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Polaris 2NV User's Manual

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5. Bronze Check Valve Typ Circulating Pump Arrow Indicates Direction of Flow Optional Two Temperature Installation 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 exces sive temperature or pressure developing in the water heat er 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 ade quate 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 amp 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 amp 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 dis charge line Must terminate a maxim
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11. 1 ZEB ue uogejueue IANO F Sioej snjd uaneque epuaJ 1 159 1980 ENUBUI 18118 jeutqoJ 9 je nee eyneuo 9 eue apo juiof e pjoooej un Jejejsu ne p seyejennoD 19 s j B5uen seJeneui 58 8 85 Sa JND Janod unenBuo ep od c wo Z9 Sulow ne JeJnsauJ zop oBund ep julod 37 eusnjir enb ja Sand ep jurod un Jjejjejsu Z uioseq ne zef e Jjednoo Jnod jeuiqou np rojduue p epouu je jueujeoe duje eJreuuoo 1 Xn amp 20 Sol QNd 599 195 sep suonepueujlul0281 xne Ju uu uulojuo2 e qisseooe jueulo oe janueui 198118 jeuiqoJ un zef ue uonejueuuje p NE N ne JeJ69ju zeB ep euejne n e ep uonej ejsur nod 6 1 1 ej e 1 es je snossep m SUONINJIJSUI 58 JANS nee ejgneuo np uononpoJd el ossedop no puodsauoo enbnoejeuBis enbejd ej ep apanbne enb JeJnsse s SIN 158 4 ze ep 1nejoeuuoo un IS nb ew y L 6b7LE VSO NVO Snoo ue uonipo e jueumguJojuoo 5996 199 9 8419 JUBAIOP seuueipeueo suonejejsur se ISNV eBeyneuo np 19 zef np jeuoneu epo gt np sunoo ue uonipe e 19 XxNad ep eouesqe ue NO jeje p 19 xneoo sepoo xne 9jluuojuoo ue 88 8151 879 yop zef ep 818 zeb op eyinpuo5 Sejnj Sa Jajaoep 1nod JUESHOPO e Ju uu n s 1914 es sed SN epoued enBuo eun sede Jedissip as jned juesuopo nes ayneyo e ejueuuie inb zeb ne juesuopo un Jajnofe jnad zeB ap
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13. 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 instal lation 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 r Sides 4 10 2 cm Min for service p Vent 0 0 cm Top 0 0 cm 4 r Front 24 61 cm Min for service TOP VIEW 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 hea
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17. 15 2cm eco Air Gap Max Adequate Drain 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 correspond ing increase in water pressure due to thermal expansion Thermal expansion can cause premature tank failure leak age This type of failure is not covered under the limited warranty Thermal expansion can also cause intermittent temperature pressure relief valve operation water dis charged 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
18. 7 Digit product number Serial number Date of installation Place of Purchase Tablevof Contents sandete meet marie 2 KE 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 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 A DANG ER avoided will result in death or injury A WARN NG 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
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25. 3 Close the manual gas shut off valve in the gas supply line near the water heater occurrence of igniter failure due to excessive condensate Important A mixing valve provided must be installed in the hot water outlet to reduce the risk of scald injury when setting the thermostat in excess of 120 F 48 9 C Many home heating systems Figure 22 used with this water heater are Temperature Dial designed for temperatures higher than 130 F 54 4 C Refer to the manufacturer s instruction manuals supplied with this type of equipment for recommended temperature settings Important Adjusting the HIGH thermostat past the 120 F 48 9 C setting on the temperature dial see figure 22 will increase the risk of scald injury Hot water can produce first degree burns within 140 F 6030 Time for 1st Temperature Degree Burn F C Less Severe Burns 110 43 3 normal shower temp 6467 pamivesod 116 467 Time for Permanent Burns 2nd amp 3rd Degree Most Severe Burns U S Government Memorandum C P S C Peter L Armstrong Sept 15 1978 Emergency Shut Down Important If overheating occurs or the gas supply fails to shut off close the manual gas supply valve Turn off the electrical supply to the unit and close the cold water supply valve Do not operate the water heater again until it has been thoroughly checked by an authorized service technician 23 OPERATIONAL CONDITION
26. 91 4 cm 36 91 4 cm Minimum Minimum i qr Q Exhaust em i 4 4 9 Exhaust 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 Figure 13 Through the Wall Termination termination manufacturer s instructions for complete installation information or contact customer service at 1 888 479 8324 or techsupport Qhotwater com For planning purposes see See Note 4 45 fom 5 figures 10 13 below for vent terminal specifications Mex Note For replacement installations previously installed 2 American Water Heater Company supplied concentric vent kits T DUIS are acceptable for use on 100 000 130 000 BTU Hr models only 2 or 3 Tee w Drain Trap Trap Figure 10 2 Inch Concentric Vent To Drain See Note 3 2 Dia Vent Exhaust 12 30 5cm Minimum Above Combustion Grade or Air Inlet Pipe Anticipated 2 or 3 Snow Level See Note 2 ry 6 25 15 7cm RUE 2 Dia PVC Inlet iem Dia Combustion Air 4 1 50 3 8cm Notes 1 Support Horizontal Pipe Every Metal Four Feet 1 2 m Support Drain Pan Vertical Pipe Every Six ft 1 8 m Piped to amp 4 16 625 42 2cm 33 375 84 77cm Increas
27. 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 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 connect the heater to the air inlet use the
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36. 5 Exhaust Pipe 2 or3 Combustion Air Inlet Pipe 2 or3 Metal Drain Pan Piped to Adequate Drain To Drain E i n las Condensate Trap Assembly 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 PITCHED ROOF INSTALLATION Exhaust 4 10 cm Max Vent 30 5 cm Mi 12 30 5 cm Min An
37. 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 Cutthe 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 moder ate 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 allow able 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 le
38. COMMON C BLUE PRESSURE ORANGE SWITCH YELLOW 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 NORMALLY OPEN NO HEATER SUPPLIED WITH KUHP SERIES RELAY Figure 20B BLOWER GAS VALVE THERMOSTAT SENSORJECO TO 120160 POWER SUPPLY D L1 BLACK FUSED DISCONNECTED 120 VAC BLACK amp WHITE WIRES IN BOLD IGNITION CONTROL 120V 60Hz COMMON C PRESSURE SWITCH YELLOW ORANGE THERMOSTAT DIAL 20 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 NORMALLY OPEN NO FUSED DISCONNECT NEUTRAL TO 120 60 POWER SUPPLY BLACK RED BLACK WHITE L2 HSI IGNITION CONTROL HSIG IGNITER 120 VAC AAAS VY YN ai T PRESSURE e YELLOW LED SWITCH od PSI LT GREEN LED GAS VALVE PSO IGNITION cy e CONTROL w THERMOSTAT SENSOR ECO TI GND e FUSED DISCONNECT HOT THERMOSTAT ONLY ROT x DAL 1 5 y RED LED NO gen COM LOWER THERMOSTAT BOARD 24V GND NEUTRAL TO 120 60 POWER SUPPL
39. See figure 5 for details Two 45 elbows are considered equivalent to one 90 elbow 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 amp 150 000 BTU HR 29 3 38 amp 43 9 KW input models only pipe must be used for 175 000 BTU Hr 51 29 kW input and above 7 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 antici pated 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 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 When terminating a vent under a veranda porch or deck venting must be installed in accordance to all lo cal and provincial codes or in the absence of local and provincial codes please refer to the CAN CSA B149 1 A v
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43. 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 per formed in accordance with CAN CSA B 149 1 current edi tion 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
44. freezing temperatures To drain the tank perform the following steps 1 Turn off the gas supply at the Manual Gas Shut off Valve Turn off the electrical supply to the water heater 2 Open a nearby hot water faucet and run until the water is no longer hot 3 Close the cold water inlet valve 4 Open the left hand access panel at the bottom of the heater see figure 23 Connect a hose to the drain valve and terminate it to an adequate drain or external to the building 5 Open the water heater drain valve and allow all of the water to drain from the tank 6 Flush tank to remove sediment 7 Close the drain valve replace access door refill the tank and restart the heater as directed under Operating Your Water Heater 24 Figure 23 Drain Valve Access Drain Valve Behind Access Door IMPORTANT Condensation may occur when refilling the tank and should not be confused with a tank leak Temperature and Pressure Relief Valve Manually operate the temperature and pressure relief valve at least once a year to make sure it is working properly To prevent water damage the valve must be properly connected to a discharge line which terminates at an adequate drain Standing clear of the outlet discharged water may be hot slowly lift and release Discharge line to drain the lever handle on the temperature and pressure
45. 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 cor rosive elements in the atmosphere is excluded from war ranty 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 pr
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49. 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 Water Heater Safety Installation Instructions Unpacking the Water Heater Location Requirements Condensate Line Intergrated Filter Installation Vent Pipe System Vent Terminations Gas Input Rate Water System Piping Gas Supply and Piping Electrical Connections Wiring Diagram Installation Checklist Operating Your Water Heater Polaris amp Operating Instructions Maintenance of Your Water Heater Troubleshooting Software Operation Sequence Parts List and Diagram Polaris Models and Dimensions 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
50. 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 Cold Inlet Thermal Expansion Tank Cold Water Supply to Fixtures Pressure Reducing Valve if required A b D Main Water ph Supply 44 Cold Water Inlet Valve 6 15 2cm Air Gap Max e Adequate Drain Storage Tank Installation When installing the Polaris amp 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 tempera tures to the water heater tank may be in excess of 120 F 48 9 C A mixing valve must be installed in the water sup ply 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 20 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 sup plied for domestic use hand wash ing showering etc a mixing valve Hot Water Outlet 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 sup ply line an expansion tank must be installed between the check valve and the water heater s cold w
51. these instructions once more If the appliance still refuses to light follow the instructions To Turn Off Appliance and call your service technician or gas supplier Temperatures shown are approximates and may vary TO TURN OFF GAS TO APPLIANCE Turn the temperature dial counterclockwise to the lowest setting Turn off electric power to appliance if service is to be performed Stacking Stacking occurs when a series of short draws of hot water 3 gallons 11 3 liters or less are taken from the water heater tank This causes increased cycling of the burner and can result in increased water temperatures at the hot water outlet A mixing valve must be installed in the hot water supply line to reduce the risk of scald injury Water Temperature Regulation AWARNING Water temperature over 125 F 51 6 C can cause severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before setting temperature at water heater Feel water before bathing or showering Temperature limiting valves are available The thermostat is adjusted to its lowest temperature setting when it is shipped from the factory Water temperature can be regulated by moving the temperature dial to the preferred setting The preferred starting point is 130 F 54 4 C however in some instances setting the water heater higher than 130 F 54 4 C can reduce the
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53. 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 Unions Optional To Heating S Vo D Shut off Valves Unions S Optional Q PE From Heating System Metal Drain Pan 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 pre vent 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 amp P or higher than normal water temperatures are the first signs of thermosiphoning The hot water line from the water heater should be ver tical past any mixing valve or supply line to the heating system to remove air bubbles from
54. 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 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 adap tor 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 Usi
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57. 45 Elbow 2 5 08 cm Max 36 9144 m Min P 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 baro metric 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 orde
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61. 9 2 1 62 05832 EXTERIOR AIR INLET EX APPROX T amp P GAS HGT SUPPLY HAUST SHIP Ee e s we WATER CONNECTIONS 15 3 4 40 1 2 41 6 3 8 5 1 2 6 5 8 50 Ib 40 1 03 1 04 162 4140 168 68 kg 15 34 40 1 2 41 6 3 8 5 1 2 6 5 8 50 Ib 40 1 03 1 04 162 4140 168 68 kg 15 34 40 1 2 41 6 3 8 5 1 2 6 5 8 50 Ib 40 1 03 1 04 162 4140 168 68 kg 15 34 54 172 55 6 3 8 5 1 2 I 6 5 8 76 Ib 40 1 38 1 40 162 140 168 79 8 kg 15 34 55 3 4 56 14 6 3 8 5 1 2 I 6 5 8 80 Ib 1 41 1 43 162 140 168 81 6 kg 40 15 34 55 3 4 56 14 6 3 8 5 1 2 I 6 5 8 80 Ib 40 1 41 1 43 162 140 168 81 6 kg 22 55 22 55 22 55 22 55 22 55 22 55 22 55 15 34 55 3 4 56 14 6 3 8 5 1 2 6 5 8 80 Ib 40 1 41 1 43 162 140 168 81 6 kg 29 NOTES 30 NOTES 31 Polarise Commercial Gas Water Heater GSW Water Heating 599 Hill Street West Fergus ON Canada N1M 2X1 Should you have any questions on obtaining technical warranty or service assistance during or after the installation of this water heater email us at techsupport gsw wh com or visit our website at www gsw wh com mor www johnwoodwaterheaters com Dors call our Technical Support line at 1 888 GSW TECH 479 8324 Copyright 2011 GSW Water Heating is a division
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69. MINATIONS 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 includ
70. NDS NO FINAL DRAFT PROVING CONTROL POWER FLAME ESTABLISHING UP TURN OFF IGNITER FOR 1 SECOND FLAME PROVING PERIOD BLOWER AND GAS VALVE REMAIN ON NO IS PRESSURE SWITCH OPEN PRESSURE SWITCH TEST IS FLAME PRESENT AND PRESSURE SWITCH CLOSED IS THERMOSTAT SATISFIED YES IS FLAME PRESENT VES TURN ON BLOWER T TURN OFF GAS VALVE TURN OFF GAS VALVE 60 SECOND TURN OFF GAS VALVE PURGE IS GAS VALVE OFF SW IS PRESSURE SWITCH CLOSED INITIAL DRAFT PROVING ITCH WAS THIS THE 3RD ATTEMPT NO 6 SECOND PRE PURGE AFTER THE PRESSURE SWITCH CLOSES WAS THIS THE 4TH SEQUENCE I E 12 TOTAL 5 FOR IGNITION NO FLAME 45 SECOND INTER PURGE SOFT LOCKOUT RESETS AFTER 60 MINUTES IS THE PRESSURE SWITCH CLOSED WITHIN 60 SECONDS HARD LOCKOUT NO TURN OFF BLOWER FOR 60 SECONDS 27 REPAIR PARTS LIST DIAGRAM When ordering repair parts always give the following information 1 2 3 4 Repair Parts List Model serial and product numbers Type of gas Item number Parts description PARTS DESCRIPTION 1 1 NPT x 2 5 BRASS NIPPLE 2 THERMOSTAT SENSOR BUSHING KA PLUGS 8 PRESSURE SWITCH 9 COMBUSTIONBLOWER 28 TOOLS REQUIRED FOR SERVICING T
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72. OOL FUNCTION VOLT OHMMETER MEASURE VOLTAGE RESISTANCE CLAMP ON AMMETER MEASURE CURRENT CLOCK GAS CONSUMPTION CALCULATE INPUT RATE READ INLET GAS PRESSURE 3 16 inch 4 76 mm ID PLASTIC TUBING 2 FT 61 CONNECT MANOMETER 1 amp 2 PHILLIPS SCREWDRIVERS REMOVE DOORS AND CONTROLS 12 30 48 cm PIPE WRENCH 2 REQUIRED REMOVE GAS LINE REMOVE BLOWER AND BURNER REMOVE BLOWER AND BURNER REMOVE IGNITER REMOVE THE GAS VALVE POLARIS MODELS amp DIMENSIONS Figure 26 pt i Nip Valve lt lt B Temperature Control Knob Exhaust Hot Water Outlet A Y D under E Air et Cold ol ater Inle ti y DP net Gas Connection m Air Inl f irtnist Exhaust Outlet Side Tape l Valve Gas Supply Contlensate E rain PJ 8 Connection e G LY LEFT SIDE FRONT TOP Table 6 Length in inches meter INPUT MBTU Liter PER HR DIA MODEL NUMBER CAP Kilowatt INCHES PC 100 34 2NV OR 2PV 34 100 2053 48 1 2 128 7 0 02930 1 23 PC 130 34 2NV OR 2PV 34 130 20R3 48 1 2 128 7 0 03809 1 23 PC 150 34 2NV OR 2PV 34 150 2053 48 1 2 128 7 0 04396 1 23 PC 130 50 2NV OR 2PV 50 20R3 62 38 189 2 0 03809 1 58 0 130 PC 150 50 2NV OR 2PV 5 150 2053 6234 189 2 0 04396 1 62 PC 175 50 3NV OR 3PV 50 175 3 63 34 189 2 0 05128 1 62 PC 199 50 3NV OR 3PV 50 199 3 63 3 4 18
73. S Water Heater Sounds During the normal operation of the water heater sounds or noises may be heard These noises are common and may result from the following 1 Normal expansion and contraction of metal parts during periods of heat up and cool down 2 Sediment buildup in the tank bottom will create varying amounts of noise and may cause premature tank fail ure Drain and flush the tank as directed under Drain ing and Flushing Safety Shut Off Pressure Switch This water heater is equipped with a pressure switch that protects the unit by shutting it down in the event that A blockage occurs in the combustion air inlet the flue gas exhaust outlet or both the inlet and outlet The condensate line freezes and the condensate backs up and fills the exhaust outlet The blower fails to operate or operates improperly The unit begins to operate at an abnormally low input level Energy Cut Off ECO A high temperature limit switch or ECO is used to shut down the water heater if the water temperature exceeds 203 F 95 C The ECO will automatically reset when the temperature cools sufficiently If the ECO shuts down the heater repetitively contact a qualified professional for Service MAINTENANCE Draining and Flushing It is recommended that the tank be drained and flushed every 6 months to remove sediment which may buildup during operation The water heater should be drained if being shut down during
74. S LAMMABLES p Flammable Vapors 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 Vehicle Stop 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 bath room 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 the termination with a minimal
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76. 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 amp Care Guide To obtain technical warranty or service assistance during or after the installation of this water heater visit our website at http Awww gsw wh com or call toll free 1 888 479 8324 When calling for assistance please have the following information ready Model number
77. Y GND BLACKWHITE IGNITION CONTROL HSIG IGNITER 120 VAC AA YY 4 PRESSURE e YELLOW LED SWITCH mr PSI GREEN LED c GAS VALVE PSO RELAY IGNITION ev o CONTROL w kt THERMOSTAT SENSOR ECO 4 GND d RED LED NO sev H COM ME THERMOSTAT THERMOSTAT DIAL GND INSTALLATION CHEGKLIST Water Heater Location Requirements O O Centrally located with the water piping system Located as close to the gas piping and vent pipe system as pos sible Located indoors and in a vertical position Protected from freezing temperatures Proper clearances from combustible surfaces main tained and not installed directly on a carpeted floor Sufficient room to service the water heater Provisions made to protect the area from water dam age Properly sized metal drain pan installed and piped to an adequate drain Installation area free of corrosive elements and flammable materials Condensate Line OO 0 0 Drain stem is fully inserted in the elbow and glued properly Trap aligned so that the exhaust pipe is in a vertical position close to the surface of the water heater Line properly sloped to adequate drain or approved condensate pump Properly vented Protected from freezing if required Vent Pipe System OO 0 00 O Vent pipe and fittings of appro
78. aks must be fixed immediately 10 Be sure tank is completely filled with water before re storing power to the water heater Follow operating instructions on Page 23 11 Ensure proper operation of the water heater then rein stall the access door If additional information is required contact the Product Service and Support Group through our website www techsupport gsw wh com Eo uum Figure 25 T 25 Torx Screws 3 EE e Gasket Pressure Tap Flange ong 25 TROUBLESHOOTING Table 5 Ignition Control Module ICM LED Error Codes Flashes visible through viewport in access door UR Pressure Switch Open gs am Fakat 84 5 UL ssvaveHamwareFad sj Hardware au 86 Pe SSCs Flame grit Contr Harcware Fault s UL Igritin Control Software Fault sj SL Soft Lockout Control Automatically resets after 60 minutes SL3 Soft Lockout Hard Lockout Control automatically resets after 60 minutes with a maximum of 3 resets followed by hard lockout requiring service SC Self Clearing Control will function normally as soon as it no longer detects the previously indicated fault when pressure switch or blower relay opens when flame is no longer sensed Blower Isolation Relay is used on models 150 000 BTU Hr and above Note If unit goes into a soft or hard lock out the ignition control module can be reset by cycling
79. ater 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 recirculat ing line to five gallons per minute Tempered Water Outlet Return Connection If Used Tempered Water Circulating Line Temperature and Pressure Relief Valve AWARNING 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 tempera tures a temperature and pressure relief valve must be installed in the opening marked T amp P RELIEF VALVE This valve must be design certified by a nationally recog nized testing laboratory that maintains periodic inspection of the production of listed equipment or materials as meet ing the requirements for Relief Valves and Automatic Shut 16 Figure 18 Polaris with Auxillary Storage Tank One or Two Temperature System With or Without Building Recirculation Termometer I Thermometer x Tap 7 Valve Hot Water Circulating Line Return Connection If Used Tank Temperature Control 170 F 76 6 C Max
80. bove roof snow level Correct relationship outlet to inlet Away from corners other vents windows etc Concentric 12 Min 30 5 cm above grade snow level 2 exhaust outlet air inlet pipe sloped down towards water heater at 1 4 per foot 21 mm per meter 3 piping sloped down towards the heater at 1 8 per foot 10 5 mm per meter Away from corners other vents windows etc Water System Piping O L L L L Temperature and pressure relief valve properly installed with a discharge line run to an open drain and protected from freezing All piping properly installed and free of leaks Heater completely filled with water A properly sized expansion tank must be installed on all closed systems A mixing valve must be installed per the manufacturer s instructions Gas Supply and Piping L L L L L L If using a flexible gas connector make sure its rating tag matches or exceeds the input of the water heater Adequate pipe size and of approved material Gas supply is the same type as listed on the water heater data plate Gas line equipped with full opening shut off valve union and drip leg Approved pipe joint compound used Chloride free soap and water solution or other ap proved means used to check all connections and fit tings for possible gas leaks Electrical Connections OOOOO Unit connected to a dedicated power supply Unit connected to a 120V electrical supply Proper polarit
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85. e The 12 Inch 30 5 cm Adequate Minimum Above Grade To Keep Drain N Inlet Opening Above Anticipated Snow Levels c Slope All Piping Down Toward Condensate the Water Heater as follows Trap Assembly To Drain 2 Piping slope 1 4 Per Foot 21 mm per meter Exhaust Pipe 2 or 3 3 Piping slope 1 8 Per Foot 10 5 mm per meter 4 18 45 7cm maximum when using 3 pipe 2 inch concentric gen piping 1 2 54cm A gt gt Combustion Max 45 Elbow Air Important Intake leg must be positioned as to Conce ntric Venti ng M u Iti ple Water not allow any water or condensate to collect or partially block the intake pipe Heate rs Al M odels When using two Polaris units install vent terminations using either Method E or Method F below For clarity T amp P discharge line not shown See the Temperature and Pressure Relief Valve section for requirements 1 Exhaust 12 30 5cm Minimum Combustion Air I clearance above anticipated snow level Roof 24 61cm Max boot flashing Figure 13E 13F 13G 36 9144 m Min gt Note For installation of more than two Polarise units follow the pattern established in Method G
86. e a pilot light It is equipped with an electronic ignition that automatically lights the burner There are three lights to indicate the various stages of operation Green Electrical power is on Yellow Thermostat is calling for heat which signals the beginning of the ignition sequence see figure 21 and Red Ignition control is signaling the gas valve to open Figure 21 Sequence of Operation ELECTRICAL POWER APPLIED TO UNIT IGNITER WARMS UP APPROX 35 SECONDS BLOWER OPERATES GAS VALVE OPENS THERMOSTAT CALLS FOR HEAT MAIN BURNER LIGHTS WATER HEATER OPERATES UNTIL CALL FOR HEAT ENDS BLOWER PREPURGE APPROX 6 SECONDS 22 When the thermostat calls for heat the blower will run for 6 seconds to purge the system of any accumulated gas or air The hot surface igniter will heat up for 35 seconds The blower will turn on and the gas valve open forcing the air and gas mixture across the hot surface igniter causing the burner to light The hot surface igniter will turn off and act as an electronic flame sensor to determine if burner ignition has been accomplished If it detects any loss of flame it will shut off the gas supply to the burner The ignition control will try to light the burner three times If the ignition control does not detect a flame after three tries it will temporarily lock out but then auto restart and go through three additional tries for ignition after 60 minutes It will repeat until ign
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88. eater 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 lo cal 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 Shutoff 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 over load protection should not exceed 15 amperes 4 Connect thi
89. ed 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 Note All Termination Piping and Fittings Are 2 Exhaust Outlet Refer to Fig 7 for Inlet Outlet Location Dimensions Figure 7 Standard Horizontal Termination pe 3 7 6cm Max unne io Exhaust 4 10 cm f Inlet m rcc 12 30 5 cm lt T oui 2 Max Coupling See Note 2 Combustion Air Inlet Termination and Exhaust Air Termination Must Be Located In The Same Pressure Zones See 12 30 5cm Min Above Note 3 Grade or Anticipated Snow Level See Notes Note 4 Support Horizontal Pipe Every Four Feet 1 2 m Support Vertical Pipe Every Six Feet 1 8 m When Using 3 Inch Pipe Reduce To 2 Inches Before Penetrating The Outside Wall 18 Inch 45 7 cm Maximum When Using 3 Inch Pipe Increase The 12 Inch 30 5 cm Minimum Above Grade To Keep Terminal Openings Above Anticipated Snow Levels Slope All Piping Down Toward the Water Heater as Follows 2 Piping slope 1 4 Per Foot 21 mm per meter 3 Piping slope 1 8 Per Foot 10 5 mm per meter 2 or 3 Tee w Drain Tap Trap To Drain See Note
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92. ent shall not terminate less than 7 ft 2 1 m above a paved sidewalk or paved driveway that is located on public property A vent shall not terminate in an area where children or animals could block pipes A vent shall not terminate in a location that is too close to shrubs or bushes Caulk all cracks seams and joints within 6 feet 1 83 m horizontally above and below the vent o0 Ff vent should terminate according to the following guidelines Combustion air inlet termination and exhaust air termi nation must be located in the same pressure zone Figure 6 Minimum Clearances for Inlet Outlet and Concentric Vent E INSIDETAIL QAir Supply Inlet M Vent Terminal Area Where Terminal Is Not Permitted US Installations Canadian Installations A 12 in 30 cm min clearance above grade A 12 in 30 cm min clearance above grade veranda porch deck balcony or m ximum 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 Clearance to permanently closed window 12 in 30 cm min vertical clearance to ventilated soffit located above the terminal within a horizontal of 2 ft 61 cm from the center line of the erminal 12 in 30 cm min clearance to unventilated soffit Clearance to outside corner 2 ft 61 cm clearance to inside corner formed by
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95. f this valve and how to shut off the water to the heater Figure 14 Input Graph 350000 ETUTH 44 kw 130 000 BTU Hr 38 kw 130000 BTU Hr 38 kw 5 Q I I e 100 000 BTU Hr 29 kw 100 000 BTU Hr 29 kw Minimum Maximum Vent Length 6 The Polaris gas water heater is shipped with a factory installed Temperature and Pressure Relief Valve Install a discharge line in the opening in the T amp 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 min utes 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 perfor mance 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 chlor
96. heat tape and or approved insulation for freeze protection Install per manufacturer s instructions Do not common drain with the temperature and pres sure 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 Donotrun the condensate line into the metal drain pan VENT PIPE SYSTEM AWARNING 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
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99. ides 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 65580 Alkalinity 200 mg liter max 13 Figure 15 Typical One Temperature System Piping Installation Tempered water to fixtures Unions Optional NOTES The pressure reducing valve must be installed on the main cold water inlet line to the structure in order to reduce pressure in the entire water system Check local codes Metal Drain Pan 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 inle
100. ition occurs or the system locks out requiring service Refer to Troubleshooting Guide on Page 26 Thermostat Sensor The sensor is a 10K ohm at 77 F 25 C thermistor Read resistance through the black wires that run to the sensor Remove wires from circuit board before checking An open or short circuit indicates sensor failure Check reading against the values listed in Table 3 The resistance should correspond with the temperature in the tank Table 3 Temperature Resistance OPERATING INSTRUCTIONS 1 Turn temperature dial counterclockwise Y to the lowest setting 2 Turn off electrical power to the appliance es Temperature Dial ae oc qot 844 cy 140 F 60 C Low HIGH This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand To clear any gas that may have accumulated wait ten 10 minutes If you smell gas STOP Refer to the safety warning on the front cover of this manual If you do not smell gas go to the next step 140 F 60 C 5 Turn on the electricity to the water heater The green power light will glow 6 Turn the temperature dial clockwise to the desired setting The yellow ignitor light will glow when the thermostat calls for heat After LOW HIGH 35 seconds the burner will fire and the red burner light will glow If the appliance will not operate after three automatic tries follow
101. ittings 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 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 Standard Horizontal 2 Pipe Alternate Horizontal 2 Pipe Vertical 2 Pipe Concentric Vent Through the Wall Concentric Vent Through the Roof Sow
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104. kage YES Fix the tubing connections Blower runs non stop YES The blower isolation relay or the ignition control Repl Tailed t and Trach code erfor module relay is stuck in a closed position eplacedaled componen Blower turns off YES Replace igniter NO niter terminal Igniter heats for 35 sec igniter terminal NO Replace ignition control module Red LED on Replace ignition control module YES Is 24 DC across gas valve leads Is 24 Vac across GV lead on Manbumerighisin4sec NO Gas supply pressure at the rectifier plug outlet ignition control module and GND within data plate range YES NO NO YES Replace gas valve rectifier plug Replace ECO Replace gas valve Red LED goes out and yellow Check amp repair the following and green LEDs stay on Blocked venting Leaking pressure switch tubing Defective pressure switch Main burner remains lit NO until call for heat ends End troubleshooting Replace ignition control module 26 SOFTWARE OPERATION SEQUENCE IGNITION CONTROL MODULE SOFTWARE OPERATION SEQUENCE TURN OFF BLOWER AND TURN IGNORE PRESSURE SWITCH ON INGNITER FOR 35 SECOND FOR 5 SECONDS HEAT UP HSI WARM UP IS PRESSURE NO SWITCH CLOSED SET THERMOSTAT STANDBY IS THERMOSTAT SATISFIED IS PRESSURE SWITCH OPEN YES YES YES STEADY STATE HEATING UNTIL THE THERMOSTAT IS SATISFIED TURN ON BLOWER AND GAS VALVE FOR 3 SECO
105. llation see figure 25 for exact placement of the rubber gasket 1 Remove the O ring from the flange removed from the old gas valve and replace it with the one provided in the gas valve kit model VK8115V part number 6903775 Reattach the elbow flange to the gas valve Tighten all four screws securely Place the three T 25 Torx screws through the proper holes in the venturi manifold flange See figure 25 Properly install a new rubber gasket provided as shown in figure 25 5 Position the gas valve and start all three screws projecting downward from the venturi manifold into the gas valve A T 25 Torx wrench has been provided in the gas valve replacement kit model VK8115V part number 6903775 Note All three T 25 Torx screws must be properly tightened to secure the seal between the gas valve and the venturi manifold 6 Reconnect the pressure tap to the port on the new gas valve see figure 25 7 Reconnect the external gas supply line to the gas pip ing on the gas valve Be sure to use approved Teflon tape or pipe joint compound suitable for gas piping Note Use a second pipe wrench on the gas piping inside the skirt to avoid cracking the gas valve or the cast fitting 8 Reconnect the electrical plug to the gas valve and secure it with the screw provided 9 Turn gas supply on and check for leaks Use a chlo ride free soap and water solution bubbles forming indicate a leak or other approved method All le
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107. ng your fingers or a small flat blade screwdriver remove the filter media from the outer clamshell hous ing handle carefully see figure 4D Toclean filter lightly tap the back of the filter support to dislodge any large debris Smaller debris may be re moved 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 Figure 4A Remove Plastic Cap Outer Clamshell Housing With Filter Base Skirt Push On amp Tighten Clamp Adaptor Rubber Outer Clamshell Housing Piped To External Air gt Suppl ids 3 x 3 x 3 TY DWV Fitting Position Cure Slope Upward NS Adaptor Rubber Boot N Outer Clamshell Housing Install A Small Portion s Of Pipe And A Pipe Cap 3 Plastic Pipe To Rest On Floor amp 2 Filter Media Filter Media shown inside the Outer Clamshell Housin NOTE if found difficult to reattach the ou
108. ngth 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 correspond ing number indicates the maximum length of inlet pipe Table 1 Maximim allowable Length in Feet Meters of Exhaust and Air Inlet Pipe For Schedule 40 CPVC OR PVC Pipe and Fittings Number of 90 Elbows short or long sweep only 0 243 4 5 6 48 14 6 Termination Option Std Horizontal 40 12 2 Alt Horizontal Vertical Concentric 44 13 4 48 14 6 125 120 115 110 105 100 N A 38 1 36 6 38 33 5 32 30 5 Std Horizontal 115 105 110 N A 5 83 5 32 100 95 90 30 5 28 9 27 4 Alt Horizontal Vertical Concentric 410 105 100 95 33 5 32 30 5 28 9 130 120 115 39 6 36 6 35 125 120 115 110 105 100 38 1 36 6 35 33 5 32 30 5 N A Notes 1 N A Not Applicable 2 The above maximum lengths are for the separate inlet and outlet pipe systems and not the combined length of both systems Maximum of 6 elbows may be used per pipe Use only short or long sweep elbows
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115. of A O Smith Enterprises Ltd All Rights Reserved 5 SJI0JP 9 pr s sudi lug uiug o v ep UOISIAIP eun 159 MSO LLOZ sJnane p 91914 vz 8 627 HOAL MS9 888 1 juesoduuoo ue anbiuyse uannos ap euBi eou Jajaddy NO ulOO9 SsJ9jeeuJojewpooMuuoF MMM NO WOD UM MS MMM Q M JIS 8101 1 5 NO uloo uw MsB o uoddnsuoei e Jeuunoo un SNOU nee epjneuo 89 ep uonejejsur sede no juepued ueneaque 19 enueJeb e e 5 18 9 sjueujeuBiesueiJ sep enbiuuoe eouejsisse eun p uonuejqo jueujeouoo suonsenb sep Zane SNOA IS LXZ INLN epeueo NO snad IS9M 19815 669 BuneeH MSD amp i24euJul09 Zeb ne nes ayneyyD sSIJe Og SANODYVINAY SANODYVINAY 6c 084 By 918 081 A 9 18 081 Y 9 18 OSL 891 0 05 0 64 89 8 S 9 Z L S NOILIQ3dX3 d XONddV Saiod av a NOILVNOWAA B3A8UV 69 0 9 9 LY eli or pr ZV9 NA NOILVLNAWITV isd 19 00 vIE SL nva a s n uu od ue sinanBuo7 99 e 891 0 0510 690 urt 99 69 8 S 9 9 9 9 v i 98 vie sS vie st c V C co 891 0 05 0 69 0 9 urt 990 69 9 9 9 9 9 9 v i 98 vie sS viest tIg g9 891 0 OV O 69 0 990 69 96 v0 0 z 691 9 9 9 TIL G 9 9 v i 98 vie sS V C co
116. oisojdxo p anbsiy ENERSEN VAM enbiuuouy 9junoos e oDBjeuoop ap edednog sign is apen ne p uonejnour ap ejnpuoo ej ap 9p pJo92e ejnuiu Jed suoj e6 bujo e uonejnoJioai ep eynpuoo e suep Jejsnfe uonej nouroe ep ejnpuoo e suep enjs jueuuno e jeuiqoJ np v nee eyneuo np eunjeueduie e op eBejDaJ np snossep ue 591609 buio oDexoois ep 59 np eunjeJeduue e 19 694 nee ejgineuo np epioJj nee p 19 8 jede o 9 eue 5 9119 HOP uonejelp ep JIoAJes9J un epioJj nee ue uonejuauige p ejnpuoo e suep 8 8 51 159 1NOJSJ UE jedejo un IS epoo np seoueBixe xne euuojuoo 819 OP UONEJ EISULT 7senbnseuiop 5516336 So mod Spneuo ejnpuoo ej SUEP 3179 Jnebuejour un Toys Sue DP SHEET PRYUSPISSI eDesn un mod ejunoj 159 nee ond Je 4 021 0 6 8v 5 einjejeduis P IS QL 94NGI4 ej ins SJON i open eios epneuo nee p eniog SL nee eyneuo np JUSUISUUONDUOJ sieanew 9 Jesneo jueAned inb 4 4 091 D Z Z8 e 591 4 5 uonejueuJi e p nee p seJnjeeduus sep jueAnos juesinpoud neo ep anejos eDejyineuo ep seuigis s 59 enbuewoay 4 06 9 6 8 e uonejueue p eJnje1eduue e Joy anod nee ue uonejueuui e p ejnpuoo e JNS 9j ejsui 9119 OP in Buej uu 1911301 UN 4 0ZL O 687 e euneuedns n 3ned nee ejineuo np
117. oo un JejeB ep sejqndeosns seuoz sep suep Sjesuepuoo sep sejnpuoo se JeurUeuoe sed ew Jue uoduul JIVSN3QNOO 3G NVANL ueneque nod ui od p wo Z OL 99109 snssaa dd Ana od 4eNe ue nod uoo um Od pz uonenuen 9 9 JUEAV u n nu JNOd uiv od y wo 59109 od 0 WO 0 eeu od 0 uio 0 snsseq winwiulw jUdWabebap ap szu w sejdwz 91 3 u n nu p 19 uonoedsuip suy xne 8109 enbeuo ins od p Wo Z 0L 1e Nes ayneyo e jueA ep od pz uio 9 ep lewu Ju uu BeB p un 1 8 syuoseud SjJUaWabebap SJUSJEJJIP 59 Jeuruuejep anod epin6 ep sues n d z eunBiJ ET ne p dwa 159 19 INjad enbsJo nee aejneuo np spiod ej Jepoddns JIOANOd anod 5 JUSUIWIESIJJNS 919 yop neeuued 97 ueuoueld np 91630 e Yop neeuued 9 pJeoe d un no 9 8 eun suep UONP E SUI eun p SEI 9 suep suonoaJip 59 sejnoj suep od c wo Z9 SUIOW ne p nes ayneyo np 59 99 Jessedop JUSAIOP uonoejoJd ep neeuued np e je 1nenBuo e nee ejneuo 9 snos 8504 sioq ep no ejeui ep neeuued un Jed 9989 919 yop 5 99 ayenbow ep Jeuoue d un ins 9j ejsur 159 nee ejneuo 9j IS 3jueyioduu e qnsnquaoo Jeuoue d un uns uonejejsu anod enBojouiou 1959 nee ajyneuo 91 nee eyneuo np jue e e nlis enbnojeuBis e ins seenbipur 1105 sejqnsnquuoo xneusjeuw xne oddeu Jed sejeu
118. ot apply any force to the gas valve or the cast flange fitting on the inlet side of the gas valve see figure 25 Such force may break or crack these components 1 Turn temperature dial counterclockwise to the lowest setting and turn off electrical power to appliance 2 Shut off the gas at the manual shut off valve on the gas supply line See figure 19 for reference Remove the access door 3 Disconnect the gas piping connection just outside the base of the water heater Note Use a second pipe wrench on the gas piping inside the skirt to avoid cracking the gas valve or the flange fitting 4 Remove the pressure tap from the gas valve see figure 25 The hose should not be disconnected 5 Remove the Phillips head screw holding the electrical plug and remove electrical plug from the gas valve 6 Remove the three T 25 Torx head brass screws that attach the gas valve to the venturi manifold using the T 25 Torx wrench supplied with the gas valve kit model VK8115V part number 6903775 7 Remove the gas valve from the unit keeping the rubber gasket with the gas valve 8 Remove the flange from the gas inlet side of the valve by removing the four 4 attachment screws Replacing the Gas Valve Important The rubber gasket that seals the gas valve to the venturi manifold must be used previous gaskets may be reused if in good condition Make sure the gasket is properly inserted into the recess on the gas valve prior to insta
119. otect 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 c drain Piped to e adequate d 1 3 4 4 45 cm Max DA At least two inches 5 cm greater than the largest gt diameter of the water Figure 1A heater The water heater should be located in an area not sub ject 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 materi als are stated on the data plate located on the front of the water heater
120. ou one 1 no esnenbe uonnios no seJnio uo sues uo es pesn punoduuoo jurof edid peAouddy eBund ep jurod un 19 uoiun pJoooeiJ un Je duoo 19118 jeuiqoJ un p eiunui zef ep linpuoo nee egyneuo np anbnejeubis anbejd e ins nbipui ej oo e juepuodsaulco zeD ue UONPJUSUWIIV eAnoJdde auejeul e 19 eyenbope 619 ne n np ejje e7 nee ejneuo np uornonpoud el essedop no puodsauoo enbejd e ep apanbne enb JEJNSSE S esi nn 159 4 zeb ep in jo uuoo UN IS OO 0 00 O zeb op d119 Ne N 19 zeD ud uone u uu V np suomnonjsul 59 uojes 9jejsur 8418 yop uneBuejsw un s uu J 58119155 s SNO INS lle su 949 HOP SUUOISUSUIIP ueiq uoisuedxe p 598 UN ne p l duay jueujejg duuoo nee ejneu sen ep ejdujexe je a9 E SUI JUBW9 O9IJON e 196 e 8111059 3969104d 19 ureJp un e juesspnoqe uoneAuop ep ejnpuoo 99 8 l e sui jueulej eu1oo enbiuueuy eyunoes e eBJeuoep ep edednos ne p N np euoejne n 0je s n u SJUSAS sane suloo sap uio id sed od 9 eueuu Jed ww G 0 e nee egneuo np UOn29JIp US Seq 9 519 SESUIJDUI 1105 od e ep sejejuozuou seuejne n se id sed od p eeu Jed ww z e nee ojyneuo np UOHOaIIP ue seq e 91 seeutpui JUOS od Z ap 118 p e9AuJe p uonenoeAo p enjos ep seuejne n eBieu ep neeAiu os np snssep ne od Z uly WO enbigue
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122. p SeJoduue G Jassedap sed jieJ4ep eu ejeuurxeui 61 91 5 e 841W09 uono loid e7 unejouofsip un no SUUOISUEUIIP ueiq e qisn un jueugjuoo aipep jinoJro un jueuje nes Jesin xneoo sepoo 19 seoueBixe xne jueuieuuojuoo nes ayneyo ne enbujoeje uonejueulje Jojoeuuo 9109 ep 959998 neeuued 8 898 nee egneuo np seq e sgooe p neeuued np e JUANOJ es enbujoe o eBejy ep wwebeip ap s pou 58 anbuoeje jueumnjeduuoo ne seooe p neeuued 9 JUEXI SIA so 1oujesse Z enbujoeje 9 98 ep ejoq e ep JUEINO9 1 nee ayneyo np enbujoeje eBe qeo np uonejejsul ep S107 senbuyoeje suoixeuuoo s uuoq 59 eJjjeuuoo JNOd s euueJBeip x ne sinofno 0Z eBeg e e anno es a ejy ep auweibelp 91 onbseway enbuy eje jueJnoo ue nee eyineuo eo jejueuure nod enbujoeje eBuoj eJ eun Jesi n sed eu lt 389 gt eJjg eJe e amp SIW ueiq 1105 uonejueuue je ne yneyo 91 xne20 sepoo 59 Jed s nb IS eAnoudde eqnj un Jed 69 159 a ejqeo Sejqeoidde sepoo se sno e JUSUIJOJUOO S SII Sep suorxeuuoo je suoisueullp SO SeJeduue ep SUIOW 81 nee ejyneuo e7 unejouofsip ejqisn uoq Jed ee69joud 159 enbugjoeje uonejueure JeiuJep eo ap uere e n1lis nee ajneuo np anbnejeubis enbejd ej ins seenbipui sejjed e juepuodsaujoo eouenb
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124. p uoneuuo e Jed sesneo seBeuiuop se euoo ejeudoud e 68 14 e enqiujuoo 981 87 snossep r uo5ej e ep Ned ayyneyo 9 snos oj ejsur 919 yop Jenbape anbijjejeu uonenoeA p Seq uf suoneJedai 59 nod 91081199 8119 310p euyijenb 921IAJ8S SP uai9IUuu29 un uoisoJJ02 e op asned e ne p 881 np 39JNJEWDJd eouej rejop ej jueAned uomnej ejsui esieAneui eun e sa qenqigje JUOS inb s jj siuduioo A s ed uou li quuold eJ ap saying 9 sojnoj o1jno u3 epoued enBuo eun saide 59 s p 193juesauUd ep enbsi 59 9 ne ap sejeuuou S9AISOJJ02 5 sep uosie1J ug einjonujs e ep 5 seuoz se no Nes ayneyo ne ejueoefpe euoz ej sed juoJeBeuuulopue u suoixeuuoo 56 no 58 np sain SA no JOJPUS un SUEP S yop nee ejineuo 97 jueyodui Vevia VSO NVO SJnoo ue UONIPS e jueuieuuojuoo seenjoejje 6119 JUSAIOP seuueipeueo suonej ejsul 591 YS VdAN L Z7Z ISNV aBeyneyo np 19 zef np jeuoneu epo gt np 51 9 ue UONIPE e Io xneo ep eouesqe ue NO jeje p 19 xneioui oJd xneoo sepoo xne lluujoJuoo Ue 9I ejsur 19 OP Nes ayneyo aD enbseway enueJeB e ep enjoxe 159 eJeudsouuje suep SJUSSSJd sjisouoo 511888 sep e ajqenque 5 eJeudsoune eun p JIUSAoJd sed yop eu uone nuaA ep 19 uonsnquioo ep 181 3uey1oduu Sepnoo ep aeJquJou 9 19 euejne
125. power to the water heater Start troubleshooting Connect heater to 120 Vac power source Main circuit breaker tripped Is green LED on Check for hot to GND and correct Check for line voltage amp wiring connections 24 Vac across NO Repl n f per wiring diagram transformer secondary gt Sethermostat OKAY Set thermostat Check 1 Wiring connections 2 Sensor Replace thermostat board Is 24 AW on ignition NG resistance See chart on page 24 Repair wiring connections or replace ECO Is yellow LED on SML Toue an 3 Thermostat dial resistance NOT OKAY sensor or thermostat potentiometer 1 flash error code YES Replace pressure switch Bl for fails to start YES lIs 115 Vac across IND on YES Reni bi Ower motor Tas IO Sta ignition control module and GND Replace blower ace ower NO ES 2 flash error code after 60 sec YES Replace ignition control module amp blower motor fails to start The blower isolation relay or the ignition control module relay is stuck in a open position Replace failed component Blower motor start NO Replace ignition control module 2 flash error code LES Is 24 Vac across the YES Are there leaks at the clear NO is there a blockage in the inlet NO Replace burner pressure switch PVC tubing connected to the and or exhaust venting pressure switch air inlet 6 sec blower pre purge barbs and or the gas valve Clear Bloc
126. pressure of 14 W C 3 486 kPa or greater the water heater and its manual shut off valve must be discon nected from the gas supply piping system and the line capped Ifthe 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 18 AWARNING 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 ELECTRICAL CONNECTIONS AWARNING 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 h
127. r 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 Full Opening Manual Gas Shut off Valve Ground Joint Union 3 7 62 m Minimum Drip Pr 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 Ifthe code requires the gas lines to be tested at a
128. r 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 vacu um 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 Ifinstalling the water heater in a closed water system install an expansion tank in the cold water line as speci fied under Closed System Thermal Expansion Page 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 o
129. relief valve to allow the valve to operate freely and return to its closed position see figure 24 If the valve fails to completely reset and continues to release water immediately shut off the manual gas valve and the cold water inlet valve and call a qualified service technician Figure 24 Temperature and Pressure Relief Valve Manual Relief 4 Valve MAINTENANGE OF YOUR WATER HEATER 3 Month Inspection At least every 3 months a visual inspection should be made of the combustion air inlet as well as the exhaust and water piping Check the water heater for the following Obstructions damage or deterioration in the venting system Make sure the exhaust and combustion air supplies are not obstructed Leaking or damaged water and gas piping Presence of flammable or corrosive materials in the installation area Presence of combustible materials near the water heater Important Verify proper operation after servicing this water heater Gas Valve The gas valve on this water heater has been permanently set at the factory for proper operation No field adjustments are needed and none should be performed Removing the Gas Valve Removal and replacement of the gas regulator valve involves the disconnection of gas piping and electrical leads This procedure must be performed by a qualified service technician Important When removing the gas valve do not use a pipe wrench or vise to grip the body Do n
130. s 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 condi tioned areas only Drain lines installed in areas that are subject to freezing temperatures should be wrapped with a nationally recognized listed
131. s 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 electri cal power may then be turned on See figure 20 for completed installation Figure 20 Electrical Connections Electrical Service Box N 5 Amp Switch Access Hole TS Conduit If Required By Code Electrical Compartment 19 WIRING DIAGRAM HEATER SUPPLIED WITH T92 SERIES RELAY Figure 20A BLOWER GAS VALVE THERMOSTAT SENSORIECO YELLOW YELLOW LED ORANGE THERMOSTAT DIAL THERMOSTAT POT TO 12060 POWER SUPPLY L1 BLACK DISCONNECTED 120 VAC BLACK amp WHITE WIRES IN BOLD IGNITION CONTROL 120V 60Hz
132. t supply but not within 18 inches 45 7 cm of the cold water connection on the water heater Donotuse PVC piping on the hot water outlet space heating supply or space heating return Donotuse any pumps valves or fittings that are not compatible with potable water Donotuse valves that may cause excessive restriction to water flow Use full flow ball or gate valves only Donotuse 50 50 tin lead solder or any lead based solder in potable water lines Use 95 5 solder or other equivalent material Donottamper 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 Donotuse this water heater as a replacement for an existing boiler installation Donotuse with piping that has been treated with chromates boiler seal or other chemicals Donot add any chemicals to the system piping which will contaminate the potable water supply 14 Thermal Expansion Tank Figure 16 Sample Mixing Valve Installation Tempered water to fixtures Heat Trap Unions Optional Mixing Valve set to 120 F 48 8 C or lower CO E aN Pressure Reducing Valve if required Main Water Cold Water Inlet Valve Check Valve sE 6
133. ter 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 Orient as needed then glue Stainless Exhaust Drain Pan Unglued Drain Stem Joint Figure 3B Condensate Drain Condensate Trap Assembly 3 Shown Overflow Line Required only when optional neutralizer cartridge is uy Neutralizer Cartridge Optional To Floor Drain or VA Condensate Pump 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 Thi
134. ter clamshell housing to the internal clamshell Adaptor Z housing apply 8 thin layer of silicone Rubber Boot J grease to the surface of the black rubber support of the Filter Media Outer Clamshell 4 Housing 7 Filter Media ZZ 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 instal lation see figure 5 below Figure 5 Correct and Incorrect Pipe Fittings Qu 665 90 Vent Elbow 90 Short Sweep Elbow 45 Vent Elbow 90 long Sweep Elbow 45 Sweep Elbow Correct Fittings Incorrect F
135. tici pated Snow Level All Termination Piping And Fittings Are 2 E Roof Line Notes 1 Support Horizontal Pipe Every 12 30 5cm Min Above Roof or Anticipated Snow Level See Note 4 Combustion Air Termination And Exhaust Air Termination Must Be Located In The Same Pressure Zones lt 4 10 cm Max 12 30 5 cm Min All Termination Piping And Fittings Are 2 See Note 3 See Note 1 Exhaust Pipe 2 or 3 Combustion Air Inlet Pipe 2 or 3 Four Feet 1 2 m Support Vertical Pipe Every Six Feet 1 8 m When Using 3 Inch Pipe Reduce To 2 Inches Before Penetrating The Roof 18 Inch 45 7 cm Maximum When Using 2 Inch Pipe Increase The 12 Inch 30 5 cm Minimum Above Grade To Keep Terminal Openings Above Anticipated Snow Levels Condensate Trap Assembly Metal Drain Pan Piped To gt 4 Adequate Drain x Drain When using three or more Polaris units install vent Venting Additional Polaris Units n us terminations per Method C or Method D When using two 2 Polaris units install vent terminations using either Method A or Method B below Figure 9A 9B Figure 96 9D 36 914 cm E 19 7 6cm Max Minimum PE el 0 QtEbxhaust 36 91 4 cm i P Minimum r Exhaust 4 10cm Max 36
136. two exterior walls 4 ft 122 cm clearance to each side of center line extending above meter regulator assembly 4 ft 122 cm clearance to service regulator vent outlet 12 in 30 cm clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance K 3ft 91 emi above if within 10 ft 3 m horizontally of mechanical air supply inlet veranda porch deck balcony or maximum anticipated snow level 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 Clearance to permanently closed window 12 in 30 cm min vertical clearance to ventilated soffit located above the terminal within a horizontal of 2 ft 61 cm from the center line of the erminal 12 in 30 cm min clearance to unventilated soffit Clearance to outside corner 2 ft 61 cm clearance to inside corner formed by two exterior walls 3 ft 91 cm within a height 15 ft 4 57 m above the meter regulator assembly 4 ft 122 cm clearance to service regulator vent outlet 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 INLET OUTLET VENT TER
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138. um 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 GAS SUPPLY AND PIPING AWARNING 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 connecto
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142. ved material Acceptable size length and number of elbows on air inlet pipe Acceptable size length and number of elbows on exhaust outlet pipe Add the air inlet filter per the manufacturer s instruction Installed in accordance with prevailing provisions of Local codes or in the absence of such National Fuel Gas Code NFPA 54 ANSI Z223 1 Current Edition Canadian Installations must be performed in accor dance with CAN CSA B149 1 Current Edition All 2 horizontal piping sloped down toward the water heater at 1 4 per foot 21 mm per meter 3 piping sloped down towards the heater at 1 8 per foot 10 5 mm per meter Not obstructed in any way Vent Termination OOO Horizontal Correct relationship outlet to inlet 12 Min 30 5 cm above grade snow level 2 exhaust outlet air inlet pipe sloped down towards water heater at 1 4 per foot 21 mm per meter 3 piping sloped down towards the heater at 1 8 per foot 10 5 mm per meter Away from corners other vents windows etc L1 D Ll 000 OO Alternate Horizontal Correct relationship outlet to inlet 12 Min 30 5 cm above anticipated snow level 2 exhaust outlet air inlet pipe sloped down towards water heater at 1 4 per foot 21 mm per meter 3 piping sloped down towards the heater at 1 8 per foot 10 5 mm per meter Away from corners other vents windows etc Vertical Inlet 12 Min 30 5 cm a
143. 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 AWARNING 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 AWARNING
144. y Water heater properly grounded Installed in accordance with prevailing provisions of local codes or in the absence of such National Fuel Gas Code NFPA 54 ANSI Z223 1 Current Edition Canadian installations must be performed in accor dance with CAN CSA B149 1 Current Edition 21 OPERATING YOUR WATER HEATER Read and understand these directions thoroughly before attempting to operate the water heater see Operating Instructions on Page 23 Check the data plate on the front of the water heater for the correct gas Do not use this water heater with any gas other than the one listed on the data plate If you have any questions or doubts consult your gas supplier or gas utility company L P Propane Models Propane gas is heavier than air and in the occurrence of a leak in the system the gas will settle on the floor level Basements crawl spaces skirted areas under mobile homes even when ventilated closets and areas below ground level will serve as pockets for the accumulation of gas Before lighting a propane gas water heater smell all around the appliance at floor level If you smell gas follow the instructions as given in the warning on the front page When your propane tank runs out of fuel turn off the gas at all gas appliances including pilot lights After the tank is refilled all appliances must be re lit according to their manufacturer s instructions Water Heater Operation This water heater does not hav

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