Polaris BSS Instruction Manual Download Page 8

8

Thank You for purchasing this water heater. Properly installed and 

maintained, it should give you years of trouble free service.

ABBREVIATIONS USED

Abbreviations found in this Instruction Manual include :

•  ANSI - American National Standards Institute

•  ASME - American Society of Mechanical Engineers

•  AHRI - Air-Conditioning, Heating and Refrigeration Institute

•  NEC - National Electrical Code

•  NFPA - National Fire Protection Association

•  UL - Underwriters Laboratory

•  CSA - Canadian Standards Association

QUALIFICATIONS

QUALIFIED INSTALLER OR SERVICE AGENCY

Installation  and  service  of  this  water  heater  requires  ability 

equivalent to that of a Qualified Agency (as defined by ANSI below) 

in the field involved. Installation skills such as plumbing, air supply, 

venting, gas supply and electrical supply are required in addition to 

electrical testing skills when performing service.

ANSI Z223.1 2006 Sec. 3.3.83:

  “Qualified  Agency”  -  “Any 

individual,  firm,  corporation  or  company  that  either  in  person  or 

through a representative is engaged in and is responsible for (a) 

the  installation,  testing  or  replacement  of  gas  piping  or  (b)  the 

connection,  installation,  testing,  repair  or  servicing  of  appliances 

and equipment; that is experienced in such work; that is familiar 

with  all  precautions  required;  and  that  has  complied  with  all  the 

requirements of the authority having jurisdiction.”

If you are not qualified (as defined by ANSI above) and licensed or 

certified as required by the authority having jurisdiction to perform 

a  given  task  do  not  attempt  to  perform  any  of  the  procedures 

described in this manual. If you do not understand the instructions 

given  in  this  manual  do  not  attempt  to  perform  any  procedures 

outlined in this manual.

PREPARING FOR THE INSTALLATION

1.  Read the entire manual before attempting to install or operate 

the  water  heater.  Pay  close  attention  to  the  General  Safety 

Information on Page 4 through Page 6. If you don’t follow the 

safety rules, the water heater may not operate safely. It could 

cause property damage, injury and/or death.

This manual contains instructions for the installation, operation, 

and maintenance of the water heater. It also contains warnings 

throughout  the  manual  that  you  must  read  and  be  aware  of. 

All  warnings  and  all  instructions  are  essential  to  the  proper 

operation  of  the  water  heater  and  your  safety.  Detailed 

installation  diagrams  are  also  found  in  this  manual.  These 

diagrams will serve to provide the installer with a reference. It 

is essential that all venting, water piping, gas piping and wiring 

be installed as shown.

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.

The principal components of the water heater are identified in 

Features and Components beginning on Page 11 in this manual. 

Use this reference to locate and identify various components on 

the water heater.

See  the  Installation  Checklist  and  Troubleshooting  on  page 

48.  By  using  this  checklist  the  user  may  be  able  to  make 

minor operational adjustments and avoid unnecessary service 

calls. However, service and diagnostic procedures should only 

be performed by a Qualified Service Agency.

NOTE:

  Costs  to  correct  installation  errors  are  not  covered 

under the limited warranty.

2.  Be sure to turn off power when working on or near the electrical 

system of the water heater. Never touch electrical components 

with wet hands or when standing in water.

3.  The  installation  must  conform  to  all  instructions  contained  in 

this  manual  and  the  local  code  authority  having  jurisdiction. 

These shall be carefully followed in all cases. Authorities having 

jurisdiction  should  be  consulted  before  installation  begins  if 

there are any questions regarding compliance with local, state 

or national codes.

In the absence of local codes, the installation must comply with 

the current editions of the National Fuel Gas Code, ANSI Z223.1/

NFPA 54 and the National Electrical Code, NFPA 70 or CAN/

CSA-B149.1,  the  Natural  Gas  and  Propane  Installation  Code 

and CSA C22.1, the Canadian Electrical Code. All documents 

are available from the Canadian Standards Association, 8501 

East  Pleasant  Valley  Road,  Cleveland,  OH  44131.  NFPA 

documents are also available from the National Fire Protection 

Association, 1 Batterymarch Park, Quincy, MA 02269.

4.  If  after  reading  this  manual  you  have  any  questions  or  do 

not  understand  any  portion  of  the  instructions,  call  the  toll 

free  number  on  the  back  cover  of  this  manual  for  technical 

assistance. In order to expedite your request, please have the 

full Model, Serial and Series number of the water heater you 

are working with available for the technician. This information is 

located on the water heater’s rating plate.

5.  Carefully  plan  the  placement  of  the  water  heater.  Examine 

the  location  to  ensure  that  it  complies  with  the  requirements 

in Locating The Water Heater on Page 15 and the Rough In 

Dimensions on Page 9.

INTRODUCTION

Summary of Contents for BSS

Page 1: ...tly 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 WH...

Page 2: ...take Moisture Protection 25 Horizontal Vent Terminal Installation 25 Vertical Vent Terminal Installation 26 Termination Clearances Sidewall Direct Vent 27 Direct Vent Installation Diagrams 28 Concentr...

Page 3: ...ot follow the safety message and how to avoid the risk of injury DANGER WARNING CAUTION CAUTION DANGER indicates an imminently hazardous situation which if not avoided will result in injury or death T...

Page 4: ...Explosion Hazard Overheated water can cause water tank explosion Properly sized Temperature Pressure Relief Valve must be installed in the opening provided Verify the power to the water heater is tur...

Page 5: ...5 GENERAL SAFETY INFORMATION...

Page 6: ...nderstand instruction manual Breathing Hazard Carbon Monoxide Gas Property Damage Hazard All water heaters eventually leak Do not install without adequate drainage CAUTION Fire and Explosion Hazard Le...

Page 7: ...tally vented gas fueled heating appliance or equipment The sign should 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 s...

Page 8: ...These diagrams will serve to provide the installer with a reference It is essential that all venting water piping gas piping and wiring be installed as shown Particular attention should be given to th...

Page 9: ...8 1 2 22 15 3 4 40 1 2 41 6 3 8 5 1 2 6 5 8 cm 123 19 55 88 40 102 87 104 14 16 19 13 97 16 82 50 130 Inches 62 3 8 22 15 3 4 54 1 2 55 6 3 8 5 1 2 6 5 8 cm 165 7 55 88 40 138 43 139 7 16 19 13 97 16...

Page 10: ...pressure must be maintained under both load and no load dynamic and static conditions Table 3 RECOVERY CAPACITIES Input Recovery Capacities Rating Btu hr Rating kW Temp Rise F 30 40 50 60 70 80 90 100...

Page 11: ...at the bottom of heater behind the Access Doors 1 30 11 15 2 3 23 34 33 CAUTION HARNESS HAS 120 VAC IN OPERATION See Venting Installation and Condensate Piping for more information Figure 2 34 GALLON...

Page 12: ...ation 50 GALLON UNIT FEATURES AND COMPONENTS CONT Figure 3 50 GALLON UNIT This is a view of the area at the bottom of heater behind the Access Doors 1 2 3 15 32 27 33 29 32 24 26 20 19 12 11 25 13 28...

Page 13: ...ndensate Drain Outlet 13 Enable Disable Switch 14 Hot Water Outlet 15 Gas Supply 16 Main Manual Gas Shutoff Valve 17 Union 18 Inlet Water Shutoff Valve 19 Cold Water Inlet 20 T P Relief Valve 21 Ratin...

Page 14: ...pressure switch that requires an increase in negative pressure to change the electrical contacts from normally closed to open The switch is connected to the pressure tap on the PVC pipe connected to...

Page 15: ...ater heater close to a 120 VAC power supply See Power Supply on Page 18 for requirements 8 Locate the water heater where an adequate supply of fresh air for combustion and ventilation can be obtained...

Page 16: ...ter heater Do not cover the outer door thermostat or temperature pressure relief valve Do not cover the instruction manual Keep it on the side of the water heater or nearby for future reference Doobta...

Page 17: ...d 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 heate...

Page 18: ...4 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 normal shower temp 116 46 7 pain threshold 116 46 7 35 minutes 45...

Page 19: ...ed in the cold water supply line an expansion tank must be installed between the check valve and the water heater s cold water inlet Set storage tank temperature five degrees lower than the water heat...

Page 20: ...ature Pressure Relief Valve on the water heater each remote storage tank that may be installed and piped to a water heating appliance must also have its own properly sized rated and approved Temperatu...

Page 21: ...the building In cold climates it is recommended that the discharge pipe be terminated at an adequate drain inside the building Shall not have any valve or other obstruction between the temperature pr...

Page 22: ...bustion air intake and the exhaust vent terminal Refer to Horizontal Vent Terminal Installation on Page 25 and Vertical Vent Terminal Installation on Page 26 GENERAL VENTING INSTRUCTIONS The following...

Page 23: ...e personal injury death or substantial property damage Installations must comply with applicable national state and local codes For Canadian installation Polypropylene vent must be listed as a ULC S63...

Page 24: ...000 ft 610 m to 7 700 ft 2 347 m IMPORTANT Do not use vent elbows in this vent pipe installation See Figure 12 90 Short Sweep Elbow 90 Long Sweep Elbow 45 Sweep Elbow Correct Fittings Incorrect Fittin...

Page 25: ...hat it vents through the roof please refer to Vertical Vent Terminal Installation on Page 26 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 Terminatio...

Page 26: ...nings above anticipated snow levels FLAT ROOF INSTALLATION On flat roof installations the air intake and the exhaust vent terminations must be a minimum of 24 inches 60 cm above any parapet vertical w...

Page 27: ...ir supply inlet into building or combustion air inlet to any other appliance 6 in 15 cm for appliances 10 000 Btuh 3 kW 12 in 30 cm for appliances 10 000 Btuh 3 kW and 100 000 Btuh 30 kW 36 in 91 cm f...

Page 28: ...uations See the section on Direct Vent Air Intake Moisture Protection on page 25 Figure 24 SIDEWALL VENT INSTALLATION ALL MODELS See Note 3 See Note 3 Drain Pan Piped To Adequate Drain See Note 1 See...

Page 29: ...t of a qualified installer or qualified service technician see Page 8 All precautions in the literature on tags and labels attached to the unit must be observed Follow all safety codes Wear safety gla...

Page 30: ...ARIS UNITS 175 000 199 000 BTU HR MODELS When using two water heaters with inputs of 175 000 BTH HR or above install vent terminations using either Method A or Method B below Figure 33 When using thre...

Page 31: ...pany will have to install a properly sized gas meter Make sure the gas supplied is the same type listed on the water heaters rating label The gas piping must be installed according to all local and st...

Page 32: ...y of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases at 11 inches water column pressure Based on a Pressure Drop of 0 5 Inch Water Column Additional tables are available in th...

Page 33: ...ay coil to this circuit This will damage the CCB circuit board and is not covered under the limited warranty CONNECTING AN EXTERNAL SUPERVISORY CONTROL The enable disable circuit is accessed from the...

Page 34: ...or state law requiring a certain temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot wat...

Page 35: ...120 F Status Heating MENU HELP GAS OFF O N Figure 38 HIGH TEMPERATURE LIMIT CONTROL ECO This water heater is equipped with an ECO energy cut out non adjustable high temperature limit switch The ECO i...

Page 36: ...ion of the various operational states The Desktop screen also displays animated Status Icons to convey operational information see Table 12 on Page 37 for descriptions of the Status Icons OVERVIEW The...

Page 37: ...control system or when the Enable Disable switch located at the base of the water heater is in disable position The Combustion Blower is being energized The Spark Igniter is being energized See Spark...

Page 38: ...ot reset the control system if the condition that caused the Fault has not been corrected Heating Disabled The heating is disabled by the Enable Disable switch located at the base of the water heater...

Page 39: ...will be displayed Tank Temperature 71 F Operating Setpoint 120 F Status Standby HELP MANUFACTURER MODEL INFORMATION MENU The Main Menu is where all control system menus are listed see Table 14 on page...

Page 40: ...fferential Adjustment on page 39 Temperatures HELP BACK Operating Setpoint 120 F Differential 8 F Tank Temperature 120 F Tank Probe Offset 0 F HEATER STATUS MENU DESCRIPTION ACTION DISPLAY Press Heate...

Page 41: ...ersion Software version for user interface module Use External Enable Enables Disables the external enable circuit External Enable Status Displays whether or not the external enable circuit has been a...

Page 42: ...last nine 9 Fault andAlert messages with a time stamp The newest event will replace the oldest Press the Fault to view details for each Fault or Alert message stored Fault History HELP BACK 1 Upper T...

Page 43: ...to Yes and press ACCEPT to save the new setting NOTE The Access Code at the bottom of the Service Contact Information screen is for manufacturing engineering purposes only There are no user settings...

Page 44: ...Sequence of Operation See the Sequence of Operation Flow Chart on page 49 Ensure the water heater is properly grounded Flame sensing requires an adequate earth ground If the water heater is not proper...

Page 45: ...42 On the water heaters covered by this manual there are test ports for supply and manifold gas pressure readings on the gas control valve Using a small flat tip pocket screw driver open the needle v...

Page 46: ...t a t s o m r e h t e h t t e S o t s e t u n i m 5 e v i f t i a W s a g y n a t u o r a e l c s a g l l e m s n e h t u o y f I n i B w o l l o F P O T S u o y f I l e b a l s i h t n o e v o b a n...

Page 47: ...The display CCB and other electrical components will still be energized and the display will read Water Heating Disabled 3 Close Main Gas Shutoff Valve see Figure 37 on page 31 GAS INPUT RATE The gas...

Page 48: ...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 pe...

Page 49: ...setting a heating cycle is activated Igniter is energized 24 V Gas Control Valve is energized gas flows to Main Burner 24 V Gas Control Valve de energized 24 V Gas Control Valve de energized Is flame...

Page 50: ...e to have the complete water heater Model Number Serial Number and Series Number available This information can be found on the rating plate affixed to the water heater For more information or technic...

Page 51: ...l continue to lock out DIAGNOSTIC CHECKS Turn off power to the water heater before performing any service Electrical Shock Hazard Label all wires prior to disconnecting when performing service Wiring...

Page 52: ...continuity when the blower is off and closed shorted when the blower is on Replace the switch if necessary ADVANCED BACK 0 days 0 hrs 0 mins ago Error Code A7 1201 Blocked Air Intake Restriction in ai...

Page 53: ...the valve being slightly opened Not shown in Figure 46 F The drain valve may be leaking at the tank fitting Not shown in Figure 46 G Leakage from recirculation plug or pipe connection Not shown in Fig...

Page 54: ...n the hose clamp at the adaptor rubber boot and slide the plastic pipe out and away from the adaptor rubber boot See Figure 14 in Integrated Filter Installation Remove the adaptor rubber boot containi...

Page 55: ...ter heater drain valve and terminate it to an adequate drain 7 Open the water heater drain valve and allow all the water to drain from the storage tank 8 Close the water heater drain valve when all wa...

Page 56: ...CONTROL BOARD LAYOUT 11 12 1 J16 J5 J3 J13 J4 J17 J10 J9 J14 J15 J1 J6 J12 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 8 8...

Page 57: ...iolet CCB J3 5V Data Data D gnd SDA data SCL data Write protect 5V Dgnd CCB J12 2 Red 3 Green 4 White Brown 5 White Blue 6 White Orange Key Gas Valve L1 Neutral Protective Earth MAIN INPUT 3 CIRCUIT B...

Page 58: ...POWER WITH APPLIANCE AS THIS MAY CAUSE ELECTRICAL LINE NOISE AND LEAD TO ERRATIC CONTROL SYSTEM OPERATION Figure 50 CIRCULATING PUMP WIRING DIAGRAM DISHWASHER LOOP WITH TOGGLE SWITCH FIELD SUPPLIED TE...

Page 59: ...s Mixing Valve Metal Drain Pan 6 15 2cm Air Gap Max Adequate Drain set to 120 F 48 8 C or lower Mixing Valve Figure 52 TYPICAL ONE TEMPERATURE SYSTEM PIPING INSTALLATION All Models Figure 53 SAMPLE MI...

Page 60: ...ixing Valve Manual Shut Off Valve Typ Mixing Valve 180 F Max Figure 54 AIR HANDLER PIPING INSTALLATION All Models Figure 55 POLARIS WITH AUXILLARY STORAGE TANK One or Two Temperature System With or Wi...

Page 61: ...61 NOTES...

Page 62: ...62 NOTES...

Page 63: ...For Tech Support please call PGC models 1 800 456 9805 SPC models 1 800 365 0024 BSS BTS models 1 800 527 1953 Copyright 2016 A O Smith Corporation All rights reserved...

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