This manual covers model numbers:
United States
Canada
PGC* 34-130-2NV or 2PV
PGC* 50-130-2NV or 2PV
PGC* 34-150-2NV or 2PV
PGC* 50-175-3NV or 3PV
PGC* 50-199-3NV or 3PV
PGC* 100-199-3NV or 3PV
PC 130-34 2NV or 2PV
PC 130-50 2NV or 2PV
PC 150-34 2NV or 2PV
PC 175-50 3NV or 3PV
PC 199-50 3NV or 3PV
PC 199-100-3NV or 3PV
* Indicates warranty period
Note:
The manufacturer of this water heater recommends that it
be professionally installed by trained and qualified service
professionals.
Polaris®
Commercial Gas
Water Heater
Installation
Instructions and
Use & Care Guide
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
To obtain technical, warranty or service assistance during or
after the installation of this water heater, visit our website at:
http://www.americanwaterheater.com
WHAT TO DO IF YOU SMELL GAS
•
Do not try to light any appliance.
•
Do not touch any electrical switch;
do not use any telephone in your
building.
•
Immediately call your gas supplier
from a neighbor’s telephone. Follow
the gas supplier’s instructions.
•
If you cannot reach your gas
supplier, call the fire department.
Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.
call toll free
1-800-456-9805
When calling for assistance, please have the following
information ready:
1.
2.
3.
4.
5.
Model number
7 Digit product number
Serial number
Date of installation
Place of Purchase
Table of Contents .......................................................... 2
INSTALLER:
•
Affix these instructions to or adjacent to the water
heater.
OWNER:
•
Retain these instructions and warranty for future
reference. Retain the original receipt as proof of
purchase.
6510314
October 2004
1
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 Instructions
• Do not use this appliance if any part has been under water. Immediately call a qualified service technician.
Water heaters subjected to flood conditions or anytime the gas controls, main burner or ignition control have been
submerged in water require replacement of the entire water heater.
• Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally
two weeks or more). Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame. To
prevent the possibility of injury under these conditions, we recommend the hot water faucet be opened for several
minutes at the kitchen sink before using any electrical appliance which is connected to the hot water system. If
hydrogen is present, there will probably be an unusual sound such as air escaping through the faucet as water
begins to flow. Do not smoke or have any 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, carbon
monoxide, and soot.
Table of Contents
Page
Water Heater Safety ............................................................................ 1-2
Installation Instructions ...................................................................... 3-23
Unpacking the Water Heater ............................................................ 3
Location Requirements .................................................................. 4-5
Condensate Line ........................................................................... 5-6
Vent Pipe System ........................................................................ 6-15
130,000 & 150,000 BTU/Hr Vent Terminations ............................ 9-11
175,000+ BTU/Hr Vent Terminations ......................................... 12-14
Gas Input Rate ................................................................................ 15
Water System Piping ................................................................. 15-18
Gas Supply and Piping ............................................................. 19-20
Electrical Connections/Wiring Diagram ..................................... 21-22
Installation Checklist ....................................................................... 23
Operating Your Water Heater .......................................................... 24-26
Polaris® Operating Instructions ........................................................... 25
Maintenance of Your Water Heater ................................................. 26-27
Troubleshooting .................................................................................... 28
Software Operation Sequence ............................................................. 29
Parts List and Diagram .................................................................... 30-31
Polaris® Models and Dimensions ........................................................ 32
2
INSTALLATION INSTRUCTIONS
Consumer Information
Unpacking the Water Heater
OBSERVE ALL GOVERNING CODES AND ORDINANCES.
This water heater is design-certified by CSA International
as a Category IV, direct vented water heater which takes
its combustion air from the outside of the structure and
exhausts all products of combustion to the outside of the
structure.
Excessive Weight Hazard
Use two or more people to move and
install water heater unless proper
handling equipment is utilized.
Failure to do so can result in back or
other injury.
This water heater must be installed according to all local
and state codes or in the absence of local and state codes
with the “National Fuel Gas Code”, ANSI Z223.1(NFPA
54)- latest edition. Canadian installations must be performed in accordance with CAN/CGA-B149. This is available from the following:
CSA America, Inc.
8501 East Pleasant Valley Road
Cleveland, OH 44131
National Fire Protection Agency
1 Batterymarch Park
Quincy, MA 02169-7471
Canadian Standards Association
178 Rexdale Boulevard
Toronto, ON M9W 1R3
Check the phone listings for the local authorities having
jurisdiction over this installation.
Installer and Owner Responsibilities
Removing Packaging Materials
Important: Do not remove any permanent instructions,
labels, or the data plate from outside of the water heater or
on the inside of panels.
•
•
•
•
Remove exterior packaging and place installation
components aside.
Inspect all parts for damage prior to installation and
start-up.
Completely read all instructions before attempting to
assemble and install this product.
After installation, dispose of packaging material in the
proper manner.
This manual has been prepared to acquaint you with the
installation, operation, and maintenance of your gas water
heater and provide important safety information in these
areas.
Read all of the instructions thoroughly before attempting
the installation or operation of this water heater.
Do not discard this manual. You or future users of this
water heater will need it for future reference.
Service to the water heater should only be performed
by a qualified service technician.
Examples of qualified service technicians include:
those trained in the plumbing and heating industry,
local gas utility personnel, or an authorized service
person.
The manufacturer and seller of this water heater will
not be liable for any damages, injuries, or deaths
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
service technician 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 on
the front of the heater. 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.
3
•
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance. Storage of or
use of gasoline or other flammable vapors
or liquids in the vicinity of this or any other
appliance can result in serious injury or death
Consider the inlet and exhaust vent system piping
when selecting the water heater location. The venting
system must be able to run from the water heater to
the termination with a minimal length and number of
elbows. Input rates are reduced as vent system length
increases. The venting system must comply with the
requirements set forth in the venting section of this
manual.
• Locate the water heater near the existing gas piping.
If installing a new gas line, locate the water heater to
minimize the pipe length and elbows.
Important: 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.
Note: The water heater must be installed according to all
local and state codes or in absence of the local and state
codes with the “National Fuel Gas Code”, ANSI Z223.1
(NFPA 54)-latest edition. Canadian installations must be
performed in accordance with CAN/CGA-B149.
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.
A qualified service technician should be contacted
for repairs. A suitable metal drain pan should be
installed under the water heater as shown below, to help
protect the property from damage which may occur from
condensate formation or leaks in the piping connections
or tank. The pan must limit the water level to a maximum
depth of 1-3/4” and be at least two inches wider than
the heater and piped to an adequate drain. Locate the
water heater near a suitable indoor drain. Outside drains
are subject to freezing temperatures which can obstruct
the drain line. The piping should be at least 3/4” ID and
pitched for proper drainage. Under no circumstances will
the manufacturer or seller of this water heater be held
liable for any water damage which is caused by your
failure to follow these instructions.
Location Requirements
The water heater design has been tested by CSA
International and complies with ANSI Z21.10.1, Section
2.35 Flammable Vapors Resistance. In garage installation
avoid damage to your water heater by installing a vehicle
stop as shown in figure below. Check state and local
codes for requirements prior to installation.
Figure 1: Garage Installation
This water heater is not certified for installation in mobile
homes.
Note: In the State of California, 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 1-800-456-9805 and request instructions.
Site Location
•
4
Select a location near the center of the water piping
system. The water heater must be installed indoors
and in a vertical position on a level surface. DO NOT
install in bathrooms, bedrooms, or any occupied room
normally kept closed. Note: The water heater may be
installed in a closet with a door off a bedroom or bathroom providing the units are installed and vented per
the manufacturer’s instructions.
34/50 GAL. MODEL SHOWN
•
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 insulation of the water piping and drain piping
to protect against freezing. The drain and controls must
be easily accessible for operation and service. Maintain
proper clearances as specified on the data plate.
Clearances and Accessibility
Notice: Minimum clearances from combustible materials are stated on the data plate located on the front of the
water heater.
• The water heater is certified for installation on a
combustible floor.
Important: If installing over carpeting, the carpeting must
be protected by a metal or wood panel beneath the water
heater. The protective panel must extend beyond the full
width and depth of the water heater by at least 3 inches
(76.2mm) in any direction or if in a alcove or closet installation, the entire floor must be covered by the panel. The
panel must be strong enough to carry the weight of the
heater when full of water.
Figure 2 may be used as a reference guide to locate the
specific clearance locations. A minimum of 24 inches of
front clearance and 4 inches on each side should be provided for inspection and service.
Figure 2: Minimum Clearance Locations
CONDENSATE LINE
Important: Do not run the condensate drain in areas
that are likely to freeze. Frozen condensate will block the
drain line and result in property damage or water heater
malfunction.
Figure 3A: 2” Condensation Trap Installation
130,000 & 150,000 BTU/Hr Models
Figure 3B: 3” Condensation Trap Installation
130,000 - 199,000(50 gal.) BTU/Hr Models
Figure 3C: 3” Condensation Trap Installation
100 Gallon Models
Condensate Trap Assembly
A condensate trap/drain stem assembly has been supplied
with the water heater and is located behind the access door
inside the base of the water heater. This assembly must be
installed between the water heater and the exhaust outlet
piping to ensure proper operation of the water heater. To
install, remove the slip-joint nut, stainless steel washer, and
O-ring from the trap assembly. Slip the nut, washer and
O-ring (in that order) over the stainless exhaust tubing and
slide them back near the base of the heater. Insert the trap
assembly over the tubing (see figure 3A or 3B accordingly)
and firmly hand-tighten (using a wrench will cause the
O-ring to seal improperly) the nut to form a water-tight
seal between the O-ring and the stainless exhaust tubing.
When tightened, the nut to heater base clearance should
be 3/4” (+/- 1/8”). On 100 gallon models the condensate
trap assembly should be glued to the exhaust pipe (see
figure 3C).
Note: The trap should be aligned so that the exhaust pipe
is in a vertical position close to the surface of the water
heater.
5
Figure 4: Condensate Drain
Condensate Drain Line
All parts of the condensate trap are glued except for the
1/2” CPVC drain stem joint at the elbow (see figure 3). This
assembly can be turned with the outlet of the tee oriented
as needed.
Once orientation direction is decided, remove the unglued
joint from the elbow at the bottom and apply a suitable
cement to joint. Re-insert the joint fully and quickly into
the elbow making sure to orient it before the cement sets.
Connect the remaining piping and run the condensate drain
line to a suitable drain.
Important: Be sure the drain stem joint is inserted against
the stop in the elbow. Failure to do so may result in
improper water heater operation.
If required by local codes, install a condensate neutralizer
cartridge on the drain line (see figure 4).
The condensate drain line must be routed to a suitable
drain. If no floor drain is available or the drain is above
the level of the condensate line, install a condensate pump
that is resistant to the acidic condensate. These pumps are
available from local distributors. If the pump is not resistant
to acidic water, a condensate neutralizer must be used
ahead of the pump.
When installing the drain line, note the following:
• Plastic pipe or tubing must be used to connect the
condensate drain to a suitable drain or condensate
pump. Do not use copper tubing, iron, or steel pipe for
the condensate drain line.
• Condensate drain lines should be installed in conditioned areas only. Drain lines installed in areas that are
subject to freezing temperatures should be wrapped
with a nationally recognized/listed heat tape and/or
approved insulation for freeze protection. Install per
manufacturer’s instructions.
• Do not common drain with the temperature and pressure relief valve or the condensate line from an air
conditioner evaporator coil.
• Slope the condensate drain toward the inside floor
drain or condensate pump.
• The condensate drain line and connection to the drain
piping must comply with all local codes.
• Do not run the condensate line into the drain pan.
6
VENT PIPE SYSTEM
Carbon Monoxide Hazard
Follow all instructions to locate and install
the vent pipe system.
Instructions can be found in this manual,
in state or local codes (or the authority
having jurisdiction), or in the absence of
such, the “National Fuel Gas Code”, ANSI
Z223.1, NFPA 54, Latest Edition. Canadian
installations must be performed in
accordance with CAN/CGA-B149.
Failure to properly locate and install the
vent pipe system can result in death or
carbon monoxide poisoning.
Venting
This water heater has a direct vent system in which all air
for combustion is taken from the outside atmosphere and
all combustion products are discharged to the outdoors.
This water heater must be properly vented for removal
of exhaust gases to the outside atmosphere. Correct
installation of the vent pipe system is mandatory for the
safe and efficient operation of this water heater and is an
important factor in the life of the unit.
Vent pipe installation must be performed in accordance
with state and local codes, or in the absence of such, the
“National Fuel Gas Code”, NFPA 54, ANSI Z223.1-latest
edition. Canadian installations must be performed in
accordance with CAN/CGA-B149.
When replacing an existing Polaris unit, it is recommended
that the venting system be reviewed for compliance with
the requirements contained in this installation manual. If the
venting is not in compliance, it is recommended that the
appropriate changes be made to bring it into compliance.
If this is not practical, and the existing venting system
complies with a prior Polaris installation manual the venting
requirements as stated in the updated installation manual
do not have to be met: however, vent length in excess of
those referenced in the manual will result in reduced input.
Note: in either case it is important that the inlet air filter
supplied with this unit be installed in the inlet combustion
air piping. (Follow installation instructions supplied with the
filter kit). Note: if the vent system is not in compliance with
the current or prior installation manuals, the manufacturer
reserves the right to evaluate the installation prior to
granting any warranty on service claims.
Important: Check to make sure the vent pipe is not
blocked in any way.
Note: Do not common vent this water heater with any
other appliance. Do not install in the same chase or
chimney with a metal or high-temperature plastic from
another gas or fuel burning appliance.
Vent Pipe Material
The following plastic materials may be used for both the
combustion air inlet and exhaust outlet piping subject to
state and local codes:
• Schedule 40 PVC or ABS
• Schedule 40 or 80 CPVC
• DWV Pipe is acceptable
Note: Use only solid (not foam core) piping.
Plastic pipe and fittings are available through most plumbing suppliers. Always check the marking on the pipe to
make sure you are using the correct material.
Important: Do not use vent elbows in this vent pipe installation (see figure 5 below).
Figure 5: Correct and Incorrect Pipe Fittings
All pipe, fittings, pipe cement, primers and procedures
must conform to American National Standard Institute and
American Society for Testing and Materials (ANSI/ASTM)
standards in the United States. This water heater has been
design certified by the Canadian Standards Association for
use with the specified (CSA) listed plastic vent pipe.
All joints in the inlet and outlet piping must be properly
cemented. Size and cut all piping before cementing.
1. Cut the pipe end square and remove all ragged edges
and burrs. Make sure the inside of the pipe is clean
and free of cuttings and loose dirt. Chamfer the end
and apply primer to the fitting and pipe.
2. Using a suitable grade of pipe cement, apply a moderate, even coat inside the fitting. Apply a liberal amount
of cement to the outside of the pipe to socket depth.
Note: It is important to select the proper pipe cement for
the type of plastic pipe being used.
3. Assemble the parts quickly while the cement is
still wet. Twist the pipe 1/4 turn during insertion
and hold for 30 seconds.
Vent Pipe Length
Vent Pipe Installation
The following guidelines should be followed when installing
the air inlet and exhaust outlet piping:
•
Venting should be as direct as possible with a minimum
number of pipe fittings.
• Vent diameter must not be reduced unless specifically
noted in the installation instructions.
• All 2” horizontal vent piping must be sloped upward
1/4 inch per foot (3” Piping must slope upward at 1/8”
per foot) so that condensate will run back to the heater
and exit through the condensate trap.
• Support all horizontal pipe runs every four feet and
all vertical pipe runs every six feet or according to
local codes.
• Vents run through unconditioned spaces where below
freezing temperatures are expected should be properly
insulated to prevent freezing. For horizontal runs, wrap
the vent pipe with nationally recognized/listed heat tape
and/or approved insulation for freeze protection. Install
per the manufacturer’s instructions.
• An air intake filter is included with the unit and must be
installed according to the installation instructions
supplied with the filter.
The combustion air inlet and exhaust outlet piping and
termination may be installed in one of the following type
terminations:
1.
2.
3.
4.
5.
Size the exhaust outlet and combustion air inlet pipes as
specified in Table 1. This table lists the maximum allowable length in feet of the exhaust outlet and combustion air
inlet pipes as related to the number of required elbows and
the termination. The specified maximum lengths are for
the separate inlet and exhaust pipe systems and not the
combined length of both systems. Minimum pipe length is
6 feet with one elbow per side.
1. Determine termination type and pipe size.
2. Determine number of elbows in exhaust pipe. Do not
include the elbows in the termination or the condensate
trap. Corresponding number indicates the maximum
length of exhaust pipe.
3. Determine number of elbows in inlet pipe. Do not
include the elbows in the termination. The corresponding number indicates the maximum length of inlet pipe.
Standard Horizontal (2 Pipe)
Alternate Horizontal (2 Pipe)
Vertical (2 Pipe)
Concentric Vent - Through the Wall
Concentric Vent - Through the Roof
7
Vent Termination Locations
The air inlet and exhaust outlet must be installed with the
following minimum clearances (see figure 6):
•
Twelve inches above grade or maximum anticipated
snow level.
• Twelve inches from any opening through which flue
gases could enter the structure.
• Four feet horizontally and vertically from gas or electric
meters, gas regulators, dryer vents, vent hoods, bathroom fan exhaust, attic fans and turbines.
• Two feet from an inside corner formed by two exterior
walls.
• Two feet from porches, decks, overhangs and other
obstructions.
In addition to maintaining the minimum clearances , the
vent should terminate according to the following guidelines:
1. Use only 2 inch pipe or a 2 inch concentric vent on
the vent termination for 130,000 & 150,000 BTU/Hr
models. For inputs of 175,000 BTU/Hr or more, use
only 3 inch pipe or a 3 inch concentric vent. Do not
expose any 3” X 2” reducers or bushings to outdoor ambient temperatures.
2. The air inlet and exhaust outlet must not terminate
under a patio, deck or any covered area.
3. Do not terminate the vent near walkways or into alleys
or other publicly accessible areas.
4. Do not terminate the vent in an area where children
or animals could block pipes.
5. Do not locate the vent terminal too close to shrubs or
bushes.
6. Caulk all cracks, seams and joints within 6 feet horizontally above and below the vent.
7. Combustion air inlet termination and exhaust air termination must be located in the same pressure zone.
Figure 6: Minimum Clearances for Inlet/Outlet and Concentric Vent
US Installations
A. 12 in (30 cm) min. clearance above grade,
veranda, porch, deck, balcony, or maximum
anticipated snow level.
B. 12 in (30 cm) min. clearance on top and side of
window or door that may be opened. Do not install
below a window or door that may be opened.
C. Clearance to permanently closed window.**
D. 12 in (30 cm) min vertical clearance to ventilated
soffit located above the terminal within a horizontal
distance of 2 ft (61 cm) from the center line of the
terminal.
E. 12 in (30 cm) min. clearance to unventilated soffit.
F. Clearance to outside corner **
G. 2 ft (61 cm) clearance to inside corner formed by
two exterior walls.
H. 4 ft (122 cm) clearance to each side of center line
extending above meter/regulator assembly.
I. 4 ft (122 cm) clearance to service regulator vent
outlet.
J. 12 in (30 cm) clearance to nonmechanical air
supply inlet to building or the combustion air inlet
to any other appliance.
K. 3 ft (91 cm) above if within 10 ft (3 m) horizontally of
mechanical air supply inlet.
Canadian Installations
A. 12 in (30 cm) min. clearance above grade,
veranda, porch, deck, balcony, or maximum
anticipated snow level.
B. 12 in (30 cm) min. clearance on top and side of
window or door that may be opened. Do not install
below a window or door that may be opened.
C. Clearance to permanently closed window.**
D. 12 in (30 cm) min vertical clearance to ventilated
soffit located above the terminal within a horizontal
distance of 2 ft (61 cm) from the center line of the
terminal.
E. 12 in (30 cm) min. clearance to unventilated soffit.
F. Clearance to outside corner.**
G. 2 ft (61 cm) clearance to inside corner formed by
two exterior walls.
H. 3 ft (91 cm) within a height 15 ft (4.57 m) above the
meter/regulator assembly.
I. 4 ft (122 cm) clearance to service regulator vent outlet.
J. 12 in (30 cm) clearance to nonmechanical air
supply inlet to building or the combustion air inlet to
any other appliance.
K. 6 ft (1.83 m) clearance to mechanical air supply inlet.
**Clearance in accordance with local installation codes and the requirements of the gas supplier.
8
INLET/OUTLET VENT TERMINATIONS (130,000 &150,000 BTU/HR)
Standard Horizontal Termination
Alternative Horizontal Termination
When 3 inch pipe is used between the water heater and the
outside wall, reduce it to 2 inch pipe before penetrating the
wall. A maximum of 18 inches of 2 inch pipe may be used
between the 3 inch transition and the inside of the wall (see
figure 7A).
The standard horizontal air inlet termination is a 2 inch
pipe which terminates at the exterior wall and utilizes a
coupling to prevent the pipe from being pushed back into the
structure. The standard horizontal exhaust outlet termination
is a 2 inch pipe which terminates 12 inches from the outside
wall. The air inlet must be located with respect to the exhaust
outlet as shown in figure 7A (bottom).
Install a drain tee assembly and trap in the inlet vent as
close to the water heater as possible. This is to drain any
water that may be in the combustion air pipe and prevent
it from entering the blower. Connect the trap drain line to a
suitable drain or downstream of the condensate trap of the
water heater.
Note: See “Venting Additional Polaris® Units” on Page 10
for correct terminations if installing more than one Polaris®
gas water heater.
The combustion air and exhaust terminations may be raised
up to 24 inches above the wall penetrations if required for
anticipated snow levels (see figure 8A). The two elbows
shown in figure 8A are considered part of the termination
and should not be included when determining the maximum
allowable vent pipe length.
Note: See “Venting Additional Polaris® Units” on Page 10
for correct terminations if installing more than one Polaris®
gas water heater.
Figure 8A: Alternate Horizontal Termination
(130,000 & 150,000 BTU/Hr Input Models)
Figure 7A: Standard Horizontal Termination (130,000 & 150,000 BTU/Hr Models)
9
VERTICAL TERMINATIONS (130,000 & 150,000 BTU/HR)
When 3 inch pipe is used between the water heater and the
roof, reduce it to 2 inch pipe before penetrating the roof. A
maximum of 18 inches of 2 inch pipe may be used between
the 3 inch transition and the inside of the roof.
The vertical inlet air termination requires a return bend
or two short or long sweep radius 90 elbows to keep the
inlet downward and prevent entry of rain. These elbows
are considered part of the termination and should not be
included when calculating the maximum allowable vent
pipe length. Refer to figure 9A for the proper location of the
air inlet with respect to the exhaust outlet termination. The
vertical exhaust outlet termination is a 2 inch pipe which
terminates at least 12 inches above the inlet air termination.
The air inlet and exhaust outlet terminations must be at
least 12 inches above the roof line or anticipated snow
levels. See figure 9A below.
Note: See “Venting Additional Polaris® Units” below if
installing more than one Polaris® gas water heater.
Figure 9A: Vertical Termination (130,000 & 150,000 BTU/Hr Models)
Venting Additional Polaris® Units
(130,000 & 150,000 BTU/hr Models)
When using two Polaris® units, install vent terminations
using either Method A or Method B below:
10
When using three or more Polaris® units, install vent
terminations per Method C or Method D:
CONCENTRIC VENT TERMINATIONS (130,000 & 150,000 BTU/HR)
For new installations, install 2” Concentric vent kit
model KGAVT0501CVT, part number 6910542. See
Manufacturer’s instructions for complete installation or call
customer service at 1-800-456-9805 for assistance.
For planning purposes, see figures 10A-13A below for vent
terminal specifications.
Note: For replacement installations, previously installed
American Water Heater Company supplied concentric vent
kits are acceptable for use on 130,000 BTU/Hr models only.
Figure 13A: Through the Wall Termination
Figure 10A: 2 Inch Concentric Vent
Figure 11A: Through the Wall Termination
Note: For concentric venting terminations (all models), see
“Concentric Venting Multiple Water Heaters” on Page 14.
Figure 12A: Through the Roof Termination
11
INLET/OUTLET VENT TERMINATIONS (175,000+ BTU/HR)
Standard Horizontal Termination
Alternative Horizontal Termination
The standard horizontal air inlet termination is a 3 inch
pipe which terminates at the exterior wall and utilizes a
coupling to prevent the pipe from being pushed back into
the structure. The standard horizontal exhaust outlet termination is a 3 inch pipe which terminates 12 inches from the
outside wall. The air inlet must be located with respect to
the exhaust outlet as shown in figure 7B (bottom).
The combustion air and exhaust terminations may be
raised up to 24 inches above the wall penetrations if
required for anticipated snow levels (see figure 8B). The
two elbows shown in figure 8B are considered part of the
termination and should not be included when determining
the maximum allowable vent pipe length.
Install a 3 inch coupling at the outside wall on both the inlet
and exhaust to prevent the terminations from being pushed
inward.
Install a drain tee assembly and trap in the inlet vent as
close to the water heater as possible. This is to drain any
water that may be in the combustion air pipe and prevent it
from entering the blower. Connect the trap drain line to a
suitable drain or downstream of the condensate trap of the
water heater.
Note: See “Venting Additional Polaris® Units” on Page 13
for correct terminations if installing more than one Polaris®
gas water heater.
Figure 8B: Alternative Horizontal Termination
(175,000+ BTU/Hr or greater input models)
Note: See “Venting Additional Polaris® Units” on Page 13
for correct terminations if installing more than one Polaris®
gas water heater.
Figure 7B: Standard Horizontal Termination (175,000+ BTU/Hr models)
12
VERTICAL TERMINATIONS (175,000+ BTU/HR)
For inputs of 175,000 BTU/Hr or greater, all termination piping and fittings are 3”. Do not reduce before penetrating
the wall.
The vertical inlet air termination requires a return bend or
two short or long sweep radius 90° elbows to keep the inlet
downward and prevent entry of rain. These elbows are considered part of the termination and should not be included
when calculating the maximum allowable vent pipe length.
Refer to figure 9B for the proper location of the air inlet
with respect to the exhaust outlet termination. The vertical
exhaust outlet termination is a 3 inch pipe which terminates
at least 12 inches above the inlet air termination.
The air inlet and exhaust outlet terminations must be at
least 12 inches above the roof line or anticipated snow
levels as shown in figure 9B below.
Note: See “Venting Additional Polaris Units” below if
installing more than one Polaris gas water heater.
®
®
Figure 9B: Vertical Termination (175,000+ BTU/Hr models)
Venting Additional Polaris® Units
(175,000+ BTU/Hr Models)
When using three or more Polaris® units, install vent
terminations per Method C or Method D:
When using two Polaris® units, install vent terminations
using either Method A or Method B below:
13
CONCENTRIC VENT TERMINATIONS (175,000 + BTU/HR)
For new installations, install 3” Concentric vent kit
model KGAVT0601CVT, part number 6910543. See
Manufacturer’s instructions for complete installation or call
customer service at 1-800-456-9805 for assistance.
Figure 13B: Concentric Vent Piping Installation
For planning purposes, see figures 10B-13B below for vent
terminal specifications.
Figure 10B: 3 Inch Concentric Vent
Figure 11B: Through the Wall Termination
Note: For concentric venting terminations (all models), see
“Concentric Venting Multiple Water Heaters” on Page 14.
Concentric Venting Multiple Water
Heaters (All Models)
Figure 12B: Through the Roof Termination
When using two Polaris® units, install vent terminations
using either Method E or Method F below:
Note: For installation of more than two Polaris® units, follow the pattern established in Method G.
14
Gas Input Rate
Figure 14: Input Graph
The gas input rate of this water heater is affected by
several environmental factors such as:
•
•
The heating value of the gas
The air and gas densities (which vary widely due to barometric pressure and temperature changes)
• Venting installations (pipe diameter, length and fittings)
• Altitude
When measuring the input rate these factors should be
incorporated into the calculations. Also measure the gas
consumption over a sufficiently long time to obtain an
accurate gas consumption rate (e.g. 3-5 minutes, not one
revolution of the meter needle).
Long vents and each additional elbow, inherently reduce
the gas input rate due to increased resistance to moving
combustion air and flue gases. The approximate maximum/
minimum input for the 130k, 150k, 175k, and the 199k
models is shown in figure 14.
WATER PIPING SYSTEM
Piping Installation
Piping, fittings, and valves should be installed according to
the installation drawing (figure 15). 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 reducing valve with a bypass should be installed
in the cold water inlet line to the entire system. This should
be placed on the supply to the entire structure 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: Do not install this water heater with iron or
galvanized piping. Use brass caps on all unused inlet/
outlet connections.
1. Install the water piping and fittings as shown in figure
15. Note: If state or local codes require, install a vacuum relief valve per the manufactures instructions in the
cold water supply line. Connect the cold water supply
(50 gal. and below use 1” NPT, 100 gal. use 1-1/2”
NPT) to the fitting marked “COLD INLET”. Do not turn
the cold water nipple. The mark should remain along
the top side of the nipple (34 & 50 gal. models only.)
Connect the hot water supply (50 gal. and below use
1” NPT, 100 gal. use 1-1/2” NPT) to the fitting marked
“HOT OUTLET”.
2. Always use a suitable grade of joint compound and be
certain that all fittings are tightened properly.
3. 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.
4. Since most commercial installations utilize higher
temperatures, the use of a tempering valve is strongly
recommended in all domestic hot water lines (i.e. public
restroom sinks, etc).
5. If installing the water heater in a closed water system,
install an expansion tank in the cold water line as speci-
fied under “Closed System/Thermal Expansion” (Page
16).
6. 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.
7. The Polaris gas water heater is shipped with a factory-installed Temperature and Pressure Relief Valve.
Install a discharge line in the opening in the T & P valve
(see instructions on Page 18).
8. After piping has been properly connected to the water
heater, remove the aerator at the nearest hot water
faucet. Open the hot water faucet and allow the tank
to completely fill with water. (To prevent damage to
the unit, DO NOT connect power until the tank is
COMPLETELY FILLED). To purge the lines of any
excess air, 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.
®
Corrosion and Water Quality
Water quality will vary from location to location and may
contain contaminates that may reduce the life or performance of the water heater. To test for contaminates a
water quality test kit is available, reference part number
6903791.
Contaminates which can reduce the life or performance
of the water heater if present in high quantities include
those which contribute to hardness (dissolved minerals
such as sodium, calcium and magnesium); plus chlorides
and sulfates. Additionally, water that is too acidic or basic
(measured as pH) can reduce the life of the water heater.
Water treatment systems (such as water softeners for
hardness) should be used and maintained properly if the
contaminate levels exceed the following:
Warranty is void in applications which exceed the
water quality requirements listed below.
Total Hardness:
12 grains per gal. (205 mg/liter) max.
Chloride:
200 mg/liter max.
pH:
6.5-8.0
Alkalinity:
200 mg/liter max.
15
Figure 15: Typical One-Temperature System Piping Installation
Tempering Valve Installation
Closed System/Thermal Expansion
A Tempering Valve should be installed, per the manufacturer’s instructions, in the hot water line. See Figure 16
(above) for sample tempering valve installation.
Most commercial installations require a check valve or
backflow prevention to be installed in the main water supply line. When a backflow prevention device or check
valve is installed, it can create a “Closed System.” Heating
water in a closed system causes normal thermal expansion and increases pressure in the water system. When
this pressure reaches 150 psi, it triggers the safety system in the T & P Relief Valve. This can result in the relief
valve releasing water during every cycle. The rapid and
repeated expansion and contraction of the water heater
components and the system piping can cause premature
failure of the relief valve, as well as the water heater itself.
Replacing the relief valve will not correct the problem.
If the water heater is installed in a closed water supply system, such as one having a backflow preventer in the cold
water supply line, means shall be provided to control thermal expansion. Contact the water supplier or local plumbing inspector on how to control this situation.
A properly sized expansion tank must be installed to prevent the water pressure from building to such a level in a
Closed System. The manufacturer of this water heater
will void the warranty if there is a failure to install a
properly sized expansion tank.
General Information
Water piping, fittings, and valves must be properly installed
for the correct and safe operation of this water heater.
Please note the following:
• The system should be installed only with piping that is
suitable for potable (drinking) water such as copper,
CPVC, or polybutylene. PVC water piping may be used
on the cold water inlet supply but not within 18 inches
of the cold water connection on the water heater.
• Do not use PVC piping on the hot water outlet,
space heating supply, or space heating return.
• 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 solder or
other equivalent material.
• Do not tamper with the thermostat, gas valve,
blower, electrical components, or temperature and
pressure relief valve. Tampering with any of the
components is dangerous and can result in death,
severe injury, or property damage. Tampering voids
all warranties. Only qualified technicians should
service these components.
• Do not use this water heater as a replacement for an
existing boiler installation.
• 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.
• Do not install check valves in the cold water supply
line to the water heater.
16
Combination Space Heating/Potable
Water System
Some water heater models are equipped with inlet/outlet
connections for use in space heating applications. If this
water heater is to be used to supply both space heating
and potable (drinking) water, the instructions listed below
must be followed (see figure 17).
• Be sure to follow the manual(s) shipped with the air
handler or other type heating system.
• This water heater is not to be used as a replacement
for an existing boiler installation.
• Do not use with piping that has been treated with chro-
Figure 17: Air Handler Piping Installation
Massachusetts code does not
allow this type of installation.
•
•
•
•
•
mates, boiler seal or other chemicals and do not add
any chemicals to the water heater piping.
If the space heating system requires water temperatures in excess of 120°F, a tempering valve should
be installed per the manufacturer’s instructions in the
potable hot water supply to limit the risk of scald injury.
Pumps, valves, piping and fittings must be compatible
with potable water.
A properly installed flow control valve is required to prevent thermosiphoning. Thermosiphoning is the result
of a continuous flow of water through the air handler
circuit during the off cycle. Weeping (blow off) of the
temperature and pressure relief valve (T & P) or higher
than normal water temperatures are the first signs of
thermosiphoning.
The hot water line from the water heater should be
vertical past any tempering valve or supply line to
the heating system to remove air bubbles from the
system.
Do not connect the water heater to any system or
components previously used with non-potable water
heating appliances when used to supply potable water.
Storage Tank Installation
When installing the Polaris® with a storage tank, see figure
18 for piping suggestions.
Piping Diagrams
See enclosed insert for additional piping diagrams.
Booster Water Heater Applications
When the Polaris® is installed as a booster water heater in
a dishwashing system, with or without a 180° recirculation
line, a water hammer arrester must be installed between
the hot water outlet of the booster water heater and the
supply line to the dishwasher (see “Polaris Commercial
Installation Plumbing Guide” for precise installation location).
17
Notes on Figure 18:
If tank temperature is set above
120°F and water is supplied for
domestic use (hand washing, showering, etc.) a tempering valve should
be installed in the hot water line to
domestic fixtures.
Installation must conform to local
code requirements. If a check valve
is installed in the cold water supply line, an expansion tank must be
installed between the check valve
and the water heater’s cold water
inlet. Set storage tank temperature
five degrees lower than the water
heater’s temperature setting. Using
the plug cock in the recirculating
line, adjust the flow in the recirculating line to five gallons per minute.
For additional information, see
“Polaris Commercial Installation
Plumbing Guide” provided with this
manual or call Customer Service at
1-800-456-9805.
Figure 18: Polaris with Auxillary Storage Tank - One or Two
Temperature System (With or Without Building Recirculation)
Temperature and Pressure
Relief Valve
Important: Only a new temperature and pressure relief
valve should be used with this 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 or piping between the relief valve and
the tank.
The Temperature & Pressure Relief Valve:
•
•
•
Must not be in contact with any electrical part.
Must be connected to an adequate discharge line.
Must not be rated higher than the working pressure
shown on the data plate of the water heater.
• The BTUH rating of the T & P valve must be greater
than, or equal to, the input rating of the water heater
The Discharge Line:
Explosion Hazard
If the temperature and pressure relief valve
is dripping or leaking, have a qualified
service technician replace it.
• Do not plug valve.
• Do not remove valve.
Failure to follow these instructions can
result in death or explosion.
For protection against excessive pressures and temperatures, a temperature and pressure relief valve must be
installed in the opening marked “T & P RELIEF VALVE”.
This valve must be design 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 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 developing in the water heater. The valve’s relief pressure must not exceed the working
pressure of the water heater as stated on the data plate.
18
•
•
•
•
•
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 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.
GAS SUPPLY AND PIPING
Figure 19: Gas Piping Installation
Explosion Hazard
Use a new AGA or CSA approved gas
supply line.
Install a shut-off valve.
Do not connect a natural gas water
heater to a L.P. Gas Supply.
Do not connect an L.P. gas water heater
to a Natural Gas Supply.
Failure to follow these instructions can
result in death, explosion, or carbon
monoxide poisoning.
34/50 GAL. MODEL SHOWN
Gas Pressure
Important: The gas supply pressure must not exceed the
maximum supply pressure as stated on the water heater’s
data plate. Minimum supply pressure should also be
maintained per the data plate.
Gas Requirements
Read the data plate to be sure the water heater is made
for the type of gas being used. This information will be
found on the data plate located on the front of the water
heater. If the information does not agree with the type of
gas available, do not install or operate the water heater.
Call your dealer.
Note: An odorant may be added by the gas supplier to
the gas used by this water heater. This odorant may fade
over an extended period of time. Do not depend upon this
odorant as an indication of leaking gas.
Gas Piping
The gas piping must be installed according to all local and
state codes or in absence of local and state codes with
the “National Fuel Gas Code”, ANSI Z223.1 (NFPA 54)latest edition. Canadian installations must be performed in
accordance with CAN/CGA-B149. Note: If using a flexible
gas connector, make sure its rating tag matches or exceeds
the input of the water heater.
Tables 2, 3A, and 3B on page 20 are provided as a sizing
reference for commonly used gas pipe materials. Consult
the “National Fuel Gas Code” for the recommended gas
pipe size of other materials. Follow the instructions below
and reference figure 19 for gas piping installation.
1. Install a readily accessible manual shut-off valve in the
gas supply line as recommended by the local utility.
Know the location of this valve and how to turn off the
gas to this unit. Note: DO NOT pipe across clean-out
port (100 gal. only.)
2. Install a drip leg as shown. The drip leg must be no
less than 3 inches long for the accumulation of dirt,
foreign material and water droplets.
3. Install a ground joint union between the water heater
and the manual shut-off valve. This is to allow easy
servicing.
4. Turn the gas supply on and check for leaks. Use a
chloride-free soap and water solution (bubbles forming
indicate a leak) or other approved method.
Note: Units with BTU/Hr inputs of 175,000 and above must
have a minimum of 3/4” NPT gas pipe supplied to the water
heater.
19
Gas Pressure Testing
Important: This water heater and its gas connection must
be leak tested before placing the appliance in operation.
• If the code requires the gas lines to be tested at
a pressure of 14” W.C. or greater, the water heater
and its manual shut-off valve must be disconnected
from the gas supply piping system and the line
capped.
• If the gas lines are to be tested at a pressure less
than 14” W.C., the water heater must be isolated
from the gas supply piping system by closing its
manual shut-off valve.
Nationally listed/recognized fuel gas and carbon
monoxide(CO) detectors are recommended in
all applications and should be installed using the
manufacturer’s instructions and local codes, rules, or
regulations.
Note: Air may be present in the gas lines and could prevent
the burner from lighting on initial start-up. The gas lines
should be purged of air by a qualified service technician
after installation of the gas piping system.
20
Explosion Hazard
Have a qualified person make sure L.P.
gas pressure does not exceed 13” water
column.
Examples of a qualified person include
licensed heating personnel, authorized
gas company personnel, and authorized
service personnel.
Failure to do so can result in death,
explosion, or fire.
ELECTRICAL CONNECTIONS
Electrical Shock Hazard
Disconnect power before
servicing.
Replace all parts and panels
before operating.
Failure to do so can result in
death 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 voltage and frequency correspond to that specified
on the water heater data plate on the front of the water
heater.
The electrical supply has the proper overload fuse
or breaker protection. The heater draws less than 7
amps.
Wire sizes and connections comply with all applicable
codes.
Wiring enclosed in approved conduit (if required by local codes).
The water heater and electrical supply are properly
grounded.
This water heater must be “hard-wired” - do not use an
extension cord to supply electrical power to this water
heater.
4. Connect this circuit (directly from the electrical service
box) to an electrical disconnect switch.
5. Ground the water heater by connecting the electrical
service ground wire to the green ground wire (provided).
Note: The power supply to this water heater must be
properly polarized, [120 volts from the hot lead (black) to
ground and 0 volts from the neutral lead (white) to ground]
otherwise, the unit will not operate.
6. After making all electrical connections, completely fill
the tank with water and check all connections for leaks.
Open the nearest hot water faucet and let it run for 3
minutes to purge the water lines of air and sediment
and to ensure complete filling of the tank. The electrical power may then be turned on. See figure 20 for
completed installation.
Figure 20A: Electrical Connections (34/50 Gal.)
Note:
The wiring diagram can be found on page 22. Always
reference the wiring diagram(s) for the correct electrical
connections.
When installing the electrical wiring to the water heater:
Figure 20B: Electrical Connections (100 Gal.)
1. Shut off the power at the electrical service box.
2. Loosen the screws securing the access panel to
the electrical compartment. (The electrical wiring
diagram for 34 & 50 gal. models can be found on the
inside of the access panel at the base of the water
heater. For 100 gal. models the wiring diagram is
located in the electrical compartment on the front of the
water heater.) Set the access panel aside.
3. Connect the electrical supply to the water heater in
accordance with local utility requirements and codes.
Use only a dedicated electrical circuit containing a
properly sized fuse or circuit breaker. Maximum overload protection should not exceed 15 amperes.
21
WIRING DIAGRAM
TO 120/60
POWER SUPPLY
FUSED
DISCONNECT
WHITE
GND
WHITE
GREEN
GREEN
GND
BLOWER
BLACK
BLUE
RED
RED
NEUTRAL
L1
BLOWER
BLACK
120V
24V
BLUE
RED
TRANSFORMER
MODELS 130,000 BTU/Hr
BROWN
GND
IND
GROUND
L2
NEUTRAL (WHITE)
GREEN
TO 120/60
POWER
SUPPLY
GREEN
RED
THERMOSTAT
SENSOR/ECO
BLACK
BLACK
120 VAC
120 VAC
(BLACK & WHITE
WIRES IN BOLD)
IND
L1
HSI
WHITE
YELLOW
THERMOSTAT
BOARD
W
PSI
SEN-1
RED
LOWER
24V
IGNITION
CONTROL
PRESSURE
SWITCH
120V/60Hz
GREEN
ONLY
WHITE
COMMON (C)
YELLOW LED
BLUE
ORANGE
NOTICE: IF ANY OF THE ORIGINAL WIRE
AS SUPPLIED WITH THE APPLIANCE
MUST BE REPLACED, IT MUST BE
REPLACED WITH 18 GAUGE STRANDED
105C WIRE OR ITS EQUIVALENT.
MODELS 150,000 BTU/Hr & Above
THERMOSTAT
SENSOR-ECO
N.O.
GND
NORMALLY OPEN
(NO)
ORANGE
W
PRESSURE
SWITCH
YELLOW
22
GAS VALVE
RELAY
IGNITION GV
CONTROL
RELAY
NO
THERMOSTAT
DIAL
C
PSO
FSG
C
HOT
COM
GREEN LED
PSI
GV
PSO
GREEN
YELLOW
LED
24 VAC
HSIG
L2
POT
RED
IGNITER
HSIG
BLACK
IGNITER
BROWN
RED
LED
GREEN
LED
HSI
IGNITION
CONTROL
L1 (BLACK)
FUSED
DISCONNECTED
GAS VALVE
YELLOW
L1
COM
RED LED
SEN-1
LOWER
THERMOSTAT
BOARD 24 V
HOT
ONLY
POT
THERMOSTAT
DIAL
GND
INSTALLATION CHECKLIST
Water Heater Location
Requirements
… 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 carpeted floor.
Sufficient room to service the water heater.
… Provisions made to protect the area from water damage. Properly sized drain pan installed and piped to an
adequate drain.
… Installation area free of corrosive elements and
flammable materials.
Condensate Line
… Drain stem is fully inserted in the elbow and glued
properly.
… Trap aligned so that the exhaust pipe is in a vertical
position close to the surface of the water heater.
… Line properly sloped to adequate drain or approved
condensate pump.
… Properly vented.
… Protected from freezing (if required).
Vent Pipe System
… Vent pipe and fittings of approved material.
… Acceptable size, length, and number of elbows on air
inlet pipe.
… Acceptable size, length, and number of elbows on
exhaust outlet pipe.
… Add the air inlet filter per the manufacturer’s instruction.
… Installed in accordance with prevailing provisions of
local codes, or in the absence of such, National Fuel
Gas Code, NFPA 54, ANSI Z223.1-Latest Edition. Canadian Installations must be performed in accordance
with CAN/CGA-B149.
… All 2” horizontal piping sloped down toward the water
heater at 1/4” per foot. 3” piping sloped down towards
the heater at 1/8” per foot.
… Not obstructed in any way.
Vent Termination
Horizontal
… Correct relationship - outlet to inlet.
… 12” Min. above grade/snow level.
… 2” exhaust outlet/air inlet pipe sloped down towards
water heater at 1/4” per foot. 3” piping sloped down
towards the heater at 1/8” per foot.
… Away from corners, other vents, windows, etc.
Alternate Horizontal
… Correct relationship - outlet to inlet.
… 12” Min. above anticipated snow level.
… 2” exhaust outlet/air inlet pipe sloped down towards
water heater at 1/4” per foot. 3” piping sloped down
towards the heater at 1/8” per foot.
… Away from corners, other vents, windows, etc.
Vertical
… Inlet - 12” Min. above roof/snow level.
… Correct relationship - outlet to inlet.
… Away from corners, other vents, windows, etc.
Concentric
… 12” Min. above grade/snow level.
… 2” exhaust outlet/air inlet pipe sloped down towards
water heater at 1/4” per foot. 3” piping sloped down
towards the heater at 1/8” per foot.
… Away from corners, other vents, windows, etc.
Water System Piping
… Temperature and pressure relief valve properly
installed with a discharge line run to an open drain and
protected from freezing.
… All piping properly installed and free of leaks.
… Heater completely filled with water.
… A properly sized expansion tank must be installed on all
closed systems.
… A tempering valve should be installed per the manufacturer’s instructions.
Gas Supply and Piping
… If using a flexible gas connector, make sure its rating
tag matches or exceeds the input of the water heater.
… Adequate pipe size and of approved material.
… Gas supply is the same type as listed on the water
heater data plate.
… Gas line equipped with full opening shut-off valve,
union and drip leg.
… Approved pipe joint compound used.
… Chloride-free soap and water solution or other approved means used to check all connections and fittings for possible gas leaks.
Electrical Connections
…
…
…
…
…
Unit connected to a dedicated power supply.
Unit connected to a 120V electrical supply.
Proper polarity.
Water heater properly grounded.
Installed in accordance with prevailing provisions of
local codes, or in the absence of such, “National Fuel
Gas Code”, NFPA 54, ANSI Z223.1-Latest Edition.
Canadian installations must be performed in accordance with CAN/CGA-B149.
23
OPERATING YOUR WATER HEATER
Read and understand these directions thoroughly before
attempting to operate the water heater (see Operating
Instructions on page 25). Check the data plate on the front
of the water heater for the correct gas. Do not use this
water heater with any gas other than the one listed on the
data plate. If you have any questions or doubts, consult
your gas supplier or gas utility company.
L.P. (Propane) Models
When the thermostat calls for heat, the blower will run for
6 seconds to purge the system of any accumulated gas or
air. The hot surface igniter will heat up for 35 seconds. The
blower will turn on and the gas valve open, forcing the air
and gas mixture across the hot surface igniter, causing the
burner to light. The hot surface igniter will turn off and act
as an electronic flame sensor to determine if burner ignition
has been accomplished. If it detects any loss of flame, it
will shut off the gas supply to the burner.
Propane gas is heavier than air and in the occurrence of
a leak in the system, the gas will settle on the floor 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. Before lighting a propane gas water heater, smell all
around the appliance at floor level. If you smell gas, follow
the instructions as given in the warning on the front page.
The ignition control will try to light the burner three times.
If the ignition control does not detect a flame after three
tries, it will temporarily lock out, but then auto restart and go
through three additional tries for ignition after 60 minutes.
It will repeat until ignition occurs or the system locks out
requiring service. Refer to Troubleshooting Guide on Page 28.
When your propane tank runs out of fuel, turn off the gas
at all gas appliances including pilot lights. After the tank
is refilled, all appliances must be re-lit according to their
manufacturer’s instructions.
The sensor is a 10K ohm at 77°F (25°C) thermistor. Read
resistance through the black wires that run to the sensor.
Remove wires from circuit board before checking. An
open or short circuit indicates sensor failure. Check
reading against the following table. The resistance should
correspond with the temperature in the tank:
Water Heater Operation
This appliance does not have a pilot light. It is equipped
with an electronic ignition that automatically lights the
burner. There are three lights to indicate the various stages
of operation; Green = Electrical power is on, Yellow =
Thermostat is calling for heat, which signals the beginning
of the ignition sequence (see figure 21), and Red = Ignition
control is signaling the gas valve to open.
Figure 21: Sequence of Operation
24
Thermostat Sensor
60°F
16°C
15,300 ohms
80°F
27°C
9,300 ohms
100°F
38°C
5,800 ohms
120°F
49°C
3,800 ohms
140°F
60°C
2,500 ohms
160°F
71°C
1,700 ohms
185°F
85°C
1,100 ohms
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 burner and can result
in increased water temperatures at the hot water outlet. A
tempering valve should be installed in the hot water supply
line to reduce the risk of scald injury.
Water Temperature 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 instruction manual before setting
temperature at water heater.
Feel water before bathing or showering.
Temperature limiting valves are available.
The thermostat is adjusted to its lowest temperature setting
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 130°F;
however, in some instances, setting the water heater higher
than 130°F can reduce the occurrence of igniter failure due
to excessive condensate.
Important: Since most commercial installations utilize
higher temperatures, the use of a tempering valve is
strongly recommended in all domestic hot water
lines (i.e. public restroom sinks, etc).
Auxiliary commercial equipment (i.e. dishwashers, laundry
equipment, etc) may require higher temperature settings.
Refer to the manufacturer’s instruction manuals supplied
with this type equipment for recommended temperature
settings.
Important: Adjusting the
Figure 22:
thermostat past the 120°F setting
Temperature Dial
on the temperature dial (see
figure 22) 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
Emergency Shut Down
Important: If overheating occurs or the gas supply fails to
shut off, close the manual gas supply valve. Turn off the
electrical supply to the unit and close the cold water supply
25
OPERATIONAL CONDITIONS
Figure 23: Hand Hole Clean-out
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”.
Safety Shut-Off (Pressure Switch)
This water heater is equipped with a pressure switch that
protects the unit by shutting it down in the event that:
•
•
•
•
A blockage occurs in the combustion air inlet, the
flue gas exhaust outlet, or both the inlet and outlet.
The condensate line freezes and the condensate
“backs up” and fills the exhaust outlet.
The blower fails to operate, or operates improperly.
The unit begins to operate at an abnormally low
input level.
Energy Cut-Off (ECO)
A high temperature limit switch, or ECO, is used to shut down
the water heater if the water temperature exceeds 203°F.
The ECO will automatically reset when the temperature cools
sufficiently. If the ECO shuts down the heater repetitively,
contact a qualified professional for service.
MAINTENANCE
Draining and Flushing
It is recommended that the tank be drained and flushed
every 6 months to remove sediment which may buildup
during operation. The water heater should be drained if
being shut down during freezing temperatures.
To drain the tank, perform the following steps:
1.
Turn off the gas supply at the Manual Gas Shut-off
Valve. Turn off the electrical supply to the water
heater
2.
Close the cold water inlet valve.
3.
Open a nearby hot water faucet.
4.
Open the access door at the bottom of the heater,
then connect a hose to the drain valve and
terminate it to an adequate drain.
Note: The drain hose should be rated for at least 200°F.
If the drain hose does not have this rating, open the cold
water inlet valve and a nearby hot faucet until the water is
no longer hot.
5. Close the cold water inlet valve.
6. Open the water heater drain valve and allow all
the water to drain from the tank.
7. Flush tank to remove sediment
Note: For water heaters with a hand hole clean-out follow
steps 8-11.
26
8. Remove screw holding the outer hand hole clean-out
cover. Then carefully remove the insulation covering
the clean-out plug. Using a 1/2” square drive ratchet
open the clean-out plug (see figure 23.) Note: After
removing the clean-out plug inspect the O-ring for damage, replace if necessary.
9. Using a Wet/Dry shop vacuum clean any debris from
the tank.
10. Lubricate O-ring with a food grade oil. Then replace
and securely tighten the clean-out plug.
11. Replace the insulation and cover plate.
12. Close the drain valve, replace access door, refill
the tank, and restart the 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.
Temperature and Pressure
Relief Valve
Manually operate the temperature and pressure relief valve
at least once a year to make
Figure 24
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
temperature and pressure
relief valve to allow the valve
to operate freely and return to its closed position (see figure
24). If the valve fails to completely reset and continues to
release water, immediately shut off the manual gas valve
and the cold water inlet valve, and call a qualified service
technician.
MAINTENANCE OF YOUR WATER HEATER
3 Month Inspection
Replacing the Gas Valve
At least every 3 months, a visual inspection should be
made of the combustion air inlet as well as the exhaust and
water piping. Check the water heater for the following:
•
Obstructions, damage, or deterioration in the venting
system. Make sure the exhaust and combustion air
supplies are not obstructed.
• Leaking or damaged water and gas piping.
• Presence of flammable or corrosive materials in the
installation area.
• Presence of combustible materials near the water
heater.
Important: Verify proper operation after servicing this water
heater.
Gas Valve
The gas valve on this water heater has been permanently
set at the factory for proper operation. No field adjustments
are needed and none should be performed.
Removing the Gas Valve
Removal and replacement of the gas regulator valve
involves the disconnection of gas piping and electrical
leads. This procedure must be performed by a qualified
service technician.
Important: When removing the gas valve, do not use a
pipe wrench or vise to grip the body. Do not apply any force
to the gas valve or the cast flange fitting on the inlet side
of the gas valve (see figure 25.) Such force may break or
crack these components.
1. Turn temperature dial counterclockwise to the lowest
setting and turn off electrical power to appliance.
2. Shut off the gas at the manual shut-off valve on the
gas supply line. See figure 19 for reference. Remove
the access door.
3. Disconnect the gas piping connection just outside
the base of the water heater . Note: Use a second
pipe wrench on the gas piping inside the skirt to avoid
cracking the gas valve or the flange fitting.
4. Remove the pressure tap from the gas valve (see
figure 25). The hose should not be disconnected.
5. Remove the Phillips head screw holding the electrical
plug and remove electrical plug from the gas valve.
6. Remove the three T-25 Torx head brass screws that
attach the gas valve to the venturi manifold, using
the T-25 Torx wrench supplied with the gas valve kit
(model VK8115V, part number 6903775.)
7. Remove the gas valve from the unit keeping the
rubber gasket with the gas valve .
8. Remove the flange from the gas inlet side of the valve
by removing the four (4) attachment screws.
Important: The rubber gasket that seals the gas valve to
the venturi manifold must be used (previous gaskets may
be reused, if in good condition). Make sure the gasket is
properly inserted into the recess on the gas valve prior to
installation (see figure 25 for exact placement of the rubber
gasket).
1. Remove the O-ring from the flange (removed from the
old gas valve) and replace it with the one provided
in the gas valve kit (model VK8115V, part number
6903775.)
2. Reattach the elbow flange to the gas valve. Tighten all
four screws securely.
3. Place the three T-25 Torx screws through the proper
holes in the venturi manifold flange. See figure 25.
4. Properly install a new rubber gasket (provided) as
shown in figure 25.
5. Position the gas valve and start all three screws
(projecting downward from the venturi manifold) into
the gas valve. A T-25 Torx wrench has been provided
in the gas valve replacement kit (model VK8115V, part
number 6903775.)
Note: All three T-25 Torx screws must be properly tightened
to secure the seal between the gas valve and the venturi
manifold.
6. Reconnect the pressure tap to the port on the new gas
valve (see figure 25).
7. Reconnect the external gas supply line to the gas piping on the gas valve. Be sure to use approved Teflon
tape or pipe joint compound suitable for gas piping.
Note: Use a second pipe wrench on the gas piping inside
the skirt to avoid cracking the gas valve or the cast fitting.
8. Reconnect the electrical plug to the gas valve and
secure it with the screw provided.
9. Turn gas supply on and check for leaks. Use a chloride-free soap and water solution (bubbles forming
indicate a leak) or other approved method. All leaks
must be fixed immediately.
10. Be sure tank is completely filled with water before restoring power to the water heater. Follow operating
instructions on Page 25.
11. Ensure proper operation of the water heater, then reinstall the access door.
If additional information is required, contact the Product
Service and Support Group at 1-800-456-9805.
Figure 25
27
TROUBLESHOOTING
Ignition Control Module (ICM) LED Error Codes: (Flashes visible through viewport in access door)
FLASHES
1
2
3
4
5
6
8
9
Rapid
INDICATED PROBLEM
Pressure Switch Closed
Pressure Switch Open
Failed Ignition
Gas Valve Hardware Fault
Flame Sense Hardware Fault
False Flame
Ignition Control Hardware Fault
Ignition Control Software Fault
L1 Polarity Detection
CONTROL REACTION
SC*
SL
SL3
SL
SC
SL**
SL
SL
SC
SL (Soft Lockout): Control Automatically resets after 60 minutes.
SL3 (Soft Lockout/Hard Lockout): Control automatically resets after 60 minutes, with a maximum of 3 resets, followed by hard lockout requiring service.
SC (Self Clearing): Control will function normally as soon as it no longer detects the previously indicated fault.
* when pressure switch or blower relay opens
** when flame is no longer sensed.
† Blower Isolation Relay is used on models 150,000 BTU/Hr and above.
Note: If unit goes into a soft or hard lock-out the ignition control module can be reset by cycling power to the water heater.
28
SOFTWARE OPERATION SEQUENCE
IGNITION CONTROL MODULE SOFTWARE OPERATION SEQUENCE
* For 175,000 BTU/Hr models and above the flame establishing period is six seconds. For the first 3 seconds the gas valve is off.
29
REPAIR PARTS LIST/DIAGRAM
31B
1
1
33
1
ALL MODELS EXCEPT
100 GALLON
When ordering repair parts always give the
following information:
1.
Model, serial, and product numbers
2.
Type of gas
3.
Item number
4.
Parts description
2
3
4
5
8
6
17
16
12
7
15
22
23
20
21
24
Repair Parts List
30
ITEM
NO.
PARTS DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31A
31B
32
33
34
35
36
37
1” NPT x 3” BRASS NIPPLE
THERMOSTAT SENSOR BUSHING
O-RING
THERMOSTAT SENSOR/ECO
INVERTED FLARE NUT
PLUG
VINYL TUBING
PRESSURE SWITCH
COMBUSTION BLOWER
4 INCH DIAMETER BLOWER GASKET
BURNER (NATURAL AND L.P. SAME)
6 INCH DIAMETER BURNER GASKET
HOT SURFACE IGNITER
IGNITER BRACKET
VENTURI MANIFOLD
REDUCING COUPLING
AIR INLET PIPE ASSEMBLY
GAS VALVE
1/2” NPT 90 DEGREE INLET FLANGE
1/2” NPT X 2” NIPPLES
1/2” NPT ELBOWS
1/2” NPT X 4.5” NIPPLE
RED LED
YELLOW LED
GREEN LED
THERMOSTAT BEZEL
TEMPERATURE SELECTOR KNOB
THERMOSTAT BOARD
IGNITION CONTROL
TRANSFORMER
2” CONDENSATE TRAP ASSEMBLY
3” CONDENSATE TRAP ASSEMBLY
COLD WATER TUBE ASSEMBLY
TEMPERATURE AND PRESSURE RELIEF VALVE
DRAIN VALVE
POTENTIOMETER
VENTURI GASKET (not pictured)
BLOWER ISOLATION RELAY (150,000+ BTU/Hr)
32
19
10
34
18
35
31A
26
14
25
30
27
13
9
11
28
37
29
TOOLS REQUIRED FOR SERVICING
TOOL
FUNCTION
VOLT OHMMETER
MEASURE VOLTAGE/RESISTANCE
CLAMP-ON AMMETER
MEASURE CURRENT
STOPWATCH
CLOCK GAS CONSUMPTION
CALCULATOR
CALCULATE INPUT RATE
U-TUBE MANOMETER
READ INLET GAS PRESSURE
3/16” ID PLASTIC TUBING - 2 FT
CONNECT MANOMETER
#1 & #2 PHILLIPS SCREWDRIVERS REMOVE DOORS AND CONTROLS
12” PIPE WRENCH (2 REQUIRED)
REMOVE GAS LINE
1/2” COMBINATION WRENCH
REMOVE BLOWER AND BURNER
1/2” SOCKET AND RATCHET
REMOVE BLOWER AND BURNER
3/8” COMBO WRENCH/NUT DRIVER REMOVE IGNITER
T-25 TORX WRENCH
REMOVE THE GAS VALVE
(ALSO HELPFUL - 9/32” and 5/16” COMBINATION WRENCHES)
REPAIR PARTS LIST/DIAGRAM
1
4
5
35
2
6
100 GALLON MODELS
When ordering repair parts always give the
following information:
1.
Model, serial, and product numbers
2.
Type of gas
3.
Item number
4.
Parts description
7
9
8
10
3
14
11
12
1
19
13
15
17
34
20
16
Repair Parts List
ITEM
NO.
PARTS DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
1-1/2” NPT x 3” BRASS NIPPLE
THERMOSTAT SENSOR BUSHING
THERMOSTAT SENSOR/ECO
CONTROL PANEL HOUSING
IGNITION CONTROL
BLOWER ISOLATION RELAY
THERMOSTAT BOARD
TRANSFORMER
SIGHT GLASS
RED LED
YELLOW LED
GREEN LED
TEMPERATURE SELECTOR KNOB
THERMOSTAT BEZEL
POTENTIOMETER
PRESSURE SWITCH
VINYL TUBING
ACCESS PANEL
CLEAN-OUT PLUG w/O-RING
CONDUIT
3” CONDENSATE TRAP ASSEMBLY
BUSHING
AIR INLET PIPE ASSEMBLY
3/4” GAS INLET PIPE
PIPE COUPLING
GAS VALVE
VENTURI MANIFOLD
IGNITER BRACKET
HOT SURFACE IGNITOR
BLOWER
4” DIAMETER BLOWER GASKET
BURNER (NATURAL & L.P. SAME)
6” DIAMETER BURNER GASKET
DRAIN VALVE
TEMPERATURE AND PRESSURE RELIEF VALVE
33
18
32
21
31
22
25
23
24
27
26
30
28
29
TOOLS REQUIRED FOR SERVICING
TOOL
FUNCTION
VOLT OHMMETER
MEASURE VOLTAGE/RESISTANCE
CLAMP-ON AMMETER
MEASURE CURRENT
STOPWATCH
CLOCK GAS CONSUMPTION
CALCULATOR
CALCULATE INPUT RATE
U-TUBE MANOMETER
READ INLET GAS PRESSURE
3/16” ID PLASTIC TUBING - 2 FT
CONNECT MANOMETER
#1 & #2 PHILLIPS SCREWDRIVERS REMOVE DOORS AND CONTROLS
12” PIPE WRENCH (2 REQUIRED)
REMOVE GAS LINE
1/2” COMBINATION WRENCH
REMOVE BLOWER AND BURNER
1/2” SOCKET AND RATCHET
REMOVE BLOWER AND BURNER
3/8” COMBO WRENCH/NUT DRIVER REMOVE IGNITER
T-25 TORX WRENCH
REMOVE THE GAS VALVE
(ALSO HELPFUL - 9/32” and 5/16” COMBINATION WRENCHES)
31
POLARIS MODELS & DIMENSIONS
34/50 Gallon Units
100 Gallon Units
Clean-out Port
32
MODEL
NUMBER
GAL.
CAP.
INPUT
(MBTU
PER HR.)
PGC 34-130-2NV OR 2PV
34
130
PGC 50-130-2NV OR 2PV
50
130
PGC 34-150-2NV OR 2PV
34
PGC 50-175-3NV OR 3PV
50
WATER
CONNECTIONS
T&P
HGT
GAS
SUPPLY
AIR
INLET/
EXHAUST
A
B
C
D
E
F
G
APPROX
SHIP.
WEIGHT
2 OR 3
48-1/2
22
15-3/4
40-1/2
41
6-3/8
5-1/2 / 6 -5/8
150
2 OR 3
62-3/8
22
15-3/4
54-1/2
55
6-3/8
5-1/2 / 6 -5/8
176
150
2 OR 3
48-1/2
22
15-3/4
40-1/2
41
6-3/8
5-1/2 / 6 -5/8
150
175
3
63-3/4
22
15-3/4
55-3/4
56-1/4
6-3/8
5-1/2 / 6 -5/8
180
VENT
DIA.
EXTERIOR
PGC 50-199-3NV OR 3PV
50
199
3
63-3/4
22
15-3/4
55-3/4
56-1/4
6-3/8
5-1/2 / 6 -5/8
180
PGC 100-199-3NV OR 3PV
100
199
3
70
28
23-1/4
56-1/4
63
6-3/8
8-1/2 / 6-3/4
468
© 2004 American Water Heater Company. All Rights Reserved