American Water Heater Polaris High Efficiency Commercial Gas Water Heater PCG3 User Manual

							1
Polaris® 
Commercial Gas 
Water Heater
Installation 
Instructions and 
Use & Care Guide
To obtain technical, warranty or service assistance during or 
after the installation of this water heater, visit our website at:
http://www.americanwaterheater.com
or 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
5.   Place of Purchase
Table of Contents...........................................................  2
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.
WARNING:  If the information in these
instructions is not followed exactly, a fire 
or explosion may result causing property 
damage, personal injury or death.
322762-001
INSTALLER:
•  Affix these instructions to or adjacent to the water 
heater.
OWNER:
•  Retain these instructions and warranty for future 
reference. Retain the original receipt as proof of 
purchase.
PRINTED IN U.S.A.  0514
LOW LEAD
CONTENT
This manual covers model numbers:
   United States
   PGC* 34-100-2NV or 2PV
   PGC* 34-130-2NV or 2PV
   PGC* 34-150-2NV or 2PV
   PGC* 50-130-2NV or 2PV
   PGC* 50-150-2NV or 2PV
   PGC* 50-175-3NV or 3PV
   PGC* 50-199-3NV or 3PV
  * Indicates warranty period
 Note:
 The manufacturer of this water heater recommends that it     
 be professionally installed by trained and qualified service  
 professionals. 
						

							2
Your safety and the safety of others are very important.
We have provided many important safety messages in this manual and on your appliance. Always read and obey all 
safety messages.
This is the safety alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word “DANGER” or
“WARNING.” These words mean:
Indicates an imminently hazardous situation which, if not 
avoided, will result in death or injury.
Indicates a hazardous situation which, if not avoided, 
could result in death or serious injury.
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you 
what can happen if the instructions are not followed.
Important Instructions
•  Do not use this water heater if any part has been under water. Immediately call a qualified service technician.   
  Water heaters subjected to flood conditions or anytime the gas controls, main burner or ignition control have been  
  submerged in water require replacement of the entire water heater.
•  Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally  
  two weeks or more). Hydrogen gas is extremely flammable and can ignite when exposed to a spark or flame. To  
  prevent the possibility of injury under these conditions, we recommend the hot water faucet be opened for several  
  minutes at the kitchen sink before using any electrical appliance which is connected to the hot water system. If  
  hydrogen is present, there will probably be an unusual sound such as air escaping through the faucet as water  
  begins to flow. Do not smoke or have any open flame near the faucet at the time it is open.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of 
substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires 
businesses to warn of potential exposure to such substances.
Warning:  This product contains a chemical known to the State of California to cause cancer, birth defects, or other 
reproductive harm. 
This appliance can cause low-level exposure to some of the substances listed in the act.
Water Heater Safety  ............................................................................ 1-2
Installation Instructions  ...................................................................... 3-22
   Unpacking the Water Heater  ............................................................ 3
  State of Massachusetts Installation Requirements  ........................... 4
  Location Requirements  ..................................................................... 5
   Condensate Line   ........................................................................... 6-7
   Intergrated Filter Installation   ............................................................ 8
  Vent Pipe System  ........................................................................ 9-12
 Vent Terminations  ...................................................................... 10-13
  Gas Input Rate  ................................................................................ 14
  Water System Piping  ................................................................. 14-17
  Gas Supply and Piping   ............................................................. 18-19
  Electrical Connections/Wiring Diagram  ..................................... 20-21
  Installation Checklist  ....................................................................... 22
Operating Your Water Heater  .......................................................... 23-25
Polaris® Operating Instructions   ........................................................... 24
Maintenance of Your Water Heater  ................................................. 25-26
Troubleshooting  .................................................................................... 27
Software Operation Sequence  ............................................................. 28
Parts List and Diagram  ......................................................................... 29
Polaris
® Models and Dimensions .......................................................... 30
Table of Contents          Page 
						

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INSTALLATION INSTRUCTIONS
Consumer Information
OBSERVE ALL GOVERNING CODES AND ORDINANCES.
This water heater is design-certified by CSA International 
as a Category IV, direct vented water heater which takes 
its combustion air from the outside of the structure and 
exhausts all products of combustion to the outside of the 
structure.
This water heater must be installed according to all local 
and state codes or in the absence of local and state codes 
with the “National Fuel Gas Code”, ANSI Z223.1(NFPA 
54)- current edition. Canadian installations must be per-
formed in accordance with CAN/CSA-B149.1 -current edi-
tion. This is available from the following:
CSA America,  Inc.
8501 East Pleasant Valley Road
Cleveland, OH 44131
National Fire Protection Agency
1 Batterymarch Park
Quincy, MA 02169-7471
Canadian Standards Association
178 Rexdale Boulevard
Toronto, ON M9W 1R3
Check the phone listings for the local authorities having 
jurisdiction over this installation.
Installer and Owner Responsibilities
This manual has been prepared to acquaint you with the 
installation, operation, and maintenance of your gas water 
heater and provide important safety information in these 
areas. 
Read all of the instructions thoroughly before attempting 
the installation or operation of this water heater. 
Do not discard this manual. You or future users of this 
water heater will need it for future reference.
Service to the water heater should only be performed 
by a qualified service technician.
Examples of qualified service technicians include: 
those trained in the plumbing and heating industry, 
local gas utility personnel, or an authorized service 
person.
The manufacturer and seller of this water heater will 
not be liable for any damages, injuries, or deaths 
caused by failure to comply with the installation and 
operating instructions outlined in this manual. 
If you lack the necessary skills required to properly install 
this water heater, or you have difficulty following the 
instructions, you should not proceed but have a qualified 
service technician perform the installation of this water 
heater.
Unpacking the Water Heater
Removing Packaging Materials
Important: Do not remove any permanent instructions, 
labels, or the data plate from outside of the water heater or 
on the inside of panels.
•  Remove exterior packaging and place installation  
components aside.
•  Inspect all parts for damage prior to installation and 
start-up.
•  Completely read all instructions before attempting to 
assemble and install this product.
•  After installation, dispose of packaging material in the 
proper manner.
Excessive Weight Hazard
Use two or more people to move and 
install water heater unless proper 
handling equipment is utilized.
Failure to do so can result in back or 
other injury.
A data plate identifying your water heater can be found on 
the front of the heater. When referring to your water heater, 
always have the information listed on the data plate readily 
available.
Massachusetts code requires this water heater to be 
installed in accordance with Massachusetts Plumbing and 
Fuel Gas Code 248 CMR section 2.00 and 5.00. See page 
4 in this manual for the Commonwealth of Massachusetts 
installation requirements.
This product is certifield to comply with a maximum weight-
ed average of 0.25% lead content as required in some 
areas.
Keep combustibles such as boxes, magazines, clothes, 
etc., away from water heater area.
Retain your original receipt as proof of purchase. 
						

							4
For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters 
installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or 
operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished 
grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied: 
INSTALLATION OF CARBON MONOXIDE DETECTORS  At the time of installation of the side wall horizontal vented gas 
fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm 
and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber 
or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each 
additional level of the dwelling, building or structure served by the sidewall horizontal vented gas fueled equipment. It shall 
be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard 
wired carbon monoxide detectors.
In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired 
carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall 
have a period of thirty (30) days to comply with the above requirements provided that during said thirty (30) day period, a 
battery operated carbon monoxide detector with an alarm shall be installed.
APPROVED CARBON MONOXIDE DETECTORS  Each carbon monoxide detector as required in accordance with the above 
provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and CSA certified. 
SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum 
height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heat-
ing appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY 
BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”
INSPECTION  The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the 
installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance 
with the provisions of 248 CMR 5.08(2)(a) 1 through 4. 
EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 
1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 
54 as adopted by the Board; and 
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the 
dwelling, building, or structure used in whole or in part for residential purposes. 
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product 
 Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with 
the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall 
include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system. 
MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED  When the manufacturer of 
a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, 
but identifies “special venting systems,” the following requirements shall be satisfied by the manufacturer:
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation
 instructions; and 
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a 
parts list and detailed installation instructions. 
A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting 
instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or 
equipment at the completion of the installation. 
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS 
						

							5
Location Requirements
The water heater design has been tested by CSA 
International and complies with ANSI Z21.10.1, Section 
2.35 Flammable Vapors Resistance.  In garage installation 
avoid damage to your water heater by installing a vehicle 
stop as shown in figure below.  Check state and local 
codes for requirements prior to installation.Important:  The water heater should be located in 
an area where leakage of the tank or connections will 
not result in damage to the area adjacent to the water 
heater or to lower floors of the structure. Due to the 
normal corrosive action of the water, the tank will 
eventually leak after an extended period of time. 
Also any external plumbing leak, including those 
from improper installation, may cause early failure 
of the water tank due to corrosion if not repaired. 
A qualified service technician should be contacted 
for repairs.  A suitable metal drain pan should be 
installed under the water heater as shown below, to 
help protect the property from damage which may 
occur from condensate formation or leaks in the piping 
connections or tank. The pan must limit the water level 
to a maximum depth of 1-3/4” (4.45 cm) and be at least 
two inches (5 cm) wider than the heater and piped to an 
adequate drain. Locate the water heater near a suitable 
indoor drain. Outside drains are subject to freezing 
temperatures which can obstruct the drain line. The 
piping should be at least 3/4” (1.91 cm) ID and pitched 
for proper drainage. Under no circumstances will the 
manufacturer or seller of this water heater be held liable 
for any water damage which is caused by your failure to 
follow these instructions.
•  The water heater should be located in an area not sub-
ject to freezing temperatures. Water heaters  located in 
unconditioned spaces (i.e., attics,  basements, etc) may 
require insulation of the  water piping and drain piping 
to protect against freezing. The drain and controls must 
be easily accessible for operation and service. Maintain 
proper clearances as specified on the data plate. 
Figure 1: Garage Installation 
Do not store or use gasoline or other 
flammable vapors and liquids in the vicinity 
of this or any other appliance. Storage of or 
use of gasoline or other flammable vapors 
or liquids in the vicinity of this or any other 
appliance can result in serious injury or death
FIRE AND EXPLOSION HAZARD
Can result in serious injury or death
This water heater is not certified for installation in mobile 
homes.
Note: In the State of California, the water heater must be 
braced, anchored, or strapped to avoid moving during an 
earthquake. Contact local utilities for code requirements in 
your area or call 1-800-456-9805 and request instructions.
Site Location
•  Select a location near the center of the water piping 
system. The water heater must be installed   indoors 
and in a vertical position on a level surface. DO NOT 
install in bathrooms, bedrooms, or any occupied room 
normally kept closed. Note: The water heater may be 
installed in a closet with a door off a bedroom or bath-
room providing the units are installed and vented per 
the manufacturer’s instructions.•  Consider the inlet and exhaust vent system piping  
when selecting the water heater location.  The venting 
system must be able to run from the water heater to 
the termination with a minimal length and number of 
elbows.  Input rates are reduced as vent system length 
increases.  The venting system must comply with the 
requirements  set forth in the venting section of this 
manual.
•  Locate the water heater near the existing gas piping. 
If installing a new gas line, locate the water heater to 
minimize the pipe length and elbows.
Important:  Air for combustion and ventilation must not 
come from a corrosive atmosphere.  Any failure due to cor-
rosive elements in the atmosphere is excluded from war-
ranty coverage.
Note:  The water heater must be installed according to all 
local and state codes or in absence of the local and state 
codes with the “National Fuel Gas Code”, ANSI Z223.1 
(NFPA 54)-current edition.  Canadian installations must be 
performed in accordance with CAN/CSA-B149.1-current 
edition. 
1-3/4” (4.45 cm) Max.
(5 cm)
Figure 1A 
						

							6
CONDENSATE LINE
Important:  Do not run the condensate drain in areas 
that are likely to freeze. Frozen condensate will block the 
drain line and result in property damage or water heater 
malfunction.
Condensate Trap Assembly
A condensate trap/drain stem assembly has been supplied 
with the water heater and is located behind the access door 
inside the base of the water heater.  This assembly must be 
installed between the water heater and the exhaust outlet 
piping to ensure proper operation of the water heater. To 
install, remove the slip-joint nut, stainless steel washer, and 
O-ring from the trap assembly.  Slip the nut, washer and 
O-ring (in that order) over the stainless exhaust tubing and 
slide them back near the base of the heater.  Insert the trap 
assembly over the tubing (see figure 3A accordingly) and 
firmly hand-tighten (using a wrench will cause the O-ring to 
seal improperly) the nut to form a water-tight seal between 
the O-ring and the stainless exhaust tubing.  When 
tightened, the nut to heater base clearance should be 3/4” 
(+/- 1/8”) tolerance (1.9 cm +/- 0.31 cm tolerance).
Note:  The trap should be aligned so that the exhaust pipe 
is in a vertical position close to the surface of the water 
heater.
Figure 2: Minimum Clearance Locations 
Back 0” (0 cm)
Sides: 4” (10.2 cm) 
Min. for service
Front: 24”  
(61 cm ) 
Min. for serviceTop: 0” (0 cm)
Vent: 0” 
(0 cm)
Sides: 4” (10.2 cm) 
Min. for service
Clearances and Accessibility
Notice:  Minimum clearances from combustible materi-
als are stated on the data plate located on the front of the 
water heater.
•  The water heater is certified for installation on a
 combustible floor. 
Important: If installing over carpeting, the carpeting must 
be protected by a metal or wood panel beneath the water 
heater. The protective panel must extend beyond the full 
width and depth of the water heater by at least 3 inches 
(7.62 cm) in any direction or if in a alcove or closet instal-
lation, the entire floor must be covered by the panel. The 
panel must be strong enough to carry the weight of the 
heater when full of water.
Figure 2 may be used as a reference guide to locate the 
specific clearance locations. A minimum of 24 inches     
(61 cm) of front clearance and 4 inches (10.2 cm) on each 
side should be provided for inspection and service. 
Figure 3A: 2” Condensation Trap Installation  
						

							7
Condensate Drain Line
All parts of the condensate trap are glued except for the 
1/2” CPVC drain stem joint at the elbow (see figure 3A).  
This assembly can be turned with the outlet of the tee 
oriented as needed.
Once orientation direction is decided, remove the unglued 
joint from the elbow at the bottom and apply a suitable 
cement to joint. Re-insert the joint fully and quickly into 
the elbow making sure to orient it before the cement sets.  
Connect the remaining piping and run the condensate drain 
line to a suitable drain.
Important:  Be sure the drain stem joint is inserted against 
the stop in the elbow.  Failure to do so may result in 
improper water heater operation.
If required by local codes, install a condensate neutralizer 
cartridge on the drain line (see figure 3B).
The condensate drain line must be routed to a suitable  
drain.  If no floor drain is available or the drain  is above 
the level of the condensate line, install a condensate pump 
that is resistant to the acidic condensate.  These pumps are 
available from local distributors.  If the pump is not resistant 
to acidic water, a condensate neutralizer must be used 
ahead of the pump.
When installing the drain line, note the following:
•  Plastic pipe or tubing must be used to connect the 
condensate drain to a suitable drain or condensate      
pump. Do not use copper tubing, iron, or steel pipe for 
the condensate drain line.
• Condensate drain lines should be installed in condi-
tioned areas only.  Drain lines installed in areas that are 
subject to freezing temperatures should be wrapped 
with a nationally recognized/listed heat tape and/or 
approved insulation for freeze protection. Install per 
manufacturer’s instructions.
• Do not common drain with the temperature and pres-
sure relief valve or the condensate line from  an air 
conditioner evaporator coil.
• Slope the condensate drain toward the inside floor 
drain or condensate pump.
• The condensate drain line and connection to the drain 
piping must comply with all local codes.
• Do not run the condensate line into the metal drain 
pan. 
VENT PIPE SYSTEM
Carbon Monoxide Hazard
Follow all instructions to locate and install 
the vent pipe system.
Instructions can be found in this manual, in 
state or local codes (or the authority having 
jurisdiction), or in the absence of such, the 
National Fuel Gas Code, ANSI Z223.1, NFPA 
54, Current Edition.  Canadian installations 
must be performed in accordance with 
CAN/CSA-B149.1, Current Edition.
Failure to properly locate and install the 
vent pipe system can result in death or 
carbon monoxide poisoning.
Venting
This water heater has a direct vent system in which all air 
for combustion is taken from the outside atmosphere and 
all combustion products are discharged to the outdoors.  
This water heater must be properly vented for removal 
of exhaust gases to the outside atmosphere.  Correct 
installation of the vent pipe system is mandatory for the 
safe and efficient operation of this water heater and is an 
important factor in the life of the unit.
Vent pipe installation must be performed in accordance 
with state and local codes, or in the absence of such, the 
National Fuel Gas Code, NFPA 54, ANSI Z223.1-current 
edition.  Canadian installations must be performed in 
accordance with CAN/CSA-B149.1-current edition.  
When replacing an existing Polaris
® unit, it is recommended 
that the venting system be reviewed for compliance with 
the requirements contained in this installation manual. If the  
venting is not in compliance, it is recommended that the 
appropriate changes be made to bring it into compliance. 
Note: It is important that the factory-installed air inlet filter 
be inspected periodically and cleaned if necessary. See 
“Integrated Filter Installation, Preventive Maintenance”. 
Note: if the vent system is not in compliance with the 
current installation manual, the manufacturer reserves 
the right to evaluate the installation prior to granting any 
warranty on service claims.
Important: Check to make sure the vent pipe is not 
blocked in any way. 
Note:  Do not common vent this water heater with any 
other appliance.  Do not install in the same chase or 
chimney with a metal or high-temperature plastic from 
another gas or fuel burning appliance.
Figure 3B: Condensate Drain 
						

							8
Integrated Filter Installation
When installing the adaptor rubber boot, note the following:
•  Remove and discard the plastic cap from the outer 
clamshell housing (see figure 4A).
• To connect the heater to the air inlet, use the vent 
adaptor rubber boot provided in the base skirt. The 
adaptor rubber boot is designed for 3” venting (see 
figure 4B). Note: If there is a need for 2” venting, then 
use plastic pipe and fittings to transition down.
• Loosen the hose clamp at the adaptor rubber boot and 
slide the plastic piping into the adaptor rubber boot. 
With piping in place, tighten the hose clamp. Install  
a 3” x 3” x 2” drain/waste/vent fitting to trap airborne 
particulates (see figure 4C). Note: If piping has been 
previously cut with a saw, be sure to remove all burrs 
and plastic shavings from the piping before installing.
Preventive Maintenance
The heater is designed to shut down if the pressure 
switch senses that the air inlet vent or the exhaust vent 
is restricted. In this case, the pressure switch will open 
and the heater will generate a 2-flash code (see the 
troubleshooting section). If troubleshooting section of 
this manual indicates that there is a blockage, note the 
following:
•  Turn off the gas supply to the water heater at the 
manual gas shut-off valve, and disconnect power to the 
water heater.
• To inspect the filter, loosen the hose clamp at the adap-
tor rubber boot and slide the plastic pipe out and away 
from the adaptor rubber boot (see figure 4C).
• Remove the adaptor rubber boot containing the outer 
clamshell housing by turning clockwise approximately 
1/2” (30.5 cm) and pulling off of the internal clamshell 
housing (see figure 4C).
• Using your fingers or a small flat blade screwdriver,   
remove the filter media from the outer clamshell hous-
ing, handle carefully (see figure 4D).
• To clean filter, lightly tap the back of the filter support 
to dislodge any large debris. Smaller debris may be re-
moved by using a vacuum cleaner. the filter media may 
be cleaned by dipping the filter media into a solution of 
warm soapy water and rinsing in clean water. Do not 
scrub, allow to air dry before reinstalling. Filter media 
may be cleaned on an average 2 to 3 times before 
replacing with a new filter media is required.
• Reinstall the filter media by doing the above steps in 
reverse order.
• Turn on the gas supply and reconnect power, refer to 
the operating instructions on front of the water heater. 
Verify proper operation of the water heater before   
leaving.
Note: The heater must never be operated without the 
filter media installed.
Figure 4B: Adaptor Rubber Boot
Push On &
Tighten Clamp
Adaptor Rubber
Boot
Outer Clamshell
Housing
Figure 4C: Air Inlet Piping
Hose Clamp
3” Plastic Pipe
Adaptor Rubber Boot
Outer Clamshell Housing
3” x 3” x 2” DWV Fitting
Piped To
External Air
Supply
Figure 4D: Filter Media
Adaptor
Rubber Boot
Remove
Filter Media Filter Media shown inside
the Outer Clamshell Housing
Outer Clamshell
HousingNOTE: if found difficult to
reattach the outer clamshell
housing to the internal clamshell
housing - apply a thin layer of silicone
grease to the surface of the black rubber
support of the Filter Media.
                         
Figure 4A: Remove Plastic Cap
Outer Clamshell
Housing With Filter
Base Skirt Gas Piping
Remove
Plastic Cap 
						

							9
Vent Pipe Material
The following plastic materials may be used for both the 
combustion air inlet and exhaust outlet piping subject to 
state and local codes:  
  •  Schedule 40 PVC
  •  Schedule 40 or 80 CPVC
  •  DWV Pipe is acceptable
Note: Use only solid (not foam core) piping.
Plastic pipe and fittings are available through most 
plumbing suppliers. Always check the marking on the pipe 
to make sure you are using the correct material.
Important: Do not use vent elbows in this vent pipe instal-
lation (see figure 5 below).
Vent Pipe Installation
The following guidelines should be followed when installing 
the air inlet and exhaust outlet piping:
•  Venting should be as direct as possible with a minimum 
number of pipe fittings.
•  Vent diameter must not be reduced unless specifically   
noted in the installation instructions.
•  All 2” horizontal vent piping must be sloped upward  
1/4 inch per foot (21 mm per meter); (3” Piping must 
slope upward at 1/8” per  foot) (10.5 mm per meter). 
This will allow condensate to run back to the heater  
and exit through the condensate trap.
•  Support all horizontal pipe runs every four feet (1.2 m) 
and all vertical pipe runs every six feet (1.8 m) or       
according to local codes. 
•  Vents run through unconditioned spaces where below  
freezing temperatures are expected should be  properly 
insulated to prevent freezing. Wrap the vent pipe with 
approved insulation for freeze protection. Install per the 
manufacturer’s instructions.
•  An air intake filter is included with the unit and must be  
  installed according to the installation instructions 
  supplied with the filter.
The combustion air inlet and exhaust outlet piping and 
termination may be installed in one of the following type 
terminations:
  1.   Standard Horizontal (2 Pipe) 
  2.   Alternate Horizontal (2 Pipe)
  3.   Vertical (2 Pipe) 
  4.    Concentric Vent - Through the Wall
  5.    Concentric Vent - Through the Roof
All pipe, fittings, pipe cement, primers and procedures 
must conform to American National Standard Institute and 
American Society for Testing and Materials (ANSI/ASTM) 
standards in the United States. This water heater has been 
design certified by the Canadian Standards Association for 
use with the specified (CSA) listed plastic vent pipe. All joints in the inlet and outlet piping must be properly 
cemented. Size and cut all piping before cementing.
1.   Cut the pipe end square and remove all ragged edges 
and burrs.  Make sure the inside of the pipe is clean 
and free of cuttings and loose dirt.  Chamfer the end 
and apply primer to the fitting and pipe.  
2.    Using a suitable grade of pipe cement, apply a moder-
ate, even coat inside the fitting.  Apply a liberal amount 
of cement to the outside of the pipe to socket depth. 
Note: It is important to select the proper pipe cement for 
the type of plastic pipe being used.
3.   Assemble the parts quickly while the cement is             
still  wet. Twist  the  pipe  1/4  turn  during  insertion                   
and hold for 30 seconds.
Vent Pipe Length
Size the exhaust outlet and combustion air inlet pipes as 
specified in Table 1. This table lists the maximum allow-
able length in feet of the exhaust outlet and combustion air 
inlet pipes as related to the number of required elbows and 
the termination. The specified maximum lengths are for 
the separate inlet and exhaust pipe systems and not the 
combined length of both systems. Minimum pipe length is 
6 feet (1.8 m) with one elbow per side.
1.   Determine termination type and pipe size.
2.   Determine number of elbows in exhaust pipe. Do not 
include the elbows in the termination or the condensate 
trap.  Corresponding number Indicates the maximum 
length of exhaust pipe.
3.   Determine number of elbows in inlet pipe.  Do not  
include the elbows in the termination.  The correspond-
ing number indicates the maximum length of inlet pipe.
Pipe 
Size in 
Inches
*2
*2 *2 *2
3
3 3 352 
(15.8)48 
(14.6)40
(12.2) 44
(13.4)32
(9.7)
100
(30.5) 125
(38.1)36
(11)
44
(13.4)40
(12.2)36
(11)32
(9.7)28
(8.5)24
(7.3)
48 
(14.6) 52 
(15.8)44
(13.4)40
(12.2)36
(11)32
(9.7)28
(8.5)
52 
(15.8)48 
(14.6)44
(13.4)40
(12.2)36
(11)32
(9.7)
130
(39.6)120
(36.6)11 5
(35)11 0
(33.5)105
(32)
11 5
(35)11 0
(33.5)105
(32)100
(30.5)90
(27.4) 95
(28.9)
120
(36.6)11 5
(35)11 0
(33.5)105
(32)100
(30.5)95
(28.9)
125
(38.1)120
(36.6)11 5
(35)11 0
(33.5)105
(32)100
(30.5) Maximim allowable Length in Feet (Meters) of Exhaust and Air Inlet Pipe
For Schedule 40 CPVC, OR PVC Pipe and Fittings
Minimum length is 6 feet (1.8 m) per pipe with 1 elbow per side.
*  3” pipe must be used for 175,000 BTU/Hr (51.29 kW) input and above.
2 Inch pipe may be used with 100,000, 130,000 & 150,000 
BTU/HR (29.3, 38, & 43.9 kW) input models only.
Figure 5: Correct and Incorrect Pipe Fittings 
						

							10
Vent Termination Locations
The air inlet and exhaust outlet must be installed with the 
following minimum clearances (see figure 6):
•  Twelve inches (30 cm) above grade or maximum antici-
pated snow level.
•  Twelve inches (30 cm) from any opening through which 
flue gases could enter the structure.
•  Four feet (122 cm) horizontally and vertically from gas 
or electric meters, gas regulators, dryer vents, vent 
hoods, bathroom fan exhaust, attic fans and turbines.
•  Two feet (61 cm) from an inside corner formed by two 
exterior walls. 
•  Two feet from porches, decks, overhangs and  other 
obstructions.
In addition to maintaining the minimum clearances , the 
vent should terminate according to the following guidelines:1.    Use only 2 inch pipe or a 2 inch concentric vent 
on the vent termination for 100,000 - 150,000 BTU/
Hr models. Do not expose any 3” X 2” reducers or 
bushings to outdoor ambient temperatures. 
2.    The air inlet and exhaust outlet must not terminate 
under a patio, deck or any covered area.
3.   Do not terminate the vent near walkways or into alleys 
or other publicly accessible areas.
4.    Combustion air inlet termination and exhaust air termi-
nation must be located in the same pressure zone.
Figure 6: Minimum Clearances for Inlet/Outlet and Concentric Vent
A.  12 in (30 cm) min. clearance above grade, 
veranda, porch, deck, balcony, or maximum 
anticipated snow level.
B.  12 in (30 cm) min. clearance on top and side of 
window or door that may be opened. Maintain a 
36 in (91 cm) minimum clearance below a window 
or door that may be opened.
C.  Clearance to permanently closed window.**
D.  12 in (30 cm) min vertical clearance to ventilated 
soffit located above the terminal within a horizontal  
distance of 2 ft (61 cm) from the center line of the  
terminal.
E.  12 in (30 cm) min. clearance to unventilated soffit.
F.  Clearance to outside corner **
G.  2 ft (61 cm) clearance to inside corner formed by 
two exterior walls.
H.  4 ft (122 cm) clearance to each side of center line 
extending above meter/regulator assembly.
I.  4 ft (122 cm) clearance to service regulator vent 
outlet.
J.  12 in (30 cm) clearance to nonmechanical air 
supply inlet to building or the combustion air inlet 
to any other appliance.
K.  3 ft (91 cm) above if within 10 ft (3 m) horizontally of 
mechanical air supply inlet.
**Clearance in accordance with local installation codes and the requirements of the gas supplier. 
A.  12 in (30 cm) min. clearance above grade,    
  veranda, porch, deck, balcony, or maximum    
  anticipated snow level.
B.  12 in (30 cm) min. clearance on top and side of  
  window or door that may be opened. Maintain         
  a 36 in (91 cm) minimum clearance below a    
  window or door that may be opened.
C.  Clearance to permanently closed window.**
D.  12 in (30 cm) min vertical clearance to ventilated  
  soffit located above the terminal within a horizontal  
  distance of 2 ft (61 cm) from the center line of the  
 terminal.
E.  12 in (30 cm) min. clearance to unventilated soffit.
F.  Clearance to outside corner. **
G.  2 ft (61 cm) clearance to inside corner formed by  
  two exterior walls.
H.  3 ft (91 cm) within a height 15 ft (4.57 m) above the  
 meter/regulator assembly.
I.  4 ft (122 cm) clearance to service regulator vent outlet.
J.  12 in (30 cm) clearance to nonmechanical air  
  supply inlet to building or the combustion air inlet to  
  any other appliance.
K.  6 ft (1.83 m) clearance to mechanical air supply inlet. US Installations Canadian Installations