Whirlpool 4220 manual

1 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 not use any phone in your building. • Immediately call your gas supplier from a neighbor ’ s phone. Follow the gas sup[...]

2 T able Of Contents W ater Heater Safety .............................................................................. 1-2 Installing Y our Gas W ater Heater ........................................................ 3-16 Unpacking the W ater Heater ........................................................... 3 Location Requirements ................[...]

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 [...]

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 Combustion Air Supply and V entilation IMPORT ANT : Air for combustion and ventilation must not come from a corrosive atmosphere. Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage. The following types of installation (not limited to the following) will require outdoor air for combustion due to chemical exp[...]

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 Direct to outdoors Vertical ducts Horizontal ducts Figure 6 Figure 7 Figure 8 T able 3 Minimum Free Area of Permanent Openings for Ventilation and Combustion Air Supply - All Air from Outdoors Only. Based on the total BTUH input rating for all gas utilizing equipment within the confined space. Opening Source 1 Square inch per 4000 BTUH 1 Square i[...]

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”). This water heater must be properly vented for the [...]

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 Installation 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 heate[...]

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 T emperature and Pressure Relief V alve 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 [...]

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 FOR YOUR SAFETY READ BEFORE LIGHTING TO TURN OFF GAS T O APPLIANCE 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. Be sure to smell next to the floor because some[...]

18 L.P .G. (Bottled Propane) Models Liquefi ed petroleum gas is over 50% heavier than air and in the occurrence of a leak in the system, the gas will settle at fl oor level. Basements, crawl spaces, skirted areas under mobile homes (even when ventilated), closets and areas below ground level will serve as pockets for the accumulation of gas. Befo[...]

19 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[...]

20 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[...]

21 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[...]

22 Replacing the Thermocouple 1. Remove the manifold assembly as directed previously . 2. Remove the retainer clip from the back of the two piece wire connector and remove the two piece wire connec- tor from the manifold door (Figure 25). 3. Pull the thermocouple from the pilot assembly (Figure 29). IMPORT ANT : Be careful not to bend or alter the [...]

23 Bracket Figure 28A Combustion Chamber Tab Flame-trap Door Gasket Figure 28B Manifold Assembly Close-up Tab Bracket Slot Manifold tube Close-up inside view of the combustion chamber. Piezoelectric Igniter System The piezoelectric igniter system consists of the igniter button, electrode, and wire. The pilot is ignited by an electric spark generate[...]

24 Removing and Replacing the Gas Control V alve/Thermostat IMPORT ANT : The gas control valve/thermostat is a standard valve with wire leads that connect to a thermal switch. Removing the Gas V alve: 1. On the gas control valve/thermostat turn the temperature dial counterclockwise to its lowest setting. Depress the dial stop and turn the gas contr[...]

25 PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION HIGH OPERA TION COSTS 1. Thermostat set too high 2. Sediment or lime in tank 3. Water heater too small for job 4. Wrong piping connections 5. Leaking faucets 6. Gas leaks 7. Wasted hot water 8. Long runs of exposed piping 9. Hot water piping in exposed wall 1. Set temperature dial to lower setting 2. D[...]

26 PILOT LIGHT TROUBLESHOOTING FLOWCHART Has the thermal switch tripped? NO Check for insufficient combustion air . Are there openings for make-up air to enter the room? Are the openings of sufficient size? See Combustion Air Supply and V entilation section in this manual for requirements. Is there a furnace/air handler in the same room as the wate[...]

27 REP AIR P ARTS ILLUSTRA TION *Pictured on next page. When ordering repair parts always give the following information: 1. Model, serial, and product number 2. T ype of gas 3. Item number 4. Parts description Repair Parts List LEGEND Special anode rod (see Anode Rod/W ater Odor section ) T emperature and Pressure Relief V alve is required, but ma[...]

28 Listed Parts Kits and Illustrations Item 12: Pilot assembly kit, which contains the pilot assembly , igniter electrode and retainer clip (Natural Gas) Item 13: Pilot assembly kit, which contains the pilot assembly , igniter electrode and retainer clip (L.P . Gas) Item 14: Burner (Natural Gas/Low Nox) Item 15: Burner (L.P . Gas) Item 16: Manifold[...]