Service manual

ManualsBrandsWhirlpool ManualsHome building and DecorAMERICAN WATERHEATERS

INSTALLATION, OPERATION, AND SERVICE MANUAL

RESIDENTIAL STORAGE TYPE GAS WATER HEATER

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED

SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT

AND OPERATION OF THIS WATER HEATER. READ THESE

INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION

OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY

RESULT IN IMPROPER INSTALLATION, OPERATION, SERVICE OR

MAINTENANCE, POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK,

SCALD INJURY, CARBON MONOXIDE POISONING, EXPLOSION,

PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

INSTALLER:

• ATTACH THESE INSTRUCTIONS TO OR ADJACENT TO THE WATER

HEATER.

• BEFORE LEAVING THE PREMISES REVIEW THIS OPERATION AND

SERVICE MANUAL TO BE SURE THE HEATER HAS BEEN INSTALLED

CORRECTLY. START AND OPERATE THE UNIT FOR ONE COMPLETE

CYCLE AND MAKE SURE THE WATER TEMPERATURE IS ACCEPTABLE

TO THE CONSUMER AT THE FIXTURES.

OWNER:

• RETAIN THESE INSTRUCTIONS AND WARRANTY FOR FUTURE

REFERENCE. RETAIN THE ORIGINAL RECEIPT AS PROOF OF

PURCHASE.

SE PUEDE OBTENER UNA VERSION ESPAÑOL DE ESTAS

INSTRUCCIONES SI ESCRIBE A LA FÁBRICA QUE APARECE EN LA

PLACA DE ESPECIFICATIONES

A SPANISH VERSION OF THESE INSTRUCTIONS MAY BE OBTAINED IF

YOU WRITE TO THE MANUFACTURER SHOWN ON THE RATING PLATE.

THIS MANUAL IS NOT TO BE USED WITH GAS STORAGE TYPE WATER

HEATERS CERTIFIED FOR INSTALLATION IN MANUFACTURED HOMES

(MOBILE HOMES).

AN ODORANT IS ADDED BY THE GAS SUPPLIER TO THE GAS

USED BY THIS WATER HEATER. SEE WARNING BELOW.

WARNING

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. IF A GAS LEAK IS

SUSPECTED, CHECK FOR LEAKS BY USING A CHLORIDE-FREE SOAP

AND WATER SOLUTION, OR OTHER APPROVED METHOD. IF A LEAK

CANNOT BE FOUND BUT IS STILL SUSPECTED, FOLLOW THE STEPS

UNDER "WHAT TO DO IF YOU SMELL GAS" AS OUTLINED ON THIS

PAGE. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN

PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

WARNING

THIS WATER HEATER MUST BE BRACED, ANCHORED, OR

STRAPPED TO AVOID FALLING OR MOVING DURING AN

EARTHQUAKE. CONTACT LOCAL UTILITIES FOR CODE

REQUIREMENTS IN YOUR AREA OR CALL THE 800 NUMBER

SHOWN ON FRONT OF THIS MANUAL AND REQUEST

INSTRUCTIONS 6600933 FOR EXAMPLES.

Recognize this symbol as an indication of Important

Safety Information.

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 telephone in your building.

• Immediately call your gas supplier from a

neighbor’s telephone. 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.

TO OBTAIN TECHNICAL, WARRANTY OR SERVICE

ASSISTANCE DURING OR AFTER THE INSTALLATION

OF THIS WATER HEATER, CALL TOLL FREE:

1-800-999-9515.

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

6510185

March 2000

Supersedes 6510160

Summary of content (33 pages)

PAGE 1
INSTALLATION, OPERATION, AND SERVICE MANUAL RESIDENTIAL STORAGE TYPE GAS WATER HEATER Recognize this symbol as an indication of Important Safety Information. THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS WATER HEATER. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION.
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Vapors from flammable liquids will explode and catch fire causing death or severe burns. Do not use or store flammable products such as gasoline, solvents or adhesives in the same room or area near the water heater. Keep flammable products: 1. far away from the water heater. 2. in approved containers, 3. tightly closed and 4. out of children’s reach. Water heater has a main burner and pilot flame. The pilot flame: 1. is on all the time and 2. will ignite flammable vapors. Vapors: 1. cannot be seen, 2.
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GENERAL SAFETY WARNINGS BEFORE ATTEMPTING TO INSTALL OR OPERATE THIS WATER HEATER, MAKE SURE YOU READ AND UNDERSTAND THE ENTIRE INSTALLATION, OPERATION AND SERVICE MANUAL. SPECIAL ATTENTION MUST BE GIVEN TO ALL THE SAFETY WARNINGS PROVIDED THROUGHOUT THIS MANUAL. FAILURE TO FOLLOW THESE WARNINGS COULD RESULT IN A FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
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GENERAL SAFETY WARNINGS (CONT.) DANGER • CONTAMINANTS IN THE GAS PIPING MAY FOUL THE THERMOSTAT CAUSING A MALFUNCTION, FIRE OR EXPLOSION. BE SURE ALL GAS PIPING IS CLEAN AND CLEAR ON THE INSIDE BEFORE ATTACHING THE GAS LINE. • HOT WATER CAN PRODUCE FIRST DEGREE BURNS WITHIN: 3 SECONDS AT 140°F (60°C) 20 SECONDS AT 130°F (54°C) 8 MINUTES AT 120°F (49°C) • 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).
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TABLE OF CONTENTS SAFETY PRECAUTIONS ..................................................... GENERAL SAFETY WARNINGS ....................................................... CONSUMER INFORMATION/RESPONSIBILITIES ............................ WATER HEATER MODIFICATION/TAMPERING .............................. TABLE OF CONTENTS ................................................................. LOCATION REQUIREMENTS AND CONSIDERATIONS .................... VENTILATION AND COMBUSTION AIR SUPPLY .......................
PAGE 7
LOCATION REQUIREMENTS AND CONSIDERATIONS (CONT.) SITE LOCATION 1. Select a location near the center of the water piping system. It must be installed indoors and in a vertical position on a level surface. DO NOT install in bathrooms, bedrooms or any occupied room normally kept closed. 2. Locate the water heater as close to the chimney or gas vent as is practical. Consider the vent system piping and combustion air supply requirements when selecting the water heater location.
PAGE 8
VENTILATION AND COMBUSTION AIR SUPPLY GENERAL INFORMATION WARNING THIS WATER HEATER AND ANY OTHER FUEL BURNING APPLIANCE MUST BE PROVIDED WITH ENOUGH FRESH AIR FOR PROPER VENTILATION OF THE FLUE GASES. MOST HOMES WILL REQUIRE THAT OUTSIDE AIR BE SUPPLIED INTO THE WATER HEATER AREA. FAILURE TO DO SO CAN RESULT IN EXPLOSION, FIRE, PROPERTY DAMAGE, CARBON MONOXIDE POISONING, PERSONAL INJURY OR DEATH.
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VENTILATION AND COMBUSTION AIR SUPPLY (CONT.) ALL AIR FROM OUTDOORS Outdoor fresh air can be provided to a confined area either directly or by the use of vertical and horizontal ducts. The fresh air can be taken from the outdoors or from crawl or attic spaces that freely communicate with the outdoors. Attic or crawl spaces cannot be closed and must be properly ventilated to the outside. Ductwork must be of the same cross-sectional area as the free area of the opening to which they connect.
PAGE 10
VENT PIPE SYSTEM GENERAL INFORMATION WARNING THE USE OF VENT DAMPERS IS NOT RECOMMENDED BY THE MANUFACTURERS OF THIS WATER HEATER. ALTHOUGH SOME VENT DAMPERS ARE CERTIFIED BY THE AMERICAN GAS ASSOCIATION LABORATORIES, THIS CERTIFICATION APPLIES TO THE VENT DAMPER DEVICE ONLY AND DOES NOT MEAN THEY ARE CERTIFIED FOR USE ON THIS WATER HEATER.
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VENT PIPE SYSTEM (CONT.) IMPORTANT: Existing vent systems must be inspected for obstructions, corrosion and proper installation. CAUTION VENT CONNECTORS MAY NOT TERMINATE WITHIN A CHIMNEY FLUE SERVING A FIREPLACE UNLESS THE FLUE OPENING IS PERMANENTLY SEALED. 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.
PAGE 12
WATER SYSTEM PIPING GENERAL INFORMATION Water piping, fittings, and valves must be properly installed for the correct and safe operation of this water heater. Please note the following: DO NOT install this water heater with iron piping. The system should be installed only with new piping that is suitable for potable (drinkable) water such as copper, CPVC, or polybutylene. DO NOT use PVC water piping. DO NOT use any pumps, valves, or fittings that are not compatible with potable water.
PAGE 13
WATER SYSTEM PIPING (CONT.) DANGER DISCHARGING WATER MAY BE HOT AND CAN CAUSE SCALD INJURIES AND PROPERTY DAMAGE. DISCHARGE LINES MUST BE PROPERLY INSTALLED AND PIPED TO AN ADEQUATE DRAIN. 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.
PAGE 14
WATER SYSTEM PIPING (CONT.) DANGER DISCHARGING WATER MAY BE HOT AND CAN CAUSE SCALD INJURIES AND PROPERTY DAMAGE. DISCHARGE LINES MUST BE PROPERLY INSTALLED AND PIPED TO AN ADEQUATE DRAIN. 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.
PAGE 15
SPECIAL APPLICATIONS COMBINATION SPACE HEATING/POTABLE WATER HEATING 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. • Be sure to follow the manual(s) shipped with the air handler system. • This water heater is not to be used as a replacement for an existing boiler installation.
PAGE 16
GAS SUPPLY AND PIPING GENERAL INFORMATION DANGER THIS WATER HEATER IS EQUIPPED FOR ONE TYPE OF GAS ONLY. DO NOT USE THIS WATER HEATER WITH ANY GAS OTHER THAN THE ONE LISTED ON THE DATA PLATE LOCATED NEAR THE GAS CONTROL. FAILURE TO USE THE CORRECT GAS CAN RESULT IN PROPERTY DAMAGE, BODILY INJURY, OR DEATH. This water heater must only be connected to gas supplied by a commercial utility. GAS PIPING Install the gas piping according to all local and state codes or with the ”National Fuel Gas Code”, ANSI Z223.
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GAS SUPPLY AND PIPING (CONT.) 4. Turn the gas supply on and check for leaks. Use a chloride-free soap and water solution (bubbles forming indicate a leak) or other approved method. Do not use an open flame. ALL LEAKS MUST BE FIXED IMMEDIATELY. DANGER DO NOT USE AN OPEN FLAME OR ANY KIND OF SPARK TO CHECK GAS PIPING FOR LEAKS. IF LEAKING GAS IS PRESENT, AN EXPLOSION OR FIRE MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
PAGE 19
START-UP/OPERATION WARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. Read these directions thoroughly before attempting to light or relight the pilot. Make sure the tank is completely filled with water before lighting the pilot. Check the data plate near the gas valve control/thermostat for the correct gas. Do not use this water heater with any gas other than the one listed on the data plate.
PAGE 20
FIGURE 17A : LIGHTING INSTRUCTIONS (ROBERTSHAW THERMOSTAT) FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these directions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. • A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly. B. BEFORE LIGHTING smell all around the appliance area for gas.
PAGE 21
FIGURE 17B : LIGHTING INSTRUCTIONS (WHITE-RODGERS THERMOSTAT) FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these directions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance has a pilot which must be lighted by a hand. • If you cannot reach your gas supplier, call the fire When lighting the pilot, follow these instructions exactly. department. B. BEFORE LIGHTING smell all around the appliance area for gas.
PAGE 22
FIGURE 17C : LIGHTING INSTRUCTIONS-PIEZOELECTRIC IGNITER (ROBERTSHAW THERMOSTAT) FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance has a pilot which is lighted by a piezoelectric igniter. When lighting the pilot, follow these instructions exactly. B. BEFORE LIGHTING smell all around the appliance area for gas.
PAGE 23
FIGURE 17D : LIGHTING INSTRUCTIONS WITH PIEZOELECTRIC IGNITER (WHITE-RODGERS THERMOSTAT) FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these directions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance has a pilot which is lighted by a piezoelectric • If you cannot reach your gas supplier, call the fire igniter. When lighting the pilot, follow these instructions department. exactly. C.
PAGE 24
FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these directions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance has a pilot which must be lighted by hand. When lighting the pilot, follow these instructions exactly. B. BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.
PAGE 25
START-UP/OPERATION (CONT.) DANGER HOT WATER CAN PRODUCE FIRST DEGREE BURNS WITHIN: 3 SECONDS AT 140°F (60°C) 20 SECONDS AT 130°F (54°C) 8 MINUTES AT 120°F (49°C) WARNING HOUSEHOLDS WITH SMALL CHILDREN, ELDERLY, IMPAIRED OR DISABLED MEMBERS AND ANYONE WITH TEMPERATURE SENSITIVE SKIN MAY REQUIRE A LOWER TEMPERATURE SETTING TO REDUCE THE RISK OF SCALD INJURY. STACKING Stacking occurs when consecutive short draws of hot water (3 gallons or less) are taken from the water heater tank.
PAGE 26
THE FAUCET AS WATER BEGINS TO FLOW. DO NOT SMOKE OR HAVE ANY 8 OPEN FLAME NEAR THE FAUCET AT THE TIME IT IS OPEN.
PAGE 27
MAINTENANCE DRAINING AND FLUSHING The water heater should be drained if being shut down during freezing temperatures. It is recommended that the tank be drained, flushed and cleaned every 6 months to remove sediment which may build-up during operation. To drain the tank perform the following steps: 1. Turn off the gas to the water heater at the Manual Gas Shutoff Valve. 2. Close the cold water inlet valve. 3. Open a nearby hot water faucet. 4.
PAGE 28
BURNER ASSEMBLY REMOVAL, CLEANING, AND REPLACEMENT REPLACING THE BURNER ASSEMBLY 1. 2. 3. Insert the burner into the burner compartment making sure that the manifold tab engages with the bracket inside the burner compartment (Figure 24). The tab is located at the bottom of the burner for L.P. models. The manifold tube will now line up with the thermostat connection. Reconnect the manifold tube and pilot tube. Do not cross thread these fittings. L.P.
PAGE 29
REMOVAL AND REPLACEMENT OF THE GAS CONTROL VALVE/ THERMOSTAT WARNING CAUTION REMOVAL AND REPLACEMENT OF THE GAS CONTROL VALVE / THERMOSTAT INVOLVES THE DISCONNECTION OF GAS PIPING, MANIFOLD TUBE, PILOT TUBE, AND THERMOCOUPLE. IT IS RECOMMENDED THAT THIS PROCEDURE BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN. WHEN REMOVING THE GAS CONTROL VALVE / THERMOSTAT DO NOT USE PIPE WRENCH OR VISE TO GRIP BODY OR ANY TYPE OF BLUNT INSTRUMENT INTO THE INLET OR OUTLET CONNECTIONS.
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TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION INSUFFICIENT HOT WATER 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Low gas pressure Orifice too small Improper calibration Thermostat set too low Sediment or lime in tank Water heater too small Wrong piping connections Leaking faucets Wasted hot water Long runs of exposed piping Hot water piping in outside wall 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
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REPAIR PARTS ILLUSTRATION REPAIR PARTS 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 NO.