Whirlpool Gas Water Heater High Efficiency Atmospheric Vent Installation Instructions And Use & Care Manual Download Page 4

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Location Requirements

The FVIR System is designed to reduce the risk of 

flammable vapor-related fires. Flammable liquids (such as 

gasoline, solvents, propane, etc,) emit flammable vapors 

which can be ignited by a gas water heater’s hot surface 

igniter or main burner. The resulting flashback and fire can 

cause death or serious burns to anyone in the area. 

This heater is equipped with a FV sensor for detecting the 
presence of flammable vapors. When the sensor detects those 
vapors, the unit will shut down and not operate. Should this 
happen, please refer to the troubleshooting guide on pages 29-30 
(numbers 9,11,12). Even though this water heater is a flammable 
vapors ignition resistant water heater and is designed to reduce 
the chances of flamm-able 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.

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death

        Do not store or use gasoline or other 
flammable vapors and liquids in the 
vicinity of this or any other appliance. 
Storage of or use of gasoline or other 
flammable vapors or liquids in the vicinity 
of this or any other appliance can result in 
serious injury or death.

Flammable Vapors

FLAMMABLES

Read and follow water heater warnings and 
instructions.

WARNING

Carbon Monoxide Poisoning Hazard

Do not install in a mobile home.
Doing so can result in death or 
carbon monoxide poisoning.

WARNING

Do not use or store flammable products such as gasoline, 

solvents, or adhesives in the same room or area near the 

water heater. If such flammables must be used, all gas 

burning appliances in the vicinity must be shut off and their 

pilot lights extinguished. Open the doors and windows for 

ventilation while flammable substances are in use. 
If flammable liquids or vapors have spilled or leaked in 

the area of the water heater, leave the area immediately 

and call the fire department from a neighbor’s home. Do 

not attempt to clean the spill until all ignition sources have 

been extinguished.
Keep combustibles such as boxes, magazines, clothes, 
etc. away from the water heater area.

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 level surface. Do not install in 

bathrooms, bedrooms, or any occupied room normally 

kept closed.

• 

Locate the water heater as close to the chimney or gas 

vent as practical. Consider the vent system piping and 

combustion air supply requirements when selecting the 

water heater location. The venting system must be able 

to run from the water heater to termination with minimal 

length and elbows. 

• 

Locate the water heater near the existing gas piping. 

If installing a new gas line, locate the water heater to 

minimize the pipe length and elbows. 

• 

The water heater should be located in an area not 

subject to freezing temperatures. Water heaters 

located in unconditioned spaces (i.e., attics, 

basements, etc.) may require insulation of the water 

piping and drain piping to protect against freezing. 

The drain and controls must be easily accessible for 

operation and service. Maintain proper clearances as 

specified on the water heater.

• 

Do not locate the water heater near an air-moving 

device. The operation of air-moving devices such 

as exhaust fans, ventilation systems, clothes dryers, 

fireplaces, etc., can affect the proper operation of 

the water heater. Special attention must be given to 

conditions these devices may create. Flow reversal of 

flue gases may cause an increase of carbon monoxide 

inside of the dwelling (Figure 2).

• 

The water heater is to be located as close as possible 

to a 120VAC outlet.  

 

NOTE:

 All electrical wiring should be in accordance to 

the NEC and all local/state elec- trical codes (extension 

cord is not allowed). 

NOTE:

  This water heater 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 and the “National Electrical Code”, 
ANSI/NFPS 70 current edition.

FV Sensor

Figure 1

Summary of Contents for Gas Water Heater High Efficiency Atmospheric Vent

Page 1: ...e or explosion 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 Installation Instructions and Use Care Guide To obtain technical warranty or service assistance during or after the inst...

Page 2: ...n 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 ha...

Page 3: ...will need it for future reference Service to 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 The manufacturer and seller of this water heater will not be liable for any damages injuries or deaths caused by failure to comply with the instal...

Page 4: ...ly and call the fire department from a neighbor s home Do not attempt to clean the spill until all ignition sources have been extinguished Keep combustibles such as boxes magazines clothes etc away from the water heater area 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 level surface Do not inst...

Page 5: ...tallation 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 three inches 76 2mm in any direction or if in an alcove or closet installation the entire floor must be covered by the panel Figure 2A may be used as...

Page 6: ...Maximum Air Gap Discharge Pipe Do Not Cap or Plug Floor Drain Gas Pressure IMPORTANT The 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 ...

Page 7: ...detergents bleaches cleaning solvents air fresheners paint and varnish removers refrigerants and many other commercial and household products When burned vapors from these products form highly corrosive acid compounds These products should not be stored or used near the water heater or air inlet Combustion and ventilation air requirements are determined by the location of the water heater The wate...

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: ...lle is known it should be used in calculating the specified free area of the opening If the design and free area are not known it can be assumed that most wood louvers will allow 20 25 of free area while metal louvers and grilles will allow 60 75 of free area Louvers and grilles must be locked open or interconnected with the equipment so that they are opened automatically during equipment operatio...

Page 10: ...ve elevation 5 400 ft 1 646 m from sea level Reducer Flue must be installed on Water Heaters Flat Side Of Hood Next To Water Connections Draft Hood Legs Legs Slot Slot Top Install The Draft Hood With The Four Screws Provided Screw Install The Draft Hood With The Four Screws Provided 50 GAL TALL NATURAL GAS 40 GAL NATURAL GAS Draft Hood Legs Screw Legs Slot Top Slot Reducer Flue Flat Side Of Hood N...

Page 11: ...anufacturer 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 may be used as a passageway for the installation of a gas vent Figure 12 Common combined...

Page 12: ...14 These valves reduce the point of use temperature of the water by mixing cold and hot water and are readily available for use 4 If installing the water heater in a closed water system install an expansion tank in the cold water line as specified under Closed System Thermal Expansion section 5 Install a shut off valve in the cold water inlet line It should be located close to the water heater and...

Page 13: ...responding 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 ...

Page 14: ...minate a maximum of six inches above a floor drain or external to the building In cold climates it is recommended that the discharge pipe be terminated at an adequate drain inside the building Must be capable of withstanding 250 F 121 C without distortion Must be installed to allow complete drainage of both the valve and discharge line T P Relief Valve and Pipe Insulation Some Models 1 Locate the ...

Page 15: ... 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 w...

Page 16: ...ge 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 Unit is to connect to a 120VAC electrical supply outlet extension cord is not allowed The water heater and the outlet are properly grounded Installed in accordance with prevailing provisions of local cod...

Page 17: ...rs Ductwork is the same cross sectional area as the openings Vent Pipe System Check for proper drafting at the water heater draft hood Refer to the Checking the Draft section of this manual for the test procedure If the procedure shows insufficient draft is present please check the following Draft hood properly installed Vent connectors securely fastened with screws and supported properly to maint...

Page 18: ...ging temperature WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life Turn on all electrical power to the appliance 2 Turn off all electrical power to the appliance if service is to be performed 3 Set the ON OFF switch on the gas control to the ON postition 7 Set the ON OFF switch on the gas control to the OF...

Page 19: ...es and flammable vapors The water heater must be installed according to all local and state codes or in the adsence of local and state codes the National Fuel Code ANSI Z223 1 NFPA 54 current edition Dilution Air Relief Opening Dilution Air Match Outer Door Floor Drain 6 Maximum Air Gap FIGURE 18 Draft Blower is energized Checking The Draft After successfully lighting the water heater allow the un...

Page 20: ...14 Follow manufacturer s instructions for installation of the valves Before changing the factory setting on the thermostat see Figure 21 Using the lowest hot water temperature that meets your needs will also provide the most energy efficient operation of the water heater Never allow small children to use a hot water tap or to draw their own bath water Never leave a child or handicapped person unat...

Page 21: ... demands for hot water including dishwashers washing machines and shower heads Excessive condensation may be noticed during the winter and early spring months when incoming water temperatures are at their lowest Good venting is essential for a gas fired water heater to operate properly as well as to carry away products of combustion and water vapor It is always recommended that a suitable metal dr...

Page 22: ...ain the tank perform the following steps 1 Turn off the gas to the water heater at the manual gas shut off valve and turn off the electrical power to the gas control thermostat valve 2 Open a nearby hot water faucet until the water is not 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 wa...

Page 23: ...umber 4 parts description See Repair Parts Section for a list of available repair parts Removing the Manifold Burner Assembly 1 Turn off the gas supply to the water heater at the manual gas shut off valve This valve is typically located beside the water heater Note the position of the shut off valve in the open on position then proceed to turn it off Figure 3 2 Disconnect power supply to the heate...

Page 24: ...be necessary to check the air intake chamber screen more frequently 2 Use a vacuum cleaner with a hose attachment to remove any dust or debris that may have accumulated on the screen Cleaning the Combustion Chamber and Air Diverter Assembly 1 Follow procedure outlined in Removing the Manifold Burner Assembly 2 Use a vacuum cleaner shop vac to remove all loose debris in the combustion chamber Figur...

Page 25: ... of Draining and Flushing section and follow the procedure 5 Disconnect the the flame sense hot surface igniter wire power supply transformer pressure switch fan and display connector wires from the thermostat Figure 24 Disconnect the manifould tube at the thermostat Figure 24 6 Refer to Gas Piping section Figure 3 and disconnect the ground joint union in the gas piping Disconnect the remaining pi...

Page 26: ...MPERATURE REGULATION section BURNER FLAME YELLOW LAZY 1 Dirt in burner ports 2 Combustion air path restricted 3 Not enough dilution air for proper com bustion 4 Main burner line clogged 5 Obstruction in main burner orifice 6 Burner flame too high 7 Flame burns at orifice thermostat not functioning properly 8 Low gas pressure 1 Turn off heater and gas clean burner head 2 Check intake venting arrang...

Page 27: ...RMATION SOOTING 1 Insufficient secondary air 2 Low gas pressure 3 Water heater flue or vent system blocked 4 Thermostat not functioning properly 5 Heater installed in a confined area 6 Burner flame yellow lazy 1 Provide ventilation to water heater Check flue way flue baffle burner 2 Check with gas utility company 3 Clean locate source and correct 4 Replace thermostat 5 Provide fresh air ventilatio...

Page 28: ...sure supply and manifold gas pressures are within requirements in the installation manual Manifold gas pressure is non adjustable if pressure is off by more than 0 3 W C 75 Pa replace the lower control 2 Low supply voltage should be 115 125 VAC 3 Ensure flame sensor is making good contact with the burner flame ensure flame is steady 4 Ensure the flame sensor is clean use pad to clean the flame sen...

Page 29: ... power for 10 seconds and then back on If this error code will not clear and the ignitor resistance is within specifications replace the lower control 9 FV SENSE Flashing Flammable Vapor Sensor has detected the presence of flammable vapors and is in lockout 1 Do not touch any electrical switch do not use any phone in the building and do not try to CONTROL DISPLAY STATUS PROBLEM SOLUTION the error ...

Page 30: ... control must be replaced 15 All Segments Flashing The self diagnostic check has detected one or both of the temperature adjustment buttons are stuck 1 Press and release each of the temperature adjustment buttons If the above action does not clear the error the control will continue to regulate the water temperature at the last setting However settings will no longer be adjustable the upper contro...

Page 31: ...D DURING TRIAL FOR IGNITION IGNITOR TURNS OFF YES NO IS FLAME SENSE LOST IS REQUEST FOR HEAT SATISFIED GAS VALVE OFF COMBUSTION FAN OFF AFTER POST PURGE DELAY GAS VALVE CLOSES LESS THAN 3 TRIES FOR IGNITION GAS VALVE CLOSES LOST LESS THAN 4 TIMES YES YES TURN OFF COMBUSTION FAN AFTER POST PURGE DISPLAY ERROR 3 ONE HOUR AUTOMATIC RESTART TIME DELAY NO NO NO YES YES NO IS PRESSURE SWITCH PROVEN OPEN...

Page 32: ...ipple Cold 5 Anode Rod 6 Cold Water Inlet Tube 7 Temperature and Pressure Valve 8 Control Display 9 Air Intake Chamber 10 Gas Control Valve Thermostat 11 Drain Valve 12 Natural Gas Burner 13 Hot Surface Igniter HSI 4 1 2 3 6 5 7 8 9 10 11 12 14 19 18 21 20 22 FOR ALL 40 GAL UNITS REDUCER FLUE MUST BE INSTALLED ABOVE ELEVATION 5 400 ft 1 646 m FROM SEA LEVEL Item No Parts Description 14 Manifold Do...

Page 33: ... assembly which contains the manifold tube gasket manifold door two piece wire connector with retainer clip and flame sense hot surface igniter assembly Natural Gas Item 15 Contains manifold component block with retainer clip Item 16 Contains manifold door gasket Item 17 Contains viewport ITEM 13 ITEM 12 ITEM 14 ITEM 15 ITEM 16 ITEM 17 ...

Page 34: ...34 NOTES ...

Page 35: ...35 NOTES ...

Page 36: ... Registered trademark TM trademark of Whirlpool U S A 2011 Whirlpool Corporation All rights reserved Manufactured under license by American Water Heater Company Tennessee Warranty provided by manufacturer ...

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