Polaris 200 series User manual

1
Instruction Manual
PRINTED 0817 100277196_ 2000547022_Rev. B
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHEN EVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
POWER DIRECT VENT GAS MODELS
WITH DIRECT SPARK IGNITION
PR MODELS
Series 200, 201
NATURAL GAS & PROPANE
ALL TECHNICAL AND WARRANTY QUESTIONS: SHOULD BE DIRECTED TO THE LOCAL DEALER FROM WHOM THE WATER HEATER WAS
PURCHASED. IF YOUARE UNSUCCESSFUL, CALLTHE TECHNICAL SUPPORT PHONE NUMBER SHOWN ON THE WATER HEATER LABELING.
RESIDENTIAL GAS WATER HEATERS
WARNING: If the information in these
instructions is not followed exactly, a fire
or explosion may result causing property
damage, personal injury or death.
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
Do not try to light any appliance.
Do not touch any electrical switch; do
not use any phone in your building.
Immediately call your gas supplier
from a neighbor’s phone. Follow the
gas supplier’s instructions.
If you cannot reach your gas supplier,
call the fire department.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
•
•
•
•
• For Your Safety •
AN ODORANT ISADDED TO THE GAS USED
BY THIS WATER HEATER.
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LOW LEAD
CONTENT

2
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE.................................3
APPROVALS.................................................................................3
GENERAL SAFETY INFORMATION.............................................4
3UHFDXWLRQV ..............................................................................4
*URXQGLQJ,QVWUXFWLRQV .............................................................4
INTRODUCTION...........................................................................7
$EEUHYLDWLRQV8VHG ..................................................................7
4XDOL¿FDWLRQV............................................................................7
Preparing For The Installation..................................................7
DIMENSIONS AND CAPACITY DATA...........................................8
5RXJK,Q'LPHQVLRQV$OO0RGHOV.............................................8
FEATURES AND COMPONENTS ..............................................10
34 Gallon Unit.........................................................................10
50 Gallon Unit.........................................................................11
&RQWUROV$QG6ZLWFKHV ...........................................................13
INSTALLATION CONSIDERATIONS ..........................................14
/RFDWLQJ7KH:DWHU+HDWHU ....................................................14
Insulation Blankets.................................................................15
&RPEXVWLRQ$LU$QG9HQWLODWLRQ ..............................................15
&RUURVLRQDQG:DWHU4XDOLW\ ..................................................15
INSTALLATION REQUIREMENTS .............................................16
Gas Supply Systems..............................................................16
Supply Gas Regulator............................................................16
3RZHU6XSSO\ .........................................................................16
Mixing Valves..........................................................................17
&LUFXODWLRQ3XPSV ..................................................................17
6SDFH+HDWLQJ$QG3RWDEOH:DWHU6\VWHP ............................18
Storage Tank Installation........................................................18
Solar Installation.....................................................................18
&ORVHG:DWHU6\VWHPV ...........................................................18
Thermal Expansion ................................................................18
Temperature-Pressure Relief Valve........................................19
&RQGHQVDWH'UDLQ ..................................................................20
VENTING INSTALLATION ..........................................................21
9HQW,QVWDOODWLRQ&RQVLGHUDWLRQV .............................................21
*HQHUDO9HQWLQJ,QVWUXFWLRQV ..................................................21
$SSURYHG9HQW,QWDNH0DWHULDO ...............................................21
Polypropylene Installations.....................................................22
Vent Pipe Termination.............................................................22
Planning The Vent System.....................................................22
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'LUHFW9HQW$LU,QWDNH0RLVWXUH3URWHFWLRQ..............................24
Horizontal Vent Terminal Installation ......................................24
9HUWLFDO9HQW7HUPLQDO,QVWDOODWLRQ...........................................25
7HUPLQDWLRQ&OHDUDQFHV6LGHZDOO'LUHFW9HQW.........................26
'LUHFW9HQW,QVWDOODWLRQ'LDJUDPV ...........................................27
&RQFHQWULF9HQW,QVWDOODWLRQ....................................................28
Venting Multiple Units.............................................................29
WATER HEATER INSTALLATION...............................................30
&RQGHQVDWH'UDLQ,QVWDOODWLRQ ................................................30
Supply Gas Line Installation...................................................30
Gas Line Leak Testing............................................................31
Purging...................................................................................31
(OHFWULFDO:LULQJ......................................................................32
:DWHU/LQH&RQQHFWLRQV .........................................................32
739DOYH'LVFKDUJH3LSH .....................................................33
TEMPERATURE REGULATION .................................................34
High Temperature Limit Control (ECO)...................................34
Thermostat Control.................................................................34
CONTROL SYSTEM OPERATION .............................................35
2YHUYLHZ ................................................................................35
Control System Navigation.....................................................35
User Settings & Control System Menus.................................38
START UP...................................................................................43
6WDUW8S&RQGLWLRQV ................................................................43
Prior to Start Up......................................................................43
Filling the Water Heater..........................................................43
Initial Start Up.........................................................................44
LIGHTING THE WATER HEATER ..............................................45
Lighting & Operation Labels...................................................45
&KHFNLQJWKH)LULQJ5DWH........................................................46
Gas Input Rate.......................................................................46
+LJK$OWLWXGH,QVWDOODWLRQV .......................................................46
TROUBLESHOOTING ................................................................47
,QVWDOODWLRQ&KHFNOLVW...............................................................47
6HTXHQFH2I2SHUDWLRQ..........................................................47
6HTXHQFH2I2SHUDWLRQ)ORZ&KDUW .......................................48
Operational Problems.............................................................49
)DXOW$QG$OHUW&RQGLWLRQV ......................................................50
LEAKAGE CHECKPOINTS.........................................................52
PERIODIC MAINTENANCE........................................................53
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,QWHJUDWHG)LOWHU3UHYHQWDWLYH0DLQWHQDQFH............................53
Temperature-Pressure Relief Valve Test................................53
'UDLQLQJDQG)OXVKLQJ ............................................................54
6HUYLFH ...................................................................................54
DIAGRAMS .................................................................................55
&&%&HQWUDO&RQWURO%RDUG/D\RXW ........................................55
Wiring Diagram.......................................................................56
&LUFXODWLRQ3XPS:LULQJ'LDJUDPV ........................................57
Piping Diagrams.....................................................................58

3
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DANGER
WARNING
CAUTION
CAUTION
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in injury or death.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result
in injury or death.
CAUTION indicates a potentially hazardous
situation which, if not avoided, could result in
minor or moderate injury.
CAUTION used without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, could result in
property damage.
APPROVALS
SAFE INSTALLATION, USE AND SERVICE
LOW LEAD
CONTENT

4
PRECAUTIONS
DO NOT USE THIS WATER HEATER IF ANY PART HAS
BEEN EXPOSED TO FLOODING OR WATER DAMAGE.
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2. Damage.
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Read and understand this instruction
manual and the safety messages
herein before installing, operating or
servicing this water heater.
Failure to follow these instructions and
safety messages could result in death
or serious injury.
This manual must remain with the
water heater.
Water temperature over 125°F (52°C)
can cause severe burns instantly
resulting in severe injury or death.
Children, the elderly and the
physically or mentally disabled are at
highest risk for scald injury.
Feel water before bathing or
showering.
Temperature limiting devices such as
mixing valves must be installed
when required by codes and to
ensure safe temperatures at fixtures.
Explosion Hazard
Overheated water can cause
water tank explosion.
Properly sized Temperature -
Pressure Relief Valve must be
installed in the opening provided.
Verify the power to the water heater is turned off before performing any service procedures.
The Enable/Disable switch at the base of the water heater disables the 24 volt gas control valve.
Electrical supply must be turned off at circuit breaker serving water heater.
Improper installation, use and service may result
in property damage.
Do not operate water heater if exposed to flooding or water
damage.
•
Install in location with drainage.
•
Fill tank with water before operation.
•
Properly sized thermal expansion tanks are required on all
closed water systems.
•
Refer to this manual for installation and service.
CAUTION
GENERAL SAFETY INFORMATION
GROUNDING INSTRUCTIONS
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5
GENERAL SAFETY INFORMATION

6
Fire Hazard
Do not install water heater on
carpeted floor.
Do not operate water heater if
exposed to flooding or water
damage.
For continued protection against
risk of fire:
Fire or Explosion Hazard
Read instruction manual before
installing, using or servicing
water heater.
Avoid all ignition sources if you smell gas.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
Use only the gas shown on the water heater rating plate.
Keep ignition sources away from faucets after extended
periods of non-use.
Maintain required clearances to combustibles.
Do not expose gas control valve/ thermostat to excessive
gas pressure.
Do not obstruct water heater air intake
with insulating blanket.
Gas and carbon monoxide detectors
are available.
Install water heater in accordance with
the instruction manual.
Breathing carbon monoxide can cause brain damage or
death. Always read and understand instruction manual.
Breathing Hazard - Carbon Monoxide Gas
Property Damage Hazard
All water heaters eventually leak.
•
Do not install without adequate drainage.
•
CAUTION
Fire and Explosion Hazard
Leak test gas connections
before placing the water heater in
operation.
Disconnect gas piping at main
gas shutoff valve before leak
testing.
Install sediment trap in accordance
with CAN/CSA B149.1.
Use joint compound or Teflon tape
compatible with propane gas.
Fire and Explosion Hazard
Excessive gas pressure to gas control
valve can cause serious injury or death.
Do not use water heater with any gas
other than the gas shown on the rating
plate.
Turn off gas lines during installation.
Contact a qualified installer or service
technician for installation and service.
Turn off power to the water heater
before performing any service.
Electrical Shock Hazard
•
Label all wires prior to disconnecting
when performing service. Wiring errors
can cause improper and dangerous
operation.
•
Verify proper operation after servicing.
•
Failure to follow these instructions can
result in personal injury or death.
•
GENERAL SAFETY INFORMATION

7
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Dimensions on Page 8.
INTRODUCTION

8
DIMENSIONS AND CAPACITY DATA
ROUGH IN DIMENSIONS: ALL MODELS
Additional
Side Taps
Air Inlet
All Models
7RS2XWOHW´137
6LGH,QOHW´137
*DV,QOHW´137
&RQGHQVDWHGUDLQRXWOHW´137
Figure 1. DIMENSIONS FOR ALL MODELS
Table 1A - ROUGH-IN-DIMENSIONS
Table 1B - ROUGH-IN-DIMENSIONS
U.S.
GALLONS INPUT (KBTU/HR) UNITS EXTERIOR WATER CONNECTIONS
T&P
HOT GAS SUPPLY
AIR INLET/EXHAUST
ABCDEFGH
34 100 ,QFKHV  22   41   
FP 123.19 55.88 40 102.87 104.14 16.19 13.97 16.82
34 130 ,QFKHV  22   41   
FP 123.19 55.88 40 102.87 104.14 16.19 13.97 16.82
34 150 ,QFKHV  22   41   
FP 123.19 55.88 40 102.87 104.14 16.19 13.97 16.82
50 130 ,QFKHV  22   55   
FP 165.7 55.88 40 138.43 139.7 16.19 13.97 16.82
50 150 ,QFKHV  22      
FP 161.925 55.88 40 141.605 142.875 16.19 13.97 16.82
50 175 ,QFKHV  22      
FP 161.925 55.88 40 141.605 142.875 16.19 13.97 16.82
50 199 ,QFKHV  22      
FP 161.925 55.88 40 141.605 142.875 16.19 13.97 16.82
U.S. GALLONS INPUT
(KBTU/HR)
VENT
DIAMETER
(in.)
APPROX SHIP. WEIGHT
(lbs.)
34 100 2 OR 3 150
34 130 2 OR 3 150
34 150 2 OR 3 150
50 130 2 OR 3 176
50 150 2 OR 3 180
50 175 3 180
50 199 3 180

9
DIMENSIONS AND CAPACITY DATA
Table 2 – CAPACITY, GAS AND ELECTRICAL CHARACTERISTICS
$SSUR[LPDWH&DSDFLW\ 0DQLIROG3UHVVXUH (OHFWULFDO&KDUDFWHULVWLFV
U.S. Gals. Liters Gas Type “WC kPA 9ROWV+] Amperes
34 129 1DW/3 00 <7
50 189 1DW/3 00 <7
*The manifold pressure is the factory setting and is not adjustable. A negative pressure will be seen with just the blower running without
the Gas Control Valve open.
All models - Maximum Supply Pressure: 14 inches W.C. (3.48kPa)
Minimum Supply Pressure for Natural Gas: 3.50” (.87kPa)
Minimum Supply Pressure for Propane Gas: 8.00” (1.99kPa)
Minimum pressure must be maintained under both load and no load (dynamic and static) conditions.
Table 3 – RECOVERY CAPACITIES
Input 5HFRYHU\&DSDFLWLHV
Rating
%WXKU Rating
(kW) Temp.
Rise F30405060708090100110120130140
C172228333944505661677278
100,000 29.3 GPH 381 286 229 190 163 143 127 114 104 95 88 82
LPH 1442 1082 865 721 618 541 481 433 393 361 333 309
130,000 38.1 GPH 495 371 297 248 212 186 165 149 135 124 114 106
LPH 1875 1406 1125 937 803 703 625 562 511 469 433 402
150,000 44.0 GPH 571 429 343 286 245 214 190 171 156 143 132 122
LPH 2163 1622 1298 1082 927 811 721 649 590 541 499 464
175,000 51.3 GPH 667 500 400 333 286 250 222 200 182 167 154 143
LPH 2524 1893 1514 1262 1082 946 841 757 688 631 582 541
199,000 58.3 GPH 758 569 455 379 325 284 253 227 207 190 175 162
LPH 2870 2152 1722 1435 1230 1076 957 861 783 717 662 615
5HFRYHU\FDSDFLW\EDVHGRQWKHUPDOHI¿FLHQF\

10
15
32
27
**33
29
32
24
31
26
20
19
**12
**11
**25
13
28
9
10
21, 22
17
17
18
14
16
This is a view of the area
at the bottom of
heater behind the
Access Doors.
1
30
11
15
2
3
23
**34
33
* CAUTION HARNESS HAS 120 VAC. IN OPERATION.
** See Venting Installation and Condensate Piping for more information.
Figure 2. 34 GALLON UNIT
VACUUM RELIEF
VALVE
*INSTALL PER
LOCAL CODES
34 GALLON UNIT
FEATURES AND COMPONENTS
**11
**12
8
4
67
5