Polaris PC 130-50 2NV, PC 150-50 2NV, PC 175-50 3NV, PC 130-34 2NV, PC 199-50 3NV User Manual

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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.

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.

PRINTED IN U.S.A. 0112

This manual covers model numbers:

Canada

PC 100-34 2NV or 2PV

PC 130-34 2NV or 2PV

PC 130-50 2NV or 2PV

PC 150-34 2NV or 2PV

PC 150-50 2NV or 2PV

PC 175-50 3NV or 3PV

PC 199-50 3NV or 3PV

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

To obtain technical, warranty or service assistance during or after the installation of this water heater, visit our website at:

http://www.gsw-wh.com

or call toll free: 1-888-479-8324

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

1.Model number

2.7 Digit product number

3.Serial number

4.Date of installation

5.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.

322761-000

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:

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

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can happen if the instructions are not followed.

Important Instructions

Do not use this water heater 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.

Table of Contents

Page

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

1-2

Installation Instructions ......................................................................

3-22

Unpacking the Water Heater ............................................................

3

Location Requirements .....................................................................

4

Condensate Line ...........................................................................

5-6

Intergrated Filter Installation ............................................................

7

Vent Pipe System ........................................................................

8-11

Vent Terminations ........................................................................

9-12

Gas Input Rate ................................................................................

13

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

13-16

Gas Supply and Piping .............................................................

17-18

Electrical Connections/Wiring Diagram .....................................

19-20

Installation Checklist .......................................................................

21

Operating Your Water Heater ..........................................................

22-24

Polaris® Operating Instructions ...........................................................

23

Maintenance of Your Water Heater .................................................

24-25

Troubleshooting ....................................................................................

26

Software Operation Sequence .............................................................

27

Parts List and Diagram .........................................................................

28

Polaris® Models and Dimensions ..........................................................

29

2

INSTALLATION INSTRUCTIONS

Consumer Information

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.

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)- current edition. Canadian installations must be performed in accordance with CAN/CSA-B149.1-current edition. 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

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.

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.

Keep combustibles such as boxes, magazines, clothes, etc., away from water heater area.

Retain your original receipt as proof of purchase.

Unpacking the Water Heater

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.

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.

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.

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/ provincial codes for requirements prior to installation.

Figure 1: Garage Installation

This water heater is not certified for installation in mobile homes.

Site Location

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.

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

4

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 state and local/provincial codes or in absence of the state and local/provincial codes with the “National Fuel Gas Code”, ANSI Z223.1 (NFPA 54)-current edition. Canadian installations must be performed in accordance with CAN/ CSA-B149.1-current edition.

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” (4.45 cm) and be at least

two inches (5 cm) 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” (1.91 cm) 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.

1-3/4” (4.45 cm) Max.

(5 cm)

Figure 1A

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 (7.62 cm) 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

(61 cm) of front clearance and 4 inches (10.2 cm) on each side should be provided for inspection and service.

Figure 2: Minimum Clearance Locations

Back 0” (0 cm)

Top: 0” (0 cm)

 

Sides: 4” (10.2 cm)

Min. for service

 

Front: 24”

Vent: 0”

(61 cm )

(0 cm)

Min. for service

 

Sides: 4” (10.2 cm)

Min. for service

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.

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 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”) tolerance (1.9 cm +/- 0.31 cm tolerance).

Note: The trap should be aligned so that the exhaust pipe is in a vertical position close to the surface of the water heater.

Figure 3A: 2” Condensation Trap Installation

5

Figure 3B: 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 3A). 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 3B).

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 metal drain pan.

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, Current Edition. Canadian installations must be performed in accordance with CAN/CSA-B149.1, Current Edition.

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-current edition. Canadian installations must be performed in accordance with CAN/CSA-B149.1-current edition.

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. Note: It is important that the factory-installed air inlet

filter be inspected at least twice each year and cleaned if necessary. See “Integrated Filter Installation, Preventive Maintenance”. Note: if the vent system is not in compliance with the current installation manual, 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.

6

Integrated Filter Installation

When installing the adaptor rubber boot, note the following:

Remove and discard the plastic cap from the outer clamshell housing (see figure 4A).

To connect the heater to the air inlet, use the vent adaptor rubber boot provided in the base skirt. The adaptor rubber boot is designed for 3” venting (see figure 4B). Note: If there is a need for 2” venting, then use plastic pipe and fittings to transition down.

Loosen the hose clamp at the adaptor rubber boot and slide the plastic piping into the adaptor rubber boot. With piping in place, tighten the hose clamp. Install a 3” x 3” x 3” TY drain/waste/vent fitting to trap airborne particulates (see figure 4C). Note: If piping has been previously cut with a saw, be sure to remove all burrs and plastic shavings from the piping before installing.

Figure 4A: Remove Plastic Cap

Outer Clamshell

Housing With Filter

Gas Piping

Remove

Plastic Cap

Base Skirt

Figure 4B: Adaptor Rubber Boot

Preventive Maintenance

The heater is designed to shut down if the pressure switch senses that the air inlet vent or the exhaust vent is restricted. In this case, the pressure switch will open and the heater will generate a 2-flash code (see the troubleshooting section). If troubleshooting section of this manual indicates that there is a blockage, note the following:

Turn off the gas supply to the water heater at the manual gas shut-off valve, and disconnect power to the water heater.

To inspect the filter, loosen the hose clamp at the adaptor rubber boot and slide the plastic pipe out and away from the adaptor rubber boot (see figure 4C).

Remove the adaptor rubber boot containing the outer clamshell housing by turning clockwise approximately 1/2” (30.5 cm) and pulling off of the internal clamshell housing (see figure 4C).

Using your fingers or a small flat blade screwdriver, remove the filter media from the outer clamshell housing, handle carefully (see figure 4D).

To clean filter, lightly tap the back of the filter support to dislodge any large debris. Smaller debris may be removed by using a vacuum cleaner. the filter media may be cleaned by dipping the filter media into a solution of warm soapy water and rinsing in clean water. Do not scrub, allow to air dry before reinstalling. Filter media may be cleaned on an average 2 to 3 times before replacing with a new filter media is required.

Reinstall the filter media by doing the above steps in reverse order.

Turn on the gas supply and reconnect power, refer to the operating instructions on front of the water heater. Verify proper operation of the water heater before leaving.

Note: The heater must never be operated without the filter media installed.

Push On &

Tighten Clamp

Adaptor Rubber

Boot

Outer Clamshell

Housing

Figure 4C: Air Inlet Piping

Hose Clamp

Piped To

External Air

Supply

3” x 3” x 3” TY DWV Fitting

 

(Position Cure Slope Upward)

Adaptor Rubber Boot

 

Install A Small Portion

Outer Clamshell Housing

 

Of Pipe And A Pipe Cap

3” Plastic Pipe

To Rest On Floor.

 

Figure 4D: Filter Media

Filter Media shown inside the Outer Clamshell Housing

 

NOTE: if found difficult to

 

reattach the outer clamshell

Adaptor

housing to the internal clamshell

housing - apply a thin layer of silicone

Rubber Boot

grease to the surface of the black rubber

support of the Filter Media.

Outer Clamshell

Housing

Remove

Filter Media

7

Vent Pipe Material

Combustion Air Inlet Piping; The following plastic materials may be used for combustion air inlet piping. IMPORTANT: Follow all local codes or, in the absence of local codes, CSA B149.1, Natural Gas and Propane

Installation Code - current edition to properly install air inlet piping.

Schedule 40 PVC

Schedule 40 or 80 CPVC

DWV Pipe and Foam Core Piping is acceptable as intake pipe only.

Exhaust Piping; Exhaust PVC or CPVC plastic piping shall be certified and marked as complying to Standard for Type BH Gas Venting System ULC-S636. In addition

plastic piping, plastic components, primers, and glues must be from a single source manufacturer and not mixed with other listed or unlisted systems. IMPORTANT: Follow all local codes or, in the absence of local codes, CSA B149.1, Natural Gas and Propane Installation Code - current edition to properly install exhaust piping.

Important: Do not use vent elbows in this vent pipe installation (see figure 5 below).

Figure 5: Correct and Incorrect Pipe Fittings

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 (21 mm per meter); (3” Piping must slope upward at 1/8” per foot) (10.5 mm per meter). This will allow condensate to run back to the heater and exit through the condensate trap.

Support all horizontal pipe runs every four feet (1.2 m) and all vertical pipe runs every six feet (1.8 m) 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.Standard Horizontal (2 Pipe)

2.Alternate Horizontal (2 Pipe)

3.Vertical (2 Pipe)

4.Concentric Vent - Through the Wall

5.Concentric Vent - Through the Roof

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

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 (1.8 m) 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.

Maximim allowable Length in Feet (Meters) of Exhaust and Air Inlet Pipe

For Schedule 40 CPVC, OR PVC Pipe and Fittings

Pipe

Size in

 

 

 

 

 

 

 

Inches

 

 

 

 

 

 

 

*2

 

52

48

44

40

36

32

 

(15.8)

(14.6)

(13.4)

(12.2)

(11)

(9.7)

*2

 

44

40

36

32

28

24

 

(13.4)

(12.2)

(11)

(9.7)

(8.5)

(7.3)

*2

52

48

44

40

36

32

28

(15.8)

(14.6)

(13.4)

(12.2)

(11)

(9.7)

(8.5)

*2

 

52

48

44

40

36

32

 

(15.8)

(14.6)

(13.4)

(12.2)

(11)

(9.7)

3

 

125

120

115

110

105

100

 

(38.1)

(36.6)

(35)

(33.5)

(32)

(30.5)

3

 

115

110

105

100

95

90

 

(35)

(33.5)

(32)

(30.5)

(28.9)

(27.4)

3

130

120

115

110

105

100

95

(39.6)

(36.6)

(35)

(33.5)

(32)

(30.5)

(28.9)

3

 

125

120

115

110

105

100

 

 

(38.1)

(36.6)

(35)

(33.5)

(32)

(30.5)

Minimum length is 6 feet (1.8 m) per pipe with 1 elbow per side.

2 Inch pipe may be used with 100,000, 130,000 & 150,000 BTU/HR (29.3, 38, & 43.9 kW) input models only.

* 3” pipe must be used for 175,000 BTU/Hr (51.29 kW) input and above.

8

Vent Termination Locations

The air inlet and exhaust outlet must be installed with the following minimum clearances (see figure 6):

Twelve inches (30 cm) above grade or maximum anticipated snow level.

Twelve inches (30 cm) from any opening through which flue gases could enter the structure.

Four feet (122 cm) horizontally and vertically from gas or electric meters, gas regulators, dryer vents, vent hoods, bathroom fan exhaust, attic fans and turbines.

Two feet (61 cm) 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 100,000 - 150,000 BTU/ Hr models. Do not expose any 3” X 2” reducers or bushings to outdoor ambient temperatures.

CAN/CSA B149.1 Section 8.14.8:

2.When terminating a vent under a veranda, porch or deck, venting must be installed in accordance to all local and provincial codes or in the absence of local and provincial codes, please refer to the CAN/CSA B149.1.

3.A vent shall not terminate less than 7 ft. (2.1 m) above a paved sidewalk or paved driveway that is located on public property.

4.A vent shall not terminate in an area where children or animals could block pipes.

5.A vent shall not terminate in a location that is too close to shrubs or bushes.

6.Caulk all cracks, seams and joints within 6 feet (1.83 m) 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. Maintain a 36 in (91 cm) minimum clearance 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. Maintain a 36 in (91 cm) minimum clearance 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.

9

INLET/OUTLET VENT TERMINATIONS

Standard 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 (45.7 cm) of 2 inch pipe may be used between the 3 inch transition and the inside of the wall (see figure 7).

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 (30.5 cm) from the outside wall. The air inlet must be located with respect to the exhaust outlet as shown in figure 7 (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 11 for correct terminations if installing more than one Polaris® gas water heater.

Alternative Horizontal Termination

The combustion air and exhaust terminations may be raised up to 24 inches (61 cm) above the wall penetrations if required for anticipated snow levels (see figure 8). The two elbows shown in figure 8 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 11 for correct terminations if installing more than one Polaris® gas water heater.

Figure 8: Alternate Horizontal Termination

.5cm)

 

(30

 

24”

 

(61 cm)

 

Max.

 

(76.

 

2

cm)

 

Figure 7: Standard Horizontal Termination

3” (7.6cm) Max.

 

4”(10cm)

12” (30.5 cm)

Max.

 

4”(10cm)

2”

Max.

Coupling

 

 

 

 

 

 

 

 

12” (30.5cm) Min. Above

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Grade or Anticipated

 

 

 

 

Snow Level. See

 

 

Notes:

Note 4.

 

 

1.Support Horizontal Pipe Every Four Feet (1.2 m). Support Vertical

Pipe Every Six Feet (1.8 m).

2.When Using 3 Inch Pipe, Reduce To 2 Inches Before Penetrating The Outside Wall.

3.18 Inch (45.7 cm) Maximum When Using 3 Inch Pipe.

4.Increase The 12 Inch (30.5 cm) Minimum Above Grade To Keep Terminal Openings Above Anticipated Snow Levels.

5.Slope All Piping Down Toward the Water Heater as

Follows:

´ 3LSLQJ VORSH ´ 3HU )RRW PP SHU PHWHU

´ 3LSLQJ VORSH ´ 3HU )RRW PP SHU PHWHU

*

*

*

10

VERTICAL TERMINATIONS

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 (45.7 cm) 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 9 for the proper location of the

air inlet with respect to the exhaust outlet termination. The vertical exhaust outlet termination is a 2 inch (30.5 cm) pipe

which terminates at least 12 inches (30.5 cm) above the inlet air termination.

The air inlet and exhaust outlet terminations must be at least 12 inches (30.5 cm) above the roof line or anticipated snow levels. See figure 9 below.

Note: See “Venting Additional Polaris® Units” below if installing more than one Polaris® gas water heater.

Figure 9: Vertical Termination

 

4” (10 cm)

 

12” (30.5 cm)

Max.

 

12”

12” (30.5cm) Min.

Min.

 

(30.5 cm)

Above Roof or

 

Min.

Anticipated Snow

 

 

Level. See Note 4.

4” (10 cm) Max.

12” (30.5 cm) Min.

Notes:

*

1.

Support Horizontal Pipe Every

 

 

Four Feet (1.2 m). Support Vertical

 

 

Pipe Every Six Feet (1.8 m).

*

2.

When Using 3 Inch Pipe, Reduce To

 

2 Inches Before Penetrating The

 

 

Roof.

 

3. 18 Inch (45.7 cm) Maximum When Using 2 Inch Pipe.

4. Increase The 12 Inch (30.5 cm) Minimum Above Grade To Keep Terminal Openings Above Anticipated Snow Levels.

Venting Additional Polaris® Units

When using three or more Polaris® units, install vent

When using two (2) Polaris® units, install vent terminations

terminations per Method C or Method D:

 

 

 

 

 

 

 

 

using either Method A or Method B below:

Figure 9C, 9D

 

 

Figure 9A, 9B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3”

36” (91.4 cm)

 

 

 

 

 

3” (7.6cm) Max.

 

 

 

(7.6cm)

 

 

Minimum

 

 

 

 

 

 

 

Max.

 

 

 

4”

4”

4” (10cm)

(10cm)

(10cm)

Max.

Max.

Max.

 

 

3”

36” (91.4 cm)

3” (7.6 cm) Max.

36” (91.4 cm)

36” (91.4 cm)

(7.6cm)

Minimum

Minimum

Minimum

Max.

 

 

4”

4”

4”

4”

4”

(10cm)

(10cm)

Max.

Max.

(10cm)

(10cm)

(10cm)

 

 

Max.

Max.

Max.

11

CONCENTRIC VENT TERMINATIONS

For new installations, install 2” or 3” ULC S636 certified PVC or CPVC concentric vent terminations may be used. See the vent termination manufacturer’s instructions for complete installation information or contact customer service at 1-888-479-8324 or techsupport@hotwater.com. For planning purposes, see figures 10-13 below for vent terminal specifications.

Note: For replacement installations, previously installed American Water Heater Company supplied concentric vent kits are acceptable for use on 100,000-130,000 BTU/Hr models only.

Figure 10: 2 Inch Concentric Vent

(14.6cm)

 

(15.7cm)

 

(8.9cm Dia.)

(3.8cm)

(42.2cm)

(4.8cm)

(84.77cm)

 

Figure 11: Through the Wall Termination

(2.54cm)

Figure 12: Through the Roof Termination

12” (30.5cm) Minimum clearance above

anticipated snow level. 24” (61cm) Max.

Figure 13: Through the Wall Termination

18” See Note 4 (45.7cm)

Max.

*

12” (30.5cm)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MinimumAbove

 

 

 

*

 

 

Grade or

 

 

 

 

 

 

 

 

Anticipated

 

 

 

 

 

 

Snow Level.

 

 

 

 

 

 

(See Note 2.)

 

 

 

 

 

 

Notes:

1. Support Horizontal Pipe Every Four Feet (1.2 m). Support Vertical Pipe Every Six ft. (1.8 m).

2. Increase The 12 Inch (30.5 cm) MinimumAbove Grade To Keep Inlet OpeningAboveAnticipated Snow Levels.

3. SlopeAll Piping Down Toward the Water Heater as follows:

´ 3LSLQJ VORSH

*

´ 3HU )RRW PP SHU PHWHU

´ 3LSLQJ VORSH

´ 3HU )RRW PP SHU PHWHU

´ FP PD[LPXP ZKHQ XVLQJ ´ SLSH

For clarity, T&P discharge line not shown. See the Temperature and Pressure Relief Valve section for requirements.

Concentric Venting Multiple Water Heaters (All Models)

When using two Polaris® units, install vent terminations using either Method E or Method F below:

2” (5.08 cm) Max.

Figure 13E, 13F, 13G

36” (.9144 m) Min.

Note: For installation of more than two Polaris® units, follow the pattern established in Method G.

2” (5.08 cm)

 

Max.

36” (.9144 m) Min.

 

12

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.

Figure 14: Input Graph

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.

6.The Polaris® 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:

12 grains per gal. (205 mg/liter) max.

Chloride:

200 mg/liter max.

pH:

6.5-8.0

Alkalinity:

200 mg/liter max.

13

Figure 15: Typical One-Temperature System Piping Installation

 

Figure 16: Sample Mixing

 

Valve Installation

 

Mixing Valve

 

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 has been provided for use with the Polaris® Gas water heater and 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, 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.

14

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.

Figure 17: Air Handler Piping Installation

 

Mixing Valve

 

6” (15.2cm)

 

Air Gap Max.

Metal Drain Pan

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

Tank

 

Valve

 

Temperature

 

 

 

 

Control

(If Used)

 

(170°F [76.6°C] Max.)

 

 

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-

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.

16

GAS SUPPLY AND PIPING

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.

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)-current edition. Canadian installations must be performed in accordance with CAN/CSA-B149.1-current edition.

Note: If using a flexible gas connector, make sure its rating tag matches or exceeds the input of the water heater.

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.

2.Install a drip leg as shown. The drip leg must be no less than 3 inches (7.62 cm) 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.

Figure 19: Gas Piping Installation

3” (7.62 cm) Minimum

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.

17

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. (3.486 kPa) 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. (3.486 kPa), 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.

Explosion Hazard

Have a qualified person make sure that the L.P. gas operating pressure does not exceed 13” water column (3.237 kPa). 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.

18

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.

Note:

The wiring diagram can be found on Page 20. Always reference the wiring diagram(s) for the correct electrical connections.

When installing the electrical wiring to the water heater:

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. models can be found on the inside of the access panel at the base 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.

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 20: Electrical Connections

19

Polaris PC 130-50 2NV, PC 150-50 2NV, PC 175-50 3NV, PC 130-34 2NV, PC 199-50 3NV User Manual

WIRING DIAGRAM

HEATER SUPPLIED WITH T92 SERIES RELAY

Figure 20A

 

 

 

 

 

BLUE

 

 

 

 

 

 

RED

24V

BLUE

RED

RED

 

 

GREEN

BROWN

 

 

 

 

 

 

 

 

 

 

 

GREEN

 

 

 

 

 

RED

 

 

 

THERMOSTAT

 

BLACK

BLACK

0

 

SENSOR/ECO

 

 

GAS VALVE

 

 

 

 

BLACK/WHITE

 

 

 

 

 

 

 

 

 

 

 

IGNITER

 

BROWN

 

 

 

 

 

WHITE

RED

POT

 

 

 

 

 

LED

 

 

 

YELLOW

 

 

 

 

 

 

 

 

 

 

 

 

 

THERMOSTAT

SEN-1

 

 

RED

 

YELLOW

BOARD

LOWER

 

 

 

 

 

 

 

YELLOW

 

 

GREEN

 

GREEN

 

LED

 

24V

 

 

 

 

 

HOT

 

 

 

 

 

COM

ONLY

 

 

 

 

RED

RELAY

 

 

 

 

 

GREEN

NO

 

 

 

 

 

LED

 

 

 

 

 

 

 

YELLOW

 

 

 

 

 

ORANGE

 

 

 

 

 

 

TRANSFORMER

120V

 

 

BLACK

 

 

 

WHITE

 

GREEN

 

 

BLACK

 

GROUND

GREEN

RELAY

1 8 6

BLACK

BLACK/RED

WHITE

IND

 

L1

 

HSI

 

HSIG

 

L2

IGNITION

W

CONTROL

PSI

120V/60Hz

 

GV

 

PSO

 

FSG

 

C

 

 

WHITE

 

BLUE

 

ORANGE

THERMOSTAT

DIAL 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.

HEATER SUPPLIED WITH KUHP SERIES RELAY

Figure 20B

 

 

 

 

 

L1

 

 

NEUTRAL

 

BLOWER

 

FUSED

 

TO 120/60

 

 

 

DISCONNECT

POWER SUPPLY

 

 

GND

WHITE

 

 

N.O.

BLOWER

 

 

 

GND

 

 

8

6 BLACK

 

 

 

 

 

 

BLACK/RED

 

 

 

COIL

 

 

 

RELAY

 

 

 

 

 

 

 

 

 

 

 

 

 

GND

1

L2

 

 

 

 

 

 

 

 

 

0

 

 

 

 

 

 

BLACK/WHITE

WHITE

 

 

 

 

 

 

RELAY

 

NEUTRAL (WHITE)

 

 

 

IND

 

L2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TO 120/60

 

 

 

L1

 

 

HSI

 

 

 

 

POWER

 

 

 

 

IGNITION

 

IGNITER

 

SUPPLY

 

 

 

 

CONTROL

 

 

 

 

 

 

 

 

 

 

FUSED

L1 (BLACK)

 

 

 

 

 

 

HSIG

 

 

 

DISCONNECTED

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

120 VAC

 

 

 

120 VAC

 

 

 

 

 

 

 

 

 

 

(BLACK & WHITE

 

 

 

 

 

 

 

 

 

 

WIRES IN BOLD)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

24 VAC

 

 

 

 

 

PRESSURE

 

 

 

 

GREEN LED

 

 

 

SWITCH

 

 

 

 

 

 

 

PSI

 

 

 

 

 

 

 

 

 

 

 

 

 

C

 

 

 

 

 

 

 

 

 

 

 

 

GAS VALVE

 

 

 

 

 

PSO

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RELAY

 

 

 

 

 

IGNITION

GV

 

 

 

COMMON (C)

 

 

 

CONTROL

 

 

 

 

 

YELLOW LED

 

W

 

THERMOSTAT

 

PRESSURE

 

 

 

 

 

 

 

SWITCH

 

 

 

 

 

 

SENSOR-ECO

 

 

 

 

 

GND

 

N.O.

 

 

 

 

RED LED

NORMALLY OPEN

 

 

COM

SEN-1

 

 

 

 

(NO)

 

 

 

 

LOWER

 

 

 

 

 

 

 

 

THERMOSTAT

 

 

 

 

 

 

 

 

BOARD

24 V

 

 

 

 

 

 

 

 

HOT

 

 

POT

THERMOSTAT

 

 

 

 

 

ONLY

 

 

 

DIAL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GND

20

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