AquaStar 38B LP User's Manual
Contents
1. Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control buttons Never use tools If a button will not push in check to make sure the buttons are being pushed in the proper sequence Follow these instructions exactly If control button s are jammed close the gas supply and call a qualified service technician Attempted forceful repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water LIGHTING INSTRUCTIONS STOP Read the safety information on the front panel of the heater 2 The Gas valve must be turned off by sliding the gas valve button to the far left under the OFF mark Wait five 5 minutes to clear out any gas If you smell gas STOP Follow B in the safety information above on this plate If you don t smell gas go to next step 4 The pilot burner is located behind the peephole in the front center of the jacket directly below the lighting instructions on the front panel of the heater 5 Slide the gas valve button to the right to the pilot position 6 Fully depress gas valve button and light pilot by2. Out amp a Check Valve amp Thermostat Radiant Floor Low Temperature Fan Coil Units Indirect Water Heater Snow Melt or Root zone Grid Pipe PRV to appropriate discharge Notes Maximum operating temperature of 38B 140 F Maximum heating capacity 40 F rise 20 F rise AquaStar 38B 30 000 BTU hr 15 000 BTU hr System shown is electric storage tank with recirculating supply drawn from the tapping for the lower heating element Schematic is for illustration and example only and must not be used for actual installation without appropriate engineering and technical advice from a professional properly licensed in the locality where the installation is made GENERAL RULES TO FOLLOW FOR SAFE OPERATION 1 You should follow these instructions when you install your heater In the United States The installation must conform with local codes or inthe absence of local codes the National Fuel Gas Code ANSI Z223 1 NFPA 54 In Canada The Installation should conform with CGA B149 1 2 INSTALLATION CODES and or local installation codes 2 Carefully plan where you install the heater Correct combustion air supply and flue pipe installation are very important If not installed correctly fatal accidents can be caused by lack of air carbon monoxide poisoning or fire 3 The place where you install the heater must have enough ventilation The National Fire Codes do not allow water heater installation in bathroom
3. wich comes with a manual shutoff valve and the gas fitting wich is connected to the heater s gas inlet There is a pressure test nipple on this gas fitting The regulator supplied with the heater is preset for the gas shown on the rating plate to the correct pressure lt is an appliance level regulator designed for low inlet pressure less than 1 2 Psig or 15 W C DO NOT connect to an unregulated or high pressure propane line or to a high pressure commercial natural gas line Fig 2 Gas Pressure Regulator The pressure regulator provided with the heater is adjusted to deliver the proper gas pressure as indicated on the rating plate and in the manual for altitude up to 2000 feet 660 meters above sea level On appliances being installed above 2000 ft 660 meters elevation the inlet gas pressure should be set at installation to the value shown below NOTE The gas pressures specified below refer to pressures taken at the test pressure nipple on the gas inlet pipe just above the regulator See Fig 2 These readings should be taken while the heater is operating at full input i e maximum water flow with the temperature dial selector turned all the way clockwise MAXIMUM INLET GAS FLOW PRESSURE SETTING Natural Gas Liquid Propane inches W C inches W C 0 2 000 ft 2 000 ft 4 500 ft Above 4 500 ft consult your local gas supplier National Fuel Gas Code requires that a sediment trap drip leg be installed
4. of 5 gallons per minute gpm Turning the dial all the way to the left counterclockwise will increase the water flowing through the heater and will produce a temperature rise of approximately 45 F at a flow rate of 1 3 gpm Given that average incoming water temperatures are 50 F this heater will produce water between 140 and 95 at these flow rates Thus one can obtain a higher flow rate but at cooler temperatures GAS CONTROL SLIDE TEMPERATURE ADJUSTMENT KNOB Fig 6 Water Flow Control Knob What is the best temperature setting Because AquaStar water heaters deliver endless hot water at the temperature you have selected there is no need to produce very hot water and then mix in cold It just does not make sense to overheat water and then mix in cold to cool it off You cannot run out of hot water with an AquaStar so set the dial for the temperature you prefer Note 105 F is the maximum recommended for a hot bath The position you select on the temperature adjustment knob will depend on the temperature of the incoming water 50 F is average in the U S If you plan to supply the AquaStar 38 B with preheated water i e solar installation the unit could overheat It will then shut off on safety when the outlet temperature reaches 185 F For a lower temperature rise the heater can be set for minimum burner output by sliding the gas valve control to the pilot setting symbol M
5. on gas appliances not so equipped The drip leg must be accessible and not subject to freezing conditions Install in accordance with the recommendations of the serving gas supplier WARNING The heater and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 0 5 psig The water heater must be isolated from the gas supply piping system by closing the manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 0 5 psig The water heater including the pressure regulator provided with it must not be operated at gas supply pressures in excess of 0 5 psig If overpressure has occurred such as through improper testing of the gas lines or emergency malfunction of the supply system the gas valve and regulator must be checked for safe operation Make sure that the regulator vent is protected against blockage Vent blockage could occur during ice storms When your connections are made check for gas leaks at all joints not just the ones you made Apply some soapy water to all gas fittings and gas valve Soap bubbles are a sign of a leak NOTE Do not apply soap solution to pilot filter screen or pilot orifice area If you have a leak shut off the gas After verifying that required gaskets are in place tighten appropriate fittings to stop leak Turn the gas on and check again with
6. setting on the AquaStar as much as possible and balance the pressure between cold and hot water after the AquaStar 6 Parts in water flow valve are corroded so that the gas passage is not fully opening Contact your service person or Controlled Energy HOT WATER TEMPERATURE FLUCTUATES 1 Unbalanced pressure in waterlines The added restriction caused by the Aquastar in the hot water system can result in uneven pressures between the cold and the hot In such cases when mixing cold water at the tap the lower hot water pressure may be overpowered by a much higher cold water pressure which may cause the Aquastar burners to shut down Make sure faucet aerators or shower heads are free of minerals Do not add any flow restrictor to the shower head 2 Cold water is mixing with the hot water between the AquaStar and the outlet See 6 under Burners do Not Ignite When Hot Water Turned On 3 Inlet water pressure is erratic due to inadequate supply water pressure or saturated pressure tank on well system Check the inlet water pressure On a private well raise minimum pressure setting to 30 psi Confirm that the pressure tank is not water logged 4 Insufficient gas pressure Check gas pressure requirements page 2 and consult gas service person Fig 9 Diagram of AquaStar 38 B Heat exchanger Pilot assembly Burner manifold gas pressure test nipple Pilot gas tubing Main gas burner k OO O
7. water energy use Each time you turn off your hot water faucet you also shut off the water heater FEATURES High Quality Materials for Long Working Life Copper heating coils for endless supply of hot water Safety thermocouple at pilot burner Automatic overheating protection shut off sensor Stainless steel burners with stabilized blue flame Built in corrosion resistant draft inducer Compact space saver mounts on a wall with two hooks Easily removable one piece cover Easy one person installation Adjustable water flow restrictor to ensure that water flow demand will not exceed the heating capacity of the heater Easy pilot flame lighting with push button piezo ignition UNPACKING THE AQUASTAR HEATER AquaStar 38B LP and 38B NG Specifications Gas Input max 40 000 Btu hr min 20 000 Btu hr Water Connection 1 2 Thread fitting H x W x D 25 3 8 x 10 5 8 x 9 1 8 Vent 4 Gas Connection 1 2 NPT thread Min Water Pressure 13 Psi at 1 3 GPM Max Water Pressure 150 Psi Shipping Weight 20 LB Net Weight 18 LB 0 5 GPM at 90 rise 1 3 GPM at 45 rise Min Water Flow 1 2 gal min LP GAS Pressure inlet min 11 W C max 14 W C LP GAS Manifold pressure 9 0 W C Natural Gas Pressure inlet min 7 W C max 14 W C Natural Gas Manifold Pressure 5 2 W C Inlet gas pressure must not exceed this value For purposes of input adjustment This heater is pack
8. 6 720 605 293 PT 862 12 98 AquaStar Qe o INSTALLATION AND OPERATING INSTRUCTIONS FOR AUTOMATIC INSTANTANEOUS TYPE WATER HEATERS FOR USE WITH NATURAL AND LIQUEFIED PETROLEUM GAS MODEL 38B LP and NG Non Modulating Suitable for water potable heating and space heating Intended for low flow domestic hot water applications with steady cold water inlet temperatures IL WARNING Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual For assistance or additional information consult a qualified installer service agency or the gas supplier Upon completion of the installation these instructions should be handed to the user of the appliance for future reference WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or death FOR YOUR SAFETY Do not store or use gasoline or other flammable combustible or corrosive 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 phone in your building Immediately call your gas supplier from a neighbor s phone 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
9. AINTENANCE AND SERVICE Approximately once a year the AquaStar should be checked cleaned and serviced as necessary To remove the front cover first remove the incandescent particle tray then pull off the temperature adjustment knob unscrew and remove the plastic collar and unscrew the central screw located at the bottom of the front cover Pull main cover out toward you and lift up and out THE FOLLOWING OPERATIONS SHOULD BE PERFORMED BY A QUALIFIED SERVICE PERSON Vent System Should be checked annually Clean and repair as needed Water _ Valve Part 8707002497 The water valve on this heater should be serviced periodically The frequency will depend on the mineral content of the water and conditions of use or whenever signs of corrosion appear at the gas and water valve joint Check that the water inlet filter 25 on Figure 10 page 14 is clean Pilot Flame The pilot flame should burn with a clean sharp blue flame and should resemble the diagram in Fig 7 If the flame is yellow or if the pilot knob has to remain depressed for a long time in order to keep the pilot lighted the pilot burner and or the pilot burner orifice may need to be cleaned the orifice may need to be replaced and or the air screen or pilot gas filter may need cleaning The pilot flame should envelop approximately 10 mm 3 8 of the tip of the thermocouple If it is too small the pilot burner must be cleaned The position of the Piezo igniter electrode sh
10. ARNING Note The burners of an instantaneous on demand water heater such as the AquaStar are only on at the time that hot water is actually being used the venting stack is therefore cold except for the short durations when hot water is being used itis therefore very important that the venting and air supply be adequate to provide a good positive draft as soon as the burners turn on The AquaStar 38B instantaneous water heaters have built in draft diverters and are designed for indoor installation only The draft diverter outlet must be connected to a clear unobstructed vent of the same size or larger In Canada CAN CGA B149 Installation Code for detailed requirements In U S A ANSI 2223 1 NFPA 54 national Fuel Gas Code for detailed requirements GAS CONNECTIONS and Gas Regulator Before connecting the gas supply check the rating plate on the right side of the front cover to be sure that the heater is rated for the same gas to which it will be connected In the United States The installation must conform with local codes or in the absence of local codes the National Fuel Gas Code ANSI Z2223 1 NFPA 54 In Canada The Installation should conform with CGA B149 INSTALLATION CODES and or local installation codes NOTE The Aquastar 38 B is supplied with a gas pressure regulator that must be installed on the heater before attaching the gas supply line See figure 2 Place the gas regulator between the gas supply connection
11. NO Inlet gas pressure test nipple Gas valve Gas control slide Piezo igniter Temperature adjustment knob Water valve LO 11 Fig 10 INTERIOR COMPONENTS DIAGRAM AND PARTS LIST Fig 10 INTERIOR COMPONENTS DIAGRAM AND PARTS LIST 38B ONOoBRWN Cover p 8 705 421 021 Temperature adjustment knob p 8 702 000 182 Panel back p 8 705 402 170 Draft divertor p 8 705 505 361 Heat exchanger p 8 705 406 233 Overheat sensor ECO p 8 707 206 040 Hot water pipe p 8 700 703 038 Main burner assembly LPG 8 708 120 301 Main burner assembly NG 8 708 120 011 Burner assembly washer p 8 710 103 008 Piezo electrode p 8 708 107 002 Pilot burner assembly p 8 718 105 048 Pilot air screen p 8 700 507 055 Pilot orifice NG 8 708 200 005 LPG 8 748 200 173 Pilot Tube n 8 700 707 334 Thermocouple p 8 747 202 083 Gas valve LPG 8 707 011 456 Gas valve NG 8 707 011 466 Electromagnet p 8 707 201 012 Thermocable p 8 747 202 209 Water valve assembly p 8 707 002 497 Water valve repair kit p 8 703 406 204 Water valve diaphragm p 8 700 503 050 Slow ignition valve p 8 708 503 061 Water valve water governor p 8 707 402 012 Water valve selector screw p 8 708 500 166 Holding bracket p 8 701 309 040 Water inlet filter p 8 700 507 001 Water valve venturi a 8 708 205 210 TANKLESS atures H o o pamuno o o Minimum Vent Size and Height NOTE Vent size must not be re
12. Note Normally this is a problem only at the time of initial installation after the pipes have been worked on or after a propane tank has been allowed to empty or after the heater has been shut down for a long time Bleed all the air trapped in the gas line Because of the very small pilot orifice especially on LP gas models bleeding out all the air could take several minutes Slide the gas valve button to pilot position and depress this button until all the air has escaped and the gas has arrived During this process press on the piezo ignition 10 button separately until the pilot flame has ignited PILOT LIGHTS BUT FLAME GOES OUT WHEN BUTTON IS RELEASED 1 Pilot push button was not pushed in far enough or was not held in long enough Slide the gas valve button to pilot position and depress this button Hold it pushed in for at least 15 seconds to give time for the pilot flame to properly heat the tip of the thermocouple 2 Pilot flame improperly aimed or is too weak so it is not properly heating the tip of the thermocouple The Pilot flame should be a sharp blue flame and aimed at the tip of the thermocouple so that it envelops 10 mm 3 8 of the thermocouple tip Pilot flame has to be properly aimed at the thermocouple See Fig 7 3 Poor thermocouple connection at the electromagnet Note Electromagnet is part 8707201012 located on the right side of the gas valve behind the piezo pushbutton assembl
13. a soapy solution Never test for gas leaks using a match or flame WATER CONNECTIONS Although water piping throughout your structure may be other than copper we recommend that copper piping be used for at least three feet before and after the heater follow local codes if more stringent Keep water inlet pipe to no less than 1 2 inch diameter to allow the full flow capacity Threaded connectors are supplied with this heater for both the hot and cold water fittings These fittings permit 1 2 NPT connections to be made Be certain there are no loose particles or dirt in the piping Blow out or flush the lines before connecting to the AquaStar A ball valve should be installed on the cold water feed line to facilitate servicing the heater For installation on a private well system be sure that the water pressure is set between 30 and 50 psi WATER FILTER WATER VALVE INLET COLD WATER Tf Fig 3 Water valve top view Connecting the pressure relief valve PRV A listed pressure relief valve supplied with the heater must be installed at the time of installation Should a discharge line be added to the PRV no valve is to be placed between the PRV and the heater No reducing coupling or other restriction may be installed in the discharge line The discharge line must be installed such that it allows complete drainage of both the PRV and the
14. ater fin coils and burners leading to a dangerous condition of venting blockage and poor unsafe combustion 4 Your hot water lines should be kept short to save energy It is always best to have hot water lines insulated Having a floor drain or sink nearby is handy in case you need to drain water from your heater WARNING The water in this water heater is cold and always remains cold exept for the times that hot water is being used DO NOT INSTALL IN AN AREA WHERE IT COULD FREEZE This heater is neither designed for nor approved for outside installation WARNING Flammable materials gasoline pressurized containers or any other items or articles that are potentially fire hazards must NOT be placed on or adjacent to the heater The appliance area must be kept free of all combustible materials gasoline and other flammable vapors and liquids COMBUSTION AIR REQUIREMENT Observe the following instructions concerning combustion air Appliances located in unconfined spaces a An unconfined space is one whose volume is greater than 50 cubic feet per 1000 Btu per hour of the combined rating of all appliances installed in the space That would be 2000 cubic feet for the AquaStar 38B alone b In unconfined spaces in buildings of conventional frame masonry or metal construction infiltration is normally adequate to provide air for combustion ventilation and dilution of flue gasses Appliances located in confined spaces The c
15. changers fins If some burners have yellow flames while others have good flames itis likely that dust lint or spider webs have partially clogged the burner venturis To clean the burners contact a gas service person Mineral Scale Build up AquaStars when operated at lower temperature settings tend not to accumulate mineral buildup If however the heater is used at the higher temperature settings and the water has a high mineral content periodic descaling may be necessary The heating coils should be flushed with a descaling solution Consult your dealer or Controlled Energy for instructions TROUBLE SHOOTING Introduction The AquaStar 38 burners are ignited by a water flow valve Numerous water related problems can cause this water valve to malfunction such as Insufficient water flow volume to activate the burners at its minimum flow requirement Dirt in the water flow valve causing it to malfunction Sediment build up in faucet aerators or shower heads Uneven pressures between cold and hot with single lever faucets Plumbing cross overs These water flow related problems can cause the heater to deliver less than its full output or to fail to ignite or to shut down completely Problems are stated in upper case bold face Most common causes for the problems follow in order of likelihood The suggested solutions require that the cover be taken off To this remove incandescent particle tray pull off the temperature adjustm
16. e too low Very low gas pressure may be caused by low delivered gas pressure a jammed gas regulator or undersized gas lines If the gas lines are undersized there may still be the specified static gas line pressure However when the water valve opens and gas enters the burners the pressure could drop sharply causing the pilot flame to go out Have a gas technician confirm the gas pressure both static and at maximum Btu output Specifications for your heater are on page 2 2 Pilot may be dirty or weak See Page 9 for instructions on pilot maintenance 3 Burners are not shutting down immediately when hot water is turned off Noie If burners don t shut down immediately when the hot water is turned off the heater will overheat and the ECO will shut off the gas Rebuild the water valve assembly repair kit from CEC part 8 703 406 204 4 Water is too hot causing overheat sensor to shut heater down Reduce burners by sliding gas control to single flame position WATER IS TOO HOT 1 Burners too forceful Note If the inlet water is quite warm slide gas valve control to single flame symbol and the heater will function on a minimum burner output 2 Temperature selection is too hot Turn the temperature adjustment knob to the left WATER IS NOT HOT ENOUGH 1 Temperature adjustment knob is set too low Change the setting Turn the temperature adjustment knob clockwise to the right 2 Water flow through the heater i
17. ed securely The box includes two water connection fittings a gas pressure regulator two hooks for hanging the heater this manual a personal letter a warranty statement and a warranty registration card Do not lose this manual as there is a charge for replacement Please complete and return the enclosed warranty registration card If you are using the AquaStar for combined space heating and potable water heating see schematic diagram below all piping and other components connected to the system must be suitable for potable water b toxic chemicals such as those commonly used for boiler treatment to prevent corrosion and freezing must not be introduced into the system and c if the space heating requires water temperatures higher than those required for do mestic potable water a mixing valve or other similar device must be provided to reduce scald hazard potential d maximum system water temperature must not exceed 140 F 60 C DO NOT CONVERT AN EXISTING CLOSED HOT WATER HEATING SYSTEM TO A COMBINATION SPACE AND POTABLE WATER HEATING SYSTEM USING THE AQUASTAR OR ANY OTHER HEAT SOURCE k Open loop potable water and combination space heating system To be used with a tank check local codes May not be permitted in some jurisdictions Cold Water In K Pressure Relief Valve Boiler Drain Primary Pump Expansion q Full Port 6 E Grundfos UP 26 99 BF Tank om Le s Taco 0011B or equivalent Hot Water
18. ent knob and unscrew and remove the plastic collar and unscrew the central screw located at the bottom of the front cover Pull main cover out toward you and lift up and out 1 No gas to the Aquastar A Gas cock on gas line may not be open B Gas valve button has not been moved to PILOT aa Slide button to right to single flame position 2 In line Aquastar gas regulator jammed usually on LP gas Replace or unjam the regulator Note The regulator furnished with thw heater is designed for low gas pressure Excessive pressure will lock it up propane only Jamming usually happens if the gas pressure between the gas tank propane and the water heater s gas regulator has not been reduceed See page 2 for recommended correct gas pressure and check with gas service person 3 Pilot orifice clogged and or air screen dirty Clogging of the pilot burner can be caused by dust and any suspended matter contained in the ambient air Although the filters can lengthen the cleaning intervals they can never completely prevent such clogging In consequence the gas jet issuing from the pilot orifice is reduced and or the air mixture is reduced The pilot flame is weak and thus can no longer heat the thermocouple sufficiently For cleaning purposes the air filter screen is pulled off washed and blown out The pilot orifice has likewise to be cleaned or exchanged Consult Controlled Energy or a gas service person 4 Air in the Gas Line
19. installer service agency or the gas supplier TABLE OF CONTENTS Specifications eee eee eee eee eee Page 2 Rules for safe Operation see eee ee eee eee eee Page 4 Locating the Heater sese se ee essere essere eee Page 4 Combustion Air Requirements cceeee Page 4 Mounting the Heater sese eee eee eee Page 5 Venting the Heater sse sese e sees rees eee neee ee Page 5 Gas Connections sse eee eee eee eee Page 6 Water Connections 0 cccceceeeeeeeeeeeeeeeneeeeees Page 6 Safety before lighting the pilot sese eee eee Page 7 Lighting iNStrUCtiONS cesi Page 8 Setting water temperature se ee eee Page 8 Maintenance amp Service eee eee eee eee Page 9 Trouble Shooting sese ee sees eee eee ee eee ee Page 10 Diagram of AquaStar nimeni Page 13 Components and Parts List sees eee Page 14 This well engineered gas water heater has all the fea tures a water heater should have It operates on the principle of heating water instantaneously on demand When a hot water faucet is opened cold water flows through the coils of the heat exchanger in the Aquastar This same flow opens the gas valve and the burners are ignited by the pilot flame The heat exchanger coils absorb the heat generated by the burners and trans fer heat to the water When the hot water faucet is shut off the gas valve automatically closes and the burners turn off Your hot water faucet is an ignition key to turn on the water heater giving you control over your hot
20. line The location of the PRV must be readily accessible for servicing or replacement and be mounted as close to the water heater as possible See Fig 4 To install the PRV a suitable fitting connected to an extension on a T fitting can be sweated to the hot water line Pressure Relief Valve E ef Fig 4 Pressure Relief Valve OPERATING INSTRUCTIONS Before proceeding with the operation of the heater make sure that the system is filled with water Make sure the water heater drain plug is closed See Figure 5 below WATER VALVE TO HEAT EXCHANGER DRAIN PLUG Fig 5 Water heater drain plug Open the cold water inlet supply to the heater fully Open a hot water faucet to permit the water to fill the heater and the piping and to eliminate the air trapped in the system Close the hot water faucet after the water flows freely and all the air has escaped from the system The water heater is now ready to work FOR YOUR SAFETY READ BEFORE LIGHTING THE PILOT A This appliance has a piezo igniter for lighting the pilot burner When lighting the pilot follow these instructions exactly B BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Donottouch any electric switch do not use any phone in your building
21. ly eliminated A plumbing crossover can be caused by a bad washer at a single lever faucet or incorrect plumbing or a mixing valve in the line etc which permits hot and cold water to mix in the plumbing The crossover will create a back pressure inthe system preventing the pressure drop in the Aquastar i e cold water is entering the water heater from both sides and the burners will not come on To confirm there is no crossover in the plumbing shut off the cold water supply to the AquaStar Open your hot water taps There should not be any water flowing If there is water flowing there is a crossover in the plumbing This is a plumbing problem not an Aquastar problem Please contact your plumber 7 Water valve parts may be dirty or components damaged Water valve and component parts must be totally free of dirt First check that the venturi is free of dirt particles In hard water areas mineral deposits can eventually 3 to 5 years in hard water areas corrode the water valve parts to a point where they will need replacing Any sign of moisture or corrosion at the joint of the water valve and the gas valve is a sign that the water valve assembly components need to be replaced immediately Note Water valve for model 38B is part 8707002497 for both LP and NG models Contact service person to clean water valve or replace if corrosion is present PILOT LIGHT GOES OUT DURING OR IMMEDIATELY AFTER HOT WATER HAS BEEN USED 1 Gas pressur
22. m and any gas control which has been underwater PROPER LOCATION FOR INSTALLING YOUR HEATER Carefully select the location of your new heater For your safety and for proper heater operation you must provide an abundant supply of combustion air and a proper venting installation 4 The heater may still operate even when improperly vented It will however be less efficient and could eventually damage the heater It could even result in human sickness or death due to oxygen deprivation and carbon monoxide poisoning Follow the guidelines below 1 Place your heater as close to a vent or chimney as possible 2 National building codes require that you do not install this appliance in bathrooms bedrooms unvented closet or any occupied rooms normally kept closed 3 Simultaneous operation of other appliances such as exhaust fans ventilation systems clothes dryers fireplaces orwood stoves could create a vacuum effect in your home which could cause dangerous combustion by products to spill back into your home rather than venting to the outside through the flue Confirm that your Aquastar is venting properly when all these other appliances are running See section on venting Do not obstruct the flow of combustion and ventilation air to the appliance If installed near a clothes dryer itis very important that the dryer be properly vented Failure to properly vent a dryer could result in a gradual accumulation of lint on the water he
23. onfined space must be provided with two permanent openings one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure Each opening must have a minimum free area of one square inch per 1000 Btu hr if all air is taken from inside the building 2000 Btu hr if all air is taken from the outside by horizontal ducts 4000 Biu hr if all air is taken from the outside by direct openings or vertical ducts Louvers grills and screens have a blocking effect If the effective free area is not known increase the sizes of your openings by 75 if your louvers are wood and by 30 if your louvers are metal Refer to the National Fuel Gas Code for complete information In buildings of tight construction all air should be taken from outside That would be 2000 cubic feet for the Aquastar 38B alone CLEARANCES The Aquastar 38 B is design certified for installation on a combustible wall and for installation in an alcove or closet with the minimum clearances to combustible and non combustible construction listed below A Top 12 inches 305 mm B Front 4 inches 102mm C Back 0 inches D Sides 4 inch 102mm E Bottom 12 inches 306 mm Clearance from vent is dependent upon the clearance rating of the venting material used For example type B 1 vent is approved for 1 inch clearance B 2 vent for 2 inch etc Note Minimum clearance to combustible materials should not be les
24. ould be approximately 3 mm 1 8 from the pilot mm Correct gap between pilot burner tip and electrode tip Piezo Electrode Air screen filter Thermocouple Piezo Electrode E N i Fig 7 Characteristic Pilot Flame To clean the pilot burner and or the pilot orifice Turn off the gas atthe unit Remove the cover of the heater To do so remove the incandescent particle tray pull off the temperature adjustment knob and unscrew and remove the knob collar Unscrew the central screw located at the bottom of the front cover Pull main cover out toward you and lift up and out Pull the air screen off wash it and blow any lint off See Fig 8 The pilot orifices should also be cleaned or replaced Do not enlarge the orifice Do not use any wire or sharp object to clean orifices Natural gas orifices are large enough that you can usually clean them by blowing through them LP orifices on the other hand are too small to clean and should be replaced See 3 in Trouble Shooting Section To access the pilot orifice remove 2 screws holding pilot assembly in place Then loosen compression fittings to expose pilot orifice AIR SCREEN PILOT ORIFICE Fig 8 Pilot burner with air screen pilot orifice Main Burner Flames The main burner flames should be blue with a more intense blue cone in the center core Yellow flames could be a sign of wrong size gas orifices or dirty burners or a blockage on the heat ex
25. pe size This appliance must be vented to the outside following all local ordinances and specifications for installing a gas appliance vent or chimney The venting system must be designed and constructed so as to develop a positive flow adequate to remove flue gasses to the outdoors Minimum vent size must be 4 Minimum height must be 6 feet provided there are no elbows Termination of vent must be 2 feet above any obstruction within a 10 foot radius Consult your gas utility or National Fuel Gas Code if vent will have elbows or share venting with another appliance The vent connector should have as much vertical rise as possible minimum 12 before any horizontal run The appliance must be located as close as practicable to a chimney or vent The vent pipe sections must be secured to each other with sheet metal screws Keep in mind the minimum clearance from the top of your heater Remember also that single wall vent pipe connectors require a 6 inch clearance from combustibles National Fuel Gas Code specifies double wall Type B vent pipe be used in cold climates and for gas vents running through attics We consider double wall vent pipe preferable in all circumstances Any vent section greater than 45 degrees from vertical is considered horizontal Horizontal sections of vent connectors must slope upwards at least 1 4 inch for every foot of its horizontal length Keep the horizontal section short and avoid too many elbows W
26. pressing hard on pilot igniter button NN This step may have to be repeated 7 Observe the pilot flame through the peephole The gas valve button should be held down at least 10 seconds with pilot burning When the gas valve button is released the pilot should continue to burn ba If the gas valve button does not pop up when released stop and immediately call your service technician or gas supplier If pilot does not stay lit repeat steps 1 through 7 If pilot will not stay lit after several tries slide the gas valve button to the left under the OFF mark and call service technician or gas supplier 8 When the pilot remains on slide the gas valve button to the right to the ON position The heater will now fire when water is drawn at a rate of 1 2 gallon or more per minute NOTE If main burner should fail to ignite make sure pilot is burning If not repeat lighting steps 1 through 7 TO TURN OFF GAS TO APPLIANCE Slide the gas valve button to the far left under the OFF mark and close the heaters individual shut off valve SETTING THE WATER TEMPERATURE To adjust the temperature on your AquaStar turn on a hot water faucet to its maximum flow At the water heater turn the large temperature adjustment knob located beneath the main gas controls on the front of the heater all the way to the right clockwise See Fig 6 This will produce a temperature rise of approximately 90 F at a flow rate
27. rmocouple If the reading is 24mv or over the thermocouple is good To test the electro magnet take another reading across the ECO spade while the pilot flame is on The reading should drop to about 15 mv If it does not and remains unchanged replace the electromagnet BURNERS DO NOT IGNITE WHEN HOT WATER IS TURNED ON 1 Pilot is not on Light the pilot See lighting instructions 2 Pilot lighting push button not turned to proper position Be sure that once the pilot flame is on that the gas valve button is slid all the way to the right to the ON position 3 Cold incoming water connection made to wrong side of heater Make sure cold water inlet connection is on the right side of heater when you are facing heater 4 Water flow rate at hot waiter tap is too low Note The AquaStar models 38 B require 1 2gallon per minute flow to activate the burners This is a flow which would fill a quart jar in 30 seconds 5 Cold water inlet filter on heater is dirty Remove the filter and clean This screen filter is located at the inlet side of the brass water valve fig 10 25 Check and clean faucet aerators too 6 Crossover in household plumbing The AquaStar burner activates when there is sufficient water pressure drop in the AquaStar water valve assembly ie when a hot water faucet is opened If there is a crossover in the plumbing the necessary pressure drop in the AquaStar will be insufficient or total
28. s bedrooms or any occupied rooms normally kept closed See the section below on locating the heater 4 You must vent your heater See section on Vent Pipe Connections Page 4 5 The appliance must be disconnected from the gas supply piping system during any pressure testing at pressures in excess of 1 2 Psig 3 5 kPa The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 Psig 3 5Kpa The appliance and its gas connection must be leak tested before placing the appliance in operation 6 Keep water heater area clear and free from combustibles and flammable liquids Do not locate the heater over any material which might burn 7 Correct gas pressure is critical for the optimum operation of this heater see specifications on page 2 Gas piping must be sized to provide the required pressure at the maximum output of the heater while all the other gas appliances are in operation Check with your local gas supplier and see the section on connecting the gas supply 8 Should overheating occur or the gas supply fail to shut off turn off the gas supply at the manual gas shut off valve on the gas line 9 Do not use this appliance if any part has been underwater Immediately call a qualified service technician to inspect the appliance and to replace any part of the control syste
29. s higher than the capacity of the AquaStar to heat it Reduce the flow demand at the faucet See flow rates at specific temperature rises on page 2 3 Btu input is too low due to insufficient gas pressure It is extremely important for a tankless instantaneous water heater to have the right size gas line to obtain the correct gas pressure See specifications on page 2 Unlike storage tank water heaters the burners of a tankless water heater must be very powerful to heat water instantaneously since they do this only at the time hot water is actually being used It is therefore imperative that the gas pressure requirement be met exactly Insufficient gas pressure will directly affect the water temperature at the time of usage See pages 2 and 13 respectively for correct gas pressure settings and where gas pressures are taken 4 Btu input is too low due to insufficient gas supply Make sure your main gas line is fully opened If using LP gas be sure that the size of the propane tank is adequate to supply the required gas pressure 5 Cold water is mixing with the hot water between the AquaStar and the outlet Compare water temperature at outlet of the AquaStar hold the AquaStar s outlet pipe with your hand and at the tap If these two are very different check for mixing valve or plumbing crossover see MAIN BURNERS WILL NOT IGNITE paragraph 6 Where automatic anti scald valves are required by code lower the temperature
30. s than 6 for single wall flue pipe Note that this clearance can be reduced if combustible material are protected as per table VI of the National fuel Gas Code or if Type B gas vent is used MOUNTING INSTALLATION The Aquastar 38 B is design certified for mounting on a wall Do not install this appliance on a carpeted wall or over floor covering which is combustible such as carpet The heater must be mounted on a wall using appropriate anchoring materials If wall is a stud wall sheathed with plasterboard it is recommended that support board s either 1x4 s or 1 2 minimum plywood first be attached across a pair of studs and then the heater should be attached to the support boards See Fig 1 Expansion and contraction of piping due to changing water temperature in the pipes imparts movement to the heater which if mounted directly to a brittle friable board such as plasterboard can cause failure of mounting Before installing the unit be certain you have the correct heater for your type of Gas Propane or Natural Gas Identification labels are found on the shipping box and on the rating plate which is located on the right side panel of the cover Also each burner orifice is stamped with a num ber 79 for LPG and 120 for Natural Gas WALL STUDS SUPPORT BOARD x4 SPACE BOARD Fig 1 Mounting the Heater VENTING Vent pipe connection WARNING Do not reduce the vent pi
31. stricted Installation must comply with national fuel gas code venting requirements for a 40 000 Btu Category appliance and any applicable local codes AquaStar INSTALLATION CHECKLIST NOTE 6 feet provided there are no elbows Termination of vent must be 2 feet above any obstruction within a 10 foot radius Consult your gas utility or National Fuel Gas Code if vent will have elbows or share venting with another appliance The vent connector should have as much vertical rise as possible minimum 12 before any horizontal run Water Pressure For installation on well systems insure that your water pressure is between 30 50 psi Replacement Parts available from North American Distributor CONTROLLED ENERGY CORP 340 Mad River Park Vermont 05673 U S A Phone 800 642 3111 Fax 802 496 6924 VULCANO Termodom sticos S A Estrada de Cacia 3800 Cacia PORTUGAL WWW CECHOT COM techsupport cechot com Recycled paper
32. y Check the tightness of the thermocouple connection nut at the electromagnet The Electro magnet connection is a large aluminum 17mm hex head nut The thermocouple end is a 5 mm brass nut which screws into the 17 mm nut Tighten the thermocouple nut snugly but not too tight 4 Poor circuit connections at the ECO Energy Cut Off overheat protection Oxidation or looseness of the ECO terminal connections can result in millivolt current loss through the thermocouple safety circuit Clean terminals with very fine sand paper or an eraser and reconnect ECO leads 5 Faulty ECO part 8707206040 If cleaning the terminals attached to the ECO did not fix the problem connect a jumper wire between the two wires and try to relight the pilot If the pilot flame now remains on replace the ECO If the flame still goes out when the button is released the ECO is not defective Go to next step 6 Faulty thermocouple part 8747202083 or electromagnet Unless these 2 parts are at least 8 to 10 years old it is very unlikely that they are faulty Before testing reconfirm that 2 is absolutely correct and that all connections are clean and tight To test the thermocouple disconnect the thermocouple lead to the ECO Insert a multi meter probe on the thermocouple ECO connection and attach the other meter lead on the spade connector of the ECO Light the pilot flame and take a reading on the meter If it reads less than 24mv replace the the
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