Professional Documents
Culture Documents
Installation
Instructions and
Use & Care Guide
http://www.whirlpoolwaterheatersupport.com
or call toll free
1-877-817-6750
When calling for assistance, please have the following
information ready:
1.
2.
3.
4.
5.
Model number
7 digit product number
Serial number
Date of installation
Place of purchase
319118-002
October 2010
1
Important Instructions
Do not use this appliance if any part has been under water. Immediately call a qualified person. Water heaters subjected to flood conditions or any time the gas controls, main burner or pilot have been submerged in water require
replacement of the entire water heater.
Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame. To
prevent the possibility of injury under these conditions, we recommend the hot water faucet be opened for several
minutes at the kitchen sink before using any electrical appliance which is connected to the hot water system. If
hydrogen is present, there will probably be an unusual sound such as air escaping through the faucet as water
begins to flow. Do not smoke or have any open flame near the faucet at the time it is open.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of
substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires
businesses to warn of potential exposure to such substances.
WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other
reproductive harm.
This appliance can cause low-level exposure to some of the substances included in the Act.
Table Of Contents
PAGE
WARNING
Consumer Information
Consumer Responsibilities
WARNING
FLAMMABLES
Flammable Vapors
Site Location
Location Requirements
WARNING
Carbon Monoxide Poisoning Hazard
Do not install in a mobile home.
Doing so can result in death or
carbon monoxide poisoning.
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
disables the water heater by shutting off the gas supply to
the water heaters burner and pilot, preventing re-ignition of
any remaining flammable vapors in the area. This will not
prevent a possible fire/explosion if the igniter is depressed
and flammable vapors have accumulated in the combustion
chamber with the pilot light off. If you suspect a flammable
vapor incident has occurred, do not use this appliance. Do
not attempt to light this appliance, or depress the igniter
button if you suspect flammable vapors have accumulated
inside or outside the appliance. Immediately call a qualified
person to inspect the appliance. Water heaters subjected
to a flammable vapors incident will show a discoloration on
the flame-trap and require replacement of the entire water
4
DISCHARGE PIPE
(DO NOT CAP OR PLUG)
METAL
DRAIN
PAN
Figure 1A
Air-moving
Devices
Exhaust
Fan
Reverse flow
of gases
6 MAXIMUM
AIR GAP
Back
Vent
Top
to
ceiling
Sides
PIPED TO AN
ADEQUATE DRAIN
Front
24 minimum
for service
Sides
Top
View
State of California
NOTE: The water heater must be braced, anchored, or
strapped to avoid moving during an earthquake.
Contact local utilities for code requirements in your area,
visit http://www.dsa.dgs.ca.gov, or call 1-916-445-8100 and
request instructions.
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
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.
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 indication of leaking gas.
Gas Piping
The gas piping must be installed according to all local and state
codes or, in the absence of local and state codes, the National
Fuel Gas Code, ANSI Z223.1(NFPA 54)-current edition.
Table 1 on page 7 provides a sizing reference for commonly
used gas pipe materials. Consult the National Fuel Gas Code
for the recommended gas pipe size of other materials.
Refer to Figure 3
NOTE: When installing gas piping, apply approved pipe joint
compound.
1. Install a readily accessible manual shut-off valve in the
gas supply line as recommended by the local utility.
Know the location of this valve and how to turn off the
gas to this unit.
2. Install a drip leg (if not already incorporated as part of
the water heater) as shown. The drip leg must be no
less than three inches long for the accumulation of dirt,
foreign material, and water droplets.
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/
thermostat.
4. Turn the gas supply on and check for leaks. Test all
connections by brushing on an approved noncorrosive
leak-detection solution. Bubbles will show a leak.
Correct any leak found.
6
Drip Leg
Gas Pressure
IMPORTANT: The gas supply pressure must not exceed the
maximum supply pressure as stated on the water heaters data
plate. The minimum supply pressure is for the purpose of input
adjustment.
WARNING
Carbon Monoxide Hazard
Water heater must be vented to outdoors.
Vent must be installed by a qualified person
using the installation instructions.
Examples of a qualified person include:
gas technicians,
authorized gas company personnel,
and authorized service persons.
beauty shops
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 BTU/HR of the total input for all gas appliances. The
table below shows a few examples of the minimum square
footage (area) required for various BTU/HR inputs.
Table 2
BTU/HR
Input
Minimum Square
Feet with
8' Ceiling
Typical Room
with 8' Ceiling
30,000
188
9 x 21
45,000
281
14 x 20
60,000
375
15 x 25
75,000
469
15 x 31
90,000
563
20 x 28
105,000
657
20 x 33
120,000
750
25 x 30
135,000
844
28 x 30
IMPORTANT:
Figure 4
Opening LocationsConfined Spaces
12 maximum
Permanent
openings to
the outside or
additional
rooms within
the building
12 maximum
Confined
Space
Confined Space
For the correct and proper operation of this water heater,
ample air must be supplied for the combustion, ventilation,
and dilution of flue gases. Small enclosures and confined
areas must have two permanent openings so that sufficient
fresh air can be drawn from outside of the enclosure. One
opening shall be within 12 inches of the top and one within
12 inches of the bottom of the enclosure as shown in
Figure 4.
The size of each opening (free area) is determined by the
total BTU/HR input of all gas utilization equipment (i.e.,
water heaters, furnaces, clothes dryers, etc.) and the
method by which the air is provided. The BTU/HR input can
be found on the water heater data plate. Additional air can
be provided by two methods:
1. All air from inside the building.
2. All air from outdoors.
8
Closet
or
other
confined
space
1 square
inch/1000
BTU/HR
(minimum
100 sq. In.)
Figure 5
All Air from Inside Building
Confined Space Installation
Gable vent
to outdoors
Install above
insulation
Confined
Space
Alternate
Air Inlet
Opening Source
Install above
insulation
Confined
Space
Figure 7
All Air from Outdoors
Through Ventilated Attic
Figure 7
Horizontal ducts
Figure 8A
Single Opening
Figure 8B
12 maximum
1 sq. inch
per
2000 BTU/HR
Figure 6
Outlet air
to attic
1 Sq. inch per
4000 BTU/HR
Inlet air duct
1 sq. inch per
4000 BTU/HR
Reference
Drawing
Vertical ducts
Open
Foundation
Vent
Gable vent
to outdoors
Inlet air
from the
crawl
space
Figure 6
All Air from Outdoors; Inlet Air from Ventilated
Crawl Space/Outlet Air to Ventilated Attic
Table 3
Outlet
air to attic
1 Sq. inch per
4000 BTU/HR
Confined
Space
Outlet
Outdoor
Air Ducts
Inlet
Figure 8A
All Air from Outdoors
Using Horizontal Ducts
1 sq. Inch
per
2000 BTU/HR
Figure 9
Draft hood Installation
Alternative
Opening
Location
Legs
Confined
Space
1 sq. Inch
Per 3000 BTU/HR
Legs
Slot
Jacket top
Slot
Vent Connectors
Chimney Connection
Listed Lined
Chimney
3 ft. minimum
*
Support
Strap
Slope up
1/4 in.
per ft.
minimum
3 ft. minimum
Support Strap
*
**
Vent
connector
slope up
1/4 in. per ft.
minimum
Figure 12
Venting Through
MAINTAIN MANUFACTURERS
a Chimney
SPECIFIED MINIMUM CLEARANCE
with Type B
Double Wall
Vent Pipe.
SUPPORT
STRAP
*MAINTAIN
CLEARANCE
VENT
CONNECTOR
SLOPE UP
1/4 IN. PER FT.
MINIMUM
SEAL
VENT CONNECTOR
UNUSED CHIMNEY
FLUE OR MASONRY
ENCLOSURE
Hot Water
Outlet
Union
Temperature and
Pressure Relief Valve
Discharge Pipe
Do Not Cap or Plug
Drain line 3/4
ID minimum
12
Pressure reducing
valve with bypass
1minimum
Metal
Drain Pan
1 3/4 depth maximum
Figure 14
Typical Mixing
Valve Installation
6 Maximum
Air Gap
Massachussetts:
Install a vacuum relief
in cold water line per
section 19 MGL 142.
Floor Drain
Cold
Water
Inlet
Tempered water
to fixtures
Mixing valve
(Set to 120F)
Use only full flow ball or gate valves. The use of valves
that may cause excessive restriction to water flow is
not recommended.
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.
Failure to follow these instructions can
result in death, or explosion.
As water is heated, it expands (thermal expansion). In
a closed system, the volume of water will grow. As the
volume of water grows, there will be a corresponding
increase in water pressure due to thermal expansion.
Thermal expansion can cause premature tank failure
(leakage). This type of failure is not covered under the
limited warranty. Thermal expansion can also cause
intermittent temperature-pressure relief valve operation:
water discharged from the valve due to excessive pressure
build up. The temperature-pressure relief valve is not
intended for the constant relief of thermal expansion. This
condition is not covered under the limited warranty.
A properly-sized thermal expansion tank should be
installed on all closed systems to control the effects of
thermal expansion. Contact a plumbing service agency or
your retail supplier regarding the installation of a thermal
expansion tank.
13
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.
Failure to follow these instructions can
result in death, or explosion.
Figure 15A
Temperature and Pressure
Relief Valve Installation
Optional location
some models only
Temperature and
Pressure Relief Valve
Discharge Pipe
(Do not cap or plug.)
Drain Line
3/4 ID minimum
6" Maximum
Air Gap
Floor
Drain
Metal Drain Pan
Special Applications
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.
If the space heating system requires water temperatures in excess of 120F, a mixing valve or an antiscald device should be installed per its manufacturers
instructions in the domestic (potable) hot water supply
to limit the risk of scald injury.
A properly installed flow control valve is required to prevent thermosiphoning. Thermosiphoning is the result
of a continuous flow of water through the air handler
circuit during the off cycle. Weeping (blow off) of the
temperature and pressure relief valve (T & P) or higher
than normal water temperatures are the first signs of
thermosiphoning.
Flow Control
Valve
Pump
In
Out
Coil
Discharge P ipe
Do Not Cap o r Plug
Air
Handler
Shut-off
Valve
6" Maximum
Air Gap
Metal Drain Pan
Floor Drain
Massachusetts code
does not allow this
type of installation.
Solar Installation
If this water heater is used as a solar storage heater
or as a backup for the solar system, the water supply
temperatures to the water heater tank may be in excess of
120F. A mixing valve or other temperature limiting valve
must be installed in the water supply line to limit the supply
temperature to 120F. The unit must be set to Standard
Mode (See Operating the Temperature Control System
section).
NOTE: Solar water heating systems can often supply water
with temperatures exceeding 180F and may result in water
heater malfunction.
15
Installation Checklist
Water Heater Location
Water heater location is important and can affect system
performance. Please check the following:
16
Explosion Hazard
LIGHTING INSTRUCTIONS
1. STOP! It is imperative that you read all safety warnings
before lighting the pilot.
5.
120 F (48.9 C)
Mark
control/temperature knob. Set the gas control/ temperature knob to the desired setting.
Igniter
Button
Status light
Index mark
Pilot
17
Burner Flames
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 the area are operating and all doors are closed when
performing the draft
test. Pass a match
Figure 17
Drafthood
flame around the
relief opening of the
Relief
Opening
drafthood. A steady
Match
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
heater until proper adjustments or repairs are made to the
vent pipe system and/or air supply requirements.
18
WARNING
Time for
Permanent Burns
2nd & 3rd Degree
(Most Severe Burns)
110
116
116
122
131
140
149
154
45 minutes
5 minutes
25 seconds
5 seconds
2 seconds
1 seconds
Figure 19A
Gas Control Valve/Thermostat
Settings
Gas Control/Temperature Knob
120F
Status Mark
Light
VAC
Igniter
19
0 Flashes
2 Flashes
4 Flashes
5 Flashes
7 Flashes
8 Flashes
9 Flashes
20
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 not
confuse this with a tank leak. Once the water reaches a
temperature of 120F and the tank warms up (usually 1-2
hours), the condensation will stop.
IMPORTANT: It is always recommended that a suitable metal
drain pan be installed under the water heater to protect the
area from water damage resulting from normal condensation
production, a leaking tank or piping connections. Refer to
Location Requirements on page 4. Under no circumstances
is the manufacturer to be held responsible for any water
damage in connection with this water heater.
Smoke/Odor
The water heater may give off a small amount of smoke
and odor during the initial start-up of the unit. This is due to
the burning off of oil from metal parts of a new unit and will
disappear after a few minutes of operation.
Safety Shut-off
This water heater is designed to automatically shut-off in the
event of the following:
1. The pilot flame is extinguished for any reason.
2. The water temperature exceeds 189F (87C).
3. Excessive contaminants in the combustion chamber.
4. The ignition of flammable vapors.
A thermopile is used to determine if a pilot flame is present and
will shut off the gas supply to the main burner and pilot if the
flame is absent. This unit is also equipped with a combustion
chamber temperature sensor that will shut off the gas supply
to the burner if poor combustion is sensed (caused by a
blocked vent or insufficient combustion air). If the gas control
valve/thermostat shuts off the gas supply, check the diagnostic
flash code and refer to the Status Light Code Troubleshooting
Chart. If necessary, also refer to the Troubleshooting Chart.
IMPORTANT: Correct any issues prior to resetting the gas
control valve/thermostat. For service information, contact the
Product Service and Support Department at 1-877-817-6750.
Reset the system by following these steps: 1.) Turn the
temperature adjustment knob to OFF. 2.) Unplug the
thermopile plug from the gas control valve/thermostat.
3.) Wait for about three minutes. 4.) Plug the thermopile
plug back into the gas control valve/thermostat. 5.) Turn the
temperature adjustment knob to PILOT and restart the water
heater as directed in this manual.
21
WARNING
1. Turn off the gas to the water heater at the manual gas
shut-off valve.
2. Open a nearby hot water faucet until the water is no
longer hot.
3. Close the cold water inlet valve.
4. Connect a hose to the drain valve and terminate it to an
adequate drain or external to the building.
5. Open the water heater drain valve and allow all of the
water to drain from the tank. Flush the tank with water
as needed to remove sediment.
6. Close the drain valve, refill the tank, and restart the
heater as directed in this manual.
If the water heater is going to be shut down for an extended
period, the drain valve should be left open.
IMPORTANT: Condensation may occur when refilling the
tank and should not be confused with a tank leak.
Routine Preventative
Maintenance
At least annually, a visual inspection should be made of
the venting and air supply system, piping systems, main
burner, pilot burner, and Flame-trap. Check the water
heater for the following:
22
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.
Failure to follow these instructions can
result in death, or explosion.
Manually operate
Figure 21
the temperature
Temperature and Pressure
Relief Valve
and pressure relief
Manual Relief
valve at least once
Valve
a year to make
sure it is working
properly. To prevent
water damage,
the valve must be
properly connected
to a discharge line
Discharge line to drain
which terminates
at an adequate
drain. Standing clear of the outlet (discharged water may
be hot), slowly lift and release the lever handle on the
temperature and pressure relief valve to allow the valve to
operate freely and return to its closed position. If the valve
fails to completely reset and continues to release water,
immediately shut off the manual gas control valve and the
cold water inlet valve and call a qualified person.
Replacement Parts
Figure24
NaturalGas(LowNox)
Burner Door Assembly
Figure 22
Gas Control Valve/
Thermostat
Pilot Assembly
Burner
Use brush on this surface.
Sensor
Wires
VAC
Temperature Sensor
Wire Connection
Thermopile
Wire
Connections
Pilot Tube
Viewport
Outer Door
Not Shown
Burner Door Screws (2)
Manifold Tube
Temperature
Sensor
Burner Door
Manifold Component Block
23
Igniter
Wire
Pilot Tube
Although not likely to occur, if debris collects on the flametrap, use a vacuum, compressed air, or a soft bristle brush
to remove it.
NOTE: If unable to inspect or clean the flame trap from
underneath, follow the Cleaning the Combustion Chamber
and Flame-trap section instructions.
Figure 27
Flame-trap visual inspection
Thermopile
Connectors
Retainer
Clip
Flashlight
Mirror
Manifold
Component
Block
3.
4.
5.
6.
Figure 26
Pilot/Thermopile Assembly
Igniter Connector
Pilot
Thermopile
Connectors
Thermopile
Pilot/Thermopile
Assembly
Pilot Tube
(Ferrule Nut
Not Shown)
7.
WARNING
Figure 28A
Combustion Chamber
Flame-trap
Bracket
Explosion Hazard
Tighten both burner door screws
securely.
Remove any fiberglass between gasket
and combustion chamber.
Door Gasket
Figure 28B
Close-up inside view of the combustion chamber
Bracket
VAC
Electrode
Wire to Electrode
Igniter Button
Pilot/Thermopile Bracket
(Opposite Side)
25
TROUBLESHOOTING CHART
PROBLEM
BURNER WILL NOT IGNITE
POSSIBLE CAUSE(S)
1.
2.
3.
4.
5.
6.
7.
8.
9.
CORRECTIVE ACTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
Light pilot
Turn temp. dial to desired temperature
Check with gas utility company
Notify utility-install trap in gas line
Clean, locate source and correct
Clean, locate source and correct
Replace thermopile
Replace thermostat
Provide fresh air ventilation
SMELLY WATER
1.
1.
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
Non-functioning igniter
Thermopile connection loose
Air in gas line
Proper Lighting Sequence not followed.
Gas Control / Temperature Knob was not
held in for sufficient time.
1.
2.
3.
4.
5.
6.
7.
8.
5.
6.
7.
8.
26
PROBLEM
PILOT WILL NOT LIGHT OR
REMAIN LIT (continued)
POSSIBLE CAUSE(S)
1.
2.
3.
4.
5.
6.
7.
8.
9.
1.
2.
3.
4.
5.
6.
7.
8.
9.
1.
2.
3.
4.
5
6.
7.
8.
9.
1.
1.
2.
3.
4.
5.
6.
7.
8.
Flue clogged
Low gas pressure
Improper calibration
Thermostat set too low
Water heater too small
Wrong piping connections
Wasted hot water
2.
3.
4.
5.
6.
7.
8.
1.
2.
3.
1.
2.
3.
THERMOSTAT FAILS TO
SHUT-OFF
1.
2.
1.
2.
Replace thermostat
Replace thermostat
COMBUSTION ODORS
1.
1.
2.
3.
Flue clogged
Heater installed in a confined area
2.
3.
1.
1.
2.
3.
4.
5.
6.
2.
3.
4.
5.
6.
CONDENSATION
1.
1.
1.
2.
3.
4.
1.
2.
3.
4.
1.
PILOT FLAME
TOO SMALL
1.
2.
9.
10.
11.
12.
1.
2.
CORRECTIVE ACTION
9.
10.
11.
12.
27
PROBLEM
CORRECTIVE ACTION
Normal operation.
2 FLASHES
4 FLASHES
5 FLASHES
7 FLASHES
8 FLASHES
1.
2.
3.
1.
2.
3.
9 FLASHES
10 FLASHES
28
NO
NO
NO
Follow the Testing the Igniter
System section in this manual.
NO
NO
YES
Is there proper drafting at the
drafthood? See Checking the
Draft section in this manual.
YES
Correct size of
openings to allow
sufficient air.
YES
YES
NO
NO
YES
NO
YES
YES
NO
29
3
6
10
9
11
Parts Description
DRAFT HOOD
FLUE BAFFLE
ANODE ROD
DRAIN VALVE
10
10
CONTROL MODULE
11
OUTER DOOR
12*
13*
14*
15*
16*
VIEWPORT ASSEMBLY
17*
18*
TEMPERATURE SENSOR
19*
THERMOPILE
30
LEGEND
Special anode rod (see page 21)
13
14
15
16
17
18
19
31
32