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Polaris PG10 User Manual

Polaris PG10
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1
Instruction Manual
PRINTED 0117 100277191
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
PG10/GHX/GSP/GTP
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.
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 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

Table of Contents

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Polaris PG10 Specifications

General IconGeneral
BrandPolaris
ModelPG10
CategoryWater heaters
LanguageEnglish

Summary

SAFE INSTALLATION, USE AND SERVICE

APPROVALS

GENERAL SAFETY INFORMATION

PRECAUTIONS

Important warnings and conditions to observe for safe operation and handling.

GROUNDING INSTRUCTIONS

Details requirements for properly grounding the water heater for safety.

INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS

INSTALLATION OF CARBON MONOXIDE DETECTORS

Mandates for installing CO detectors for safe operation.

APPROVED CARBON MONOXIDE DETECTORS

Compliance standards for required carbon monoxide detectors.

SIGNAGE

Requirements for warning signs related to gas vent terminals.

INSPECTION

Role of the gas inspector in approving installations.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED

Manufacturer's responsibilities for providing venting system instructions.

MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED

Manufacturer's responsibilities when venting systems are not included.

INTRODUCTION

ABBREVIATIONS USED

Glossary of common abbreviations used throughout the manual.

QUALIFICATIONS

Defines the required skills and qualifications for installers and service technicians.

PREPARING FOR THE INSTALLATION

Essential steps to take before beginning the water heater installation.

DIMENSIONS AND CAPACITY DATA

ROUGH IN DIMENSIONS: ALL MODELS

Detailed measurements and connection points for installation.

FEATURES AND COMPONENTS

34 GALLON UNIT

Detailed diagram and labeling of components for the 34-gallon model.

FEATURES AND COMPONENTS (CONT.)

50 GALLON UNIT

Detailed diagram and labeling of components for the 50-gallon model.

CONTROLS AND SWITCHES

BLOCKED OUTLET SWITCH

Safety switch that shuts off the unit due to exhaust vent blockage.

BLOCKED INTAKE SWITCH

Safety switch that shuts off the unit due to intake air blockage.

WATER HEATING ENABLE/DISABLE SWITCH

Switch to enable or disable water heating operation for external control.

SPARK IGNITER

Component responsible for igniting the main burner.

CONFIGURATION KEY

Stores operational data and settings for the control board.

INSTALLATION CONSIDERATIONS

LOCATING THE WATER HEATER

Guidelines for choosing the best location for the water heater, considering safety and access.

INSTALLATION CONSIDERATIONS

COMBUSTION AIR AND VENTILATION

Importance of adequate airflow for combustion and proper venting to the outdoors.

INSULATION BLANKETS

Information regarding the necessity and proper use of insulation blankets.

CORROSION AND WATER QUALITY

Factors affecting water heater lifespan and recommended water quality standards.

GAS SUPPLY SYSTEMS

SUPPLY GAS REGULATOR

Instructions for installing and setting gas pressure regulators.

POWER SUPPLY

Electrical requirements including voltage, frequency, and grounding.

DEDICATED POWER WIRING AND BREAKERS

Recommendations for a stable and clean electrical power source.

POWER FLUCTUATIONS AND ELECTRICAL NOISE

Potential issues with power quality and the need for filters.

MIXING VALVES

CIRCULATION PUMPS

Guidance on installing and wiring circulating pumps for system requirements.

SPACE HEATING AND POTABLE WATER SYSTEM

STORAGE TANK INSTALLATION

Suggestions for installing the water heater with a separate storage tank.

SOLAR INSTALLATION

Considerations for using the water heater as a solar storage or backup unit.

CLOSED WATER SYSTEMS

Requirements for closed water systems, including thermal expansion tanks.

TEMPERATURE-PRESSURE RELIEF VALVE

CONDENSATE DRAIN

VENTING INSTALLATION

VENT INSTALLATION CONSIDERATIONS

Factors affecting vent pipe installation for safe and efficient operation.

GENERAL VENTING INSTRUCTIONS

Standard procedures for installing air inlet and exhaust outlet piping.

APPROVED VENT/INTAKE MATERIAL

Lists approved materials for vent and intake air piping systems.

VENTING INSTALLATION

POLYPROPYLENE INSTALLATIONS

Specific instructions for installing polypropylene vent materials.

VENT PIPE TERMINATION

Guidelines for determining the location of vent pipe terminations.

PLANNING THE VENT SYSTEM

Procedures for sizing and planning vent systems based on elevation.

INTEGRATED FILTER INSTALLATION

DIRECT VENT AIR INTAKE MOISTURE PROTECTION

INTAKE AIR CONDENSATE TEE INSTALLATION

Specifics on installing a tee fitting for condensate drainage in the air intake.

HORIZONTAL VENT TERMINAL INSTALLATION

VERTICAL VENT TERMINAL INSTALLATION

FLAT ROOF INSTALLATION

Specific clearance requirements for vent terminals on flat roofs.

TERMINATION CLEARANCES SIDEWALL DIRECT VENT

DIRECT VENT INSTALLATION DIAGRAMS

CONCENTRIC VENT INSTALLATION

VENTING MULTIPLE UNITS

VENTING ADDITIONAL POLARIS® UNITS (100,000, 130,000 & 150,000 BTU/HR MODELS)

Venting configurations for multiple 100-150k BTU/hr units.

VENTING ADDITIONAL POLARIS® UNITS (175,000 & 199,000 BTU/HR MODELS)

Venting configurations for multiple 175-199k BTU/hr units.

CONCENTRIC VENTING MULTIPLE WATER HEATERS (ALL MODELS)

Venting configurations for multiple concentric vent units.

WATER HEATER INSTALLATION

CONDENSATE DRAIN INSTALLATION

Steps for correctly connecting the condensate drain line.

SUPPLY GAS LINE INSTALLATION

Guidance on installing gas supply lines, including shut-off valves and sediment traps.

GAS LINE LEAK TESTING

PURGING

Steps for purging gas lines before system operation.

ELECTRICAL WIRING

ENABLE/DISABLE CIRCUIT (For Building Management Systems)

How to connect external controls to the enable/disable circuit.

CONNECTING AN EXTERNAL SUPERVISORY CONTROL

Detailed steps for wiring external supervisory controls.

WATER LINE CONNECTIONS

Requirements for connecting water piping to the heater.

WATER PIPING DIAGRAMS

References to diagrams for typical water piping applications.

THERMOMETERS (NOT SUPPLIED)

WATER (POTABLE) HEATING AND SPACE HEATING

T&PVALVE DISCHARGE PIPE

TEMPERATURE REGULATION

HIGH TEMPERATURE LIMIT CONTROL (ECO)

Description of the energy cut-out safety switch.

THERMOSTAT CONTROL

How to set and adjust the water temperature using the thermostat.

MODULATION

How the unit adjusts its firing rate for efficient operation.

HIGH TEMPERATURE APPLICATIONS

Considerations for high-temperature water needs.

CONTROL SYSTEM OPERATION

OVERVIEW

Description of the control system's main components and their functions.

CONTROL SYSTEM NAVIGATION

How to navigate the control system's LCD display and menus.

STATUS ICONS

OPERATING STATES

CONTROL SYSTEM MENUS

USER SETTINGS & CONTROL SYSTEM MENUS

TEMPERATURES

How to adjust operating set point and differential for desired water temperature.

TEMPERATURES (CONT)

HEATER STATUS MENU

Displays current operational status, switch states, and component activity.

DISPLAY SETTINGS

HEATER INFORMATION

CURRENT FAULT

FAULT HISTORY

FAULT OCCURRENCE

RESTORE FACTORY DEFAULTS

SERVICE CONTACT INFORMATION

START UP CONDITIONS

SMOKE/ODOR

Explanation for initial smoke or odor during first use.

PRIOR TO START UP

Essential preparation steps and safety checks before lighting the unit.

FILLING THE WATER HEATER

Critical procedure for filling the tank with water before operation.

INITIAL START UP

REQUIRED TEST EQUIPMENT

Lists necessary tools for performing start-up tests and adjustments.

PREPARATION

Steps for preparing the unit and connecting test equipment for start-up.

LIGHTING THE WATER HEATER

LIGHTING & OPERATION LABELS

Highlights the importance of following labels affixed to the water heater.

CHECKING THE FIRING RATE

HIGH ALTITUDE INSTALLATIONS

Special considerations for installing water heaters at high altitudes.

GAS INPUT RATE

Factors affecting gas input rate and how to measure it.

TROUBLESHOOTING

INSTALLATION CHECKLIST

A summary of key installation points to verify before troubleshooting.

SEQUENCE OF OPERATION

Describes the step-by-step process the control system follows during operation.

SEQUENCE OF OPERATION FLOW CHART

OPERATIONAL PROBLEMS

ROUGH STARTING, ROUGH OPERATION

Identifies causes and checks for improper ignition or operation.

MOMENTARY IGNITION

Addresses situations where the burner ignites briefly but fails to sustain.

NOT ENOUGH OR NO HOT WATER

Troubleshooting steps for insufficient or absent hot water supply.

WATER IS TOO HOT

Diagnosing and resolving issues with excessively hot water temperatures.

NOISY OPERATION

Explains normal operating noises and potential sources of unusual sounds.

REPLACEMENT PARTS

Information on ordering replacement parts and required serial numbers.

FAULT AND ALERT CONDITIONS

FAULT CONDITIONS

Describes fault messages that lock out operation and require service.

ALERT CONDITIONS

Describes alert messages that allow continued operation but need servicing.

RESETTING CONTROL SYSTEM LOCK OUTS

Procedure to reset the control system after a fault condition.

DIAGNOSTIC CHECKS

General safety warnings and procedures for performing diagnostic checks.

FAULT AND ALERT MESSAGES

Lists common fault and alert messages with possible causes and repairs.

FAULT AND ALERT MESSAGES (CONT)

POSSIBLE CAUSES - CHECK/REPAIR

Lists potential causes and checks for specific fault messages like Blocked Air Intake.

LEAKAGE CHECKPOINTS

PERIODIC MAINTENANCE

VENTING SYSTEM INSPECTION

Annual checks for obstructions, leaks, and deterioration in the vent system.

INTEGRATED FILTER PREVENTATIVE MAINTENANCE

Procedures for cleaning and maintaining the air intake filter.

TEMPERATURE-PRESSURE RELIEF VALVE TEST

Steps for testing the T&P relief valve to ensure proper operation.

DRAINING AND FLUSHING

SERVICE

Guidance on contacting a qualified service technician for persistent issues.

DIAGRAMS

CCB - CENTRAL CONTROL BOARD LAYOUT

Diagram showing the arrangement of connectors on the Central Control Board.

WIRING DIAGRAM

CIRCULATION PUMP WIRING DIAGRAMS

CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK OR BUILDING RECIRCULATION

Specific wiring diagram for circulation pumps in storage tank setups.

PIPING DIAGRAMS

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