Whirlpool SG1J4040T3NOV 5K 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 Water 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 fl ammable vapor ignition incident. New technology used in meeting these standards makes this product more sensitive to installation errors or improper installation[...]

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 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 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 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. During the heating cycle of the wat[...]

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 Install[...]

15 Installation Checklist W ater Heater Location □ 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 vertical position. Protected from freezing temperatures. □ Proper clearances from combustible surfaces maintained and not installed directly on a car[...]

16 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[...]

17 Checking the Draft After successfully lighting the water heater , allow the unit to operate for 15 minutes and check the drafthood relief opening for proper draft. Make sure all other appliances in the area are operating and all doors are closed when performing the draft test. Pass a match flame around the relief opening of the drafthood. A stea[...]

18 Operating the T emperature Control System W ater T emperature Adjustment The water temperature can be adjusted from 1 10°F to 150°F . T urn the Gas Control/T emperature Knob to the desired setting/temperature. Operating Modes and Settings • Standard Mode - The controller adjusts the water heater to maintain the temperature set by the user . [...]

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 Pilot Assembly 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 connector from the manifold door (Figure 25). 3. Locate and remove the screws on the underside of the burner . Remove the screw securing the pilot assembly t[...]

23 1. Check the door gasket for damage or imbedded debris prior to installation. Figure 28A Combustion Chamber Door Gasket Bracket Flame-trap Figure 28B Manifold Assembly Close-up Close-up inside view of the combustion chamber. Manifold Tube Bracket Tab Slot Piezoelectric Igniter System The piezoelectric igniter system consists of the igniter butto[...]

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. Turn the gas control/temperature knob to the “OFF” position (Figure 19). 2. Turn of f the gas at the manual shut-off valve on the gas supply p[...]

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

26 Thermal Switch Thermal Switch Location 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, push in and hold the gas control/ temperature knob until the pilot is lit and maintains a stable flame, (status light will blink) then release the gas contr[...]

27 REP AIR P ARTS ILLUSTRA TION 1 2 3 4 8 5 10 11 9 7 6 Item No. Parts Description 1 DRAFTHOOD 2 REDUCER RING - SOME MODELS 3 FLUE BAFFLE 4 HEA T TRAP (COLD) - SOME MODELS 5 HEA T TRAP (HOT) - SOME MODELS 6 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 10 GAS CONTROL V AL VE/TH[...]

28 Listed Parts Kits and Illustrations Item 12: Pilot assembly kit, which contains the pilot assembly , thermopile, and retainer clip (Natural Gas) Item 13: Burner (Natural Gas/Low Nox) Item 14: Manifold door assembly which contains the manifold tube, gasket, door , pilot tube, thermopile, two piece wire connector with retainer clip, thermal switch[...]