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

Polaris PGC Specifications

General

Brand	Polaris
Model	PGC
Category	Water Heater
Language	English

Summary

COMMERCIAL GAS WATER HEATERS

POLARIS - POWER DIRECT VENT GAS MODELS WITH DIRECT SPARK IGNITION

Identifies the product line and key features.

MODELS PGC/SPC/BSS/BTS Series 200, 201 NATURAL GAS & PROPANE

Lists specific model series and fuel types.

SAFE INSTALLATION, USE AND SERVICE

SAFETY ALERT SYMBOLS

Explains hazard symbols (Danger, Warning, Caution).

GENERAL SAFETY INFORMATION

PRECAUTIONS

Lists general safety precautions to follow before operation.

GROUNDING INSTRUCTIONS

Details requirements for proper electrical grounding.

GENERAL SAFETY INFORMATION

WARNING Breathing Hazard - Carbon Monoxide Gas

Highlights the dangers of carbon monoxide gas.

DANGER Flammable Vapors

Warns about explosion hazards from flammable vapors.

GENERAL SAFETY INFORMATION

WARNING Electrical Shock Hazard

Warns about electrical shock hazards.

WARNING Fire and Explosion Hazard

Specific fire and explosion warnings.

INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS

INSTALLATION OF CARBON MONOXIDE DETECTORS

Requirements for CO detector installation.

INTRODUCTION

QUALIFIED INSTALLER OR SERVICE AGENCY

Defines requirements for qualified personnel.

DIMENSIONS AND CAPACITY DATA

ROUGH IN DIMENSIONS: ALL MODELS

Provides detailed rough-in dimensions for all models.

DIMENSIONS AND CAPACITY DATA

TABLE 2 - CAPACITY, GAS AND ELECTRICAL CHARACTERISTICS

Details capacity, gas type, and electrical specifications.

FEATURES AND COMPONENTS

34 GALLON UNIT

Identifies components of the 34-gallon model.

FEATURES AND COMPONENTS (CONT.)

50 GALLON UNIT

Identifies components of the 50-gallon model.

FEATURES AND COMPONENTS (CONT.)

LIST OF COMPONENTS

Provides a numbered list of all components.

CONTROLS AND SWITCHES

BLOCKED INTAKE SWITCH

Describes the blocked intake pressure switch.

INSTALLATION CONSIDERATIONS

LOCATING THE WATER HEATER

Provides guidance on choosing a suitable location.

DANGER Flammable Vapors

Warns about flammable vapors in installation location.

INSTALLATION CONSIDERATIONS (CONT.)

COMBUSTION AIR AND VENTILATION

Explains requirements for combustion air.

CORROSION AND WATER QUALITY

Discusses water quality impact on the heater.

INSTALLATION REQUIREMENTS

GAS SUPPLY SYSTEMS

Details requirements for gas supply systems.

POWER SUPPLY

Specifies power supply requirements.

INSTALLATION REQUIREMENTS (CONT.)

MIXING VALVES

Instructions for installing mixing valves.

CIRCULATION PUMPS

Information on using circulation pumps.

INSTALLATION REQUIREMENTS (CONT.)

SPACE HEATING AND POTABLE WATER SYSTEM

Guidelines for combined heating and potable water systems.

THERMAL EXPANSION

Explains thermal expansion and its control.

INSTALLATION REQUIREMENTS (CONT.)

TEMPERATURE-PRESSURE RELIEF VALVE

Details about the T&P relief valve.

T&P VALVE DISCHARGE PIPE REQUIREMENTS

Specifies requirements for the T&P discharge pipe.

INSTALLATION REQUIREMENTS (CONT.)

CONDENSATE DRAIN INSTALLATION

Instructions for installing the condensate drain.

VENTING INSTALLATION

VENT INSTALLATION CONSIDERATIONS

Key factors to consider during vent installation.

VENTING INSTALLATION (CONT.)

VENT PIPE TERMINATION

Details on vent pipe termination types and locations.

PLANNING THE VENT SYSTEM

Guidance on planning the vent system layout.

VENTING INSTALLATION (CONT.)

TABLE 7A. Elevations up to 2000 Ft.

Maximum vent pipe lengths for lower elevations.

INTEGRATED FILTER INSTALLATION

Instructions for installing the air intake filter.

VENTING INSTALLATION (CONT.)

DIRECT VENT AIR INTAKE MOISTURE PROTECTION

How to protect the air intake from moisture.

HORIZONTAL VENT TERMINAL INSTALLATION

Steps for installing horizontal vent terminals.

VENTING INSTALLATION (CONT.)

VERTICAL VENT TERMINAL INSTALLATION

Steps for installing vertical vent terminals.

PITCHED ROOF INSTALLATION (ALL MODELS)

Requirements for pitched roof vent termination.

TERMINATION CLEARANCES SIDEWALL DIRECT VENT

DIRECT VENT (using outdoor air for combustion)

Overview of direct vent configurations.

DIRECT VENT INSTALLATION DIAGRAMS

SIDEWALL VENT INSTALLATION (ALL MODELS)

Diagram for sidewall vent installation.

CONCENTRIC VENT INSTALLATION

SAFETY CONSIDERATIONS

Safety precautions for concentric venting.

VENTING MULTIPLE UNITS

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

Venting configurations for specific models.

CONCENTRIC VENTING MULTIPLE WATER HEATERS (ALL MODELS)

Concentric venting for multiple units.

WATER HEATER INSTALLATION

CONDENSATE DRAIN INSTALLATION

Steps for installing the condensate drain.

SUPPLY GAS LINE INSTALLATION

Guidelines for installing the gas supply line.

WATER HEATER INSTALLATION (CONT.)

GAS LINE LEAK TESTING

Procedure for leak testing gas connections.

ELECTRICAL WIRING

ENABLE/DISABLE CIRCUIT (For Building Management Systems)

How to use the enable/disable circuit for BMS.

WATER LINE CONNECTIONS

Requirements for water line connections.

ELECTRICAL WIRING (CONT.)

T&P VALVE DISCHARGE PIPE

Specifics on T&P valve discharge pipe.

TEMPERATURE REGULATION

HIGH TEMPERATURE LIMIT CONTROL (ECO)

Explanation of the ECO switch.

THERMOSTAT CONTROL

How to control the thermostat settings.

CONTROL SYSTEM OPERATION

CONTROL SYSTEM NAVIGATION

How to navigate the control system menus.

THE DESKTOP SCREEN

Description of the default screen display.

CONTROL SYSTEM OPERATION (CONT.)

STATUS ICONS

Explains the meaning of status icons.

CONTROL SYSTEM OPERATION (CONT.)

OPERATING STATES

Lists and describes common operating states.

CONTROL SYSTEM MENUS

Overview of available control system menus.

USER SETTINGS & CONTROL SYSTEM MENUS

OPERATING SET POINT AND DIFFERENTIAL ADJUSTMENT

How to adjust operating set point and differential.

USER SETTINGS & CONTROL SYSTEM MENUS (CONT.)

HEATER STATUS MENU

Menu to check the status of heater components.

USER SETTINGS & CONTROL SYSTEM MENUS (CONT.)

DISPLAY SETTINGS

Options for adjusting display settings.

HEATER INFORMATION

Displays operational history and component versions.

USER SETTINGS & CONTROL SYSTEM MENUS (CONT.)

CURRENT FAULT

Displays active fault messages.

FAULT HISTORY

Lists past fault and alert messages.

USER SETTINGS & CONTROL SYSTEM MENUS (CONT.)

SERVICE CONTACT INFORMATION

Access to enter service contact details.

START UP

FILLING THE WATER HEATER

Instructions for filling the water heater tank.

START UP (CONT.)

INITIAL START UP

Step-by-step guide for initial start-up.

REQUIRED TEST EQUIPMENT

Lists necessary equipment for testing.

LIGHTING THE WATER HEATER

FOR YOUR SAFETY READ BEFORE LIGHTING

Critical safety warnings before lighting the unit.

OPERATING INSTRUCTIONS

Steps for operating the water heater.

LIGHTING THE WATER HEATER (CONT.)

CHECKING THE FIRING RATE

How to check the actual firing rate.

HIGH ALTITUDE INSTALLATIONS

Considerations for high altitude installations.

TROUBLESHOOTING

INSTALLATION CHECKLIST

Checklist for common installation errors.

SEQUENCE OF OPERATION

Detailed explanation of the operational sequence.

TROUBLESHOOTING (CONT.)

SEQUENCE OF OPERATION FLOW CHART

Visual flow chart of the sequence of operation.

OPERATIONAL PROBLEMS

NOT ENOUGH OR NO HOT WATER

Common causes for lack of hot water.

WATER IS TOO HOT

Troubleshooting excessively hot water.

OPERATIONAL PROBLEMS (CONT.)

FAULT AND ALERT CONDITIONS

Understanding fault and alert messages.

FAULT AND ALERT MESSAGES

List of displayed fault/alert messages.

FAULT AND ALERT MESSAGES (CONT)

POSSIBLE CAUSES - CHECK/REPAIR

Potential causes and checks for faults.

LEAKAGE CHECKPOINTS

PERIODIC MAINTENANCE

VENTING SYSTEM INSPECTION

How to inspect the venting system.

TEMPERATURE-PRESSURE RELIEF VALVE TEST

Procedure for testing the T&P relief valve.

PERIODIC MAINTENANCE (CONT.)

DRAINING AND FLUSHING

Instructions for draining and flushing the tank.

DIAGRAMS

CCB - CENTRAL CONTROL BOARD LAYOUT

Diagram of the central control board layout.

WIRING DIAGRAM

CIRCULATION PUMP WIRING DIAGRAMS

CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK OR BUILDING RECIRCULATION

Wiring diagram for storage tank recirculation.

PIPING DIAGRAMS

FIGURE 52: TYPICAL ONE-TEMPERATURE SYSTEM PIPING INSTALLATION (All Models)

Diagram for single temperature system piping.

FIGURE 53: SAMPLE MIXING VALVE INSTALLATION (All Models)

Diagram showing mixing valve installation.

PIPING DIAGRAMS (CONT.)

FIGURE 54: AIR HANDLER PIPING INSTALLATION (All Models)

Diagram for air handler piping installation.

FIGURE 55: POLARIS WITH AUXILIARY STORAGE TANK, One or Two Temperature System (With or Without Building Recirculation)

Diagram for systems with auxiliary storage tanks.

NOTES

POLARIS