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Gas Input Rate
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 100k, 130k, and 150k 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.
The water supply pressure should not exceed 80 psi
(551.5 kPa). If this occurs, a pressure reducing valve with a bypass 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: 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
(use 1” 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. Connect the hot water supply (use 1” 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. If installing the water heater in a closed water system, install an expansion tank in the cold water line as specified under “Closed System/Thermal Expansion” (Page
14).
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.
Figure 14: Input Graph
6. The
®
gas water heater is shipped with a factoryinstalled Temperature and Pressure Relief Valve.
Install a discharge line in the opening in the T & P valve
(see instructions on Page 16).
7. 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.
Table 2:
Total Hardness:
Chloride: pH:
Alkalinity:
12 grains per gal. (205 mg/liter) max.
200 mg/liter max.
6.5-8.0
200 mg/liter max.
13
Figure 15: Typical One-Temperature System Piping Installation
Figure 16: Sample Mixing
Valve Installation
Un-tempered Hot
Water Outlet
Mixing Valve
Un-tempered Hot
Water Outlet
Mixing Valve
(set to 120° F
[48.8° C] or lower)
Check local codes.
Metal Drain Pan
6” (15.2cm)
Air Gap Max.
Adequate Drain
Mixing Valve Installation
A mixing valve must be installed, per the manufacturer’s instructions, in the domestic hot water line. See Figure 16 for a sample tempering valve installation.
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, PEX or polybutylene. PVC water piping may be used on the cold water inlet supply but not within 18 inches (45.7 cm) 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.
Closed System/Thermal Expansion
As water is heated, it expands (thermal expansion). In a closed system, the volume of water will increase. As the volume of water increases, 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 temperature-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 installed 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 thermal expansion tank. The manufacturer of this water heater will void the warranty if there is a failure to install a properly sized expansion tank.
Combination Space Heating/Potable
Water System
Some water heater models are equipped with inlet/ outlet connections for use in space heating applications.
Note: this water heater, “Suitable for combination water
(potable) heating and space heating and not suitable for space heating applications only.” 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.
14
Figure 17: Air Handler Piping Installation
Un-tempered Hot
Water Outlet
Mixing Valve
Metal Drain Pan
6” (15.2cm)
Air Gap Max.
Adequate Drain
• Do not use with piping that has been treated with chromates, 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 (48.9°C), a mixing valve (provided) must 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 mixing 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.
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
(48.9°C). A mixing valve must be installed in the water supply line to limit the supply temperature to 120°F (48.9°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.
15
Notes on Figure 18:
If tank temperature is set above
120°F (48.9°C) and water is supplied for domestic use (hand washing, showering, etc.) a mixing valve must 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 valve in the recirculating line, adjust the flow in the recirculating line to five gallons per minute.
Figure 18: Polaris
®
with Auxillary Storage Tank - One or Two
Temperature System (With or Without Building Recirculation)
Mixing
Valve
Tank
Temperature
Control
(170°F [76.6°C] Max.)
(If Used)
Temperature and Pressure
Relief Valve
Explosion Hazard
• Temperature-pressure relief valve must comply with ANSI Z21.22-CSA 4.4 and
ASME code.
• A properly-sized temperature-pressure relief valve must be installed in the opening provided.
• Do not plug, block, or cap the discharge line.
• Failure to follow this warning can result in excessive tank pressure, serious injury or death.
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 Shut-
16 off 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.
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:
• 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 (15.2 cm) 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.
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