Polaris GAS WATER HEATER Installation, Operation And Service Manual
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Polaris GAS WATER HEATER Installation, Operation And Service Manual

High efficiency gas water heater
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INSTALLATION, OPERATION, AND SERVICE MANUAL
HIGH EFFICIENCY GAS WATER HEATER
THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED
SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT
AND OPERATION OF THIS WATER HEATER. READ THESE
INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION
OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN IMPROPER INSTALLATION, OPERATION, SERVICE OR
MAINTENANCE, POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK,
SCALD INJURY, CARBON MONOXIDE POISONING, EXPLOSION,
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
INSTALLER:
•
ATTACH THESE INSTRUCTIONS TO OR ADJACENT TO THE WATER
HEATER.
•
BEFORE LEAVING THE PREMISES REVIEW THIS OPERATION AND
SERVICE MANUAL TO BE SURE THE HEATER HAS BEEN INSTALLED
CORRECTLY. START AND OPERATE THE UNIT FOR ONE COMPLETE
CYCLE AND MAKE SURE THE WATER TEMPERATURE IS ACCEPTABLE
TO THE CONSUMER AT THE FIXTURES.
OWNER:
•
RETAIN THESE INSTRUCTIONS AND WARRANTY FOR FUTURE
REFERENCE. RETAIN THE ORIGINAL RECEIPT AS PROOF OF PURCHASE.
THIS MANUAL IS NOT TO BE USED WITH GAS STORAGE TYPE
WATER
HEATERS
CERTIFIED
MANUFACTURED HOMES (MOBILE HOMES).
WARNING
AN ODORANT IS ADDED BY THE GAS SUPPLIER TO THE GAS USED BY
THIS WATER HEATER. THIS ODORANT MAY FADE OVER AN EXTENDED
PERIOD OF TIME. DO NOT DEPEND UPON THIS ODORANT AS AN
INDICATION OF LEAKING GAS. IF A GAS LEAK IS SUSPECTED, CHECK
FOR LEAKS BY USING A CHLORIDE-FREE SOAP AND WATER SOLUTION,
OR OTHER APPROVED METHOD. IF A LEAK CANNOT BE FOUND BUT IS
STILL SUSPECTED, FOLLOW THE STEPS UNDER "WHAT TO DO IF YOU
SMELL GAS" AS OUTLINED ON THIS PAGE. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN PROPERTY DAMAGE, PERSONAL INJURY,
OR DEATH.
WARNING
THIS WATER HEATER MUST BE BRACED, ANCHORED, OR STRAPPED
TO AVOID FALLING OR MOVING DURING AN EARTHQUAKE. CONTACT
LOCAL UTILITIES FOR CODE REQUIREMENTS IN YOUR AREA OR CALL
THE 800 NUMBER SHOWN ON FRONT OF THIS MANUAL AND REQUEST
INSTRUCTIONS 6600933 FOR EXAMPLES.
FOR
INSTALLATION
IN
Recognize this symbol as an indication of Important
Safety Information.
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 telephone in your building.
• Immediately call your gas supplier from a
neighbor's telephone. 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.
TO OBTAIN TECHNICAL, WARRANTY OR SERVICE
ASSISTANCE DURING OR AFTER THE INSTALLATION
OF THIS WATER HEATER, CALL TOLL FREE:
1-800-456-9805
WHEN CALLING FOR ASSISTANCE, PLEASE HAVE THE
FOLLOWING INFORMATION READY:
1.
MODEL NUMBER
2.
7 DIGIT PRODUCT NUMBER
3.
SERIAL NUMBER
4.
DATE OF INSTALLATION
6510189
March 2000
Supersedes 6510166

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Summary of Contents for Polaris GAS WATER HEATER

  • Page 1 INSTALLATION, OPERATION, AND SERVICE MANUAL HIGH EFFICIENCY GAS WATER HEATER THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED Recognize this symbol as an indication of Important SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT Safety Information. AND OPERATION OF THIS WATER HEATER. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION.

  • Page 2: Safety

    Water heaters using bottled propane or liquefied petroleum gas (LPG) are different from natural gas models. A natural gas water heater will not function safely on bottled propane or liquefied petroleum gas (LPG) and a propane gas water heater will not function safely on natural gas. Do not attempt to convert a water heater from natural gas to LPG or from LPG to natural gas.

  • Page 3: General Safety Warnings

    GENERAL SAFETY WARNINGS BEFORE ATTEMPTING TO INSTALL OR OPERATE THIS WATER HEATER, MAKE SURE YOU READ AND UNDERSTAND THE ENTIRE INSTALLATION, OPERATION AND SERVICE MANUAL. SPECIAL ATTENTION MUST BE GIVEN TO ALL THE SAFETY WARNINGS PROVIDED THROUGHOUT THIS MANUAL. FAILURE TO FOLLOW THESE WARNINGS COULD RESULT IN A FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

  • Page 4: Table Of Contents

    GENERAL SAFETY WARNINGS DANGER • • TURN OFF THE ELECTRIC POWER AT THE FUSE BOX OR SERVICE HYDROGEN GAS CAN BE PRODUCED IN A HOT WATER SYSTEM PANEL BEFORE MAKING ANY ELECTRICAL CONNECTIONS. FAILURE THAT HAS NOT BEEN USED FOR A LONG PERIOD OF TIME TO DO SO CAN CAUSE AN ELECTRICAL SHOCK RESULTING IN (GENERALLY TWO WEEKS OR MORE).

  • Page 6: Consumer Information/Responsibilities

    This manual has been prepared to acquaint you with the installation, • Do not cover any access panels leading to burner or electrical operation, and maintenance of your gas water heater and to provide compartments. Do not cover the thermostat controls or doors. important safety information in these areas.

  • Page 7: Location Requirements And Considerations

    CAN IGNITE THEM CAUSING PROPERTY DAMAGE, SERIOUS BURNS OR DEATH. NEVER STORE OR USE FLAMMABLE SUBSTANCES IN THE SAME ROOM OR AREA CONTAINING A GAS WATER HEATER. IF SUCH FLAMMABLES MUST BE USED, ALL GAS BURNING APPLIANCES IN THE VICINITY MUST BE SHUT OFF AND THEIR PILOT LIGHTS EXTINGUISHED.

  • Page 8: Location Requirements And Considerations

    LOCATION REQUIREMENTS AND CONSIDERATIONS (CONT.) 5. The water heater should be located in an area not subject to freezing temperatures. Water heaters located in unconditioned spaces (i.e. attics, REFER TO THE DATA PLATE ON THE WATER HEATER FOR THE CORRECT basements, garages, etc.) may require the insulation of the water piping CLEARANCES FROM COMBUSTIBLE MATERIALS..

  • Page 9: Condensate Trap Assembly And Drain Line

    SEE PAGE 30 FOR ALTERNATE AIR INLET DRAIN TEE ASSEMBLY CONDENSATE TRAP ASSEMBLY AND DRAIN LINE CAUTION RUN THE CONDENSATE DRAIN IN CONDITIONED AREAS ONLY OR IN SUCH A MANNER AS TO PREVENT FREEZING. FREEZING CONDENSATE CAN BLOCK THE DRAIN LINE RESULTING IN PROPERTY DAMAGE OR WATER HEATER MALFUNCTION. CONDENSATE TRAP ASSEMBLY Water vapor in the combustion products will condense inside the water heater and vent piping.

  • Page 10: Exhaust And Inlet Air Piping

    EXHAUST AND INLET AIR PIPING (CONT.) TABLE I MAXIMUM ALLOWABLE LENGTH IN FEET OF EXHAUST VENT PIPE LENGTH AND INTAKE AIR PIPE - ABS AND PVC PIPE AND FITTINGS Size the exhaust outlet and combustion air intake pipes as specified PIPE in Table 1.
  • Page 11 EXHAUST AND INLET AIR PIPING (CONT.) CONCENTRIC VENT TERMINATION Refer to Figures 6, 7, and 8 and install the vent terminal according to the following instructions: Determine the location for the concentric vent termination (See "Vent Termination Locations"). Cut a 5 inch diameter hole through the wall at the chosen location.
  • Page 12 EXHAUST AND INLET AIR PIPING (CONT.) HORIZONTAL DIRECT VENT TERMINAL INSTALLATIONS STD. HORIZONTAL TERMINATION When 3 in. pipe is used between the water heater and the outside wall, reduce it to 2 in. pipe before penetrating the wall. A maximum of 18 inches of 2 in.

  • Page 13: Vertical Termination

    EXHAUST AND INLET AIR PIPING (CONT.) VERTICAL TERMINATION When 3 in. pipe is used between the water heater and the roof, reduce it to 2 in. pipe before penetrating the roof. A maximum of 18 inches of 2 in. pipe may be used.
  • Page 14 GAS INPUT RATE: The gas input rate of this water heater is affected by several environmental factors such as: • The heating value of the gas • The air and gas densities (which vary widely due to barometric pressure and temperature changes). •...

  • Page 15: Water System Piping

    WATER SYSTEM PIPING GENERAL INFORMATION THE TEMPERATURE & PRESSURE RELIEF VALVE: • Must not be in contact with any electrical part. Water piping, fittings, and valves must be properly installed for the correct and safe operation of this water heater. Please note the following: •...

  • Page 16: Piping Installation

    WATER SYSTEM PIPING (CONT.) PIPING INSTALLATION Piping, fittings, and valves should be installed according to the installation drawing (Figure 13). If the indoor installation area is subject to freezing temperatures, the water piping must be protected by insulation. Water supply pressure should not exceed 80% of the working pressure of the water heater.

  • Page 17: Water System Piping

    If the space heating system requires water temperatures in excess of 120°F, a tempering valve or an anti-scald device should be installed See Figure below for typical water piping installation for Polaris water per its manufacturer’s instructions in the domestic (potable) hot heater used in conjunction with a solar storage tank.

  • Page 18: Gas Supply And Piping

    GAS SUPPLY AND PIPING GENERAL INFORMATION GAS PIPING DANGER This water heater must only be connected to gas supplied by a commercial supplier. DANGER THE GAS LINE MUST BE OF ADEQUATE Install the gas piping according to all local and SIZE SO AS TO PREVENT UNDUE THIS WATER HEATER IS EQUIPPED FOR state codes or with the ”National Fuel Gas...
  • Page 19 GAS SUPPLY AND PIPING (CONT.) When installing gas piping, use a pipe joint compound that is resistant to the action of propane (LPG) gases. Apply the compound to male threads only. CAUTION CONTAMINANTS IN THE GAS PIPING MAY FOUL THE GAS VALVE CAUSING A MALFUNCTION, FIRE, OR EXPLOSION.

  • Page 20: Electrical Connections

    ELECTRICAL CONNECTIONS DANGER THIS WATER HEATER MUST HAVE AN UNINTERRUPTED GROUND ACCORDING TO THE LATEST EDITION OF THE NATIONAL ELECTRICAL CODE, ANSI/NFPA 70 OR THE PREVAILING LOCAL CODES. DO NOT USE GAS OR WATER PIPING AS AN ELECTRICAL GROUND. GROUND THE WATER HEATER BY CONNECTING A GROUNDING WIRE FROM THE ELECTRICAL SERVICE BOX TO THE GREEN GROUND WIRE LOCATED IN THE JUNCTION BOX ON THE WATER HEATER.

  • Page 21: Installation Check List

    INSTALLATION CHECK LIST ELECTRICAL WATER HEATER LOCATION ◊ Unit connected to a dedicated 120 volt, 15 ampere supply. ◊ Centrally located with the water piping system. Located as close to the gas piping and vent pipe system as possible. ◊ Proper polarity.

  • Page 22: Start-Up/Operation

    Basements, crawl spaces, skirted areas under mobile homes (even when ventilated), closets and areas below ground level will serve as pockets for the accumulation of gas. Before lighting an L.P. gas water heater, smell all around the appliance at floor level. If you smell gas, follow the directions as given on this page.

  • Page 23: For Your Safety Read Before Operating

    FIGURE 17 POLARIS LIGHTING INSTRUCTION FOR YOUR SAFETY READ BEFORE OPERATING W A R N I N G If you do not follow these directions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

  • Page 24: Operational Conditions

    OPERATIONAL CONDITIONS WATER HEATER SOUNDS During the normal operation of the water heater, sounds or noises may be heard. These noises are common and may result from the following: Normal expansion and contraction of metal parts during periods of heat-up and cool-down.

  • Page 25: Gas Regulator Adjustment

    MAINTENANCE (cont.) Read the pressure on the gauge. It should be negative .20 inches of WARNING water column. If not, turn the regulator adjustment screw to adjust to this OBSTRUCTIONS OR HOLES IN THE VENT PIPE CAN CAUSE TOXIC reading. MAKE CERTAIN YOU ARE READING NEGATIVE PRESSURE FUMES TO ENTER THE STRUCTURE RESULTING IN CARBON MONOXIDE AND NOT POSITIVE PRESSURE.
  • Page 26 Disconnect the pipe nipple on the inlet of the gas regulator valve. Unscrew the gas regulator valve counterclockwise and remove. If the Polaris is an L.P. model, check to make sure that the "divider" blade is positioned at either the 10 or 2 o'clock position. There will be a black line marked on the hexagonal part of the orifice holder denoting the position of the divider.

  • Page 27: Removal And Replacement Of Gas Regulator Valve

    TROUBLESHOOTING GUIDE POLARIS ELECTRONIC CONTROL BOARD UTEC Status Indicator LED Error Conditions: Flashing 1 Time - Control is in lock-out because the inducer pressure switch is stuck closed. Flashing 2 Times - Control is in lock-out because the pressure switch did not close.

  • Page 28: Troubleshooting Guide

    1018-525 SOFTWARE OPERATION SEQUENCE CONTROL POWER TURN OFF BLOWER, AND TURN IGNORE PRESSURE SWITCH ON IGNITER FOR 35 SECOND FOR 5 SECONDS WARM-UP IS PRESSURE SWITCH IS PRESSURE SWITCH OPEN CLOSED IS PRESSURE SWITCH OPEN TURN ON BLOWER AND GAS VALVE FOR 3 SECONDS STEADY STATE HEATING TURN OFF IGNITER FOR 1 SECOND FLAME PROVING PERIOD...

  • Page 29: Software Operation Sequence

    REPAIR PARTS REPAIR PARTS LIST ITEM When ordering repair parts always give the following information: PARTS DESCRIPTION 1. Model, serial and product number TRANSFORMER 2. Type of gas THERMOSTAT SENSOR/ECO 3. Item number THERMOSTAT BOARD 4. Parts description THERMOSTAT POTENTIOMETER O-RING Replacement parts may be ordered through your local distributor.

  • Page 30: Repair Parts List

    REPAIR PARTS DIAGRAM...

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