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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 phone in your building.
•
Immediately call your gas supplier
from a neighbor's phone. 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
service agency or the gas supplier.
Thank you for buying this energy efficient water heater.
We appreciate your confidence in our products.
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOU ARE UNSUCCESSFUL, CALL THE TECHNICAL SUPPORT PHONE NUMBER SHOWN ON THE WATER HEATER LABELING.
PRINTED 0117
RESIDENTIAL GAS WATER HEATERS
LOW LEAD
CONTENT
qualified
installer,
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
Instruction Manual
POWER DIRECT VENT GAS MODELS
•
For Your Safety
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
1
WITH DIRECT SPARK IGNITION
MODELS
PG10/GHX/GSP/GTP
Series 200, 201
NATURAL GAS & PROPANE
•
100277191
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Table of Contents
Summary of Contents for Polaris PG10
- Page 1 Instruction Manual RESIDENTIAL GAS WATER HEATERS POWER DIRECT VENT GAS MODELS WITH DIRECT SPARK IGNITION MODELS PG10/GHX/GSP/GTP Series 200, 201 NATURAL GAS & PROPANE LOW LEAD CONTENT WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
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Page 2: Table Of Contents
TABLE OF CONTENTS SAFE INSTALLATION, USE AND SERVICE.........3 Concentric Vent Installation ............29 APPROVALS .................3 Venting Multiple Units .............30 GENERAL SAFETY INFORMATION ..........4 WATER HEATER INSTALLATION ..........31 Precautions ................4 Condensate Drain Installation ..........31 Grounding Instructions .............4 Supply Gas Line Installation ...........31 INSTALLATION REQUIREMENTS FOR MASSACHUSETTS ..7 Gas Line Leak Testing ............32 INTRODUCTION ................8... -
Page 3: Safe Installation, Use And Service
SAFE INSTALLATION, USE AND SERVICE The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. -
Page 4: General Safety Information
GENERAL SAFETY INFORMATION PRECAUTIONS GROUNDING INSTRUCTIONS This water heater must be grounded in accordance with the National DO NOT USE THIS WATER HEATER IF ANY PART HAS Electrical Code and/or local codes. These must be followed in all BEEN EXPOSED TO FLOODING OR WATER DAMAGE. cases. - Page 5 GENERAL SAFETY INFORMATION...
- Page 6 GENERAL SAFETY INFORMATION Fire or Explosion Hazard Fire Hazard Do not store or use gasoline or other flammable vapors and For continued protection against liquids in the vicinity of this or any other appliance. risk of fire: Do not install water heater on Avoid all ignition sources if you smell gas.
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Page 7: Installation Requirements For Massachusetts
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements should be satisfied: INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas... -
Page 8: Introduction
INTRODUCTION Thank You for purchasing this water heater. Properly installed and is essential that all venting, water piping, gas piping and wiring maintained, it should give you years of trouble free service. be installed as shown. ABBREVIATIONS USED Particular attention should be given to the installation of thermometers at the locations indicated in the piping diagrams as these are necessary for checking the operation of the water Abbreviations found in this Instruction Manual include :... -
Page 9: Dimensions And Capacity Data
DIMENSIONS AND CAPACITY DATA ROUGH IN DIMENSIONS: ALL MODELS All Models Additional Side Taps Air Inlet Figure 1 . DIMENSIONS FOR ALL MODELS Table 1A - ROUGH-IN-DIMENSIONS T&P EXTERIOR WATER CONNECTIONS AIR INLET/EXHAUST U.S. INPUT SUPPLY UNITS GALLONS (KBTU/HR) Inches 48-1/2 15-3/4 40-1/2... - Page 10 DIMENSIONS AND CAPACITY DATA Table 2 – CAPACITY, GAS AND ELECTRICAL CHARACTERISTICS Approximate Capacity *Manifold Pressure Electrical Characteristics U.S. Gals. Liters Gas Type “WC Volts/Hz Amperes Nat./LP 120/60 <7 Nat/LP 120/60 <7 * The manifold pressure is the factory setting and is not adjustable. A negative pressure will be seen with just the blower running without the Gas Control Valve open.
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Page 11: Features And Components
FEATURES AND COMPONENTS 34 GALLON UNIT **11 **25 **12 **34 21, 22 **33 This is a view of the area at the bottom of heater behind the **11 Access Doors. **12 VACUUM RELIEF VALVE * CAUTION HARNESS HAS 120 VAC. IN OPERATION. ** See Venting Installation and Condensate Piping for more information. -
Page 12: Gallon Unit
FEATURES AND COMPONENTS (CONT.) 50 GALLON UNIT **11 **25 **12 **34 21, 22 This is a view of the area at the bottom of heater behind the Access Doors. **33 **11 **12 VACUUM RELIEF VALVE * CAUTION HARNESS HAS 120 VAC. IN OPERATION. ** See Venting Installation and Condensate Piping for more information. - Page 13 FEATURES AND COMPONENTS (CONT.) Control Assembly Blocked Intake Switch Blocked Outlet Switch Blower Assembly Burner Assembly Flame Sensor Igniter Assembly Gas Control Valve Assembly Display Board 10: Display Enclosure ** 11: Exhaust Elbow Assembly ** 12: Condensate Drain Outlet 13: Enable / Disable Switch 14: Hot Water Outlet 15: Gas Supply 16: Main Manual Gas Shutoff Valve...
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Page 14: Controls And Switches
CONTROLS AND SWITCHES BLOCKED OUTLET SWITCH The Blocked Outlet Switch is set up to shut the unit off when a build- This model is provided with two pressure switches. These switches up of positive pressure in the exhaust vent pipe occurs. This switch are essential to the safe and proper operation of the unit. -
Page 15: Installation Considerations
INSTALLATION CONSIDERATIONS LOCATING THE WATER HEATER 11. Do not locate the water heater where the subsequent installation of the vent (exhaust) or intake air terminations CAUTION would be objectionable due to noise at the termination(s). This includes locations close to or across from windows and doors. -
Page 16: Insulation Blankets
• Do obtain new warning and instruction labels from the manufacturer for placement on the blanket directly over the existing labels. • Do inspect the insulation blanket frequently to make certain it does not sag, thereby obstructing combustion air flow. COMBUSTION AIR AND VENTILATION A gas water heater cannot operate properly without the correct amount of air for combustion. -
Page 17: Installation Requirements
INSTALLATION REQUIREMENTS GAS SUPPLY SYSTEMS If a positive lock-up regulator is required follow these instructions: 1. Positive lock-up gas pressure regulators must be rated at or above the input Btu/hr rating of the water heater they supply. 2. Supply gas regulators shall have inlet and outlet connections not less than the minimum supply gas line size for the water heater they supply 3. -
Page 18: Mixing Valves
or electrical line noise such as EMI (electro magnetic interference) HOT WATER or RFI (radio frequency interference) may cause erratic control OUTLET system operation and malfunction. 12” TO 15” (30-38 cm) A high quality power supply filter/suppressor must be installed TEMPERED WATER if the above conditions exist. -
Page 19: Space Heating And Potable Water System
SPACE HEATING AND POTABLE WATER SYSTEM devices such as pressure reducing valves, check valves, and back flow preventers. Devices such as these cause the water system to Your water heater is equipped with additional side taps for use in be a closed system. space heating applications. -
Page 20: Temperature-Pressure Relief Valve
connections for all models. NOTE: If using copper tubing, solder tubing to an adapter before attaching the adapter to the water heater connections. Do not Explosion Hazard solder the water lines directly to the water heater connections. It will damage the tank, T & P Valve and Pipe Insulation (if supplied). Temperature-Pressure Relief Valve Fit pipe insulation over the incoming cold water line and the hot must comply with ANSI Z21.22-... -
Page 21: Condensate Drain
• Shall be of material listed for hot water distribution. The Condensate Cleanout Cap must be on and tight when unit is in operation. • Shall be installed so as to allow complete drainage of both the Temperature-Pressure Relief Valve and the discharge NOTE: If the “Blocked Exhaust “... -
Page 22: Venting Installation
Do not attempt to connect Polypropylene with sealant cement. When replacing an existing Polaris unit, it is recommended that the venting system be reviewed for compliance with the • Piping must be sized and cut before cementing. Cut the pipe requirements contained in this instruction manual. -
Page 23: Polypropylene Installations
CPVC pipe materials: Polypropylene vent systems do not use cement to connect the pipe • CPVC 41 ASTM-D2846 or CSA B137.6 and elbow sections but use a push together gasket seal method. Do not attempt to connect Polypropylene with sealant cement. All •... -
Page 24: Integrated Filter Installation
Table 5. M & G Duravent PolyPro Nominal Pipe Flue Outlet Adapter Ring 90 Degree Vent Material Terminal(s) Diameter Adapter Connector Connector Elbow 2PPS & 2PPS-BG for Exhaust; 2” 2PPS-AD PPS-PAC 2PPS-LB 2PPS-E90 2PPS 2PPS-E90 & 2PPS-BG for Intake (Direct Vent only) 3PPS &... -
Page 25: Direct Vent Air Intake Moisture Protection
HORIZONTAL VENT TERMINAL INSTALLATION Hose Clamp NOTE: If you are installing your system so that it vents through the Piped To External Air roof, please refer to Vertical Vent Terminal Installation on Page 26. Supply 1. A f t e r t h e p o i n t s o f t e r m i n a t i o n h a v e b e e n determined (see Vent Pipe Termination on page 23) use the cover plates as templates to mark the holes for the vent pipes to be inserted through the wall. -
Page 26: Vertical Vent Terminal Installation
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 Figures 21 and 22 for the proper location of the air inlet with respect to the exhaust outlet termination. -
Page 27: Termination Clearances Sidewall Direct Vent
TERMINATION CLEARANCES SIDEWALL DIRECT VENT DIRECT VENT (using outdoor air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION Figure 23 Vent terminal clearances for “Direct Vent” installations. Direct Vent configurations use outdoor air for combustion. US INSTALLATIONS US INSTALLATIONS Clearance in accordance with local installation Clearance above grade, veranda, porch, Clearance to each side of center line 12 inches (30 cm) -
Page 28: Direct Vent Installation Diagrams
DIRECT VENT INSTALLATION DIAGRAMS Notes: 1. Support Horizontal Pipe Every Four Feet. Support Vertical Pipe Every Six Feet. Note 6 2. Increase the 12" minimum above grade to keep terminal openings above anticipated snow 12" Min. Above Tee with levels. Grade or Drain Tap Anticipated... -
Page 29: Concentric Vent Installation
CONCENTRIC VENT INSTALLATION For new installations of 100,000, 130,000 & 150,000 BTU/hr units, install 2” Concentric vent kit model KGAVT0501CVT, part number 100093946. For new installations of 175,000 & 199,000 btu/hr units, install 3” Concentric vent kit model KGAVT0601CVT, part number 100093947. See Manufacturer’s instructions for complete installation or call the technical support number listed on the back cover of this manual. -
Page 30: Venting Multiple Units
Method D: When concentric venting three or more water heaters, install vent terminations using Method G below: Figure 32 VENTING ADDITIONAL POLARIS® UNITS (175,000 & 199,000 BTU/HR MODELS) When using two water heaters with inputs of 175,000 BTH/HR or Figure 35... -
Page 31: Water Heater Installation
WATER HEATER INSTALLATION CONDENSATE DRAIN INSTALLATION NOTE: In cold climates it is recommended the condensate drain be terminated at a suitable drain inside the building. 1. Ensure the water heater’s enable/disable switch is in the “disable” 4. Ensure the condensate drain line is not elevated above the position. -
Page 32: Gas Line Leak Testing
Table 8. Natural Gas Capacity (Cu. f t/hr) Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity of 0.60 (natural gas). Nominal Iron Length of Pipe, Feet Pipe Size, in. -
Page 33: Electrical Wiring
ELECTRICAL WIRING CCB enclosure and Figure 48 on page 56 for the CCB layout. Install field wiring to the enable/disable circuit: If you lack the necessary skills required to properly install the electrical wiring to this water heater, do not proceed but have a 1. -
Page 34: T&P Valve Discharge Pipe
circulating pump is used, it is important to note that the flow rate should be slow so that there will be a minimum of turbulence inside the water heater storage tank. Adjust flow by throttling a full port ball valve installed in the circulating line on the outlet side of the pump. -
Page 35: Temperature Regulation
TEMPERATURE REGULATION HIGH TEMPERATURE LIMIT CONTROL (ECO) In addition to using the lowest possible temperature setting that satisfies the demand of the application, a mixing valve can be installed This water heater is equipped with an ECO (energy cut out) non at the water heater (see Figure 8 on Page 18) or at the hot water taps adjustable high temperature limit switch. -
Page 36: Control System Operation
CONTROL SYSTEM OPERATION OVERVIEW CONTROL SYSTEM NAVIGATION The water heaters covered in this manual are equipped with an All operational information and user settings are displayed and electronic control system that regulates water temperature inside accessed from the UIM. The UIM houses the control system’s LCD the storage tank. - Page 37 STATUS ICONS Status Icons are displayed on the Desktop screen and convey operational and diagnostic information. Icons are described in the table below. See Figure 40 on Page 36. Ensure the water heater is properly grounded. Flame sensing requires an adequate earth ground. If the water heater is not properly grounded it will cause Ignition Failure.
- Page 38 OPERATING STATES The current operational state of the water heater is displayed on the Desktop screen as the Status. The common operational states are described in the table below. Table 13 – OPERATING STATES State Description The water heater is not in an active heating cycle. IE: the Tank Temperature is at or above the Operating Set Point minus Standby temperature differential.
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Page 39: User Settings & Control System Menus
USER SETTINGS & CONTROL SYSTEM MENUS TEMPERATURES OPERATING SET POINT AND DIFFERENTIAL ADJUSTMENT The Operating Set Point is adjustable from 90°F (42°C) to 160°F (71°C). The factory setting is 120°F (49°C). The Differential is adjustable from 2° to 20°F. The factory setting is 8°F. These user settings are accessed from the Temperatures menu. These instructions explain how to adjust these settings and navigate the control system. - Page 40 TEMPERATURES (CONT) DESCRIPTION/ACTION DISPLAY • Differential - Adjustable user setting that changes the tank temperature differential with a range of 2° to 20°F. The factory Temperatures setting is 8°F. Operating Setpoint 120°F > • Tank Probe Offset - adjustable user setting, range -5° to +5°F (factory setting 0°F).
- Page 41 DISPLAY SETTINGS DESCRIPTION/ACTION DISPLAY Press Display Settings from the Main Menu to enter this menu. Display Settings This menu contains adjustable display options for viewing information on the UIM’s LCD screen. Use the Slidebar to Temperature Units °F > navigate the menu. Brightness 5 >...
- Page 42 CURRENT FAULT DESCRIPTION/ACTION DISPLAY Press Current Fault from the Main Menu and press the Operational Blocked Exhaust Button under "SELECT" to enter this menu. This menu contains non adjustable operational information. Use the Slidebar to navigate the 0 days 0 hrs 0 mins ago menu.
- Page 43 SERVICE CONTACT INFORMATION The control system has a discrete menu that Installing contractors and/or service agents can access to enter contact information for their customers. This contact information will be displayed with all Fault and Alert messages. DESCRIPTION/ACTION DISPLAY Contact Information From the Desktop Screen (see Figure 40 on page 36) press Show Contact No >...
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Page 44: Start Up
START UP START UP CONDITIONS ground. If the water heater is not properly grounded it will cause Ignition Failure. See Electrical Wiring on page 33. SMOKE/ODOR Be certain that the water heater is full of water, that air is purged It is not uncommon to experience a small amount of smoke and odor from the gas and water lines and that there are no leaks in the gas during the initial start-up. -
Page 45: Initial Start Up
INITIAL START UP MANIFOLD GAS SUPPLY GAS PRESSURE PRESSURE TEST PORT REQUIRED TEST EQUIPMENT TEST PORT • One U-tube manometer, recommended ranges; 0-14” W.C. (0- (Non-Adjustable) 3.5 kPa) and 0-35” W.C. (0-8.7 kPa) or pressure gauges. • One digital manometer can be used in place of U-tube manometers or pressure gauges. -
Page 46: Lighting The Water Heater
LIGHTING THE WATER HEATER LIGHTING & OPERATION LABELS The instruction label below is affixed to the water heater's covered by this manual at the factory and must be followed when lighting and operating the water heater. FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury... -
Page 47: Checking The Firing Rate
The approximate maximum/minimum input for all PG10, 1. Ensure there are no other gas fired appliances connected to GHX, BSP, and BTP models is shown in Figure 44. -
Page 48: Troubleshooting
TROUBLESHOOTING INSTALLATION CHECKLIST Components beginning on page 11 for the location of various water heater components described below. See the Sequence of The list below represents some of the most critical installation Operation Flow Chart on page 49 also. requirements that, when overlooked, often result in operational problems, down time and needless parts replacement. -
Page 49: Sequence Of Operation Flow Chart
SEQUENCE OF OPERATION FLOW CHART If tank temperature drops below Operating Set Point minus Differential setting a heating cycle is activated Control System performs diagnostic checks Control System Locks Out Normal State of all pressure switches and ECO are checked Displays Fault Msg Pressure Switches and ECO are verified closed Combustion Blower is energized... -
Page 50: Operational Problems
OPERATIONAL PROBLEMS If the Main Burner ignites momentarily but does not sustain ignition allow the water heater to try to ignite up to two more times until control system locks out and the Ignition Failure Fault message is displayed on the control system's LCD. If the water heater is experiencing rough starts - see Rough Starting, Rough Operation on this page. -
Page 51: Fault And Alert Conditions
FAULT AND ALERT CONDITIONS are operational problems. This is not a complete list. Along with each of the Fault and Alert messages described there will be a list FAULT CONDITIONS of possible causes and things to check and repair. When the control system declares a Fault condition it will display a Only qualified service technician, as defined in Qualifications using Fault message on the control system's LCD with an exclamation "!"... - Page 52 FAULT AND ALERT MESSAGES (CONT) Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualified service technician in your area. POSSIBLE CAUSES - CHECK/REPAIR DISPLAYED FAULT/ALERT MESSAGE • If Blocked Intake error occurs before blower runs, make sure Blocked Air Intake pressure switch connections are clean and tight.
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Page 53: Leakage Checkpoints
LEAKAGE CHECKPOINTS A: Hot Water Outlet Never use this water heater unless it is completely filled with water. To prevent damage to the tank, the tank must be filled with water. C: T & P Water must flow from the hot water faucet before turning “ON” gas Connection to the water heater. -
Page 54: Periodic Maintenance
PERIODIC MAINTENANCE (See Figure 16 in Integrated Filter Installation). Should overheating occur or the gas supply fails to shut off, turn off the manual gas control valve to the appliance. • To clean filter, lightly tap the back of the filter support to dislodge any large debris. -
Page 55: Draining And Flushing
NOTE: Excessive water pressure is the most common cause of 2. Turn off the gas supply at the Main Gas Shutoff Valve (see Figure 37 on Page 31) if the water heater is going to be shut Temperature-Pressure Relief Valve leakage. Excessive water system down for an extended period. -
Page 56: Diagrams
DIAGRAMS CCB - CENTRAL CONTROL BOARD LAYOUT Figure 48... -
Page 57: Wiring Diagram
WIRING DIAGRAM CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING. CCB J17 Low Voltage Field CCB J5 CCB J16 CCB J1 CCB J3 Blower Logic Low Voltage In HIGH Voltage In Transformer... -
Page 58: Circulation Pump Wiring Diagrams
CIRCULATION PUMP WIRING DIAGRAMS CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK OR BUILDING RECIRCULATION FIELD SUPPLIED TEMPERATURE CONTROL INSTALLED IN THE STORAGE TANK OR CIRCULATING LOOP RETURN LINE NOTE: USE SEPARATE 120 VAC POWER SUPPLY FOR PUMP CIRCUIT. DO NOT SHARE POWER WITH APPLIANCE AS THIS MAY CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM OPERATION. -
Page 59: Piping Diagrams
PIPING DIAGRAMS NOTE: Follow the Mixing Valve manufacturers instructions when installing the mixing valve. Mixing Valve Check local codes. Metal Drain 6" (15.2cm) Air Gap Max. Adequate Drain Figure 51: TYPICAL ONE-TEMPERATURE SYSTEM PIPING INSTALLATION (All Models) NOTE: Follow the Mixing Valve manufacturers instructions when installing the mixing valve. - Page 60 Figure 53: AIR HANDLER PIPING INSTALLATION (All Models) NOTE: Follow the Mixing Valve manufacturers instructions Manual Shut Off Valve (Typ) when installing the mixing valve. Mixing Valve (160°F Max.) Figure 54: POLARIS WITH AUXILLARY STORAGE TANK, One or Two Temperature System (With or Without Building Recirculation)
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Page 61: Notes
NOTES... - Page 62 NOTES...
- Page 63 For Tech Support please call PG10 models: 1-800-456-9805 GHX models: 1-800-365-0024 GSP/GTP models: 1-800-527-1953 Copyright © 2016 A. O. Smith Corporation. All rights reserved.