American International PG10*50-175-3NV or 3PV manual

1 This manual covers model numbers: United States Canada PG10* 34-100-2NV or 2PV PG10* 34-130-2NV or 2PV PG10* 50-130-2NV or 2PV PG10* 34-150-2NV or 2PV PG10* 50-175-3NV or 3PV PG10* 50-199-3NV or 3PV PG10* 100-199-3NV or 3PV PR 100-34 2NV or 2PV PR 130-34 2NV or 2PV PR 130-50 2NV or 2PV PR 150-34 2NV or 2PV PR 175-50 3NV or 3PV PR 199-50 3NV or 3P[...]

2 Y our 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 aler[...]

3 INST ALLA TION 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 h[...]

4 Location Requirements The water heater design has been tested by CSA International and complies with ANSI Z21.10.1, Section 2.35 Flammable V apors 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. Importan[...]

5 CONDENSA TE 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 T rap Assembly A condensate trap/drain stem assembly has been supplied with the water heater and is located behind the access door inside [...]

6 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 3). 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-i[...]

7 V ent 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 or ABS • 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 plumb- ing [...]

8 V ent T ermination Locations The air inlet and exhaust outlet must be installed with the following minimum clearances (see figure 6): • T welve inches above grade or maximum anticipated snow level. • T welve inches from any opening through which flue gases could enter the structure. • Four feet horizontally and vertically from gas or electr[...]

9 INLET/OUTLET VENT TERMINA TIONS (100,000 - 150,000 BTU/HR) Standard Horizontal T ermination When 3 inch pipe is used between the water heater and the outside wall, reduce it to 2 inch pipe before penetrating the wall. A maximum of 18 inches of 2 inch pipe may be used between the 3 inch transition and the inside of the wall (see figure 7A). The st[...]

10 VERTICAL TERMINA TIONS (100,000 - 150,000 BTU/HR) When 3 inch pipe is used between the water heater and the roof, reduce it to 2 inch pipe before penetrating the roof. A maximum of 18 inches of 2 inch pipe may be used between the 3 inch transition and the inside of the roof. The vertical inlet air termination requires a return bend or two short [...]

11 CONCENTRIC VENT TERMINA TIONS (100,000 - 150,000 BTU/HR) For new installations, install 2” Concentric vent kit model KGA VT0501CVT , part number 6910542. See Manufacturer ’s instructions for complete installation or call customer service at 1-800-456-9805 for assistance. For planning purposes, see figures 10A-13A below for vent terminal spec[...]

12 INLET/OUTLET VENT TERMINA TIONS (175,000+ BTU/HR) Figure 8B: Alternative Horizontal T ermination (175,000+ BTU/Hr or greater input models) Figure 7B: Standard Horizontal T ermination (175,000+ BTU/Hr models) Standard Horizontal T ermination The standard horizontal air inlet termination is a 3 inch pipe which terminates at the exterior wall and u[...]

13 VERTICAL TERMINA TIONS (175,000+ BTU/HR) Figure 9B: V ertical T ermination (175,000+ BTU/Hr models) For inputs of 175,000 BTU/Hr or greater , all termination pip- ing and fittings are 3”. Do not reduce before penetrating the wall. The vertical inlet air termination requires a return bend or two short or long sweep radius 90° elbows to keep th[...]

14 CONCENTRIC VENT TERMINA TIONS (175,000 + BTU/HR) Figure 10B: 3 Inch Concentric V ent For new installations, install 3” Concentric vent kit model KGA VT0601CVT , part number 6910543. See Manufacturer ’s instructions for complete installation or call customer service at 1-800-456-9805 for assistance. For planning purposes, see figures 10B-13B [...]

15 Figure 14: Input Graph 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 baro- metric pressure and temperature changes) • V enting installations (pipe diameter , length and fittings) • Altitude W[...]

16 Figure 15: T ypical One-T emperature System Piping Installation T empering V alve Installation A tempering valve has been provided for use with the Polaris® Gas water heater and must be installed, per the manufacturer ’s instructions, in the domestic hot water line. See Figure 16 for a sample tempering valve installation. General Information [...]

17 • If the space heating system requires water temperatures in excess of 120°F , a tempering valve (provided) must be installed per the manufacturer ’s instructions in the potable hot water supply to limit the risk of scald injury . • Pumps, valves, piping and fi ttings must be compatible with potable water . • A properly installed fl o[...]

18 T emperature and Pressure Relief V alve For protection against excessive pressures and tempera- tures, a temperature and pressure relief valve must be installed in the opening marked “T & P RELIEF V AL VE”. This valve must be design certified by a nationally recog- nized testing laboratory that maintains periodic inspection of the produc[...]

19 GAS SUPPL Y AND PIPING Gas Requirements Read the data plate to be sure the water heater is made for the type of gas being used. This information will be found on the data plate located on the front of the water heater . If the information does not agree with the type of gas available, do not install or operate the water heater . Call your dealer[...]

20 Gas Pressure T esting Important : This water heater and its gas connection must be leak tested before placing the appliance in operation. •  If the code requires the gas lines to be tested at a pressure of 14” W .C. or greater , the water heater and its manual shut-off valve must be disconnected from the gas supply piping system and the l[...]

21 Electrical Shock Hazard Disconnect power before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. ELECTRICAL CONNECTIONS Figure 20A: Electrical Connections (34/50 Gal.) If you lack the necessary skills required to properly install the electrical wiring to this water heater , do no[...]

22 WIRING DIAGRAM MODELS 130,000 BTU/Hr & Below 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 EQUIV ALENT . THERMOST A T BOARD IGNITION CONTROL IGNITION CONTROL BLOWER HSI HSIG L1 L2 IND 120 V AC 24 V AC GAS V ALVE RELA Y RED LED GREEN LED YELLOW [...]

23 INST ALLA TION CHECKLIST W ater 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 installe[...]

24 OPERA TING YOUR W A TER HEA TER Read and understand these directions thoroughly before attempting to operate the water heater (see Operating Instructions on page 25). 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 qu[...]

25 Stacking Stacking occurs when a series of short draws of hot water (3 gallons 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 tempering valve must be installed in the hot water supply line to reduce the risk of scald injury . W at[...]

26 OPERA TIONAL CONDITIONS MAINTENANCE W ater 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[...]

27 MAINTENANCE OF YOUR W A TER HEA TER 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 n[...]

28 TROUBLESHOOTING Ignition Control Module (ICM) LED Error Codes: (Flashes visible through viewport in access door) FLASHES INDICA TED PROBLEM CONTROL REACTION 1 Pressure Switch Closed SC* 2 Pressure Switch Open SL 3 Failed Ignition SL3 4 Gas V alve Hardware Fault SL 5 Flame Sense Hardware Fault SC 6 False Flame SL** 8 Ignition Control Hardware Fau[...]

29 SOFTW ARE OPERA TION SEQUENCE IGNITION CONTROL MODULE SOFTW ARE OPERA TION SEQUENCE * For 175,000 BTU/Hr models and above the flame establishing period is six seconds. For the first 3 seconds the gas valve is off.[...]

30 REP AIR P ARTS LIST/DIAGRAM ITEM NO. P ARTS DESCRIPTION 1 1” NPT x 3” BRASS NIPPLE 2 THERMOST A T SENSOR BUSHING 3 O-RING 4 THERMOST A T SENSOR/ECO 5 INVERTED FLARE NUT 6 PLUG 7 VINYL TUBING 8 PRESSURE SWITCH 9 COMBUSTION BLOWER 10 4 INCH DIAMETER BLOWER GASKET 11 BURNER (NA TURAL AND L.P . SAME) 12 6 INCH DIAMETER BURNER GASKET 13 HOT SURF [...]

31 REP AIR P ARTS LIST/DIAGRAM ITEM NO. P ARTS DESCRIPTION 1 1-1/2” NPT x 3” BRASS NIPPLE 2 THERMOST A T SENSOR BUSHING 3 THERMOST A T SENSOR/ECO 4 CONTROL P ANEL HOUSING 5 IGNITION CONTROL 6 BLOWER ISOLA TION RELA Y 7 THERMOST A T BOARD 8 TRANSFORMER 9 SIGHT GLASS 10 RED LED 11 YELLOW LED 12 GREEN LED 13 TEMPERA TURE SELECTOR KNOB 14 THERMOST [...]

32 POLARIS MODELS & DIMENSIONS C lea n-out P ort MODEL NUMBER GAL. CAP . INPUT (MBTU PER HR.) VENT DIA. EXTERIOR W A TER CONNECTIONS T&P HGT GAS SUPPL Y AIR INLET/ EXHAUST APPROX SHIP . WEIGHT A B C D E F G PG10 34-100-2NV OR 2PV 34 100 2 OR 3 48-1/2 22 15-3/4 40-1/2 41 6-3/8 5-1/2 / 6-5/8 150 PG10 34-130-2NV OR 2PV 34 130 2 OR 3 48-1/2 22 [...]