Whirlpool ES50R92-45D, ES50R123-45D, ES40R92-45D, ES40R123-45D Owner’s Manual

WATER

HEATERS

Installation

Instructions and

Use & Care Guide

To obstain technical, warranty, or service assistance during or after the

installation of this water heater, visit our website at:

http://www.whirlpoolwaterheatersupport.com

or call tool free

1-877-817-6750

When calling for assistance, please have the following information ready:

1. Model Number 4. Date of Installation

2.7 Digit Product Number 5. Place of Purchase

3. Serial Number

Table Of Contents PAGE

Water Heater Safety ............................................................................ 2

Installing Your Electric Water Heater ................................................... 3-9

Unpacking Instructions ................................................................... 3

Location Requirements .................................................................. 4

Water System Piping ................................................................... 5

Electrical Requirements ................................................................. 7

Installation Checklist ...................................................................... 9

Operating Your Water Heater ............................................................. 10-12

Water Heater Start-Up ................................................................... 10

Water Temperature Regulation ...................................................... 10

Energy Smart _ Module/Operational Modes ................................... 11

Electronic Thermostat .................................................................... 12

Smart Grid Technology .................................................................. 13

Operational Conditions ................................................................... 14

Maintenance of Your Water Heater .................................................... 15-23

Diagnostic Code (ESM) .................................................................. 17-18

Diagnostic Code (ET) .................................................................... 19-20

Trouble Shooting Chart ..................................................................... 21

Repair Parts illustration ................................................................... 22

Thermostat Wiring Diagram ............................................................ 23

LOW LEAD

COMPLIANT

PRINTED IN THE U.S.A 0411 PART NO. 318686-000

WATER HEATER SAFETY

Your safety and the safety or 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 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

This is the safety alert symbol. "WARNING". These words mean:

DANGER: indicates an imminently hazardous situation which, if not avoided, will result in death or injury.

WARNING: indicates a potentially hazardous situation which, if not avoided, could result in death or injury.

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

IMPORTANT: 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 probably be an unusal 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 in the Act.

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, NFPA70. 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 elec- tric water heater and provide important safety information

in these areas.

We urge you to read all of the instructions thoroughly be- fore 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 instal-

lation 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 directions, you should not proceed but have a qualified person perform the installation of this water

heater.

Examples of a qualified personnel include:

licensed plumbers, authorized electric company person-

nel, and authorized service person.

Massachusetts code requires this water heater to be

installed in accordance with Massachusetts Plumbing and Fuel Code 248-CMR 2.00: State Plumbing Code and

248-CMR 5.00. A data plate identifying your water heater can be found

adjacent to the energy smart module. When referring to your water heater always have the information listed on the data plate readily available, to include the model and

serial number.

Retain your original receipt as proof of purchase.

Insulation Blankets

The use of an insulation blanket on this water heater is not needed nor recommended. The purpose of an insula-

tion blanket is to reduce the standby heat loss encoun- tered with storage tank heaters. Your water heater meets or exceeds the National Appliance Energy Conservation

Act standards with respect to insulation and standby loss

requirements, making an insulation blanket unnecessary.

Unpacking the Water Heater

Excessive Weight Hazard

Use two or more people to move and install

water heater.

Failure to do can result in back or other injury.

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 and understand 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. It must be installed indoors and in a vertical

position on a level surface, in an area where water leakage will not cause consequential damage.

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.

The water heater should be located in an area not subject to freezing temperatures. Water heaters located

in unconditioned spaces (i.e., attics, garages, base- ments, 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 opera- tion and service.

Keep combustibles such as boxes, magazines, clothes,

etc., away from the water heater area.

Do not use this water heater in conjunction with a spa or hot tub.

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. Also, any external plumbing leak, including those

from improper installation, may cause early failure of the water tank due to corrosion if not

repaired. If the homeowner is uncomfortable with making the repair, a qualified person should be

contacted. A suitable metal drain pan should be installed under the water heater as shown below. This

metal drain pan is to protect the property from damage which may occur from normal condensate formation

on the tank or leaks in the tank and pipe connections. The metal drain 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 or

seller of this water heater be held liable for any water damage that is caused by your failure to

follow these instructions.

NOTE: The water heater shall be located so it is not subject to physical damage by moving vehicles or area

flooding.

Figure 2 Residential Garage Installation

! I

Vehicle

Stop

Metal Drain Pan

Drain

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.

Figure 1

2 1/2" Max

Atleast2"inchesgreaterthan the diameter ofthewater

heater.

Pipeto

adequate

drain

Water System Piping

Piping Installation

Piping, fittings, and valves should be installedaccording to the installation drawing (Figure 3). If the indoor in-

stallation area is subject to freezing temperatures, the water piping must be protected by insulation.

Water supply pressure should be around 50 to 60 psi and should not exceed 80 psi. If this occurs, a pressure

reducing valve should be installed in the cold water inlet 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 com- pound and be certain that all fittings are drawn up tight.

1. Install the water piping and fitting as shown in Figure 3. Connect the cold water supply (3/4" NPT) to the fitting marked "Cold". Connect the hot water supply (3/4" NPT) to the fitting marked "Hot".

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 dielectric unions in both the hot and cold water supply lines is recommended for

ease of removing the water heater for service or replacement.

3. Some local codes may require, and the manufac- turer of this water heater recommends, installing a mixing valve in the domestic hot water line as shown in Figure 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 discharge line from the temperature and pressure relief valve 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.

Then open the cold water shut off valve 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 3 Water Piping Installation

HotWater U ValveWith Bypass 7

Outlet _ _

In a Closed System use a

_.f Thermal Expansion Tank.

Pressure Reducing

" +

. _:"IT"- II ColdWater II Water

umc _ _ _ InletValve Cold Water bupply

I[]1 t_ Fixtures

_ T e2 perea Ruerlee__/da,v e

Discharge line 6" maximum

1" LI_ %/ Drainline _

Min. I_ I 41-- _) _liP-. _4_,IrDum iM:t_aSla_haUSue_::relief

Metal Drain Pan

2-1/2" depth max.

Figure 4 tMixing Valve Mixed Water Top Water Connections To Fixtures

Follow The Mixing Valve

Manufacturer's Instructions

I I above drain

[ _::_ ,_'_ in cold water line per

,_ t_//Z_/,_2_4k..._ Drain section 19 MGL 142.

Unmixed

Mixing Valve

(Set To 120oF)

Supply to

Cold Water

_ Inlet

Please note the following:

DO NOT install this water heater with iron piping. The system should be installed only with piping that

is suitable for potable (drinkable) water such as copper, CPVC, or polyethylene (PEX).

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 tin-lead solder in potable water lines. Use 95/5 tin antimony or other equivalent material.

DO NOT tamper with the energy smart module, electronic thermostat, temperature sensors, heat- ing elements, electrical connections, or temperature

and pressure relief valve. Tampering voids all war- ranties. Only qualified person should service these

components. DO NOT use with piping that has been treated with

chromate's, 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

Typically, a closed system includes a pressure reducing valve (PRV) on the cold water inlet (supply line).As water

is heated, it expands (thermal expansion). In a closed sys- tem, the volume of water will grow. As the volume of water

grows, there will be a corresponding 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 tempera- ture-pressure relief valve is not intended for the constant

relief of thermal expansion. This condition is not covered under the limited warranty.

A properly-sized thermal expansion tank should be in- stalled on all closed systems to control the harmful effects of thermal expansion. Contact a plumbing service agency

or your retail supplier regarding the installation of a ther- mal expansion tank.

Expansion Tank Sizing Chart

Inlet

Water

Pressure

Expansion

Tank

Capacity

Needed

40psi

50psi

60psi

70psi 80psi

A thermal expansion tank can help prevent damage to the water heater and other appliances (i.e.: washing machine,

ice maker, dishwasher, etc.).

IMPORTANT: Do not plug or remove the temperature and

pressure relief valve (T&P valve).

Water Heater Capacity (Gallons)

30 40 50 66 82

2 2 2 5 5 2 2 2 5 5

2 2 5 5 5 2 2 5 5 5 2 5 5 5 5

Temperature and Pressure

Relief Valve

Explosion Hazard

• Temperature-pressure relief valve must comply with ANSI

Z21.22-CSA 4.4 and ASME code.

• Properly sized temperature- pressure relief valve must be

installed in opening provided.

• Can result in overheating and excessive tank pressure.

• Can cause serious injury or death.

Figure 5 Temperature and Pressure

Relief Valve Installation

F models only

Drain Pan

Optional location some

Temperature and

/_ Pressure Relief Valve

Ii,

Discharge Line

3/4inch min.Do not cap or plug.

6inch

maximum

' Drain "__)

For protection against excessive pressures and temperatures, a temperature and pressure relief valve must be installed inthe opening marked "T&P RELIEF VALVE" (See Figure 5). This valve must be design certi-

fied 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 for Hot Water Supply Systems, ANSI Z21.22. The function of the temperature and pressure relief valve is to discharge water in large quantities in the

event of excessive temperature or pressure develop- ing in the water heater. The valve's relief pressure must

not exceed the working pressure of the water heater as stated on the rating plate.

IMPORTANT: Only a new temperature and pressure relief valve should be used with your water heater. Do

not use an old or existing valve as it may be damaged or not adequate for the working pressure of the new water

heater. Do not place any valve between the relief valve and the tank.

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 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.

• Must terminate 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 termi- nated at an adequate drain inside the building.

• Must be capable of withstanding 250 ° F (121oC) without distortion.

• Must be installed to allow complete drainage of both the valve and discharge line.

T&P Relief Valve and Pipe Insulation"

6. Spread the slit open and slip the insulation over the cold water (inlet) pipe. Apply gentle pressure

along the length of the insulation to ensure it is fully seated around the pipe. Also ensure that the base of

insulation is flush with the water heater. Once seated, secure the insulation with duct tape, electrical tape, or equivalent.

7. Repeat steps 5 through 6 for the hot water (outlet) pipe.

8. Add additional sections of pipe insulation as needed.

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° F (48.8° C). A mixing valve or other temperature limiting valve must be installed in the water supply line to limit the supply temperature to 120° F (48.8° C).

Note: Solar water heating systems can often supply water with temperatures exceeding 180° F (82.2 ° C) and may

result in water heater malfunction.

1. Locate the temperature and pressure relief valve on the water heater (also known as a T&P Relief Valve, (Figure 6).

2. Locate the slit running the length of the insulation. 3 Spread this slit open and slip it up under the T&P

Relief Valve (See Figure 6). Apply gentle pressure to the insulation to ensure it isfully seated on the T&P Relief Valve. Once sealed, secure the insulation with a section of duct tape, electrical tape, or equivalent.

IMPORTANT: The insulation or tape must not block the discharge opening or hinder access to the manual relief lever. Ensure a discharge pipe is installed into the T&P valve discharge opening per the instructions

manual.

4. Locate the hot water (outlet) & cold water (inlet) pipes to the water heater.

5. Locate the slit running the length of a section of pipe insulation.

Figure 6 Temperature and Pressure

Relief Valve Installation

_ Lever

-_-- T&P Relief V_

T&P Relief Valve Drain Line

T&P Relief Valve Insulation

Electrical Requirements

Electric Shock Hazard

Disconnect power before

Replace all parts and panels

__ ervicing.

If you lackthe 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.

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.

• Wiringisenclosedinapprovedconduit(ifrequired bylocalcodes).

• Thewaterheaterandelectricalsupplyareproperly grounded.

Alwaysreferencethewiringdiagramforthecorrectelectri-

calconnection.Thecompletewiringdiagramcanalsobe

foundonthetopofthewaterheaternearthejunctionbox

cover. Wheninstallingtheelectricalwiringtothewaterheater

• Althoughthiswaterheaterisequippedwith"Dry-fire" protection,besurethetankiscompletelyfilledwith

water,andallairispurgedfromthetankbefore

makinganyelectricalconnections(SeeFigure7).

Figure 7 Heating Element

Figure 8

Wiring Diagram

_rtGrid |

Wir_

Harness

, _w/ , I_---o,_. ;

Water H eater _" i!r!_elnd inal

Figure 8A

Junction Box

i| Approved Breaker

Connectors /

........... d Power

Electrical Service ground

Junction Box Cover

Circuit

•, i To 240v ",, i 1 Phase

supply

NOTE: Applying electrical power to elements that are not submerged in water will destroy them. The manufacturer will not warranty any

elements damaged in this manner.

Check and turn off power to the electrical wiring of the water heater before making any electrical connections

to the water heater.

Remove the junction box cover that is secured by one screw (Figure 8A). Place the cover and screw aside

and view the wiring diagram. Locate the four power wires inside the junction box (there will be TWO red wires and TWO black wires).

Connect the electrical supply to the water heater in accordance with the local utility requirements and

codes. Astandard 1/2 inch opening has been made in the junction box for the conduit connections (Fig- ure 8A). NOTE: Use only 10 gauge solid copper wire

for the electrical connections and an appropriate size double pole circuit breaker.

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.

Ground the water heater by connecting the bare cop- per ground wire from the home's electrical service to the green ground screw (located on the electrical jun- ction box on top of the water heater). See Figures 8

and 8A.

There are TWO black wires and TWO red wires in the water heater. The smaller red and black wires are

used by the Smart Grid connector.

BlackWires

Figure 8B Electronic Thermostat (ET)

Energy Smart c_

Module (ESM)

Wiring Harness (Junction Box)

Wiring Harness

( ET to ESM )\

From Home

Electrical Service

RedWires

(3)

'2" Conduit

Connection

Electronic

Thermostat

Ground Wire

( Attached To T-Stat Bracket Screw )

+ 16 hidden pages