Whirlpool Energy Smart Residential Electric Water... Product information sheet

WATER HEATERS
TM
Energy Smart ®
Residential Electric
Water Heater
Installation Instructions
and Use & Care
Guide
Toobtain technical, warranty, or service assistance during or
after the installationof this water heater,call toll free:
1-877-817-6760
When calling for assistance, please havethe following
information ready:
1. Model Number
2. 7 Digit Product Number
3. Serial Number
4. Date of Installation
5. Placeof Purchase
Table OfContents PAGE
Water Heater Safety .......................................................................... 2
Installing Your Electric Water Heater ................................................ 3-8
Unpacking Instructions ................................................................ 3
Location Requirements ................................................................ 4
Water System Piping ............................................................... 5
ElectricalRequirements ................................................................. 7
Installation Checklist ................................................................... 8
Operating Your Water Heater ......................................................... 9-11
Water Heater Start-Up ................................................................. 9
Water Temperature Regulation .................................................... 9
Operating the Temperature Control System ............................... 10
Operational Conditions ..................................................................... 11
Maintenance of Your Water Heater .............................................. 12-13
Diagnostic Code and Trouble Shooting Chart ................................... 14
Repair Parts Illustration ..................................................................... 15
i
6510288
March 2003

Your safety and the safety of others are very important.
We have provided many important safety messages in this manual and on your appliance. Always read and obey all
safety messages.
This is the safety alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word "DANGER" or
"WARNING." These words mean:
You can be killed or seriously injured if you don't
immediately follow instructions.
You can be killed or seriously injured if you don't
follow instructions.
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you
what can happen if the instructions are not followed.
Important Safety Instructions
CAUTION: Hydrogen gas is produced in a hot water system served by this heater that has not been used for a long
period of time (2 weeks or more). Hydrogen is extremely flammable. To reduce the risk of injury under these
conditions, it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using
any electrical appliance connected to the hot water system. When hydrogen is present, there will be an unusual
sound such as air escaping through the pipe as the water begins to flow. There should be no smoking or open flame
near the faucet at the time it is open.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of
substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires
businesses to warn of potential exposure to such substances.
Warning: This product contains a chemical known to the State of California to cause cancer, birth defects, or other
reproductive harm.
This appliance can cause low-level exposure to some of the substances listed, including formaldehyde.

INSTALLING YOUR WATER HEATER
Consumer Information
This water heater should be installed in accordance
with the local code authority having jurisdiction, the
power company or electric utility, and this installation
manual. In the absence of local code requirements,
follow the regulations set forth in the latest edition of the
National Electric Code, NFPA 70. This is available from
the following:
National Fire Protection Agency
1 Batterymarch Park
Quincy, MA 02269
American National Standards Institute
1430 Broadway
New York, NY 10018
Check your phone listings for the local authorities
having jurisdiction over your installation.
Consumer Responsibilities
This manual has been prepared to acquaint you with
the installation, operation, and maintenance of your
electric water heater and to provide important safety
information in these areas.
We urge you to read all of the instructions thoroughly
before attempting the installation or operation of this
water heater. This manual should be kept for future
reference.
The manufacturer of this water heater will not be liable
for any damages caused by failure to comply with the
installation and operating instructions outlined in this
manual.
If you lack the necessary skills required to properly
install this water heater or you have difficulty following
the instructions, you should not proceed but have a
qualified person perform the installation of this water
heater. Massachusetts code requires this water heater
to be installed in accordance with Massachusetts
Plumbing and Fuel Gas Code 248 CMR section 2.00
and 5.00.
A data plate identifying your water heater can be found
adjacent to the element door. When referring to your
water heater always have the information listed on the
data plate readily available.
Retain your original receipt as proof of purchase.
Unpacking the Water Heater
Removing Packaging Materials
Important: Do not remove any permanent instructions,
labels, or the data label from outside of the water heater
or on the inside of panels.
Remove exterior packaging and place installation
components aside.
Do not remove the envelope bag containing the
water heater literature from the side of the water
heater.
Inspect all parts for damage prior to installation and
start-up.
Completely read all instructions before attempting
to assemble and install this product.
_. Replace this manual inside the envelope bag when
installation is complete.
_. After installation, dispose of packaging material in
the proper manner.

Location Requirements
Site location
Select a location near the center of the water piping
system, tt must be installed indoors and in a vertical
position on a level surface.
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 the water piping and drain piping to be
insulated to protect against freezing. The drain and
controls must be easily accessible for operation and
service.
Do not use this water heater in conjunction with a spa
or hot tub.
Note: Local codes and requirements in your area may
require the water heater to be installed such that the
bottom element is elevated from the floor at least 18
inches.
Important: 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. It is
recommended that a suitable drain pan be installed
under the water heater as shown below. This pan is to
3rotect the property from damage which may occur
from normal condensate formation on the tank or
leaks in the tank and pipe connections. The pan must
limit the water level to a maximum depth of 2-1/2
inches and be two inches wider than the heater and
piped to an adequate drain. Locate the water heater
near a suitable indoor drain. Outdoor drains are
subject to freezing temperatures which can obstruct
the drain line. The piping should be at least 3/4"1D
and pitched for proper drainage.
Under no circumstance will the manufacturer be
held liable for any water damage in connection
with this water heater.
0
21/2" Max
t Pipe to
adequate
drain
At least 2" inches greater than
the diameter of the water
heater.
Note: The water heater shall be located so it is not
subject to physical damage by moving vehicles or area
flooding.
Figure 1
Residential Garage
Installation
Vehicle
Stop
Drain Drain
Pan
State of California
Note: The water heater must be braced, anchored, or
strapped to avoid moving during an earthquake. Contact
local utilities for code requirements in your area or call
1-877-817-6750 and request instructions.

Water System Piping
Piping Installation
Piping, fittings, and valves should be installed according
to the installation drawing (Figure 2). If the indoor
installation area is subject to freezing temperatures, the
water piping must be protected by insulation.
Water supply pressure should not exceed 80% of the
working pressure of the water heater. The working
pressure is stated on the water heater's data plate. If
this occurs a pressure limiting valve with a bypass may
need to be installed in the cold water supply line. This
should be placed on the supply to the entire house in
order to maintain equal hot and cold water pressures.
Important: Heat cannot be applied to the water fittings
on the heater as they may contain nonmetallic parts. If
solder connections are used, solder the pipe to the
adapter before attaching the adapter to the hot and cold
water fittings.
Important: Always use a good grade of joint compound
and be certain that all fittings are drawn up tight.
1. Install the water piping and fittings as shown in
Figure 2. Connect the cold water supply (3/4 NPT)
to the fitting marked "C". Connect the hot water
supply (3/4 NPT) to the fitting marked "H".
Important: Some models may contain energy saving
heat traps to prevent the circulation of hot water within
the pipes. Do not remove these inserts.
2. The installation of unions in both the hot and cold
water supply lines is recommended for ease of
removing the water heater for service or
replacement.
3. The manufacturer of this water heater recommends
installing a tempering valve in the domestic hot
water line as shown in Figures 3 and 4. These
valves reduce the point-of-use temperature of the
hot water by mixing cold and hot water and are
readily available. Contact a licensed plumber or the
local plumbing authority.
4. If installing the water heater in a closed water
system, install a relief valve or expansion tank in
the cold water line as specified under "Closed
System/Thermal Expansion".
5. Install a shut-off valve in the cold water inlet 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.
.
.
Install a temperature and pressure relief valve and
discharge line in the opening marked "T & P
RELIEF VALVE". Install as specified under
"Temperature and Pressure Relief Valve."
After piping has been properly connected to the
water heater, open the nearest hot water faucet and
allow the tank to completely fill with water. To purge
the lines of any excess air and sediment, keep the
hot water faucet open for 3 minutes after a constant
flow of water is obtained. Close the faucet and
check all connections for leaks.
Figure 2
Water Piping Installation In A Closed System
Use Either:
1 Thermal Expansion Tank
2 Pressure Relief Valve
O _ Pressure Reducing
Valve With Bypas_7Hot Water
Outlet _ I_ _t 11 Ma,.
• ,L--_C-,---_ II ColdWater U sWuat)_r
Union _ ----------- Inlet Valve Cold Water PP Y
/Supply to
Fixtures
/Temperature and
Pressure Relief Valve
Discharge line
6 inches maximum
above drain
Drain line
linch / (_) _3/4inch ID l
Min --_ I _-- ,_) U/minimum Massachusetts:
• I| _ /.Install vacuum relief I
/Dram in cold water line per
f ::_ j¢" section 19 MGL 142• /
sJ
Drain Pan
2-1/2 inch depth max.
Figure 3
Tempering Valve
Side Connection
Follow the tempering Hot
valve manufacturer's Water Out
instructions _1_
Tempered water
to fixtures
Tempering valve
set to 120 °F max.
._ Cold Water In
Figure 4
Tempering Valve
Top Water Connections
Follow the
tempering valve
manufacturer's
instructions
Cold
Water
inlet
t
Tempered
water to
fixtures Tempering Valve
(Set to 120 °F)

Please note the following:
DO NOT install this water heater with iron piping.
The system should be installed only with new piping
that is suitable for potable (drinkable) water such as
copper, CPVC, or polybutylene. DO NOT use PVC
water piping.
DO NOT use any pumps, valves, or fittings that are
not compatible with potable water.
DO NOT use valves that may cause excessive
restriction to water flow. Use full flow ball or gate
valves only.
DO NOT use 50/50 tin-lead solder (or any lead
based solder) in potable water lines. Use 95/5 tin-
antimony or other equivalent material.
DO NOT tamper with the electronic control board,
temperature sensors, heating elements, electrical
connections, or temperature and pressure relief
valve. Tampering voids all warranties. Only qualified
technicians should service these components.
DO NOT use with piping that has been treated with
chromates, boiler seal, or other chemicals.
DO NOT add any chemicals to the system piping
which will contaminate the potable water supply.
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, backfiow preventer,
or water pressure reducing valve. This will create a
closed water system. During the heating cycle of the
water heater, the water expands causing pressure
inside the water heater to increase. This may cause the
temperature and pressure relief valve to discharge
small quantities of hot water. To prevent this from
happening, there are two recommendations:
1. Install a diaphragm-type expansion tank that is
suitable for potable water on the cold water supply
line. The expansion tank must have a minimum
capacity of 1.5 U.S. gallons for every 50 gallons of
stored water.
.Install a 125 PSI pressure relief valve in the cold
water supply line. Make sure the discharge of this
valve is directed to an open drain and protected
from freezing. Contact the local water supplier or
plumbing inspector for information on how to
control this situation. Do not plug the temperature
and pressure relief valve.
Temperature and Pressure
Relief Valve
Explosion Hazard
If the temperature and pressure relief
valve is dripping or leaking, have a
licensed plumber repair it.
Do not plug valve.
Do not remove valve.
Failure to follow these instructions can
result in death or explosion.
Figure 5
Temperature and Pressure
Relief Valve Installation Optional location some
r'-'l Fmodels only
Temperature and
,/_ Pressure Relief Valve
Discharge Line
314 inch rain.
Do not cap or plug.
Drain Pan (_ __._ 6ianxChmum
Drain _
For protection against excessive pressures and
tern peratures, a tern peratu re and pressu re relief valve
must be installed in the opening marked "T & P RELIEF
VALVE" (See Figure 5).
Caution: To reduce the risk of excessive pressures and
temperatures in this water heater, install temperature
and pressure relief protective equipment required by
local codes, but not less than a combination
temperature and pressure relief valve certified by a
nationally recognized testing laboratory that maintains
periodic inspection of the production of listed equipment
or materials, as meeting the requirements for Relief
Valves and Automatic Shutoff Devices for Hot Water
Supply Systems, ANSI 721.22 -1986. This valve must
be marked with the maximum set pressure not to
exceed the marked maximum working pressure of the
water heater. Install the valve into an opening provided
and marked for this purpose in the water heater, and
orient it or provide tubing so that any discharge from the
valve exits only within 6 inches above, or at any
distance below, the structural floor, and does not
contact any live electrical part. The discharge opening
must not be blocked or reduced in size under any
circumstance.

Important:Onlyanewtemperatureandpressurerelief
valveshouldbeusedwithyourwaterheater.Donot
useanoldorexistingvalveasitmaybedamagedor
notadequatefortheworkingpressureofthenewwater
heater.Donotplaceanyvalvebetweenthereliefvalve
andthetank.
The Temperature & Pressure Relief Valve:
)- Must be connected to an adequate discharge line.
Must not be in contact with any electrical part.
_- Must not be rated higher than the working pressure
shown on the data plate of the water heater.
The Discharge Line:
_- Must terminate a maximum of 6 inches above a
floor drain or external to 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.
_. Must not be smaller than the pipe size of the relief
valve or have any reducing coupling installed in the
discharge line.
_. Must not be capped, blocked, plugged, or contain
any valve between the relief valve and the end of
the discharge line.
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 120°E A tempering valve or other temperature
limiting valve must be installed in the water supply line
to limit the supply temperature to 120°R
Note: Solar water heating systems can often supply
water with temperatures exceeding 180°F and may
result in water heater malfunction.
Electrical Requirements
Electric Shock Hazard
Disconnect power before
servicing.
Replace all parts and panels
before operating.
Failure to do so can result in
death or electric shock.
Fire Hazard
Use 10 gauge solid copper wire.
Use a UL approved strain relief.
Connect ground wire to green
ground screw.
Failure to do so can result in
death, fire, or electrical shock.
If you lack the necessary skills required to properly
install the electrical wiring to this water heater, do not
proceed, but have a qualified electrician perform the
installation.
When making the electrical connections, always make
sure:
The electrical supply has the proper overload fuse
or circuit breaker protection.
Wire sizes and connections comply with all
applicable codes.
Wiring is enclosed in approved conduit (if required
by local codes).
The water heater and electrical supply are properly
grounded.
Figure 6 and the wiring diagram can be found on the
next page. Always reference the wiring diagram for the
correct electrical connection. The wiring diagram can
also be found on the inside of the junction box cover.
When installing the electrical wiring to the water heater:
1. Shut off the power to the unit.
2. Be sure tank is completely filled with water before
making any electrical connections.
3. Remove junction box cover that is secured by 3
screws. Place the cover aside and view the wiring
diagram on the inside.
4. Connect the electrical supply to the water heater in
accordance with the local utility requirements and
codes. A standard 1/2 inch opening has been made
in the junction box for the conduit connections. Use
approved conduit with copper wires only or Romex.

5. Groundthewaterheaterbyconnectingthe
groundingwirefromtheelectricalservicegroundto
the(green)groundscrewlocatedinthejunction
box.Note: Onlyuse10gaugewiresforelectrical
connectionsanda30amperedoublepolebreaker.
6. Connecttheredandblackwirestotheincoming
powerleads.
7. Replacecoverandsecurewithscrews.
Figure 6
Field Wiring
240V - 30A Service
Junction Box
Cover
Orange Wire
Leads
Black
Wire
Field Wiring
Compartment
L_ Ground Screw
(green)
Color Code
Stripe
Red Wire
Blu
r_ Electronic
Control Board
Temperature
Sensor Socket
Wiring Diagram
240 Volts Only
LI L2 FUSED DISCONNECT
CIRCUIT BREAKER
Io o IEL,O,R,C,,L
S_RVlCE
/8L,cK I_
CONNECTOR
ELECTRONIC
CONTROL
BOARD
III I-....
H_TER
GROU_ID
TOO
L_. =__
UPPER
SENSOR
LOWER
ELEMENT 6603491
Installation Checklist
Water Heater Location
_" Centrally located with the water piping system.
_" Located indoors and in a vertical position.
_" Protected from freezing temperatures.
_" Provisions made to protect the area from water
damage.
_" Drain pan installed and piped into an adequate
drain.
_" Sufficient clearance to service the water heater.
Water System Piping
_" Temperature and pressure relief valve properly
installed with a discharge line plumbed to an open
drain and protected from freezing.
_" All piping properly installed and free of leaks.
_" Water heater completely filled with water.
_" Closed system pressure buildup precautions
installed.
_" Tempering valve installed per manufacturer's
instructions.
Electrical Connections
Wiring and connections comply with all applicable
codes.
Water heater and electrical supply are properly
grounded.
Proper overload fuse or circuit breaker protection
installed.

OPERATING YOUR WATER HEATER
Water Heater Start-Up
1. Before operating the water heater, make sure the
water heater has been properly installed.
2. Completely fill the tank with water.
3. Carefully read and understand the section, "Water
Temperature Regulation", of this manual and adjust
the temperature control knob to the desired setting.
4. Read the section, "Operating Mode Descriptions"
on page 10 and select the desired operating mode.
5. After the tank is completely filled with water, turn on
power to the water heater. Note: The water heater
performs self-diagnostics that takes approximately
10 minutes. During this time, the elements may not
be energized. If a failure is detected, the Diagnostic
Light flashes the related failure code. See page 14
for "Diagnostic Code Chart."
Important: Operation of this water heater without
access doors or insulation could result in much higher
water temperatures than the desired set point,
increasing the risk of scald injury. Do not operate
water heater with the access doors or insulation
removed, r'-m
Access Doors
Important: Do not attempt to operate this water heater
if the temperature sensor(s), electronic control board, or
surrounding insulation has been exposed to water in
any way. Immediately call a qualified service technician
to inspect the water heater and replace any
temperature sensor(s), electronic control board, or
insulation that has been exposed to water. Do not
attempt to repair these parts. Water heaters subjected
to flood conditions or any time the temperature
sensor(s) or electronic control board have been
submerged in water require replacement of the entire
water heater.
Safety Shut-off
This water heater is equipped with a high limit control
switch that is designed to shut off the power to the
elements if the water temperature exceeds170°F
(77°C). Use the diagnostic control chart on page 14 to
help determine the cause of the high limit shut-off. After
the cause has been corrected, reset the control as
directed under "Reset Function" on page 10.
Water Temperatu re
Regulation
Water temperature over 125°F can cause
severe burns instantly or death from
scalds.
Children, disabled, and elderly are at
highest risk of being scalded.
See the instruction manual before setting
temperature at water heater.
Feel water before bathing or showering.
Temperature limiting valves are available.
The temperature control is adjusted to a setting of
120°F or lower when it is shipped from the factory.
Water temperature can be regulated by adjusting the
temperature control system to the preferred setting as
shown in "Operating the Temperature Control System."
The recommended starting point is 120°F. There is a
hot water scald potential if the temperature control
is set too high.
Important: Adjusting the temperature past 120°F on the
temperature control will increase the risk of scald injury.
Hot water can produce first degree burns within:
120°F (49°C) more than 5 minutes
130°F (54°C) at 20 seconds
140°F (60°C) at 3 seconds
150°F (66°C) at 1-1/2 seconds
160°F (71°C) at less than 1 second

Operating the Temperature Control System
Figure 7
Temperature Control
System
Water Temperature Adjustment
The water temperature can be adjusted from 80°F to 150°F. Use the temperature control knob to change to the
desired temperature.
Operating Mode Descriptions
1. Smart Mode - The controller operates the water heater to maintain the customer's selected temperature.
2. Energy Smart Mode - The controller adjusts the water temperature to lowest temperature required to meet the
household demands. This mode minimizes operating costs. The controller will not adjust temperature higher than
customer's selected set point or lower than 115°E
3. Low Temperature Mode - The controller limits the water temperature to 120°F or at the temperature selected
whichever is lower. See page 9 for more information on scalds.
4. Vacation/Cabin Mode - The controller adjusts the water temperature to approximately 50°F. This mode is
recommended when the water heater is not in use for a long period of time. This effectively turns the water heater
off and prevents the water from freezing.
Diagnostic Indicator Light Analysis
Light On - Indicates power applied and operating correctly.
Light Off - Indicates no power or a controller problem.
One Flash - Indicates the power was applied to water heater before the tank filled with water.
Two Flashes - Indicates the high limit temperature has been reached.
Three Flashes - Indicates a problem with the temperature sensors.
Four Flashes - Check upper element.
Five Flashes - Check lower element.
Reset Function
The reset function is used to restart the Temperature Control System after an error condition has been detected and
corrected.
Reset the control by pushing the red reset button on the controller. After a reset, the control performs self diagnostics
before normal operations begin. This takes approximately 10 minutes.
10

Operation Conditions
Anode Rod/Water Odor
Each water heater contains at least one anode rod,
which will slowly deplete while protecting the glass-lined
tank from corrosion and prolonging the life of the water
heater. Certain water conditions will cause a reaction
between this rod and the water. Once the anode is
depleted, the tank will start to corrode, eventually
developing a leak.
The most common complaint associated with the anode
rod is a "rotten egg smell" produced from the presence
of hydrogen sulfide gas dissolved in the water. Do not
remove this rod permanently as it will void any
warranties, stated or implied.
The parts list includes a special anode that can be
ordered if water odor or discoloration occurs. This rod
may reduce but not eliminate water odor problems. The
water supply system may require special filtration
equipment from a water conditioning company to
successfully eliminate all water odor problems.
Artificially softened water is exceedingly corrosive
because the process substitutes sodium ions for
magnesium and calcium ions. The use of a water
softener may decrease the life of the water heater tank.
The anode rod should be removed from the water
heater tank every 3 years for inspection. If the rod is
more than 50% depleted, the anode rod should be
replaced. (See "Replacing the Anode Rod" in the
maintenance section.)
Water Heater Sounds
During the normal operation of the water heater,
sounds or noises may be heard. These noises are
common and may result from the following:
1. Normal expansion and contraction of metal parts
during periods of heat-up and cool-down.
2. Sediment buildup in the tank bottom will create
varying amounts of noise and may cause
premature tank failure. Drain and flush the tank as
directed under "Draining and Flushing".
Stacking
Stacking occurs when a series of short draws of hot
water (3 gallons or less) are taken from the water
heater tank. This causes increased cycling of the heater
elements and can result in increased water
temperatures at the hot water outlet. An anti-scald
device is recommended in the hot water supply line to
reduce the risk of scald injury.
11

MAINTENANCE OF YOUR WATER HEATER
If you lack the necessary skills required to properly service this water heater or you have difficulty following the
instructions, you should not proceed but have a qualified person perform the maintenance of this water heater.
Draining and Flushing
It is recommended that the tank be drained and flushed
every 6 months to remove sediment which may buildup
during operation. To drain the tank perform the following
steps:
1. Turn off the power to water heater.
2. Close the cold water inlet valve and open a nearby
hot water faucet.
3. Connect a hose to the drain valve and terminate it
to an adequate drain.
Important: Drain hose should be rated for at least
200°R If the drain hose does not have this rating, open
the cold water inlet valve and open a nearby hot water
faucet until water is no longer hot.
4. Open the water heater drain valve and allow all the
water to drain from the tank. Flush the tank with
water as needed to remove sediment.
5. Close the drain valve and refill the tank until water
flows from the open hot water faucet. Allow water to
run for a couple of minutes to make sure all air is
out of tank.
6. Restart the water heater as directed under
"Operating Your Water Heater." If the water heater
is going to be shut down for an extended period,
the drain valve should be left open.
Replacing the Anode Rod
1. Turn off the power to the water heater.
2. Shut off the water supply and open a nearby hot
water faucet to depressurize the water tank.
3. Drain approximately 5 gallons of water from the
tank. (Refer to "Draining and Flushing" for proper
procedures.) Close drain valve.
4. Remove old anode rod.
5. Use Teflon_' tape or approved pipe sealant on
threads and install new anode rod.
6. Turn on water supply and open nearby hot water
faucet to purge air from water system.
7. Restart the water heater as directed under
"Operating Your Water Heater." See the "Repair
Parts Illustration" for anode rod location on
page 15.
Temperature and Pressure
Relief Valve
Explosion Hazard
If the temperature and pressure relief
valve is dripping or leaking, have a
licensed plumber repair it.
Do not plug valve.
Do not remove valve.
Failure to follow these instructions can
result in death or explosion.
Manually operate the temperature and pressure relief
valve at least once a year to make sure it is working
properly. To prevent water
damage, the valve must
be properly connected to
a discharge line which
terminates at an
adequate drain.
Standing clear of the
outlet (discharged water
may be hot), slowly lift
and release the lever
handle on the
Figure 8Temperature and Pressure
Relief Valve
i_Manual Relief
Discharge line to drain
temperature and pressure relief valve to allow the
valve to operate freely and return to its closed position.
If the valve fails to completely reset and continues to
release water, immediately shut off the electrical power
and the cold water inlet valve and call a qualified
service technician.
12

Heating Element
Replacement
Electrical Shock Hazard
_¢ isconnect power before
servicing.
Replace all parts and panels
before operating.
Failure to do so can result
in death or electrical shock.
Replacement heating elements must be of the same
style and voltage/wattage rating as the ones presently
in the water heater. This information can be found on
the flange or terminal block of the element or on the
water heater data plate.
1. Shut off the electric power to the water heater.
2. Drain the water heater as directed under "Draining
and Flushing".
3. Remove the access door(s), insulation and element
cover(s).
4. Disconnect the electric wires from the heating
element (Figure 9). Remove the screw-in elements
by turning the element counterclockwise with an
1-½ inch socket wrench. Remove the existing
gasket.
Figure 9
Etement Wiring
Connection
Ground /
Wire (green)
Screws
Element
5. Clean the area where the gasket fits to the tank. If
you are replacing the bottom element, remove the
accumulated sediment on the bottom of the tank.
Refer to "Draining and Flushing."
6. Make sure the replacement element has the correct
voltage and wattage rating. Position the new gasket
on the element and insert it into the water heater
tank (Figure 10). Tighten the element by turning it
clockwise until secure.
Figure 10 Temperature Sensor
SensorElementand Temperature BracketSens°r_ /1/1/1
Screw-in /t
Element /i
XSpud _._ /i
,__tlj,_
/1
Gasket ,4
.Close the drain valve. Open the nearest hot water
faucet and allow the tank to fill completely with
water. To purge the lines of any excess air and
sediment, keep the hot water faucet open for 3
minutes after a constant flow of water is obtained.
8. Check for leaks around the element(s).
9. Connect the electric wires to the heater element.
Make sure all wires are secure.
10. Replace the insulation and access door(s).
Important: Operation of this water heater without
access doors or insulation could result in much higher
temperatures than the desired set point, increasing the
risk of scald injury. Do not operate water heater with the
access doors or insulation removed.
11. Make certain the tank is filled with water.
12. Restore the electric power supply to the water
heater.
13

Diagnostic Code Chart
DIAGNOSTIC LIGHT INDICATES CORRECTIVE ACTION*
LIGHTON Normaloperation None
NOLIGHT Nopowertocontrolboardor diagnostic 1. Checkfor blownfusesortrippedbreaker
lightburnedout 2. Checkpowerleadsoncontrolboardwith meterfor 240volts
3. If powerisokay,replacecontrolboard
1 FLASH Poweronwith nowaterin tank 1. Addwaterandresettemperaturecontrolsystem.See"Reset
Function"onpage10
2FLASHES Watertemperatureexceededhighlimit 1. Makesureupperandloweraccessdoorsandinsulationare
properlyin place
2. Checkelementcircuitsfor resistanceof5- 25ohms
3. Replaceelementifnecessaryandresetcontrolsystem
3FLASHES Sensorfailure 1. Removepower
2. Checktemperaturesensorfor openor shortedcircuit
3. Ifnoproblemisfound,replacesensors
4FLASHES Upperelementcircuitfailure 1. Removepower
2. Checkelementcircuitfor resistanceof5- 25ohms
3. Checkwiresatelementandboardfordamage
4. Ifthis4flashesconditioncontinues,replacecontrolboard
5FLASHES Lowerelementcircuitfailure 1. Removepower
2. Checkelementcircuitfor resistanceof5- 25ohms
3. Checkwiresatelementandboardfordamage
4. Ifthis5flashesconditioncontinues,replacecontrolboard
*These instructions are brief and intended as guidance for a qualified service technician. If you lack the necessary
skills to perform these procedures call 1-877-817-6750 for assistance.
14
Troubleshooting Chart
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION
NO HOTWATER 1. Nopowerto heater 1. Referto"No Light"of DiagnosticCodeChart
2. Hightemperaturelimitshut-down 2. Referto"2 Flashes"of DiagnosticCodeChart
3. Defectivesensor 3. Referto"3 Flashes"of DiagnosticCodeChart
INSUFFICIENTHOTWATER
HIGHOPERATIONCOSTS
1. Defectivelowerelement
2. Temperaturesettoolow
3. Sedimentor limein tank
4. DefectiveDipTube
5. Heatertoosmallfor job
6. Wrongpipingconnections
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
1.
2.
3.
4.
5.
7. Leakingfaucets
8. Wastedhotwater
9. Longrunsof exposedpipe
10.Hotwaterpipingonoutsidewall
1. Temperaturesettoohigh
2. Sedimentor limein tank
3. Heatertoosmallforjob
4. Leakingfaucets
5. Wastedhotwater
6. Longrunsof exposedpiping 6.
7. Hotwaterpipingin exposedwall 7.
1. Upperelementdefective 1.
2. Leakingfaucets 2.
1. Excessivewaterpressure 1.
2. Closedsystem 2.
3. DefectiveT & Pvalve 3.
1. Sulfidesinthe water 1.
Referto"5 Flashes"of DiagnosticCodeChart
Settemperaturetodesiredsetting
Drain.Determineifwatertreatmentis needed
ReplaceDipTube
CheckandInstalladequatewaterheater
Correctpiping
Repairfaucets
Advisecustomer
Insulatepiping
Insulatepiping
Lowertemperaturecontrolor changeto EnergySaverMode
Drain.Flush-Providewatertreatmentif needed
Installadequateheater
Repairfaucets
Advisecustomer
Insulatepiping
Insulatepiping
SLOWHOTWATERRECOVERY Referto"4 Flashes"of DiagnosticCodeChart
Repairfaucets
DRIPFROMT&P VALVE Usepressurereducingvalveandpressurereliefvalve(Seepage
6)
Seepage6,"ClosedSystem/ThermalExpansion"
ReplaceT &Pvalve
WATERODOR Seepage11,"WaterOdor"

REPAIR PARTS ILLUSTRATION
ALTERNATE
T&P
LOCATION
J
®
®
©\
®
Repair Parts
Repair parts may be ordered through your plumber,
local distributor, home improvement center, or by calling
1-877-817-6750. When ordering repair parts always
give the following information:
1. Model, serial and product number
2. Item number
3. Parts description
Repair Parts List
Legend
• Special anode rod (See page 1!)
• Temperature and Pressure Relief Valve is required, but may not
be factory installed.
• Specify element type when ordering
ITEM PARTS DESCRIPTION
No.1 ACCESS DOORS
2 INSULATION PLUG
3 ELEMENT COVERS
4 LOWER ELEMENT•
5 UPPER ELEMENT •
6 ELEMENT GASKET
7 TEMPERATURE SENSOR
8 TEMPERATURE AND PRESSURE RELIEF VALVE •
9 HEAT TRAPS
10 DIP TUBE
11 ANODE ROD •
12 NIPPLE
13 DRAIN VALVE
14 JUNCTION BOX
© 2003 American Water Heater Company. All Rights Reserved. ® Registered trademark/TM Trademark of Whirlpool, U.S.A Printed in the U.S.A.
ENERGY SMART is a trademark of American Water Heater Company used under license.
15