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Polaris PG10 User Manual

Polaris PG10
63 pages
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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.
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

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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