AquaStar 80 VPS manual

W ARNING: 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 vicinty of this or any other appliance. WHA T T O DO IF YOU SMELL GAS • Do not t[...]

2 T ABLE OF CONTENTS Specifications .............................................................................. Page 3 Rules for Safe Operation ............................................................. Page 4-5 General Overview of Aquastar .................................................... Page 6 Locating the Heater for Safe Proper Combust[...]

3 AquaStar 80 VP and 80 VP "S" Specifications: Gas input..................................max: 77,500 Btu min: 25,000 Btu W ater Connection........................1/2" sweat fitting H x W x D..........................................27" x 12" x 9" V ent...................................................................[...]

4 CAUTION: RULES FOR SAFE OPERA TION 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 mu[...]

5 RULES FOR SAFE OPERA TION 1. Y ou should follow these instructions when you install your heater . In the United States: The installation must con- form with local codes or , in the absence of local codes, the National Fuel Gas Code ANSI Z223.1/ NFP A 54. In Canada: The installation should conform with CGA B149.(1,2) INST ALLA TION CODES and/ or l[...]

6 I. hot water outlet J. thermostat adjustment screw K. gas inlet L. manual gas valve M. cold water inlet screen P. pilot starting button R. water valve venturi piston S. pilot filter X W V T S R P M Z K H J G F D E C B A I Y Fig. 2 Parts of AquaStar 80 L T. pilot V. overheat shut off sensor W. draft hood X. rating plate-serial # & gas type, et[...]

7 LOCA TING YOUR HEA TER FOR SAFE PROPER COMBUSTION 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 install a proper vent. The heater may still operate even when improperly installed. However , an improper installation will be less efficien[...]

8 heater . Use the adhesive tape which is included in the package to stick the pattern to the wall. Keep in mind that the heater needs to have cer- tain minimum clearances (See paragraph 7 on this page), and that the heater must be level. Drill four holes into the wall at the studs (16 inches on center) as indicated on the template. Use a 1/8 inch [...]

9 3. Connecting the Gas Line In the United States: The installation must con- form with local codes or , in the absence of local codes, the National Fuel Gas Code ANSI Z223. 1/NFP A 54. In Canada: The installation should conform with CGA B149 INST ALLA TION CODES and/or lo- cal installation codes. IMPORT ANT An appliance gas pressure regula- tor ha[...]

10 Sweat your cold water pipe to the AquaStar inlet elbow fitting. NOTE: The inlet filter screen and water flow restrictor can be damaged by heat if the cold water inlet elbow is attached to the AquaStar when it is sweated to the cold water inlet pipe. The inlet and outlet elbow fit- tings seal by means of a union connection with a washer type gask[...]

11 is lighted. Keep the center knob pressed all the way in for at least 10 seconds after pilot is lighted. Release push knob and turn it clockwise to If pilot goes out, wait 5 minutes before relighting. FOR YOUR SAFETY READ BEFORE LIGHTING W ARNING: If you do not follow these instructions exactly , a fire or explosion may result causing property da[...]

12 SETTING THE W A TER TEMPERA TURE The AquaStar 80 water heater contains a flow restrictor set at 3 1/4 gpm. Its purpose is to as- sure that the hot water temperature will always be within a comfortable range regardless of how high one may turn on the hot water faucet or how many faucets may be turned on. Y our AquaStar model 80 also has an automa[...]

13 valve discharges by itself, a problem exists and service is required. This could be due to a de- fective relief valve or to overheating. Pilot Flame: The pilot flame should burn with a clean sharp blue flame and should resemble Fig.4 below . If the flame is yellow , or if the central button Fig. 2 (P) has to remain de- pressed for a long time in[...]

14 gas pressure. Excessive pressure will lock it up. This problem usually happens if the gas pressure between the gas tank and the water heater has not been reduced. See page 3 of your manual for specified gas pressures. T o unjam a regulator , remove the nickel size screw plug on the front. Inside you will see another large screw . Draw a line dow[...]

15 3. Poor circuit connections at the ECO (Energy Cut-Off) Oxidation or looseness of the ECO screw con- nections can result in millivolt current loss through the thermocouple safety circuit. Clean terminals with very fine sand paper or an eraser and re- tighten terminal screws. (See letter V in Fig 2, page 6). 4. Faulty Energy Cut Off (ECO)- Part 3[...]

16 7. W ater valve parts may be dirty or compo- nents damaged. Note: If #4 is OK, skip this. W ater valve and component parts must be totally free of dirt. In hard water areas, mineral depos- its can eventually (3-5 years) corrode water valve parts to a point where they will need replacing. Note: there is a small bleed hole under the gas valve at t[...]

17 2. W ater flow through the heater is higher than the capacity of the AquaStar to heat it If the AquaStar flow restrictor has been removed, the flow through the heater might be higher than its capacity to heat it. Reduce the flow to a range within which the heater can maintain temperature. See flow chart on Page 18. AquaStar water heat- ers have [...]

18 5. Cold water is mixing with the hot water between the AquaStar and the outlet Compare water temperature at outlet of AquaStar and at the tap. Check for automatic mixing valve plumbing crossover (see #6 - MAIN BURNERS DO NOT IGNITE WHEN HOT W A TER IS ON). 6. Parts in water flow valve (#34343) are corroded The gas valve will not open fully if wa[...]

19 Pilot Burner Hairpin Retaining Clip Thermocouple Retaining Clip Pilot Injector Pilot Filter Housing Gasket Gasket Filter Pilot Tube T o Electromagnet T o E.C.O. Screen Retaining Clip Pilot Burner Pilot Flames NOTE: Pilot flame must be sharp blue, not soft and yellow View of Pilot Flame as seen from above Thermocouple Screen Air Screen Main Burne[...]

20 Thermostat Tubing to Heat Exchanger Calibration Screw Thermostat Piston Assembly Spring Correct height of spring - 5/32" or 4mm Note: Unless setting #8 (145° ± 5, this is scalding hot water) is needed for some rare occa- sion we highly recommend run- ning the heater on setting 4 or 5. This will also avoid the need to mix a lot of cold wat[...]

21 PROCEDURE FOR REPLACING A THERMOSTAT Into Left Side of Heat Exchanger 5. Pull down on the thermostat piston assembly to remove it from the gas valve. NOTE: There is a Steel Wedge and an "O" Ring which should come out with the piston assembly. If they do not, reach up with tweezers and/or a magnet for the Steel Wedge and remove them. Be[...]

22 DESCRIPTION OF OPERA TION OF AQUAST AR 80/125 MODELS WATER PATH Cold water entering the Cold Water Inlet passes through a nylon mesh Water Filter Screen (#21) which filters out dirt and debris. Water then passes through the Water Flow Restrictor (#8) which prevents water flow from exceeding 3.25 gallons per minute. The flow control is there to h[...]

23 DIAGRAMATIC LAYOUT 1 7 . WATER TEMPERATURE PROBE (THERMOSTAT SENSOR) 1 8 . GAS LINE PRESSURE TEST NIPPLE 1 9 . OVERHEAT SENSOR SWITCH 2 0. THERMOSTATIC WATER TEMPERATURE SELECTOR 2 1 . WATER FILTER SCREEN 2 2. GAS PRESSURE TESTING NIPPLE 2 3. VENTURI PISTON 2 4 . GAS REGULATOR 25. PUSH ROD ASSEMBLY 9 . PILOT LIGHT 1 0 . PILOT LIGHT ORIFICE 1 1 .[...]

24 SPARE PARTS LIST 38798 - RIGHT SIDE PANEL 38799 - LEFT SIDE PANEL 22527 - TEMPERATURE SELECTOR KNOB 23617 - PANEL RETAINING SCREW 28329 - PILOT STARTER KNOB 36540 - FRONT PANEL 33993 - INCANDESCENT PARTICLE TRAY HOUSING COMPONENTS DIAGRAM AQUASTAR 80 38798 38799[...]

25 SPARE PARTS LIST 00839 - PILOT WASHER 00869 - RETAINING NUT FOR GAS INLET FITTING 00910 - RETAINING NUT FOR COLD INLET AND HOT WATER OUTLET 02147 - NG GAS PILOT INJECTOR 02434 - L P GAS PILOT INJECTOR 05964 - GAS FITTING WASHER 08565 - BURNER ASSEMBLY 20887 - THERMOCOUPLE 22040 - THERMOSTAT SENSING ELEMENT RETAINING SCREW 22045 - BURNER MANIFOLD[...]

26 VALVE ASSEMBLY COMPONENTS DIAGRAM AQUASTAR 80 22039 - SCREW FOR MANIFOLD CLAMP 22041 - WATER VALVE RETAINING SCREW 22043 - THERMOCOUPLE PUSH BUTTON COVER RETAINING SCREW 22064 - TIGHTENING SCREW FOR WATER VALVE 23617 - REGULATOR COVER SCREW 23951 - THERMOSTAT SETTING COVER ASSEMBLY 23952 - GAS VALVE ASSEMBLY 31857 - LP GAS INJECTORS 32570 - WATE[...]

27 INST INST INST INST INST ALLA ALLA ALLA ALLA ALLA TION CHECKLIST TION CHECKLIST TION CHECKLIST TION CHECKLIST TION CHECKLIST Gas Line Size* For installation on well systems, insure that your water pressure is between 30 - 50 psi. Semi-rigid T ubing 1/2" 5/8" 3/4" 7/8" Liquid Propane Natural Gas Model 80 2 5 " 100' 1[...]

28 GENERAL Controlled Energy Corporation (CEC) will furnish a replacement heat exchanger and will furnish a replacement of any other part, which fails in normal use and service within the applicable periods specified below , in accordance with the terms of this warranty . The CEC replacement will be warranted for the unexpired portion of the origin[...]