Polaris 200 series Instruction Manual
Polaris 200 series Instruction Manual

Polaris 200 series Instruction Manual

Residential gas water heaters
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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
service agency or the gas supplier.
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.
PRINTED 0817
RESIDENTIAL GAS WATER HEATERS
LOW LEAD
CONTENT
qualified
installer,
KEEP THIS MANUAL IN THE POCKET ON HEATER FOR FUTURE REFERENCE
WHEN EVER MAINTENANCE ADJUSTMENT OR SERVICE IS REQUIRED.
Instruction Manual
POWER DIRECT VENT GAS MODELS
For Your Safety
AN ODORANT IS ADDED TO THE GAS USED
BY THIS WATER HEATER.
1
WITH DIRECT SPARK IGNITION
PR MODELS
Series 200, 201
NATURAL GAS & PROPANE
100277196_ 2000547022_Rev. B

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Summary of Contents for Polaris 200 series

  • Page 1 Instruction Manual RESIDENTIAL GAS WATER HEATERS POWER DIRECT VENT GAS MODELS WITH DIRECT SPARK IGNITION PR MODELS Series 200, 201 NATURAL GAS & PROPANE LOW LEAD CONTENT WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
  • Page 2: Table Of Contents

    TABLE OF CONTENTS SAFE INSTALLATION, USE AND SERVICE.........3 ............28 APPROVALS .................3 Venting Multiple Units .............29 GENERAL SAFETY INFORMATION ..........4 WATER HEATER INSTALLATION ..........30 ................4 ..........30 .............4 Supply Gas Line Installation ...........30 INTRODUCTION ................7 Gas Line Leak Testing ............31 ..............7 Purging ...................31 ................7 ..............32 Preparing For The Installation ..........7...
  • Page 3: Safe Installation, Use And Service

    SAFE INSTALLATION, USE AND SERVICE 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. DANGER indicates an imminently hazardous situation which, if not avoided, DANGER will result in injury or death.
  • Page 4: General Safety Information

    GENERAL SAFETY INFORMATION PRECAUTIONS GROUNDING INSTRUCTIONS DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN EXPOSED TO FLOODING OR WATER DAMAGE. 2. Damage. 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.
  • Page 5 GENERAL SAFETY INFORMATION...
  • Page 6 GENERAL SAFETY INFORMATION Fire or Explosion Hazard Fire Hazard Do not store or use gasoline or other flammable vapors and For continued protection against liquids in the vicinity of this or any other appliance. risk of fire: Avoid all ignition sources if you smell gas. Do not install water heater on carpeted floor.
  • Page 7: Introduction

    INTRODUCTION ABBREVIATIONS USED heater. QUALIFICATIONS QUALIFIED INSTALLER OR SERVICE AGENCY NOTE: ANSI Z223.1 2006 Sec. 3.3.83: PREPARING FOR THE INSTALLATION Dimensions on Page 8.
  • Page 8: Dimensions And Capacity Data

    DIMENSIONS AND CAPACITY DATA ROUGH IN DIMENSIONS: ALL MODELS All Models Additional Side Taps Air Inlet Figure 1 . DIMENSIONS FOR ALL MODELS Table 1A - ROUGH-IN-DIMENSIONS T&P EXTERIOR WATER CONNECTIONS AIR INLET/EXHAUST U.S. INPUT SUPPLY UNITS GALLONS (KBTU/HR) 123.19 55.88 102.87 104.14...
  • Page 9 DIMENSIONS AND CAPACITY DATA Table 2 – CAPACITY, GAS AND ELECTRICAL CHARACTERISTICS U.S. Gals. Liters Gas Type “WC Amperes <7 <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.
  • Page 10: Features And Components

    FEATURES AND COMPONENTS 34 GALLON UNIT **11 **25 **12 **34 21, 22 **33 This is a view of the area at the bottom of heater behind the **11 Access Doors. **12 VACUUM RELIEF VALVE * CAUTION HARNESS HAS 120 VAC. IN OPERATION. ** See Venting Installation and Condensate Piping for more information.
  • Page 11: Gallon Unit

    FEATURES AND COMPONENTS (CONT.) 50 GALLON UNIT **11 **25 **12 **34 21, 22 This is a view of the area at the bottom of heater behind the Access Doors. **33 **11 **12 VACUUM RELIEF VALVE * CAUTION HARNESS HAS 120 VAC. IN OPERATION. ** See Venting Installation and Condensate Piping for more information.
  • Page 12 FEATURES AND COMPONENTS (CONT.) Control Assembly Burner Assembly Flame Sensor Igniter Assembly Gas Control Valve Assembly 14: Hot Water Outlet 15: Gas Supply 16: Main Manual Gas Shutoff Valve 17: Union 18: Inlet Water Shutoff Valve 20: T & P Relief Valve 21: Rating Plate 22: Labels 23: Drain Valve...
  • Page 13 CONTROLS AND SWITCHES BLOCKED OUTLET SWITCH Blocked Outlet Switch the Vent System beginning on page 22. BLOCKED INTAKE SWITCH prevent air from entering the unit. Also Verify the intake air pipe Blocked Intake Switch System beginning on page 22. 34 GALLON UNIT WATER HEATING ENABLE/DISABLE SWITCH IMPORTANT: Blocked Outlet...
  • Page 14: Installation Considerations

    INSTALLATION CONSIDERATIONS LOCATING THE WATER HEATER installation of the vent (exhaust) or intake air terminations CAUTION Property Damage Hazard • All water heaters eventually leak. • Do not install without adequate drainage. requirements prior to installation. in the area. Figure 5. GARAGE INSTALLATION...
  • Page 15: Insulation Blankets

    • • COMBUSTION AIR AND VENTILATION piping system as possible. CEILING TOP VIEW TOP VIEW OF CLOSET OF CLOSET 0" MIN. WITHOUT DOOR WITHOUT DOOR LEFT RIGHT 0" MIN. 0" MIN. WALL WALL WATER WATER HEATER HEATER *24" MIN. (61 cm) *4"...
  • Page 16: Installation Requirements

    INSTALLATION REQUIREMENTS GAS SUPPLY SYSTEMS they supply or explosion from leaking gas. There must be: PSI Gauge). Water heaters require gas regulators that are properly • • • POWER SUPPLY CSA C22.1. DEDICATED POWER WIRING AND BREAKERS SUPPLY GAS REGULATOR POWER FLUCTUATIONS AND ELECTRICAL NOISE...
  • Page 17: Mixing Valves

    HOT WATER OUTLET 12” TO 15” (30-38 cm) TEMPERED WATER OUTLET number for more information. CHECK COLD NOTE: VALVE WATER INLET MIXING CHECK VALVE VALVE TO TANK MIXING VALVES INLET Figure 8 Water temperature over 125°F (52°C) Mixing valves are available at plumbing supply stores. Consult a can cause severe burns instantly resulting in severe injury or death.
  • Page 18: Storage Tank Installation

    SPACE HEATING AND POTABLE WATER SYSTEM THERMAL EXPANSION • or other type heating system. • only. • existing boiler installation. • relief of thermal expansion. • • • NOTE: • any mixing valve or supply line to the heating system to remove Water STORAGE TANK INSTALLATION Sweat...
  • Page 19: Temperature-Pressure Relief Valve

    NOTE: Explosion Hazard Temperature-Pressure Relief Valve must comply with ANSI Z21.22- CSA 4.4 and ASME code. of the heater. Fit T & P valve insulation over valve. Make sure that Properly sized temperature- pressure relief valve must be installed in opening provided. TEMPERATURE-PRESSURE RELIEF VALVE Can result in overheating and excessive tank pressure.
  • Page 20 in operation. NOTE: pipe. Old trap piping is not compatible with new trap piping. Burn hazard. THIS SIDE VIEW EXHAUST (VENT) OF EXHAUST ELBOW Hot water discharge. ELBOW AND ARROW INDICATE CONDENSATE THE LOCATION OF DRAIN LINE THE PRESSURE Keep clear of Temperature- CONNECTION PORT Pressure Relief Valve...
  • Page 21: Venting Installation

    VENTING INSTALLATION Vent Terminal Installation on Page 25. GENERAL VENTING INSTRUCTIONS • • • • VENT INSTALLATION CONSIDERATIONS • • • • • Note: • Note: Important: APPROVED VENT/INTAKE MATERIAL Note: • • ULC S636 Polypropylene - See Polypropylene Installations. PVC pipe materials: •...
  • Page 22: Polypropylene Installations

    • VENT PIPE TERMINATION • SDR Series ASTM-D2241 or CSA B137.3 CPVC pipe materials: • CPVC 41 ASTM-D2846 or CSA B137.6 • termination types: • SDR Series ASTM-F442 Polypropylene - See Polypropylene Installations. Alternate Horizontal (2 Pipe) - See Figure 20 •...
  • Page 23 Table 5. M & G Duravent PolyPro Nominal Pipe Flue Outlet Adapter Ring 90 Degree Vent Material Terminal(s) Diameter Adapter Connector Connector Elbow 2PPS-AD PPS-PAC 2PPS-LB 2PPS-E90 2PPS 3PPS-AD PPS-PAC 3PPS-LB 3PPS-E90 3PPS Table 6. Centrotherm InnoFlue SW Nominal Pipe Flue Outlet Adapter Ring...
  • Page 24: Horizontal Vent Terminal Installation

    HORIZONTAL VENT TERMINAL INSTALLATION Hose Clamp NOTE: If you are installing your system so that it vents through the Piped To External Air Supply 1. A f t e r t h e p o i n t s o f t e r m i n a t i o n h a v e b e e n CONCEALED WIRING AND PIPING INSIDE OF WALL.
  • Page 25 WHEN TERMINATING THROUGH A ROOF, THE FOLLOWING SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE FOLLOWED. pipe every six feet. *Refer to Figure 11 for Inlet /Outlet Location Dimensions FLAT ROOF INSTALLATION Alternate Horizontal Termination Figure 20 horizontally. VERTICAL VENT TERMINAL INSTALLATION Exhaust Notes: See Note 3...
  • Page 26 TERMINATION CLEARANCES SIDEWALL DIRECT VENT DIRECT VENT (using outdoor air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION Figure 23 CANADIAN INSTALLATIONS CANADIAN INSTALLATIONS requirements of the gas supplier. 6 feet (1.83 m) of the terminal 7 feet (2.13 m)†...
  • Page 27 DIRECT VENT INSTALLATION DIAGRAMS Notes: 1. Support Horizontal Pipe Every Four Feet. Support Vertical Pipe Every Six Feet. Note 6 2. Increase the 12" minimum above grade to keep terminal openings above anticipated snow levels. 12" Min. Above Tee with Grade or 3.
  • Page 28 CONCENTRIC VENT INSTALLATION Note: installation. SAFETY CONSIDERATIONS Figure 29. Through the Roof Termination Tee with Drain Trap Trap See Note 4 NOTES: Figure 26. 2 Inch Concentric Vent 1. Support Horizontal Pipe Every Four Feet. Support Vertical Pipe Every Six Feet. 3"...
  • Page 29: Venting Multiple Units

    VENTING MULTIPLE UNITS VENTING ADDITIONAL POLARIS® UNITS (100,000, 130,000 & 150,000 BTU/HR MODELS) Figure 34 CONCENTRIC VENTING MULTIPLE WATER HEATERS (ALL MODELS) Figure 31 Figure 32 VENTING ADDITIONAL POLARIS® UNITS (175,000 & 199,000 BTU/HR MODELS) Figure 35 Figure 33...
  • Page 30: Water Heater Installation

    WATER HEATER INSTALLATION CONDENSATE DRAIN INSTALLATION NOTE: position. every three feet. operation. (pressure port). EXHAUST/CONDENSATE CONDENSATE DRAIN (VENT) ELBOW LINE - FIELD INSTALLED PRESSURE PORT DRAIN LINE TO TERMINATE NO 1/2” NPT CONDENSATE MORE THAN 6 DRAIN INCHES (15.2 cm) CONNECTION ABOVE DRAIN BUILDING...
  • Page 31: Gas Line Leak Testing

    Table 8. Natural Gas Capacity (Cu. f t/hr) Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity of 0.60 (natural gas). Nominal Iron Length of Pipe, Feet Pipe Size, in.
  • Page 32 ELECTRICAL WIRING • • Figure 48 on page 55. • • • tension NOTE: amperes. NOTE: NOTE: operate. in Table 12 on page 36. NOTE: ENABLE/DISABLE CIRCUIT (For Building Management Systems) WATER LINE CONNECTIONS Mixing Valves on page 17. Temperature-Pressure Relief Valve on page 19. NOTE: WATER PIPING DIAGRAMS beginning on Page 58.
  • Page 33 NOTE: T&P VALVE DISCHARGE PIPE Valve on Page 19. Explosion Hazard remote storage tanks. THERMOMETERS (NOT SUPPLIED) Temperature-Pressure Relief Valve must comply with ANSI Z21.22- CSA 4.4 and ASME code. Properly sized temperature- pressure relief valve must be WATER (POTABLE) HEATING AND SPACE HEATING installed in opening provided.
  • Page 34: Temperature Regulation

    TEMPERATURE REGULATION HIGH TEMPERATURE LIMIT CONTROL (ECO) THERMOSTAT CONTROL DANGER Water temperature over 125°F (52°C) can cause severe burns instantly resulting in severe injury or death. Children, elderly and the physically settings. or mentally disabled are at highest risk for scald injury. Feel water before bathing or showering.
  • Page 35: Control System Operation

    CONTROL SYSTEM OPERATION OVERVIEW CONTROL SYSTEM NAVIGATION THE DESKTOP SCREEN been no user input for several minutes. • • Operating Set Point. The Operating Set Point is the BOARD • POWER SUPPLY • BOARD TRANSFORMER Figure 39 UIM (user interface module) Desktop Screen Shown LCD Touch Display Title Bar...
  • Page 36 STATUS ICONS Table 12 – Status Icons Icon Description NOTE:...
  • Page 37 OPERATING STATES Table 13 – OPERATING STATES State Description Water Heating Pre-Purge Spark Igniter Ignition Inter-Purge Heating Post-Purge Fault NOTE: CONTROL SYSTEM MENUS Table 14 – CONTROL SYSTEM MENUS Menu Description Temperatures Heater Status Display Settings Heater Information Current Fault Fault History NOTE:...
  • Page 38: User Settings & Control System Menus

    USER SETTINGS & CONTROL SYSTEM MENUS TEMPERATURES OPERATING SET POINT AND DIFFERENTIAL ADJUSTMENT minus the Differential setting. NOTE: DESCRIPTION/ACTION DISPLAY MANUFACTURER / MODEL INFORMATION Operating Set Point 120°F Status: Standby MENU HELP Main Menu Temperatures > Heater Status > Display Settings >...
  • Page 39 TEMPERATURES (CONT) DESCRIPTION/ACTION DISPLAY • Differential Temperatures Operating Setpoint 120°F > • Tank Probe Offset Differential 8°F > NOTE: temperature varies greatly from the Operating Set Point setting. Tank Probe Offset 0°F > BACK HELP HEATER STATUS MENU DESCRIPTION/ACTION DISPLAY Top of Menu Press Heater Status from the Main Menu to enter this menu.
  • Page 40 DISPLAY SETTINGS DESCRIPTION/ACTION DISPLAY Press Display Settings from the Main Menu to enter this menu. Display Settings Temperature Units °F > navigate the menu. Brightness 5 > • Temperature Units Backlight Delay 30s > Language English > • Backlight Delay •...
  • Page 41 CURRENT FAULT DESCRIPTION/ACTION DISPLAY Blocked Exhaust 0 days 0 hrs 0 mins ago navigate the menu. Error Code: A8-1201 Restriction in exhaust pipe. Check exhaust pipe and termination for blockage. Press the Advanced button for BACK ADVANCED Main menu. FAULT HISTORY DESCRIPTION/ACTION DISPLAY Fault History...
  • Page 42 SERVICE CONTACT INFORMATION DESCRIPTION/ACTION DISPLAY Contact Information Show Contact No > Change Contact Name > Change Contact Phone > Current Contact Info: (000) 000-0000 menu item. BACK HELP Contact Information Show Contact Yes > Change Contact Name > Change Contact Phone >...
  • Page 43: Start Up

    START UP START UP CONDITIONS SMOKE/ODOR FILLING THE WATER HEATER PRIOR TO START UP DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN on Page 11. on page 46.
  • Page 44: Initial Start Up

    INITIAL START UP MANIFOLD GAS SUPPLY GAS PRESSURE PRESSURE TEST PORT REQUIRED TEST EQUIPMENT TEST PORT (Non-Adjustable) • • NOTE: GAS CONTROL VALVE TOP DETAIL VIEW PREPARATION Figure 42 SUPPLY GAS VALVE CONNECTION position. 3. Close the manual gas shut off valve, see Figure 37 on page 31. COMBUSTION AIR INLET VENTURI...
  • Page 45: Lighting The Water Heater

    LIGHTING THE WATER HEATER LIGHTING & OPERATION LABELS FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. l l i i f i l l i Operating Set Point...
  • Page 46: Gas Input Rate

    CHECKING THE FIRING RATE NOTE: 3600 x H = Btu/hr Figure 44 Example: HIGH ALTITUDE INSTALLATIONS 3600 x 1050 = 300,000 Btu/hr (87.9 kW) 12.6 • • Breathing Hazard - Carbon Monoxide Gas • • Special consideration must be taken with •...
  • Page 47: Troubleshooting

    TROUBLESHOOTING INSTALLATION CHECKLIST WATER HEATER LOCATION Operating Set Point minus the Differential setting, a heating VENTING Ensure the maximum equivalent feet of pipe has not been on page 29. GAS SUPPLY AND PIPING minimum supply gas line size requirements. See Supply beginning on Page 31.
  • Page 48 SEQUENCE OF OPERATION FLOW CHART If tank temperature drops below Operating Set Point minus Differential setting a heating cycle is activated Control System performs diagnostic checks Control System Locks Out Normal State of all pressure switches and ECO are checked Displays Fault Msg Pressure Switches and ECO are verified closed Combustion Blower is energized...
  • Page 49: Operational Problems

    OPERATIONAL PROBLEMS 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 for the Ignition Failure Fault message. or serious injury. This manual must remain with the water heater.
  • Page 50 FAULT AND ALERT CONDITIONS FAULT CONDITIONS NOTE: ALERT CONDITIONS RESETTING CONTROL SYSTEM LOCK OUTS DIAGNOSTIC CHECKS Electrical Shock Hazard • Turn off power to the water heater before performing any service. • Label all wires prior to disconnecting when performing service. Wiring errors can cause improper and dangerous operation.
  • Page 51 FAULT AND ALERT MESSAGES (CONT) in your area. POSSIBLE CAUSES - CHECK/REPAIR DISPLAYED FAULT/ALERT MESSAGE • Blocked Air Intake 0 days 0 hrs 0 mins ago • Error Code: A7-1201 Restriction in air intake. Check intake pipe and • termination for blockage. Press the Advanced button for •...
  • Page 52: Leakage Checkpoints

    LEAKAGE CHECKPOINTS A: Hot Water Outlet C: T & P D: T & P Outlet H: Temperature area. D. *The temperature-pressure relief valve may be leaking at the tank Figure 46). Figure 46). I: Flue Outlet Out Cap Figure 46 on Page 44..
  • Page 53: Periodic Maintenance

    PERIODIC MAINTENANCE • VENTING SYSTEM INSPECTION • • • Breathing Hazard - Carbon Monoxide Gas • • Flue gases may escape if vent pipe is not connected. • • Be alert for obstructed, sooted or deteriorated vent Wiring on Page 33, Control System Operation on Page 36, system to avoid serious injury or death.
  • Page 54 NOTE: 2. Turn off the gas supply at the Main Gas Shutoff Valve (see DO NOT PLUG THE TEMPERATURE-PRESSURE RELIEF VALVE from the storage tank. OPENING. THIS CAN CAUSE PROPERTY DAMAGE, SERIOUS INJURY OR DEATH. Explosion Hazard TO FLUSH THE WATER HEATER STORAGE TANK: Temperature-Pressure Relief Valve must comply with ANSI Z21.22- CSA 4.4 and ASME code.
  • Page 55: Diagrams

    DIAGRAMS CCB - CENTRAL CONTROL BOARD LAYOUT Figure 48...
  • Page 56: Wiring Diagram

    WIRING DIAGRAM CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING. CCB J17 Low Voltage Field CCB J5 CCB J16 CCB J1 CCB J3 Blower Logic Low Voltage In HIGH Voltage In Transformer...
  • Page 57 CIRCULATION PUMP WIRING DIAGRAMS CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK OR BUILDING RECIRCULATION FIELD SUPPLIED TEMPERATURE CONTROL INSTALLED IN THE STORAGE TANK OR CIRCULATING LOOP RETURN LINE NOTE: USE SEPARATE 120 VAC POWER SUPPLY FOR PUMP CIRCUIT. DO NOT SHARE POWER WITH APPLIANCE AS THIS MAY CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM OPERATION.
  • Page 58: Piping Diagrams

    PIPING DIAGRAMS NOTE: Follow the Mixing Valve manufacturers instructions when installing the mixing valve. Mixing Valve Check local codes. Metal Drain 6" (15.2cm) Air Gap Max. Adequate Drain Figure 51: TYPICAL ONE-TEMPERATURE SYSTEM PIPING INSTALLATION (All Models) NOTE: Follow the Mixing Valve manufacturers instructions when installing the mixing valve.
  • Page 59 Figure 53: AIR HANDLER PIPING INSTALLATION (All Models) NOTE: Follow the Mixing Valve manufacturers instructions Manual Shut Off Valve (Typ) when installing the mixing valve. Mixing Valve (160°F Max.) Figure 54: POLARIS WITH AUXILLARY STORAGE TANK, One or Two Temperature System (With or Without Building Recirculation)
  • Page 60 NOTES...
  • Page 61 NOTES...
  • Page 62 For Tech Support please call PR models: 1-888-479-8324 599 Hill Street West Fergus, ON Canada, N1M2X1...

This manual is also suitable for:

201 series

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