Polaris PGC User manual

1
Instruction Manual
PRINTED 1216 100277192
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHENEVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
POWER DIRECT VENT GAS MODELS
WITH DIRECT SPARK IGNITION
MODELS
PGC/SPC/BSS/BTS
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 YOU ARE UNSUCCESSFUL, CALL THE TECHNICAL SUPPORT PHONE NUMBER SHOWN ON THE WATER HEATER LABELING.
COMMERCIAL 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 IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
Thank you for buying this energy efcient water heater.
We appreciate your condence in our products.
LOW LEAD
CONTENT

2
TABLE OF CONTENTS
SAFE INSTALLATION, USE AND SERVICE.................................3
APPROVALS .................................................................................3
GENERAL SAFETY INFORMATION.............................................4
Precautions ..............................................................................4
Grounding Instructions .............................................................4
INSTALLATION REQUIREMENTS FOR MASSACHUSETTS .........7
INTRODUCTION...........................................................................8
Abbreviations Used ..................................................................8
Qualications............................................................................8
Preparing For The Installation ..................................................8
DIMENSIONS AND CAPACITY DATA...........................................9
Rough In Dimensions: All Models.............................................9
FEATURES AND COMPONENTS ..............................................11
34 Gallon Unit.........................................................................11
50 Gallon Unit.........................................................................12
Controls And Switches ...........................................................14
INSTALLATION CONSIDERATIONS ..........................................15
Locating The Water Heater ....................................................15
Insulation Blankets .................................................................16
Combustion Air And Ventilation ..............................................16
Corrosion and Water Quality ..................................................16
INSTALLATION REQUIREMENTS .............................................17
Gas Supply Systems ..............................................................17
Supply Gas Regulator ............................................................17
Power Supply .........................................................................17
Mixing Valves..........................................................................18
Circulation Pumps ..................................................................18
Dishwashing Machines...........................................................18
Space Heating And Potable Water System............................19
Storage Tank Installation ........................................................19
Solar Installation.....................................................................19
Closed Water Systems ...........................................................19
Thermal Expansion ................................................................19
Temperature-Pressure Relief Valve........................................20
Condensate Drain ..................................................................21
VENTING INSTALLATION ..........................................................22
Vent Installation Considerations .............................................22
General Venting Instructions ..................................................22
Approved Vent/Intake Material ...............................................22
Polypropylene Installations.....................................................23
Vent Pipe Termination.............................................................23
Planning The Vent System .....................................................23
Integrated Filter Installation ....................................................24
Direct Vent Air Intake Moisture Protection..............................25
Horizontal Vent Terminal Installation ......................................25
Vertical Vent Terminal Installation...........................................26
Termination Clearances Sidewall Direct Vent.........................27
Direct Vent Installation Diagrams ...........................................28
Concentric Vent Installation....................................................29
Venting Multiple Units.............................................................30
WATER HEATER INSTALLATION...............................................31
Condensate Drain Installation ................................................31
Supply Gas Line Installation...................................................31
Gas Line Leak Testing............................................................32
Purging ...................................................................................32
Electrical Wiring......................................................................33
Water Line Connections .........................................................33
T&P Valve Discharge Pipe .....................................................34
TEMPERATURE REGULATION .................................................35
High Temperature Limit Control (ECO)...................................35
Thermostat Control.................................................................35
CONTROL SYSTEM OPERATION .............................................36
Overview ................................................................................36
Control System Navigation.....................................................36
User Settings & Control System Menus .................................39
START UP ...................................................................................44
Start Up Conditions ................................................................44
Prior to Start Up......................................................................44
Filling the Water Heater..........................................................44
Initial Start Up.........................................................................45
LIGHTING THE WATER HEATER ..............................................46
Lighting & Operation Labels ...................................................46
Checking the Firing Rate........................................................47
Gas Input Rate .......................................................................47
High Altitude Installations .......................................................47
TROUBLESHOOTING ................................................................48
Installation Checklist...............................................................48
Sequence Of Operation..........................................................48
Sequence Of Operation Flow Chart .......................................49
Operational Problems.............................................................50
Fault And Alert Conditions ......................................................51
LEAKAGE CHECKPOINTS.........................................................53
PERIODIC MAINTENANCE........................................................54
Venting System Inspection .....................................................54
Ingegrated Filter Preventative Maintenance...........................54
Temperature-Pressure Relief Valve Test ................................54
Draining and Flushing ............................................................55
Service ...................................................................................55
DIAGRAMS .................................................................................56
CCB-Central Control Board Layout ........................................56
Wiring Diagram.......................................................................57
Circulation Pump Wiring Diagrams ........................................58
Piping Diagrams .....................................................................59
NOTES ........................................................................................61

3
The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others.
Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and
others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important
that the meaning of each safety message is understood by you and others who install, use, or service this water heater.
All safety messages will generally tell you about the type of hazard, what can happen if you do not follow the safety message, and
how to avoid the risk of injury.
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.
Immediately call a qualified service technician to inspect
the water heater and to make a determination on what steps
should be taken next.
If the unit is exposed to the following, do not operate heater
until all corrective steps have been made by a qualied service
technician.
1. External re.
2. Damage.
3. Firing without water.
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 Te mperature-
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
This water heater must be grounded in accordance with the National
Electrical Code and/or local codes. These must be followed in all
cases. Failure to ground this water heater properly may also cause
erratic control system operation.
This water heater must be connected to a grounded permanent
wiring system; or an equipment grounding conductor must be
run with the circuit conductors and connected to the equipment
grounding terminal or lead on the water heater.

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 NFPA 54 or 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
For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed
in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by
the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above nished grade in the
area of the venting, including but not limited to decks and porches, the following requirements should be satised:
INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas
fueled equipment, the installing plumber or gastter should observe that a hard wired carbon monoxide detector with an alarm
and battery back-up is installed on the oor level where the gas equipment is to be installed. In addition, the installing plumber
or gastter should observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each
additional level of the dwelling, building or structure served by the sidewall horizontal vented gas fueled equipment. It should
be the responsibility of the property owner to secure the services of qualied licensed professionals for the installation of hard
wired carbon monoxide detectors.
In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired
carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent oor level.
In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner should
have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a battery
operated carbon monoxide detector with an alarm should be installed.
APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above
provisions should comply with NFPA 720 and be ANSI/UL 2034 listed and CSA certied.
SIGNAGE A metal or plastic identication plate should be permanently mounted to the exterior of the building at a minimum
height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating
appliance or equipment. The sign should read, in print size no less than one-half (1/2) inch in size, GAS VENT DIRECTLY
BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.
INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment should not approve the
installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance
with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
1. The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA
54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the
dwelling, building, or structure used in whole or in part for residential purposes.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product
Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with
the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system should
include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer
of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the
flue gases, but identifies special venting systems, the following requirements should be satisfied by the manufacturer:
1. The referenced special venting system instructions should be included with the appliance or equipment installation
instructions; and
2. The special venting systems should be Product Approved by the Board, and the instructions for that system should include a
parts list and detailed installation instructions.
A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting
instructions, all parts lists for venting instructions, and/or all venting design instructions should remain with the appliance or
equipment at the completion of the installation.
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS

8
Thank You for purchasing this water heater. Properly installed and
maintained, it should give you years of trouble free service.
ABBREVIATIONS USED
Abbreviations found in this Instruction Manual include :
• ANSI - American National Standards Institute
• ASME - American Society of Mechanical Engineers
• AHRI - Air-Conditioning, Heating and Refrigeration Institute
• NEC - National Electrical Code
• NFPA - National Fire Protection Association
• UL - Underwriters Laboratory
• CSA - Canadian Standards Association
QUALIFICATIONS
QUALIFIED INSTALLER OR SERVICE AGENCY
Installation and service of this water heater requires ability
equivalent to that of a Qualied Agency (as dened by ANSI below)
in the eld involved. Installation skills such as plumbing, air supply,
venting, gas supply and electrical supply are required in addition to
electrical testing skills when performing service.
ANSI Z223.1 2006 Sec. 3.3.83: “Qualied Agency” - “Any
individual, rm, corporation or company that either in person or
through a representative is engaged in and is responsible for (a)
the installation, testing or replacement of gas piping or (b) the
connection, installation, testing, repair or servicing of appliances
and equipment; that is experienced in such work; that is familiar
with all precautions required; and that has complied with all the
requirements of the authority having jurisdiction.”
If you are not qualied (as dened by ANSI above) and licensed or
certied as required by the authority having jurisdiction to perform
a given task do not attempt to perform any of the procedures
described in this manual. If you do not understand the instructions
given in this manual do not attempt to perform any procedures
outlined in this manual.
PREPARING FOR THE INSTALLATION
1. Read the entire manual before attempting to install or operate
the water heater. Pay close attention to the General Safety
Information on Page 4 through Page 6. If you don’t follow the
safety rules, the water heater may not operate safely. It could
cause property damage, injury and/or death.
This manual contains instructions for the installation, operation,
and maintenance of the water heater. It also contains warnings
throughout the manual that you must read and be aware of.
All warnings and all instructions are essential to the proper
operation of the water heater and your safety. Detailed
installation diagrams are also found in this manual. These
diagrams will serve to provide the installer with a reference. It
is essential that all venting, water piping, gas piping and wiring
be installed as shown.
Particular attention should be given to the installation of
thermometers at the locations indicated in the piping diagrams
as these are necessary for checking the operation of the water
heater.
The principal components of the water heater are identied in
Features and Components beginning on Page 11 in this manual.
Use this reference to locate and identify various components on
the water heater.
See the Installation Checklist and Troubleshooting on page
48. By using this checklist the user may be able to make
minor operational adjustments and avoid unnecessary service
calls. However, service and diagnostic procedures should only
be performed by a Qualied Service Agency.
NOTE: Costs to correct installation errors are not covered
under the limited warranty.
2. Be sure to turn off power when working on or near the electrical
system of the water heater. Never touch electrical components
with wet hands or when standing in water.
3. The installation must conform to all instructions contained in
this manual and the local code authority having jurisdiction.
These shall be carefully followed in all cases. Authorities having
jurisdiction should be consulted before installation begins if
there are any questions regarding compliance with local, state
or national codes.
In the absence of local codes, the installation must comply with
the current editions of the National Fuel Gas Code, ANSI Z223.1/
NFPA 54 and the National Electrical Code, NFPA 70 or CAN/
CSA-B149.1, the Natural Gas and Propane Installation Code
and CSA C22.1, the Canadian Electrical Code. All documents
are available from the Canadian Standards Association, 8501
East Pleasant Valley Road, Cleveland, OH 44131. NFPA
documents are also available from the National Fire Protection
Association, 1 Batterymarch Park, Quincy, MA 02269.
4. If after reading this manual you have any questions or do
not understand any portion of the instructions, call the toll
free number on the back cover of this manual for technical
assistance. In order to expedite your request, please have the
full Model, Serial and Series number of the water heater you
are working with available for the technician. This information is
located on the water heater’s rating plate.
5. Carefully plan the placement of the water heater. Examine
the location to ensure that it complies with the requirements
in Locating The Water Heater on Page 15 and the Rough In
Dimensions on Page 9.
INTRODUCTION

9
DIMENSIONS AND CAPACITY DATA
ROUGH IN DIMENSIONS: ALL MODELS
Additional
Side Taps
Air Inlet
All Models
Top Outlet: 1” NPT
Side Inlet: 1” NPT
Gas Inlet: 1/2” NPT
Condensate drain outlet: 1/2” NPT
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
A B C D E F G H
34 130 Inches 48-1/2 22 15-3/4 40-1/2 41 6-3/8 5-1/2 6-5/8
cm 123.19 55.88 40 102.87 104.14 16.19 13.97 16.82
34 150 Inches 48-1/2 22 15-3/4 40-1/2 41 6-3/8 5-1/2 6-5/8
cm 123.19 55.88 40 102.87 104.14 16.19 13.97 16.82
50 130 Inches 62-3/8 22 15-3/4 54-1/2 55 6-3/8 5-1/2 6-5/8
cm 165.7 55.88 40 138.43 139.7 16.19 13.97 16.82
50 150 Inches 63-3/4 22 15-3/4 55-3/4 56-1/4 6-3/8 5-1/2 6-5/8
cm 161.925 55.88 40 141.605 142.875 16.19 13.97 16.82
50 175 Inches 63-3/4 22 15-3/4 55-3/4 56-1/4 6-3/8 5-1/2 6-5/8
cm 161.925 55.88 40 141.605 142.875 16.19 13.97 16.82
50 199 Inches 63-3/4 22 15-3/4 55-3/4 56-1/4 6-3/8 5-1/2 6-5/8
cm 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.)
34 130 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

10
DIMENSIONS AND CAPACITY DATA
Table 2 – CAPACITY, GAS AND ELECTRICAL CHARACTERISTICS
Approximate Capacity *Manifold Pressure Electrical Characteristics
U.S. Gals. Liters Gas Type “WC kPA Volts/Hz Amperes
34 129 Nat./LP 0 0 120/60 <7
50 189 Nat/LP 0 0 120/60 <7
*The manifold pressure is the factory setting and is not adjustable. A negative pressure will be seen with just the blower running without
the Gas Control Valve open.
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 Recovery Capacities
Rating
(Btu/hr) Rating
(kW) Temp.
Rise
F 30 40 50 60 70 80 90 100 110 120 130 140
C 17 22 28 33 39 44 50 56 61 67 72 78
130000 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
150000 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
175000 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
199000 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
Recovery capacity based on 95% thermal efciency.