Whirlpool SG1J4040T3NOV 7K manual

1 Ultra Low Nox Gas W ater Heater with the Flame Lock™ Safety System Installation Instructions and Use & Care Guide Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHA T TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do no[...]

2 Important Instructions • Do not use this appliance if any part has been under water . Immediately call a qualified service technician. W ater 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[...]

3 INST ALLING YOUR GAS W A TER HEA TER Important Information About This W ater 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 more sensitive to installation errors or improper installation e[...]

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 t[...]

5 IMPORT ANT : 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 lea[...]

6 Gas Supply Gas Requirements IMPORT ANT : 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 de[...]

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 1 100 73 152 285 590 890 63 130 245 500 760 56 11 5 215 440 670 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 11 0 225 350 26 55 100 210 320 10 20 30 40 [...]

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,[...]

9 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. Duct[...]

10 V ent 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 V entilation” section). This water heater must be properly vented [...]

11 Chimney Connection IMPORT ANT : 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 s[...]

12 W ater System Piping 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. W ater supply pressure should not exceed 80% of the working pressure of the water heater . The working pres[...]

13 Please note the following: • The system should be installed only with piping that is suitable for potable (drinkable) water such as copper , CPVC, or polybutylene. This water heater must not be installed using iron piping or PVC water piping. • Use only pumps, valves, or fittings that are compatible with potable water . • Use only full flo[...]

14 For protection against excessive pressures and temperatures, a temperature and pressure relief valve must be installed in the opening marked “T & P RELIEF V AL VE” (see Figure 15A). This valve must be design certified by a nationally recognized testing laboratory that maintains periodic inspection of the production of listed equipment or[...]

15 Special Applications Combination Space Heating/Potable W ater 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 follo[...]

16 W ater Heater Location W ater heater location is important and can affect system performance. Please check the following: □ Installation area free of corrosive elements and flammable materials. □ 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 v[...]

17 OPERA TING YOUR W A TER HEA TER Lighting Instructions Read and understand these directions thoroughly before attempting to light or re-light the pilot. Make sure the viewport is not missing or damaged. (See Figure 23) Make sure the tank is completely filled with water before lighting the pilot. Check the data plate near the gas control valve/the[...]

18 Checking the Draft After successfully lighting the water heater , allow the unit to operate for 15 minutes and check the draft hood relief opening for proper draft. Make sure all other appliances in the area are operating and all doors are closed when Burn Hazard Do not touch vent. Doing so can result in burns. W ARNING White Rodgers Gas V alve [...]

19 The thermostat is adjusted to its lowest temperature 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 is 120°F . Align the index bar on the thermostat with the desired water temperature as shown in Figure 19. There is a hot water scald [...]

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[...]

21 MAINTENANCE OF YOUR W A TER HEA TER 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. T o drain the tank, perform the following steps: 1. T urn off the gas to the wa[...]

22 Replacement Parts IMPORT ANT : 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, [...]

23 Replacing the Thermocouple 1. Remove the Burner Door 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 assembly (Figure 25). 3. Pull the thermocouple from the pilot assembly (Figure 29). IMPORT ANT : Be careful not to bend or alter the posi[...]

24 Replacing the Burner Door Assembly 1. Check the door gasket for damage or imbedded debris prior to installation. Piezoelectric Igniter System The piezoelectric igniter system consists of the igniter button, electrode, and wire. The pilot is ignited by an electric spark generated when the igniter button is pressed. The electrode should be centere[...]

25 Removing and Replacing the Gas Control V alve/Thermostat IMPORT ANT : The gas control valve/thermostat is a standard valve with a right-hand thread thermocouple. Use only factory authorized replacement parts. Removing the Gas V alve: 1. Turn the gas control knob on the combination gas control valve/thermostat clockwise to the “OFF” position.[...]

26 PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION PILOT WILL NOT REMAIN LIT 1 . Air in gas line 2. Dirt in gas lines 3. Pilot line or orifice clogged 4. Thermocouple connection loose 5. Non-functioning thermocouple 6. Cold drafts 7. Flammable vapors incident, Flame Lock TM function utilized 8. Low gas pressure 9. Air for combustion obstructed 10. Pilo[...]

27 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, hold down the reset button until the pilot is lit and maintains a stable flame, then slowly release the reset button. YES Section A: Pilot light will not light. Section B: Pilot light will not re[...]

28 Item No. Parts Description 1 DRAFT HOOD 2 REDUCER RING - SOME MODELS 3 FLUE BAFFLE 4 HEA T TRAP (COLD) - SOME MODELS 5 HEA T TRAP (HOT) - SOME MODELS 6A COLD W A TER DIP TUBE 6B COLD W A TER DIP TUBE 7 ANODE ROD 8 TEMPERA TURE & PRESSURE RELIEF V AL VE (LOCA TED TOP OR SIDE) 9 DRAIN V AL VE 10A GAS CONTROL V AL VE/THERMOST A T 10B GAS CONTRO[...]

29 Listed Parts Kits and Illustrations Item 12: Pilot assembly which contains the pilot assembly and igniter electrode. (Natural Gas) Item 13: Burner Door assembly which contains the burner , gasket, door , pilot tube, two piece wire connector with retainer clip, and pilot assembly . (Natural Gas/Low Nox) Item 14: Contains two piece wire connector [...]

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