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American Water Heater Polaris High Efficiency Commercial Gas Water Heater PCG3 User Manual
American Water Heater Polaris High Efficiency Commercial Gas Water Heater PCG3 User Manual
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21 WIRING DIAGRAM HEATER SUPPLIED WITH T92 SERIES RELAY HEATER SUPPLIED WITH KUHP SERIES RELAY NOTICE: IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH 18 GAUGE STRANDED 105C WIRE OR ITS EQUIVALENT.THERMOSTAT BOARDIGNITION CONTROL IGNITION CONTROL BLOWERHSI HSIG L1L2 IND 120 VAC 24 VAC GAS VALVE RELAY RED LED GREEN LED YELLOW LED THERMOSTAT SENSOR-ECO C GV W POT N.O. 24 V HOT ONLY COM THERMOSTAT DIAL TO 120/60 POWER SUPPLY SEN-1 LOWER IGNITER GND GND GND GND FUSED DISCONNECT L1NEUTRAL GND PSIPSO PRESSURE SWITCH BLACK WHITE WHITE RED LED YELLOW LED GREEN LEDBROWN YELLOW RED THERMOSTAT DIAL ORANGE GAS VALVE BROWNBLUE BLUE WHITE IGNITER RED GREEN YELLOW ORANGE RED 24V 120V TRANSFORMER BLACK GREENGROUND BLACK BLACK/WHITE IGNITION CONTROL 120V/60Hz BLOWER GREEN WHITE THERMOSTAT BOARD NO COM RELAYPOT SEN-1 LOWER 24V HOT ONLY THERMOSTAT SENSOR/ECO YELLOW REDRED RED GREENBLACK GREEN BLUE IND L1 HSI HSIG L2 W PSI GV PSO FSG C COMMON (C) PRESSURE SWITCH NORMALLY OPEN (NO) NEUTRAL (WHITE) L1 (BLACK) FUSED DISCONNECTEDTO 120/60 POWER SUPPLY 120 VAC (BLACK & WHITE WIRES IN BOLD) BLACK/WHITEBLACK/RED L2 N.O. WHITE BLACK/RED RELAY BLACK 8 6 01 GREEN WHITEBLACK RELAY68 10RELAY COIL Figure 20A Figure 20B
22 INSTALLATION CHECKLIST Water Heater Location Requirements … Centrally located with the water piping system. Located as close to the gas piping and vent pipe system as pos- sible. … Located indoors and in a vertical position. Protected from freezing temperatures. … Proper clearances from combustible surfaces main- tained and not installed directly on a carpeted floor. Sufficient room to service the water heater. … Provisions made to protect the area from water dam- age. Properly sized metal drain pan installed and piped to an adequate drain. … Installation area free of corrosive elements and flammable materials. Condensate Line … Drain stem is fully inserted in the elbow and glued properly. … Trap aligned so that the exhaust pipe is in a vertical position close to the surface of the water heater. … Line properly sloped to adequate drain or approved condensate pump. … Properly vented. … Protected from freezing (if required). Vent Pipe System … Vent pipe and fittings of approved material. … Acceptable size, length, and number of elbows on air inlet pipe. … Acceptable size, length, and number of elbows on exhaust outlet pipe. … Add the air inlet filter per the manufacturer’s instruction. … Installed in accordance with prevailing provisions of Local codes, or in the absence of such, National Fuel Gas Code, NFPA 54, ANSI Z223.1-Current Edition. Canadian Installations must be performed in accor- dance with CAN/CSA-B149.1-Current Edition. … All 2” horizontal piping sloped down toward the water heater at 1/4” per foot (21 mm per meter). 3” piping sloped down towards the heater at 1/8” per foot (10.5 mm per meter). … Not obstructed in any way. Vent Termination Horizontal … Correct relationship - outlet to inlet. … 12” Min. (30.5 cm) above grade/snow level. … 2” exhaust outlet/air inlet pipe sloped down towards water heater at 1/4” per foot (21 mm per meter). 3” piping sloped down towards the heater at 1/8” per foot (10.5 mm per meter). … Away from corners, other vents, windows, etc. Alternate Horizontal … Correct relationship - outlet to inlet. … 12” Min. (30.5 cm) above anticipated snow level. … 2” exhaust outlet/air inlet pipe sloped down towards water heater at 1/4” per foot (21 mm per meter). 3” piping sloped down towards the heater at 1/8” per foot (10.5 mm per meter). … Away from corners, other vents, windows, etc. Vertical … Inlet - 12” Min. (30.5 cm) above roof/snow level. … Correct relationship - outlet to inlet. … Away from corners, other vents, windows, etc. Concentric … 12” Min. (30.5 cm) above grade/snow level. … 2” exhaust outlet/air inlet pipe sloped down towards water heater at 1/4” per foot (21 mm per meter). 3” piping sloped down towards the heater at 1/8” per foot (10.5 mm per meter). … Away from corners, other vents, windows, etc. Water System Piping … Temperature and pressure relief valve properly installed with a discharge line run to an open drain and protected from freezing. … All piping properly installed and free of leaks. … Heater completely filled with water. … A properly sized expansion tank must be installed on all closed systems. … A mixing valve must be installed per the manufacturer’s instructions. Gas Supply and Piping … If using a flexible gas connector, make sure its rating tag matches or exceeds the input of the water heater. … Adequate pipe size and of approved material. … Gas supply is the same type as listed on the water heater data plate. … Gas line equipped with full opening shut-off valve, union and drip leg. … Approved pipe joint compound used. … Chloride-free soap and water solution or other ap- proved means used to check all connections and fit- tings for possible gas leaks. Electrical Connections … Unit connected to a dedicated power supply. … Unit connected to a 120V electrical supply. … Proper polarity. … Water heater properly grounded. … Installed in accordance with prevailing provisions of local codes, or in the absence of such, National Fuel Gas Code, NFPA 54, ANSI Z223.1-Current Edition. Canadian installations must be performed in accor- dance with CAN/CSA-B149.1-Current Edition.
23 OPERATING YOUR WATER HEATER Read and understand these directions thoroughly before attempting to operate the water heater (see Operating Instructions on Page 24). Check the data plate on the front of the water heater for the correct gas. Do not use this water heater with any gas other than the one listed on the data plate. If you have any questions or doubts, consult your gas supplier or gas utility company. L.P. (Propane) Models Propane gas is heavier than air and in the occurrence of a leak in the system, the gas will settle on the floor level. 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 a propane gas water heater, smell all around the appliance at floor level. If you smell gas, follow the instructions as given in the warning on the front page. When your propane tank runs out of fuel, turn off the gas at all gas appliances including pilot lights. After the tank is refilled, all appliances must be re-lit according to their manufacturer’s instructions. Water Heater Operation This water heater does not have a pilot light. It is equipped with an electronic ignition that automatically lights the burner. There are three lights to indicate the various stages of operation; Green = Electrical power is on, Yellow = Thermostat is calling for heat, which signals the beginning of the ignition sequence (see figure 21), and Red = Ignition control is signaling the gas valve to open. Figure 21: Sequence of Operation When the thermostat calls for heat, the blower will run for 6 seconds to purge the system of any accumulated gas or air. The hot surface igniter will heat up for 35 seconds. The blower will turn on and the gas valve open, forcing the air and gas mixture across the hot surface igniter, causing the burner to light. The hot surface igniter will turn off and act as an electronic flame sensor to determine if burner ignition has been accomplished. If it detects any loss of flame, it will shut off the gas supply to the burner. The ignition control will try to light the burner three times. If the ignition control does not detect a flame after three tries, it will temporarily lock out, but then auto restart and go through three additional tries for ignition after 60 minutes. It will repeat until ignition occurs or the system locks out requiring service. Refer to Troubleshooting Guide on Page 27. Thermostat Sensor The sensor is a 10K ohm [at 77°F (25°C)] thermistor. Read resistance through the black wires that run to the sensor. Remove wires from circuit board before checking. An open or short circuit indicates sensor failure. Check reading against the values listed in Table 3. The resistance should correspond with the temperature in the tank: Table 3: Temperature I Resistance 60°F 16°C 15,300 ohms 80°F 27°C 9,300 ohms 100°F 38°C 5,800 ohms 120°F 49°C 3,800 ohms 140°F 60°C 2,500 ohms 160°F 71°C 1,700 ohms 185°F 85°C 1,100 ohms
24occurrence of igniter failure due to excessive condensate. Important: A mixing valve (provided) must be installed in the hot water outlet to reduce the risk of scald injury when setting the thermostat in excess of 120°F (48.9°C). Many home heating systems used with this water heater are designed for temperatures higher than 130°F (54.4°C). Refer to the manufacturer’s instruction manuals supplied with this type of equipment for recommended temperature settings. Important: Adjusting the thermostat past the 120°F (48.9°C) setting on the temperature dial (see figure 22) will increase the risk of scald injury. Hot water can produce first degree burns within: (48.9°C)* (54.4°C)* (60°C)* (48.9°C)* (54.4°C)* (60°C)* * Temperatures shown are approximates and may vary. (48.9°C) (54.4°C) (60°C) Figure 22: Temperature Dial Stacking Stacking occurs when a series of short draws of hot water (3 gallons [11.3 liters] or less) are taken from the water heater tank. This causes increased cycling of the burner and can result in increased water temperatures at the hot water outlet. A mixing valve must be installed in the hot water supply line to reduce the risk of scald injury. Water Temperature Regulation The thermostat is adjusted to its lowest temperature setting when it is shipped from the factory. Water temperature can be regulated by moving the temperature dial to the preferred setting. The preferred starting point is 130°F (54.4°C); however, in some instances, setting the water heater higher than 130°F (54.4°C) can reduce the Water temperature over 125°F (51.6°C) can cause severe burns instantly or death from scalds. Children, disabled and elderly are at highest risk of being scalded. See instruction manual before setting temperature at water heater. Feel water before bathing or showering. Temperature limiting valves are available. Water Temperature °F (°C)Time for 1st Degree Burn (Less Severe Burns)Time for Permanent Burns 2nd & 3rd Degree (Most Severe Burns) 110 (43.3) 116 (46.7) 122 (50) 131 (55) 140 (60) (U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978) (normal shower temp.) (pain threshold) 35 minutes 45 minutes 116 (46.7) 1 minute 5 minutes 5 seconds 25 seconds 2 seconds 5 seconds 1 second 2 seconds 149 (65) 154 (67.8) instantaneous 1 second Table 4 Emergency Shut Down Important: If overheating occurs or the gas supply fails to shut off, close the manual gas supply valve. Turn off the electrical supply to the unit and close the cold water supply valve. Do not operate the water heater again until it has been thoroughly checked by an authorized service technician.
25 OPERATIONAL CONDITIONS MAINTENANCE 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: 1. Normal expansion and contraction of metal parts during periods of heat-up and cool-down. 2. Sediment buildup in the tank bottom will create varying amounts of noise and may cause premature tank fail- ure. Drain and flush the tank as directed under “Drain- ing and Flushing”. Safety Shut-Off (Pressure Switch) This water heater is equipped with a pressure switch that protects the unit by shutting it down in the event that: • A blockage occurs in the combustion air inlet, the flue gas exhaust outlet, or both the inlet and outlet. • The condensate line freezes and the condensate “backs up” and fills the exhaust outlet. • The blower fails to operate, or operates improperly. • The unit begins to operate at an abnormally low input level. Energy Cut-Off (ECO) A high temperature limit switch, or ECO, is used to shut down the water heater if the water temperature exceeds 203°F (95°C). The ECO will automatically reset when the temperature cools sufficiently. If the ECO shuts down the heater repetitively, contact a qualified professional for service. Draining and Flushing It is recommended that the tank be drained and flushed every 6 months to remove sediment which may buildup during operation. The water heater should be drained if being shut down during freezing temperatures. To drain the tank, perform the following steps: 1. Turn off the gas supply at the Manual Gas Shut-off Valve. Turn off the electrical supply to the water heater. 2. Open a nearby hot water faucet and run until the water is no longer hot. 3. Close the cold water inlet valve. 4. Open the left-hand access panel at the bottom of the heater (see figure 23). Connect a hose to the drain valve and terminate it to an adequate drain or external to the building. 5. Open the water heater drain valve and allow all of the water to drain from the tank. 6. Flush tank to remove sediment. 7. Close the drain valve, replace access door, refill the tank, and restart the heater as directed under “Operating Your Water Heater”. IMPORTANT: Condensation may occur when refilling the tank and should not be confused with a tank leak. Temperature and Pressure Relief Valve Manually operate the temperature and pressure relief valve at least once a year to make sure it is working properly. To prevent water damage, the valve must be properly connected to a discharge line which terminates at an adequate drain. Standing clear of the outlet (discharged water may be hot), slowly lift and release the lever handle on the temperature and pressure relief valve to allow the valve to operate freely and return to its closed position (see figure 24). If the valve fails to completely reset and continues to release water, immediately shut off the manual gas valve and the cold water inlet valve, and call a qualified service technician. Drain Valve Behind Access Door Figure 23: Drain Valve Access Figure 24Figure 24
26 MAINTENANCE OF YOUR WATER HEATER 3 Month Inspection At least every 3 months, a visual inspection should be made of the combustion air inlet as well as the exhaust and water piping. Check the water heater for the following: • Obstructions, damage, or deterioration in the venting system. Make sure the exhaust and combustion air supplies are not obstructed. • Leaking or damaged water and gas piping. • Presence of flammable or corrosive materials in the installation area. • Presence of combustible materials near the water heater. Important: Verify proper operation after servicing this water heater. Gas Valve The gas valve on this water heater has been permanently set at the factory for proper operation. No field adjustments are needed and none should be performed. Removing the Gas Valve Removal and replacement of the gas regulator valve involves the disconnection of gas piping and electrical leads. This procedure must be performed by a qualified service technician. Important: When removing the gas valve, do not use a pipe wrench or vise to grip the body. Do not apply any force to the gas valve or the cast flange fitting on the inlet side of the gas valve (see figure 25.) Such force may break or crack these components. 1. Turn temperature dial counterclockwise to the lowest setting and turn off electrical power to appliance. 2. Shut off the gas at the manual shut-off valve on the gas supply line. See figure 19 for reference. Remove the access door. 3. Disconnect the gas piping connection just outside the base of the water heater . Note: Use a second pipe wrench on the gas piping inside the skirt to avoid cracking the gas valve or the flange fitting. 4. Remove the pressure tap from the gas valve (see figure 25). The hose should not be disconnected. 5. Remove the Phillips head screw holding the electrical plug and remove electrical plug from the gas valve. 6. Remove the three T-25 Torx head brass screws that attach the gas valve to the venturi manifold, using the T-25 Torx wrench supplied with the gas valve kit (model VK8115V, part number 6903775.) 7. Remove the gas valve from the unit keeping the rubber gasket with the gas valve . 8. Remove the flange from the gas inlet side of the valve by removing the four (4) attachment screws. Figure 25 Replacing the Gas Valve Important: The rubber gasket that seals the gas valve to the venturi manifold must be used (previous gaskets may be reused, if in good condition). Make sure the gasket is properly inserted into the recess on the gas valve prior to installation (see figure 25 for exact placement of the rubber gasket). 1. Remove the O-ring from the flange (removed from the old gas valve) and replace it with the one provided in the gas valve kit (model VK8115V, part number 6903775.) 2. Reattach the elbow flange to the gas valve. Tighten all four screws securely. 3. Place the three T-25 Torx screws through the proper holes in the venturi manifold flange. See figure 25. 4. Properly install a new rubber gasket (provided) as shown in figure 25. 5. Position the gas valve and start all three screws (projecting downward from the venturi manifold) into the gas valve. A T-25 Torx wrench has been provided in the gas valve replacement kit (model VK8115V, part number 6903775.) Note: All three T-25 Torx screws must be properly tightened to secure the seal between the gas valve and the venturi manifold. 6. Reconnect the pressure tap to the port on the new gas valve (see figure 25). 7. Reconnect the external gas supply line to the gas pip- ing on the gas valve. Be sure to use approved Teflon tape or pipe joint compound suitable for gas piping. Note: Use a second pipe wrench on the gas piping inside the skirt to avoid cracking the gas valve or the cast fitting. 8. Reconnect the electrical plug to the gas valve and secure it with the screw provided. 9. Turn gas supply on and check for leaks. Use a chlo- ride-free soap and water solution (bubbles forming indicate a leak) or other approved method. All leaks must be fixed immediately. 10. Be sure tank is completely filled with water before re- storing power to the water heater. Follow operating instructions on Page 24. 11. Ensure proper operation of the water heater, then rein- stall the access door. If additional information is required, contact the Product Service and Support Group through our website: www.americanwaterheater.com.
27 TROUBLESHOOTING Table 5: Ignition Control Module (ICM) LED Error Codes: (Flashes visible through viewport in access door) FLASHES INDICATED PROBLEM CONTROL REACTION 1 Pressure Switch Closed SC* 2 Pressure Switch Open SL 3 Failed Ignition SL3 4 Gas Valve Hardware Fault SL 5 Flame Sense Hardware Fault SC 6 False Flame SL** 8 Ignition Control Hardware Fault SL 9 Ignition Control Software Fault SL Rapid L1 Polarity Detection SC SL (Soft Lockout): Control Automatically resets after 60 minutes. SL3 (Soft Lockout/Hard Lockout): Control automatically resets after 60 minutes, with a maximum of 3 resets, followed by hard lockout requiring service. SC (Self Clearing): Control will function normally as soon as it no longer detects the previously indicated fault. * when pressure switch or blower relay opens ** when flame is no longer sensed. † Blower Isolation Relay is used on models 150,000 BTU/Hr and above. Note: If unit goes into a soft or hard lock-out the ignition control module can be reset by cycling power to the water heater.
28 SOFTWARE OPERATION SEQUENCE IGNITION CONTROL MODULE SOFTWARE OPERATION SEQUENCE
29 REPAIR PARTS LIST/DIAGRAM ITEM NO.PARTS DESCRIPTION 1 1” NPT x 2.5” BRASS NIPPLE 2 THERMOSTAT SENSOR BUSHING 3 O-RING 4 THERMOSTAT SENSOR/ECO 5 INVERTED FLARE NUT 6 PLUG 7 VINYL TUBING 8 PRESSURE SWITCH 9 COMBUSTION BLOWER 10 4 INCH (10.16 cm) DIAMETER BLOWER GASKET 11 BURNER (NATURAL AND L.P. SAME) 12 6 INCH (15.24 cm) DIAMETER BURNER GASKET 13 HOT SURFACE IGNITER 14 IGNITER BRACKET 15 VENTURI MANIFOLD 16 REDUCING COUPLING 17 INLET AIR / FILTER ASSEMBLY 18 GAS VALVE 19 1/2” NPT 90 DEGREE INLET FLANGE 20 1/2” NPT X 2” NIPPLES 21 1/2” NPT ELBOWS 22 1/2” NPT X 4.5” NIPPLE 23 RED LED 24 YELLOW LED 25 GREEN LED 26 THERMOSTAT BEZEL 27 TEMPERATURE SELECTOR KNOB 28 THERMOSTAT BOARD 29 IGNITION CONTROL 30 TRANSFORMER 31A 2” (DN 50mm) CONDENSATE TRAP ASSEMBLY 31B 3” (DN 80mm) CONDENSATE TRAP ASSEMBLY 32 COLD WATER TUBE ASSEMBLY 33 TEMPERATURE AND PRESSURE RELIEF VALVE 34 DRAIN VALVE 35 POTENTIOMETER 36 VENTURI GASKET (not pictured) 37 BLOWER ISOLATION RELAY TOOLS REQUIRED FOR SERVICING TOOL FUNCTION VOLT OHMMETER MEASURE VOLTAGE/RESISTANCE CLAMP-ON AMMETER MEASURE CURRENT STOPWATCH CLOCK GAS CONSUMPTION CALCULATOR CALCULATE INPUT RATE U-TUBE MANOMETER READ INLET GAS PRESSURE 3/16-inch (≈ 4.76 mm) ID PLASTIC TUBING (2 FT [61 cm])CONNECT MANOMETER #1 & #2 PHILLIPS SCREWDRIVERS REMOVE DOORS AND CONTROLS 12” (30.48 cm) PIPE WRENCH (2 REQUIRED)REMOVE GAS LINE SAE 1/2” COMBINATION WRENCH REMOVE BLOWER AND BURNER SAE 1/2” SOCKET AND RATCHET REMOVE BLOWER AND BURNER SAE 3/8” COMBO WRENCH/NUT DRIVERREMOVE IGNITER T-25 TORX WRENCH REMOVE THE GAS VALVE (ALSO HELPFUL - SAE 9/32” and 5/16” COMBINATION WRENCHES) When ordering repair parts always give the following information: 1. Model, serial, and product numbers 2. Type of gas 3. Item number 4. Parts description Repair Parts List
30 POLARIS MODELS & DIMENSIONS MODEL NUMBERGAL. CAP.INPUT (MBTU PER HR.)VENT DIA. EXTERIORWATER CONNECTIONST&P HGTGAS SUPPLYAIR INLET/EX- HAUSTAPPROX SHIP. WEIGHT A B C D E F G PGC* 34-100-2NV OR 2PV 34 100 2 OR 348-1/2 2215-3/4 40-1/2 41 6-3/8 5-1/2 / 6-5/8 150 PGC* 34-130-2NV OR 2PV 34 130 2 OR 348-1/2 22 15-3/440-1/2 41 6-3/8 5-1/2 / 6-5/8 150 PGC* 34-150-2NV OR 2PV 34 150 2 OR 348-1/2 22 15-3/440-1/2 41 6-3/8 5-1/2 / 6-5/8 150 PGC* 50-130-2NV OR 2PV 50 130 2 OR 362-3/8 22 15-3/454-1/2 55 6-3/8 5-1/2 / 6-5/8 176 PGC* 50-150-2NV OR 2PV 50 150 2 or 363-3/4 22 15-3/455-3/4 56-1/4 6-3/8 5-1/2 / 6-5/8 180 PGC* 50-175-3NV OR 3PV 50 175 363-3/4 22 15-3/455-3/4 56-1/4 6-3/8 5-1/2 / 6-5/8 180 PGC* 50-199-3NV OR 3PV 50 199 363-3/4 22 15-3/455-3/4 56-1/4 6-3/8 5-1/2 / 6-5/8 180 * Indicates warranty period Figure 26 Table 6: