Instruction Manual RESIDENTIAL GAS WATER HEATERS POWER DIRECT VENT GAS MODELS WITH DIRECT SPARK IGNITION MODELS PG10/GHX/GSP/GTP 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. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
TABLE OF CONTENTS START UP....................................................................................43 Start Up Conditions.................................................................43 Prior To Start up......................................................................43 Filling The Water Heater..........................................................43 Initial Start Up..........................................................................44 Lighting & Operation Labels.................
SAFE INSTALLATION, USE AND SERVICE The proper installation, use and servicing of this water heater is extremely important to your safety and the safety of others. Many safety-related messages and instructions have been provided in this manual and on your own water heater to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual.
GENERAL SAFETY INFORMATION PRECAUTIONS GROUNDING INSTRUCTIONS This water heater must be grounded in accordance with the National Electrical Code and/or local codes. These must be followed in all cases. Failure to ground this water heater properly may also cause erratic control system operation. DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN EXPOSED TO FLOODING OR WATER DAMAGE.
GENERAL SAFETY INFORMATION 5
GENERAL SAFETY INFORMATION Fire or Explosion Hazard Fire Hazard Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. For continued protection against risk of fire: Do not install water heater on carpeted floor. Do not operate water heater if exposed to flooding or water damage. Avoid all ignition sources if you smell gas. Do not expose gas control valve / thermostat to excessive gas pressure.
INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS 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 porch
INTRODUCTION Thank You for purchasing this water heater. Properly installed and maintained, it should give you years of trouble free service. is essential that all venting, water piping, gas piping and wiring be installed as shown. ABBREVIATIONS USED Particular attention should be given to the installation of thermometers at the locations indicated in the piping diagrams as these are necessary for checking the operation of the water heater.
MODEL CHARACTERISTICS Table 1 – GAS AND ELECTRICAL CHARACTERISTICS *Manifold Pressure Electrical Characteristics Gas Type “WC kPA Volts/Hz Amperes Nat./LP 0 0 120/60 <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. All models - Maximum Supply Pressure: 14 inches W.C. (3.48kPa) Minimum Supply Pressure for Natural Gas: 3.50” (.87kPa) Minimum Supply Pressure for Propane Gas: 8.
FEATURES AND COMPONENTS 34 GALLON NOMINAL CAPACITY UNIT **11 **25 5 **12 6 7 31 4 17 14 **34 20 8 32 33 30 9 11 23 15 24 10 27 21, 22 1 28 18 17 32 2 3 **33 19 15 This is a view of the area at the bottom of heater behind the Access Doors. **11 16 **12 26 29 13 VACUUM RELIEF VALVE * CAUTION HARNESS HAS 120 VAC. IN OPERATION. ** See Venting Installation and Condensate Piping for more information. *INSTALL PER LOCAL CODES Figure 1.
FEATURES AND COMPONENTS (CONT.) 50 GALLON NOMINAL CAPACITY UNIT **11 **25 5 **12 6 7 31 4 17 14 **34 20 8 32 33 9 30 11 23 15 10 1 24 2 27 3 21, 22 28 18 17 32 **33 This is a view of the area at the bottom of heater behind the Access Doors. 19 15 **11 16 **12 26 29 13 VACUUM RELIEF VALVE * CAUTION HARNESS HAS 120 VAC. IN OPERATION. ** See Venting Installation and Condensate Piping for more information. *INSTALL PER LOCAL CODES Figure 2.
FEATURES AND COMPONENTS (CONT.
CONTROLS AND SWITCHES BLOCKED OUTLET SWITCH This model is provided with two pressure switches. These switches are essential to the safe and proper operation of the unit. All switches are wired in series. The controller is set up to shut the unit down whenever there is a failure of any of the switches. It is important to understand the purpose of each switch. The Blocked Outlet Switch is set up to shut the unit off when a buildup of positive pressure in the exhaust vent pipe occurs.
INSTALLATION CONSIDERATIONS LOCATING THE WATER HEATER 11. Do not locate the water heater where the subsequent installation of the vent (exhaust) or intake air terminations would be objectionable due to noise at the termination(s). This includes locations close to or across from windows and doors. See Venting Installation beginning on page 21. CAUTION Property Damage Hazard • All water heaters eventually leak. • Do not install without adequate drainage.
• Do obtain new warning and instruction labels from the manufacturer for placement on the blanket directly over the existing labels. • Do inspect the insulation blanket frequently to make certain it does not sag, thereby obstructing combustion air flow. COMBUSTION AIR AND VENTILATION A gas water heater cannot operate properly without the correct amount of air for combustion. Never obstruct the flow of ventilation air. If you have any doubts or questions at all, call your gas supplier.
INSTALLATION REQUIREMENTS GAS SUPPLY SYSTEMS If a positive lock-up regulator is required follow these instructions: 1. Positive lock-up gas pressure regulators must be rated at or above the input Btu/hr rating of the water heater they supply. 2. Supply gas regulators shall have inlet and outlet connections not less than the minimum supply gas line size for the water heater they supply 3.
or electrical line noise such as EMI (electro magnetic interference) or RFI (radio frequency interference) may cause erratic control system operation and malfunction. HOT WATER OUTLET 12” TO 15” (30-38 cm) A high quality power supply filter/suppressor must be installed if the above conditions exist. Call the technical support phone number for more information.
SPACE HEATING AND POTABLE WATER SYSTEM devices such as pressure reducing valves, check valves, and back flow preventers. Devices such as these cause the water system to be a closed system. Your water heater is equipped with additional side taps for use in space heating applications. See Features and Components on Page 10 for locations.
connections for all models. NOTE: If using copper tubing, solder tubing to an adapter before attaching the adapter to the water heater connections. Do not solder the water lines directly to the water heater connections. It will damage the tank, T & P Valve and Pipe Insulation (if supplied). Explosion Hazard Temperature-Pressure Relief Valve must comply with ANSI Z21.22CSA 4.4 and ASME code. Fit pipe insulation over the incoming cold water line and the hot water line.
• Shall be of material listed for hot water distribution. • Shall be installed so as to allow complete drainage of both the Temperature-Pressure Relief Valve and the discharge pipe. • Must terminate a maximum of six inches (15.2 cm) above a floor drain or external to the building. In cold climates, it is recommended that the discharge pipe be terminated at an adequate drain inside the building.
VENTING INSTALLATION before locating the vent termination near walkways, windows and building entrances. Direct venting into dead spaces such as alleys, atriums, and inside corners can cause recirculation of flue gases. Recirculation of flue gases will cause sooting, and icing of the combustion air intake during severe cold weather. To prevent the recirculation of flue gases, maintain as much distance as possible between the combustion air intake and the exhaust vent terminal.
CPVC pipe materials: • CPVC 41 ASTM-D2846 or CSA B137.6 • Schedule 40, 80 ASTM-F441 or CSA B137.6 • SDR Series ASTM-F442 Polypropylene - See Polypropylene Installations. • M & G Duravent PolyPro vent system • Centrotherm InnoFlue vent system Approved vent pipe materials that must be used in Canada: • ULC S636 PVC / CPVC • ULC S636 Polypropylene - See Polypropylene Installations. Approved intake air pipe materials that must be used in Canada: PVC pipe materials: • DWV ASTM-D2665 or CSA B181.
Table 4. M & G Duravent PolyPro Nominal Pipe Diameter Flue Outlet Adapter Adapter Connector Ring 90 Degree Vent Material Connector Elbow 2” 2PPS-AD PPS-PAC 2PPS-LB 2PPS-E90 2PPS 2PPS & 2PPS-BG for Exhaust; 2PPS-E90 & 2PPS-BG for Intake (Direct Vent only) 3” 3PPS-AD PPS-PAC 3PPS-LB 3PPS-E90 3PPS 3PPS & 3PPS-BG for Exhaust; 3PPS-E90 & 3PPS-BG for Intake (Direct Vent only) Terminal(s) Table 5.
HORIZONTAL VENT TERMINAL INSTALLATION Hose Clamp NOTE: If you are installing your system so that it vents through the roof, please refer to Vertical Vent Terminal Installation on Page 25. 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 determined (see Vent Pipe Termination on page 22) use the cover plates as templates to mark the holes for the vent pipes to be inserted through the wall. BEWARE OF CONCEALED WIRING AND PIPING INSIDE OF WALL.
and prevent entry of rain. These elbows are considered part of the termination and should not be included when calculating the maximum allowable vent pipe length. Refer to Figures 20 and 21 for the proper location of the air inlet with respect to the exhaust outlet termination. The air inlet and exhaust outlet terminations must be at least 12 inches above the roof line or anticipated snow levels. WHEN TERMINATING THROUGH A ROOF, THE FOLLOWING SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE FOLLOWED.
TERMINATION CLEARANCES SIDEWALL DIRECT VENT DIRECT VENT (using outdoor air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION G HH D E L B B B C M B F I B J K B Figure 22 Vent terminal clearances for “Direct Vent” installations. Direct Vent configurations use outdoor air for combustion.
DIRECT VENT INSTALLATION DIAGRAMS Notes: 1. Support Horizontal Pipe Every See Four Feet. Support Vertical Note 6 Pipe Every Six Feet. 2. Increase the 12" minimum above grade to keep terminal openings above anticipated snow 12" Min. Above levels. Grade or Anticipated 3. Slope all piping 1/8" per foot down Snow Level. toward water heater. 4. When venting with 2" pipe, a sufficient See Note 2.
CONCENTRIC VENT INSTALLATION For new installations of 100,000, 130,000 & 150,000 BTU/hr units, install 2” Concentric vent kit model KGAVT0501CVT, part number 100093946. For new installations of 175,000 & 199,000 btu/hr units, install 3” Concentric vent kit model KGAVT0601CVT, part number 100093947. See Manufacturer’s instructions for complete installation or call the technical support number listed on the back cover of this manual.
VENTING MULTIPLE UNITS When using three or more water heaters with inputs of 175,000 BTH/ HR or above, install vent terminations per Method C or Method D: VENTING ADDITIONAL POLARIS® UNITS (100,000, 130,000 & 150,000 BTU/HR MODELS) When using two water heaters with inputs of 150,000 BTH/HR or below, install vent terminations using either Method A or Method B below: Figure 33 CONCENTRIC VENTING MULTIPLE WATER HEATERS (ALL MODELS) When concentric venting two water heaters, install vent terminations using e
WATER HEATER INSTALLATION CONDENSATE DRAIN INSTALLATION NOTE: In cold climates it is recommended the condensate drain be terminated at a suitable drain inside the building. 4. Ensure the condensate drain line is not elevated above the condensate drain connection on the Exhaust/Condensate Elbow, see Figure 35. 5. Brace the condensate drain line with floor mounted standoffs every three feet. 6.
Table 7. 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 Pipe Size, in.
ELECTRICAL WIRING CCB enclosure and Figure 47 on page 55 for the CCB layout. If you lack the necessary skills required to properly install the electrical wiring to this water heater, do not proceed but have a qualified electrician perform the installation. Refer to the Power Supply section on Page 17 for additional requirements. Install field wiring to the enable/disable circuit: 1. Turn off power at the water heater’s enable/disable switch and the breaker that supplies power to the water heater. 2.
circulating pump is used, it is important to note that the flow rate should be slow so that there will be a minimum of turbulence inside the water heater storage tank. Adjust flow by throttling a full port ball valve installed in the circulating line on the outlet side of the pump. Never throttle flow on the suction side of a pump. See Figure 53 in Piping Diagrams.
TEMPERATURE REGULATION HIGH TEMPERATURE LIMIT CONTROL (ECO) In addition to using the lowest possible temperature setting that satisfies the demand of the application, a mixing valve can be installed at the water heater (see Figure 7 on Page 17) or at the hot water taps to further reduce system water temperature. Never allow small children to use a hot water tap or draw their own bath water. Never leave a child or disabled person unattended in a bathtub or shower.
CONTROL SYSTEM OPERATION OVERVIEW CONTROL SYSTEM NAVIGATION The water heaters covered in this manual are equipped with an electronic control system that regulates water temperature inside the storage tank. Heating cycles and ignition are managed by the control system. The ECO (energy cut out), flame sensor, pressure switches and temperature probes are monitored by the control system. The Combustion Blower, Spark Ignition Transformer, 24 Volt Gas Control Valve are all powered by the control system.
STATUS ICONS Status Icons are displayed on the Desktop screen and convey operational and diagnostic information. Icons are described in the table below. See Figure 39 on Page 35. Ensure the water heater is properly grounded. Flame sensing requires an adequate earth ground. If the water heater is not properly grounded it will cause Ignition Failure. See Electrical Wiring on Page 32. Table 11 – Status Icons Icon Description Water temperature in the tank has fallen.
OPERATING STATES The current operational state of the water heater is displayed on the Desktop screen as the Status. The common operational states are described in the table below. Table 12 – OPERATING STATES State Standby Input Verification Water Heating Disabled Pre-Purge Spark Igniter Energized Igniter Activiation Description The water heater is not in an active heating cycle. IE: the Tank Temperature is at or above the Operating Set Point minus temperature differential.
USER SETTINGS & CONTROL SYSTEM MENUS TEMPERATURES OPERATING SET POINT AND DIFFERENTIAL ADJUSTMENT The Operating Set Point is adjustable from 90°F (42°C) to 160°F (71°C). The factory setting is 120°F (49°C). The Differential is adjustable from 2° to 20°F. The factory setting is 8°F. These user settings are accessed from the Temperatures menu. These instructions explain how to adjust these settings and navigate the control system.
TEMPERATURES (CONT) DESCRIPTION/ACTION DISPLAY • Differential - Adjustable user setting that changes the tank temperature differential with a range of 2° to 20°F. The factory setting is 8°F. • Tank Probe Offset - adjustable user setting, range -5° to +5°F (factory setting 0°F). NOTE: These settings should only be used if the hot water supply temperature varies greatly from the Operating Set Point setting.
DISPLAY SETTINGS DESCRIPTION/ACTION DISPLAY Press Display Settings from the Main Menu to enter this menu. This menu contains adjustable display options for viewing information on the UIM’s LCD screen. Use the Slidebar to navigate the menu. • Temperature Units - Adjustable user setting that changes temperature units display to Celsius °C or Fahrenheit °F. • Backlight Delay - Adjustable user setting that determines how long the UIM’s LCD backlight remains illuminated after a key has been pressed.
CURRENT FAULT DESCRIPTION/ACTION DISPLAY Press Current Fault from the Main Menu and press the Operational Button under "SELECT" to enter this menu. This menu contains non adjustable operational information. Use the Slidebar to navigate the menu. Blocked Exhaust 0 days 0 hrs 0 mins ago Error Code: A8-1201 This menu contains the current Fault or Alert error message. The time the Fault or Alert message occurred appears directly below.
SERVICE CONTACT INFORMATION The control system has a discrete menu that Installing contractors and/or service agents can access to enter contact information for their customers. This contact information will be displayed with all Fault and Alert messages. DESCRIPTION/ACTION DISPLAY Contact Information From the Desktop Screen (see Figure 39 on page 35) press and hold down the middle (unmarked) Operational Button for 30 seconds and then release it. It is located between the "MENU" and "HELP" buttons.
START UP START UP CONDITIONS ground. If the water heater is not properly grounded it will cause Ignition Failure. See Electrical Wiring on page 32. SMOKE/ODOR Be certain that the water heater is full of water, that air is purged from the gas and water lines and that there are no leaks in the gas and water lines. Ensure all inlet water valves are open. It is not uncommon to experience a small amount of smoke and odor during the initial start-up.
INITIAL START UP MANIFOLD GAS PRESSURE TEST PORT (Non-Adjustable) REQUIRED TEST EQUIPMENT • One U-tube manometer, recommended ranges; 0-14” W.C. (03.5 kPa) and 0-35” W.C. (0-8.7 kPa) or pressure gauges. • One digital manometer can be used in place of U-tube manometers or pressure gauges. Recommended ranges; -14.00 to +14.00” W.C. (0-3.5 kPa) resolution 0.01” W.C. and 0-35” W.C. (0-8.7 kPa) resolution 0.10” W.C. NOTE: All test equipment must be acclimated to ambient temperature before calibration and use.
LIGHTING THE WATER HEATER LIGHTING & OPERATION LABELS The instruction label below is affixed to the water heater's covered by this manual at the factory and must be followed when lighting and operating the water heater. 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. FLAMMABLE BEFORE OPERATING: ENTIRE SYSTEM MUST BE FILLED WITH WATER AND AIR PURGED FROM ALL LINES.
CHECKING THE FIRING RATE When measuring the input rate these factors should be incorporated into the calculations. Also measure the gas consumption over a sufficiently long time to obtain an accurate gas consumption rate (e.g. 3-5 minutes, not one revolution of the meter needle). Long vents and each additional elbow, inherently reduce the gas input rate due to increased resistance to moving combustion air and flue gases.
TROUBLESHOOTING Components beginning on page 10 for the location of various water heater components described below. See the Sequence of Operation Flow Chart on page 48 also. INSTALLATION CHECKLIST The list below represents some of the most critical installation requirements that, when overlooked, often result in operational problems, down time and needless parts replacement. This is not a complete list. Before performing any troubleshooting procedures use the list below to check for installation errors.
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 Normal State of all pressure switches and ECO are checked Pressure Switches and ECO are verified closed NO Combustion Blower is energized 30 Second Pre-Purge cycle Igniter is energized 24 V Gas Control Valve is energized gas flows to Main Burner Is flame sensed at the Main Burner ? (control system monitors the flame sens
OPERATIONAL PROBLEMS If the Main Burner ignites momentarily but does not sustain ignition allow the water heater to try to ignite up to two more times until control system locks out and the Ignition Failure Fault message is displayed on the control system's LCD. If the water heater is experiencing rough starts - see Rough Starting, Rough Operation on this page.
FAULT AND ALERT CONDITIONS are operational problems. This is not a complete list. Along with each of the Fault and Alert messages described there will be a list of possible causes and things to check and repair. FAULT CONDITIONS When the control system declares a Fault condition it will display a Fault message on the control system's LCD with an exclamation "!" mark. The control system will lock out and disable heating operation until the condition is corrected.
FAULT AND ALERT MESSAGES (CONT) Call the technical support phone number listed on the back cover for further technical assistance or to locate a qualified service technician in your area. POSSIBLE CAUSES - CHECK/REPAIR DISPLAYED FAULT/ALERT MESSAGE • If Blocked Intake error occurs before blower runs, make sure pressure switch connections are clean and tight.
LEAKAGE CHECKPOINTS A: Hot Water Outlet Never use this water heater unless it is completely filled with water. To prevent damage to the tank, the tank must be filled with water. Water must flow from the hot water faucet before turning “ON” gas to the water heater. C: T & P Connection A *Condensation may be seen on the hot water outlet pipe in humid weather or the hot water outlet connection may be leaking. B.
PERIODIC MAINTENANCE Should overheating occur or the gas supply fails to shut off, turn off the manual gas control valve to the appliance. • 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 system to avoid serious injury or death. • Do not store corrosive chemicals in vicinity of water heater.
NOTE: Excessive water pressure is the most common cause of Temperature-Pressure Relief Valve leakage. Excessive water system pressure is most often caused by “thermal expansion” in a “closed system.” See Closed Water Systems and Thermal Expansion on Page 18. The Temperature-Pressure Relief Valve is not intended for the constant relief of thermal expansion. 2. Turn off the gas supply at the Main Gas Shutoff Valve (see Figure 36 on Page 30) if the water heater is going to be shut down for an extended period.
DIAGRAMS CCB - CENTRAL CONTROL BOARD LAYOUT 6 5 4 J16 3 2 1 J13 J3 8 7 6 5 J5 4 3 2 1 J9 4 7 8 9 10 11 12 3 1 2 3 J14 4 5 6 3 1 4 2 J15 8 5 4 3 2 1 2 1 J4 4 3 2 J10 1 2 J17 6 5 1 4 3 2 1 1 8 7 9 4 6 J1 J12 3 2 1 3 1 2 J6 4 3 2 1 Figure 47 55 6 5 4
Blower Speed 56 Protective Earth 1 Black 2 White 3 Green 4 White / Blue 5 White / Green 2 White / Orange Green Black White GROUND SCREW White Black 2 White 3 Black Transformer Primary Figure 48: WIRING SCHEMATIC (All Models) 1 Blue 3 Yellow 4 Orange 5 Violet 9 White 8 Black 1 Blue Enable/Disable 2 White/Blue 1 Brown 6 White/Green 5 Orange 4 Blue No factory connections 3 Yellow 4 Orange 5 Violet White / Red White / Blue 1 Blue 4 White/Green 3 Orange CCB J1 HIGH Voltage In Data + Da
CIRCULATION PUMP WIRING DIAGRAMS CIRCULATING PUMP WIRING DIAGRAM STORAGE TANK OR BUILDING RECIRCULATION 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.
PIPING DIAGRAMS NOTE: Follow the Mixing Valve manufacturers instructions when installing the mixing valve. Mixing Valve Check local codes. Metal Drain Pan 6" (15.2cm) Air Gap Max. Adequate Drain Figure 50: TYPICAL ONE-TEMPERATURE SYSTEM PIPING INSTALLATION (All Models) NOTE: Follow the Mixing Valve manufacturers instructions when installing the mixing valve. Mixing Valve (set to 120° F [48.
NOTE: Follow the Mixing Valve manufacturers instructions when installing the mixing valve. Mixing Valve Drain 6" Max. Above Drain Figure 52: AIR HANDLER PIPING INSTALLATION (All Models) Manual Shut Off Valve (Typ) NOTE: Follow the Mixing Valve manufacturers instructions when installing the mixing valve. Mixing Valve (160°F Max.
For Tech Support please call PG10 models: 1-800-456-9805 GHX models: 1-800-365-0024 GSP/GTP models: 1-800-527-1953 Copyright © 2017 A. O. Smith Corporation. All rights reserved.
