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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 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 115°F. A 
tempering valve or other temperature limiting valve must 
be installed in the water supply line to limit the supply 
temperature to 115°F. 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 180°F and may 
result in water heater malfunction.

Figure 15B 
T&P Relief Valve Insulation 

T&P Relief Valve

T&P Relief Valve
Drain Line

Manual Relief Lever

T&P Relief Valve Insulation

T&P Relief Valve and Pipe Insulation 

(Some Models)

1.  Locate the T&P Relief Valve on the water heater. 
2.  Locate the slit running the length of the insulation.

Spread this slit open and slip it over the T&P Relief Valve. 
See Figure 15B. Apply gentle pressure to the insulation 
to ensure it is fully seated on the T&P Relief Valve.  Once 
sealed secure the insulation with a section of tape.
IMPORTANT: The insulation or tape should not block 
or cover the T&P Relief Valve drain opening. Also the 
insulation or tape should not block or hinder access to the 
T&P Relief valve manual relief lever.

4.  Next locate the hot water (outlet) & cold water (inlet) pipes 

to the water heater.  

5.  Select one of the sections of pipe insulation and locate the 

slit that runs the length of the insulation. 

6.  Spread the slit open at the base of the insulation and slip 

it over the cold water (inlet) pipe. Apply gentle 
pressure along the length of the insulation to ensure it is 
fully seated around the cold water pipe. Also ensure that 
the base of insulation is flush with the water heater. Once 
seated, secure the insulation with a section of tape.

7.  Repeat steps 5 through 6 for the hot water (outlet) pipe.

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.

• 

The unit must be set to standard mode (See Operating 
the Temperature Control System section).

• 

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.

• 

Do not use with piping that has been treated with 
chromates, boiler seal or other chemicals and do not 
add any chemicals to the water heater piping.

• 

If the space heating system requires water tempera-
tures in excess of 115°F, a tempering valve or an anti-
scald device should be installed per its manufacturer’s 
instructions in the domestic (potable) hot water supply 
to limit the risk of scald injury.

• 

Pumps, valves, piping and fittings must be compatible 
with potable water.

• 

A properly installed flow control valve is required to pre-
vent 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.

• 

The domestic hot water line from the water heater 
should be vertical past any tempering valve or supply 
line to the air handler to remove air bubbles from the 
system. Otherwise, these bubbles will be trapped in the 
air handler heat exchanger coil, reducing the efficiency.

• 

Do not connect the water heater to any system or 
components previously used with non-potable water 
heating appliances when used to supply potable water.

Some jurisdictions may require a backflow preventer 
in the incoming cold water line. This may cause the 
temperature and pressure relief valve on the water heater 
to discharge or weep due to expansion of the heated water. 
A diaphragm-type expansion tank suitable for potable 
water will normally eliminate this weeping condition. Please 
read and follow the manufacturer’s instructions for the 
installation of such tanks.

Also see “Water System Piping” (Page 12) for additional 
instructions on the safe and correct installation and 
operation of this water heater.

Summary of Contents for 6510374

Page 1: ...sion may result causing property damage personal injury or death 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 Table of Contents 2 6510374 W10100870 February 2006 Energy Smart Gas Water Heater with the Flame Lock Safety System To obtain technical warranty or se...

Page 2: ...if any part has been under water Immediately call a qualified service technician 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 extre...

Page 3: ...the Flame Lock Safety System should only be performed by a qualified person Examples of a qualified person include licensed plumbers authorized gas company personnel and authorized service personnel IMPORTANT This water heater has a resettable thermal switch installed as part of the Flame Lock Safety System DO NOT attempt to disable or modify this feature in any way IMPORTANT The manufacturer and ...

Page 4: ...y and call the fire department from a neighbor s home Do not attempt to clean the spill until all ignition sources have been extinguished Do not store combustible materials boxes magazines clothes etc on or in close proximity to the water heater Site Location Select a location near the center of the water piping system The water heater must be installed indoors and in a vertical position on a leve...

Page 5: ...ble materials are stated on the data plate adjacent to the gas control valve thermostat of the water heater The water heater is certified for installation on a combustible floor IMPORTANT If installing over carpeting the carpeting must be protected by a metal or wood panel beneath the water heater The protective panel must extend beyond the full width and depth of the water heater by at least thre...

Page 6: ... gas supply pressure must not exceed the maximum supply pressure as stated on the water heater s data plate The minimum supply pressure is for the purpose of input adjustment Gas Pressure Testing IMPORTANT This water heater and its gas connection must be leak tested before placing the appliance in operation If the code requires the gas lines to be tested at a pressure exceeding 14 W C the water he...

Page 7: ...e is excluded from warranty coverage The following types of installation not limited to the following will require outdoor air for combustion due to chemical exposure and may reduce but not eliminate the presence of corrosive chemicals in the air beauty shops photo processing labs buildings with indoor pools water heaters installed in laundry hobby or craft rooms water heaters installed near chemi...

Page 8: ...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 BTUH input of all gas utilization equipment i e water heaters furnaces clothes dryers etc and the method by which the air is provided The BTUH input can be found on the ...

Page 9: ...r supply openings consideration must be given to the blocking effect of protection louvers grilles and screens These devices can reduce airflow which in turn may require larger openings to achieve the required minimum free area Screens must not be smaller than 1 4 mesh If the free area through a particular design of louver or grille is known it should be used in calculating the specified free area...

Page 10: ...ng water heater be sure to use the new drafthood supplied with the water heater Figure 9 Drafthood Installation Sheet Metal Screws four provided Drafthood Jacket top Install the drafthood with the four screws provided Legs Slots Slots Legs Vent Pipe Size It is important that you follow the guidelines in these instructions for sizing a vent pipe system If a transition to a larger vent size is requi...

Page 11: ...erminate with a listed cap or other roof assembly and be installed according to their manufacturer s instructions Gas vents must be supported to prevent damage joint separation and maintain clearances to combustible materials Figures 11 and 12 IMPORTANT This gas vent must be terminated in a vertical position to facilitate the removal of the burnt gases An unused chimney flue or masonry enclosure m...

Page 12: ...t line It should be located close to the water heater and be easily accessible Know the location of this valve and how to shut off the water to the heater 6 A temperature and pressure relief valve must be installed in the opening marked Temperature and Pressure T P Relief Valve on the water heater A discharge line must be added to the opening of the T P Relief Valve Follow the instructions under T...

Page 13: ... the requirements for Relief Valves and Automatic Shut off Devices for Hot Water Supply Systems ANSI Z21 22 The function of the temperature and pressure relief valve is to discharge water in large quantities in the event of excessive temperature or pressure developing in the water heater The valve s relief pressure must not exceed the working pressure of the water heater as stated on the data plat...

Page 14: ... water outlet pipe 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 The unit must be set to standard mode See Operating the Tempe...

Page 15: ...s for possible gas leaks Correct any leak found Important Information About Your Water Heater This gas water heater was manufactured to voluntary safety standards to reduce the likelihood of a flammable vapor ignition incident New technology used in meeting these standards makes this product less tolerant of installation errors or improper installation environments Please review the following info...

Page 16: ...s completely filled with water before lighting the pilot Check the data plate near the gas control valve thermostat for the correct gas Do not use this water heater with any gas other than the one listed on the data plate If you have any questions or doubts consult your gas supplier or gas utility company Explosion Hazard Replace viewport if glass is missing or damaged Failure to do so can result ...

Page 17: ...rson Figure 17 Match Relief Opening Drafthood Figure 18 Flame Characteristics Tips may have a yellow tint Yellow inner cones are satisfactory Correct flame soft blue Water Temperature Regulation The thermostat is adjusted to the pilot position when it is shipped from the factory Water temperature can be regulated by moving the temperature dial to the preferred setting The preferred starting point ...

Page 18: ...Failure 6 Flashes Indicates Upper Sensor Failure 7 Flashes Indicates Electronic Control Failure 8 Flashes Indicates Valve Failure Continuous Solid Flash indicates system shutdown NOTE If the pilot lights but will only stay lit with the knob depressed in the pilot position look for the following status light codes 6 Second Solid Light followed by 4 Flashes The unit will not relight because it detec...

Page 19: ...vice and Support Department for service information at 1 877 817 6750 3 Inspect your installation for any problems with venting or combustion air 4 Reset the thermal switch by depressing the small button in the center of the thermal switch A high temperature limit switch or ECO Energy Cut Off in the tank is used to shut off the unit if the water temperature exceeds 180 F 83 C The ECO is a single u...

Page 20: ...supplies are not obstructed Build up of soot and carbon on the main burner and pilot burner Check for a soft blue flame Leaking or damaged water and gas piping Presence of flammable or corrosive materials in the installation area Presence of combustible materials near the water heater After servicing this water heater check to make sure it is working properly See Operating Your Water Heater sectio...

Page 21: ...d manifold tube at the gas control valve thermostat Figures 22 23 6 Grasp the manifold tube and push down slightly to free the manifold tube pilot tube and thermopile 7 Carefully remove the manifold assembly from the combustion chamber NOTE Be sure not to damage internal parts Removing the Burner from the Manifold Assembly Natural Gas Burner Low Nox 1 Take off the burner by removing the two 2 scre...

Page 22: ...Assembly Page 23 Figure 25 Two Piece Wire Connector Assembly Thermopile Connector Two Piece Wire Connector Pilot Tube Igniter Wire Retainer Clip Burner and other fittings not show for clarity Manifold Door Figure 26 Pilot Assembly Pilot Assembly Thermopile Connector Igniter Connector Thermal Switch Connectors Pilot Thermopile External Inspection Cleaning of the Flame trap Inspect the wrap around f...

Page 23: ...re 28B 4 Inspect the door gasket and make sure there is no fiberglass insulation between the door gasket and the combustion chamber 5 Replace the two screws which secure the manifold assembly door to the combustion chamber Tighten securely There should be no space between the gasket part of the manifold door and combustion chamber IMPORTANT Do not operate the water heater if the door gasket does n...

Page 24: ...ions Bubbles forming indicate a leak Correct any leak found If additional information is required contact the Service Department at 1 877 817 6750 TEFLON is a registered trademark of E I Du Pont De Nemours and Company 5 No leaks at pilot and manifold connection 6 Manifold door screws securely tightened 7 Depress the button on the thermal switch 1 Manifold door gasket properly sealed 2 Viewport not...

Page 25: ...iping dip tube must be in cold inlet 8 Advise customer DRIP FROM RELIEF VALVE 1 Excessive water pressure 2 Heater stacking 3 Closed water system 1 Use a pressure reducing valve and relief valve 2 Lower the thermostat setting 3 See Closed System Thermal Expansion THERMOSTAT FAILS TO SHUT OFF 1 Thermostat not functioning properly 2 Improper calibration 1 Replace thermostat 2 Replace thermostat COMBU...

Page 26: ...ng Refrigeration authorized service provider to correct the combustion air supply ventilation issue Correct size of openings to allow sufficient air NO YES YES YES NO Check the vent system for restrictions obstructions and check the vent termination height Refer to the Installation Instructions section of this manual for specific requirements NO Section C Pilot light will not remain lit Contact Cu...

Page 27: ... PILOT ASSEMBLY KIT Natural Gas 13 BURNER Natural Gas Low Nox 14 MANIFOLD DOOR ASSEMBLY Natural Gas Low Nox 15 TWO PIECE WIRE CONNECTOR WITH RETAINER CLIP 16 MANIFOLD DOOR GASKET 17 VIEWPORT ASSEMBLY 18 THERMISTORS Pictured on next page 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 Lis...

Page 28: ...opile 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 DESIGN and FLAME LOCK are trademarks of Whirlpool U S A 2006 Whirlpool Corporation All rights reserved...

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