 1 1-1/4 1-1/2 132 278 520 1050 1600 92 190 350 730 1100 73 152 285 590 890 63 130 245 500 760 56 115 215 440 670 50 105 195 400 610 46 96 180 370 560 43 90 170 350 530 40 84 160 320 490 38 79 150 305 460 34 72 130 275 410 31 64 120 250 380 28 59 110 225 350 26 55 100 210 320 10 20 30 40 50 60 70 80 90 100 125 150 175 200 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). After the length of pipe has b

• Whirlpool Energy Smart Gas Water Heater, 24 Removing and Replacing the Gas Control Valve/Thermostat IMPORTANT: The gas control valve/thermostat is a standard valve with wire leads that connect to a thermal switch. Removing the Gas Valve: 1. Turn the gas control/temperature knob to the “OFF” position (Figure 19). 2. Turn off the gas at the manual shut-off valve on the gas supply pipe (Figure 3). 3. Drain the water heater. Refer to the section of “Draining and Flushing” on page 20 and follow the procedure. 4. Disconnect the igniter wire from the igniter button. Disconnect the thermopile, pilot tube, two wire leads at the thermal switch, and manifold tube at the gas control valve/thermostat (Figure 22).

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