INSTALLATION AND OPERATING INSTRUCTIONS FOR AUTOMATIC
INSTANTANEOUS TYPE WATER HEATERS FOR USE WITH NATURAL AND
LIQUEFIED PETROLEUM GAS
MODEL 125B LPL and 125B NGL (Non-Modulated)
Suitable for heating potable water
Certified for space heating in combination with potable water only
Not certified for space heating only. Intended for either recirculation to storage or cold water inlet flow that
is non-varying. For variable flow, install the 125 B or the 125 X model.
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 installer, service agency or the gas supplier.
TABLE OF CONTENTS
Specifications .................................................... Page 2
Rules for safe operation ...................................... Page 4
Locating the Heater ............................................ Page 5
CombustionAir Requirements ............................ Page 5
Mounting the Heater ........................................... Page 6
Venting the Heater ............................................. Page 6
Gas Connections ............................................... Page 7
Water Connections ............................................ Page 8
Safety before lighting the pilot ............................ Page 9
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.
Lighting instructions ........................................... Page 9
About Water Temperature .................................. Page 9
Warning: If you do not follow these instructions exactly, a
Maintenance & Service....................................... Page 9
fire or explosion may result causing property damage,
Trouble Shooting .............................................. Page 10
personal injury or loss of life
Diagram ofAquaStar......................................... Page 13
Components and Parts List .............................. Page 14
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FRONT VIEW
SIDE VIEW
MINIMUM INSTALLATION CLEARANCES FROM COMBUSTIBLEAND NON
COMBUSTIBLE MATERIALS FOR ALCOVE OR CLOSET INSTALLATIONS
MODEL 125BL
TOP (A)
12"
4"
FRONT (B)
BACK
0"
SIDES
4"
FLOOR (C)
FLUE DIAMETER
12" *
5"
* Some local codes require 18” in garage installations
AQUASTAR MODEL 125BL
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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.
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.
Notes
1. Maximum to tank water temperature from 125 BL 140°F
2. Maximum heating capacity:
40°F rise
20°F rise
AquaStar 125BL -
80,000 BTU/hr
40,000 BTU/hr
3. System shown is electric storage tank with recirculating supply
drawn from the tapping for the lower heating element.
4. If circulation flow to the Aquastar 125BL is restricted, it may be
necessary to adjust the temperature slide control to prevent
overheating.
*Pipe PRV to appropriate discharge
**Tempering valve is required when tank water temperature is over
130 F.
5. 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
occupied rooms normally kept closed. See the section below
on locating the heater.
1. You should follow these instructions when you install 4. You must vent your heater. See section on VENTING,
your heater. In the United States: The installation must Page 6.
conform with local codes or, in the absence of local codes,
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
the National Fuel Gas CodeANSI Z223.1/NFPA54.
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 any pressure testing of the gas supply piping system at
combustion air supply and flue pipe installation are very test pressures equal to or less than 1/2 Psig (3.5kPa).
important. If not installed correctly, fatal accidents can be The appliance and its gas connection must be leak tested
caused by lack of air, carbon monoxide poisoning or fire.
before placing the appliance in operation.
3. The place where you install the heater must have enough 6. Keep water heater area clear and free from combustibles
ventilation. The National Fire Codes do not allow gas fired and flammable liquids. Do not locate the heater over any
water heater installation in bathrooms, bedrooms or any material which might burn.
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7. Correct gas pressure is critical for the optimum
WARNING: The water in this water heater is cold
operation of this heater (see specifications on page 2). Gas and always remains cold except for the times that hot
piping must be sized to provide the required pressure at water is being used DO NOT INSTALL IN AN AREA
the maximum output of the heater, while all the other gas WHERE IT COULD FREEZE.
appliances are in operation. Check with your local gas This heater is neither designed for nor approved for
supplier, and see the section on connecting the gas supply. outside installation.
Drain the heater entirely if freezing temperatures are
8. Should overheating occur or the gas supply fail to shut anticipated in area where heater is installed by
off, turn off the gas supply at the manual gas shut off valve disconnecting both the inlet and outlet elbow connections
on the gas line.
at the rear of heater. Additionally remove the drain plug
under the water valve. See Fig 0.
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 system and any gas control which has been
underwater.
PROPER LOCATION FOR INSTALLING
YOUR HEATER
Fig. 0 - Water heater drain plug
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.
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:
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 REQUIREMENTS
1. Place your heater as close to a vent or chimney as
possible.
The AquaStar water heater holds cold water in its copper
heat exchanger and brass water valve when not in use.
Because of this, any cold air that comes in through the
unit’s vent pipe is capable of freezing these components.
This Installation Manual specifies the minimum vertical vent
pipe and the amount of combustion air required for this
unit. The vent pipe must not be restricted and its 6 foot
minimum height (provided there are no elbows) must
terminate 2 feet above any obstruction within a 10 foot
radius.
When all requirements are followed, the unit will operate
properly and safely. However, there may still be a risk of
freezing due to negative draft if all the combustion appliances
in the area are not being supplied with a sufficient amount
of make-up air. Awood stove or furnace can rob the make-
up air in theAquaStar’s vent pipe, leaving the cold infiltrating
air capable of freezing the cold water in theAquaStar heat
exchanger. More make up air is the solution. Follow the
instructions on venting and checking adequacy of make up
air. A HVAC specialist should be used to design solutions
for providing more make-up air if necessary.
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
or wood 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 it is
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 heater fin coils and burners, leading to a
dangerous condition of vent blockage and poor unsafe
combustion.
Observe the following instructions concerning combustion
air.
Appliances located in unconfined spaces:
4. Your hot water lines should be kept short to save energy.
It is always best to have hot water lines insulated.
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 5850 cubic feet for theAquaStar 125BL 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
This product is not approved for manufactured homes
(mobile home), recreational vehicles (RV) or boats.
Reference ANSI Z21.10.3.
This product is neither designed or approved for
outside installations.
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dilution of flue gases.
which, if mounted directly to a brittle, friable board, such
Appliances located in confined spaces:) The confined 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 Btu/hr if all air is taken from the outside by direct
openings or vertical ducts.
Or the confined space must be providedwith one permanent
openingor duct that is within 12 inches of the ceiling of the
enclosure. This opening must have a minimum free area of
one square inch per:
as plasterboard, can cause failure of mounting.
In earthquake-prone zones, CEC recommends that
installers use a large washer and lag screw through the
existing holes used to hang the heater to affix the upper
third of the heater to the mounting board. To affix the lower
third of the heater, CEC recommends that two new holes
be drilled in the heater’s frame, each one 16 inches below
the top two holes, and that washers and lag screws be
used to secure the lower portion of the heater to a spacing
board.
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 number
- 3000 Btu/hr if all air is taken from the outside by a direct
opening or vertical duct.
(79 for LPG and 120 for Natural Gas).
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.
WALL STUDS
13 ¼”
SUPPORT BOARD
CLEARANCES
TheAquastar 125 BLis 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 (306 mm)
1” X 4”
SPACE BOARD
Fig. 1 - Mounting the Heater
B. Front 4 inches (102 mm)
C. Back 0 inches
D. Sides 4 inches (102mm)
E. Bottom 12 inches (306 mm)
The incandescent particle tray (shipped loose in the carton
with the water heater) must be attached at the bottom of
the water heater front cover at the time of installation. Use
the screws provided. See figure 2
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.
Note: Minimum clearance to combustible materials should
not be less 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.
SCREWS
INCANDESCENT PARTICLE TRAY
MOUNTING INSTALLATION
Fig. 2 - Incandescent Particle Tray Illustration
TheAquastar 125 BL is design certified for mounting on a
wall. Secure the two L shaped hooks provided with the
heater to a wall surface. Place them 13 ¼ inches apart as
VENTING
Vent pipe connection. WARNING: Do not reduce
the vent pipe size.
shown in Fig 1.
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.
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 5". 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 Gas Fuel
Expansion and contraction of piping due to changing water
temperature in the pipes imparts movement to the heater
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Code if vent will have elbows or share venting with
another appliance.
5” X 6” ADAPTOR
The vent connector should have as much vertical rise
as possible (minimum 12”) before any horizontal run.
Optional powervent available in order to sidewall vent.
Contact your local dealer. 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.
Optional power vent available in order to sidewall vent.
Contact your local dealer.
USED ON HIGH ALTITUDE
Fig. 3 - Flue Adaptor for High Altitude Canadian
Installations
WARNING: Failure TO INCREASE THE VENT SIZE
TO SIX INCHESAND/or assure that the manifold pressure
is set to proper value listed for applications at high altitudes
will cause unsafe venting, asphyxiation, and will void CSA
Certification.
GAS CONNECTIONS and Gas Regulator
To check the draft:
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 Z223.1/NFPA 54.
In Canada: The Installation should conform with CGA B149
INSTALLATION CODES and /or local installation codes.
NOTE: The Aquastar 125 BL is supplied with a gas
pressure regulator that must be installed on the heater
before attaching the gas supply line. See figure 4.
Failure to install the gas regulator as shown in figure
4 will be a violation of CSA certification of the unit.
The regulator supplied with the heater is preset for
the gas shown on the rating plate to the correct
pressure. It 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.
Close all doors and windows to the outside.
Turn on all appliances that force air out of the building.
These include all exhaust/ventilation fans, furnaces, clothes
dryers, wood burning stoves, etc.
Open all doors between theAquaStar and these other ap-
pliances.
Run the unit for at least 10 minutes. Then hold an ordinary
mirror at the side above the front shell. Any flue gases
backdrafting will cause the mirror to fog. This is a serious
health hazard and must be corrected. Poor venting can
result in soot building up inside the heater, overheating of
the heater and freezing of the heat exchanger in a freezing
environment.
The mirror will remain clear with a properly functioning draft.
WARNING
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 vent pipe is therefore
cold except for the short durations when hot water is being
used, it is therefore very important that the venting and air
supply be adequate to provide a good positive draft as soon
as the burners turn on. See venting guide on back page.
GAS INLET PIPE
PRESSURE TAP
TheAquaStar 125BLinstantaneous 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.
PLASTIC VENT CAP
PRESSUREREGULATOR
(with directional arrow on
reverse side pointing
upward)
In Canada, CAN/CGA-B149 Installation Code for detailed
requirements
In U.S.A., ANSI Z223.1 - NFPA 54, national Fuel Gas
Code for detailed requirements.
Fig. 4 - Installation of Gas Pressure Regulator
The flue connection for the AquaStar 125BL is 5 inches.
However, in CANADA, for installations at high altitude (2000-
4500 feet above sea level) a six inch flue is required. A 5"
by 6" flue adaptor must be affixed to the flue collar of the
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.
AquaStar with at least two screws. See figure 3.
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NOTE: The gas pressures specified below refer to NOTE: Do not apply soap solution to pilot filter screen or
pressures taken at the test pressure nipple on the gas pilot orifice area. If you have a leak, shut off the gas. After
inlet pipe just above the regulator (See Fig 4). These verifying that required gaskets are in place, tighten
readings should be taken while the heater is operating appropriate fittings to stop leak. Turn the gas on and check
at full input — i.e. with the gas control positioned all again with a soapy solution. Never test for gas leaks using
the way to the right.
a match or flame.
MAXIMUM INLET GAS FLOW PRESSURE SETTING
WATER CONNECTIONS
When facing the heater, the cold water inlet is on your right
and the hot water outlet is on your left.
Altitude
Natural Gas
inches W.C:
5.7"
Liquid Propane
inches W.C:
10.5"
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.
Remember that water pressure must be sufficient to activate
the heater when drawing hot water from the top floor. If the
hot and cold connections to the heater are reversed, the
heater will not function. The AquaStar 125BL is provided
with two flexible type connectors that must be connected
to the inlet and outlet fittings of the water valve as shown in
Figs 5 and 6. ½” Galvanized or brass fittings work best
when connected to the connectors. See Fig 6. These
connectors seal to the water valve by means of a union
connection with a washer type gasket at the joint. No pipe
dope or thread tape is to be used at these joints. Be certain
there are no loose particles or dirt in the piping. Blow out or
flush the lines before connecting to theAquaStar. Full port
valves should be installed on both the cold water feed line
and the hot water outlet 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.
0' - 2.000 ft
2.000 ft - 4.500 ft
4.6"
8.4"
Above 4.500 ft consult your local gas supplier.
GAS LINE SIZING
-It is strongly recommended that the Natural Gas pipe
be Black Iron pipe the entire distance from the outside
meter to the inlet of theAquastar regulator. 1/2” Black
Iron pipe up to 10 feet, 3/4” Black Iron pipe up to 40
feet and 1” Black Iron pipe up to 150 feet distances.
Flex line tubing is NOT recommended, but if used
then oversize it.
-It is strongly recommended that the LP Gas pipe be
semi-rigid copper or Black Iron pipe from the outside
regulator to the inlet of the Aquastar regulator. For
semi-rigid copper piping: 5/8” up to 20 feet and 3/4”
up to 60 feet distances. For Black Iron piping: 1/2” up
to 45 feet and 3/4” up to 160 feet distances. Flex line
tubing is NOT recommended, but if used then oversize
it.
WASHER
THESE FIGURESARE FORAQUASTAR SUPPLY ONLY,
ALL OTHER APPLIANCES IN THE BUILDING WILL NEED
TO BE INCLUDED IN THE PIPE SIZING.
WATER FILTER
WATER VALVE
National Fuel Gas Code requires that a sediment trap (drip
leg) be installed 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.
FLEX
CONNECTORS
WASHER
WARNING: The heater 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.
Fig. 5 - Water valve and water
connectors, top view
SWEATEDASSEMBLY
THREADEDASSEMBLY
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 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.
1/2” FLEX
1/2” FLEX
PIPE PRV TO
APPROPRIATE
DISCHARGE
PIPE PRV TO
APPROPRIATE
DISCHARGE
Fig. 6-Plumbing connections for the Aquastar 125BL
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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.
Connecting the pressure relief valve (PRV)
A listed pressure relief valve supplied with the heater must
be installed at the time of installation. 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.
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.
The discharge line must be installed such that it allows
complete drainage of both the PRV and the 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 7.
To install the PRV, a suitable fitting connected to an
extension on a “T” fitting can be sweated to the hot water
line.
LIGHTING INSTRUCTIONS (as seen on front
cover of heater)
1. STOP! Read the safety information above on this plate.
2. The gas valve must be turned off by depressing the gas
valve off button ( ).
3. 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 the next step.
4. The pilot burner is located behind the peephole in the
front center of the jacket directly below this instruction
plate.
5. Depress PILOT button ( ) and light pilot by pushing
PILOT INGITER button (
repeated.
). This may have to be
6. Observe the pilot flame through the peephole. The pilot
button ( ) should be held down at least 10 seconds
Fig. 7 - Pressure Relief Valve
OPERATING INSTRUCTIONS
Before proceeding with the operation of the heater make
sure that the system is filled with water.
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 operate.
with pilot burning. When the pilot button is released the
pilot should continue to burn.
- 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 6.
- If pilot will not stay lit after several tries, depress the OFF
button (
supplier.
), and call your service technician or gas
FOR YOUR SAFETY READ BEFORE
LIGHTING THE PILOT
7. When lit, depress the ON button (
). The heater will
now fire when water is drawn at a rate greater than the
threshold flow rate.
Warning: If you do not follow these instructions
exactly, a fire or explosion may result causing property
damage, personal injury or loss of life
NOTE: If main burner should fail to ignite, make sure
pilot is burning. If not, repeat lighting steps 1 through 6.
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.
TO TURN OFF GAS TO APPLIANCE
Depress the OFF button ( ) and close the gas supply to
the heater.
INFORMATION ABOUT WATER TEMPERATURE
WHAT TO DO IF YOU SMELL GAS
- Do not try to light any appliance.
The AquaStar 125B LPL and 125B NGL water heaters
produce a 90°F temperature rise at 1.8 gallons per minute.
As the flow rate is increased above 1.8, gallons per minute,
the temperature will decrease.
- Do not touch any electric 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.
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.
MAINTENANCE AND SERVICE
(see maintenance table on back of manual)
Approximately once a year, theAquaStar should be checked
and cleaned. To remove the front cover, first remove the
incandescent particle tray, then unscrew the central screw
located at the bottom of the front cover. Pull main cover out
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toward you and lift up and out. THE FOLLOWING To access the pilot orifice, remove 2 screws holding pilot
OPERATIONS SHOULD BE PERFORMED BY A assembly in place. Then loosen compression fittings to
QUALIFIED SERVICE PERSON:
expose pilot orifice.
Vent System: Should be checked annually. Clean and repair
as needed.
Water Valve (Part # 8707002478): The water valve on this
heater should be serviced periodically. Lubricate component
#25 on page 14 with a small amount of silicon, faucet or
AIR SCREEN
lithium grease every two years to keep its o rings fresh and
pushrod sliding smoothly. Every 3-5 years replace
components #25 and #27 on page 14. 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. Periodically check that the water inlet
filter (#32 on page 14) is clean as well.
PILOT ORIFICE
Pilot Flame: The pilot flame should burn with a clean sharp
blue flame and should resemble the diagram in Fig 8. 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
(NG), the orifice may need to be replaced(LP), and or the
air screen 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. To obtain
a spark, the position of the Piezo igniter electrode should
Fig. 9 - 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 exchangers fins. If
some burners have yellow flames while others have good
flames, it is likely that dust, lint or spider webs have partially
clogged the burner venturis. To clean the burners contact a
gas service person
be approximately 3 mm (1/8") from the pilot burner tip.
3mm
Mineral Scale Build-up: The AquaStars heater, when
operated at lower temperatures settings, do not accumulate
mineral build-up. 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.
Correct gap between pilot
burner tip and piezo electrode
tip
Piezo Electrode
Air screen filter
TROUBLE SHOOTING (see maintenance table)
Introduction
The AquaStar 125 BL burners are activated 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
do this, remove incandescent particle tray and unscrew
the central screw located at the bottom of the front cover.
Pull main cover out toward you and lift up and out.
Thermocouple
Piezo
Electrode
Fig. 8 - Characteristic Pilot Flame
To clean the pilot burner and/ or the pilot orifice : Turn
off the gas at the unit. Remove the cover of the heater. To
do so, remove incandescent particle tray and 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 9). 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.
PILOT LIGHT WILL NOT LIGHT
1. No gas to the AquaStar
A. Gas cock on gas line may not be open.
B. Gas valve button has not been pushed in on “PILOT”
position.
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C. Gas regulator may be shut or damaged.
Tighten the thermocouple nut snugly but not too tight.
2. In-line AquaStar gas regulator jammed (usually on 4. Poor circuit connections at the ECO. (Energy Cut-
LP gas)
Off overheat protection)
Replace or unjam the regulator. Note: The regulator
furnished with the heater is designed for low gas pressure.
Excessive pressure will lock it up (propane only).
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
Jamming usually happens if the gas pressure between the an eraser and reconnect ECO leads.
gas tank (propane) and the water heater’s gas regulator
has not been reduced. See page 2 for recommended correct 5. Faulty ECO (part #8707206017)
gas pressure.
If cleaning the terminals attached to the ECO did not fix
the problem, connect a jumper wire between the two wires
3. Pilot orifice clogged and/or air screen dirty, or pilot and try to relight the pilot. If the pilot flame now remains
gas filter is dirty. on, replace the ECO. If the flame still goes out when the
Clogging of the pilot burner can be caused by dust and any button is released, the ECO is not defective. Go to next
suspended matter contained in the ambient air. Although step.
the filters can lengthen the cleaning intervals, they can never
completely prevent such clogging. In consequence the gas 6. Faulty thermocouple (part #8747202083) or
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
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.
exchanged. To clean the pilot consult a gas service person Consult a gas service person to test and change the
.
thermocouple.
4. Air in the Gas Line
BURNERS DO NOT IGNITE WHEN HOT WATER IS
Note: Normally this is a problem only at the time of initial TURNED ON OR WHEN A CIRCULATOR PUMP IS
installation, after the pipes have been worked on, or after a OPERATING
propane tank has been allowed to empty, or after the heater
has been shut down for a long time.
1. Pilot is not on.
Bleed all the air trapped in the gas line. Because of the Light the pilot. See lighting instructions.
very small pilot orifice (especially on LP gas models),
bleeding out all the air could take several minutes. Depress 2. Gas valve button not positioned on Burner Position
Be sure once the pilot flame is on, that after a 15 to 20
the pilot button ( ) until all the air has escaped, and the
gas has arrived. During this process, press repeatedely on
the piezo ignition button until the pilot flame has ignited.
second wait, the main burner button (
the way in.
) is pushed all
PILOT LIGHTS BUT FLAME GOES OUT WHEN BUTTON
IS RELEASED
3. Water flow rate at hot water tap is too low.
Note: The AquaStar models 125BL require 1.8 gallon per
minute flow to activate the burners. This is a flow which
would fill a quart jar in 8 seconds.
1. Pilot push button was not pushed in far enough or
was not held in long enough
Once pilot flame has been lighted. Hold button pushed in
for at least 15 seconds to give time for the pilot flame to
properly heat the tip of the thermocouple.
4 . Cold water inlet filter on heater is dirty.
Remove filter and clean. This screen filter is located at the
inlet side of the brass water valve (fig 11, #32). Check and
clean faucet aerators too.
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 8.
5. Inadequate pump used on a recirculating loop
If unit is plumbed in a recirculating loop system verify that
the primary circulator pump is sized properly. GF 26-96,
Taco 009 or equivalent is required. See diagram on page 4.
6. Crossover in household plumbing
3. Poor thermocouple connection at the
electromagnet
TheAquaStar burner activates when there is sufficient water
pressure drop in theAquaStar water valve assembly — ie.
when a hot water faucet is opened. If there is a crossover in
the plumbing, the necessary pressure drop in theAquaStar
will be insufficient, or totally 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 in the
Note: Electromagnet is part #8707201094 located on the
right side of the gas valve behind the piezo pushbutton
assembly. 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.
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system preventing the pressure drop in the Aquastar (i.e. temperature relay for the primary circulator pump is possibly
cold water is entering the water heater from both sides and set too high.
the burners will not come on).
To confirm there is no crossover in the plumbing, shut off WATER IS NOT HOT ENOUGH
the cold water supply to theAquaStar. Open your hot water
taps.
1. Water flow rate is too high.
There should not be any water flowing. If there is water Decrease the flow rate.
flowing, there is a crossover in the plumbing. This is a
plumbing problem, not anAquastar problem. Please contact 2. Gas flow is not optimal
your plumber.
Move gas control slide to the right.
7. Water valve parts may be dirty or components
damaged.
3. Temperature (aquastat) control is set too low
First check that the venturi is free from dirt particles.
If unit is plumbed in a recirculating loop system the aquastat
Water valve and component parts must be totally free of temperature relay for the primary circulator pump is possibly
dirt. In hard water areas, mineral deposits can eventually set too low.
(3 to 5 years in hard water areas) corrode the water valve
parts to a point where they will need replacing. Any sign of 4. Btu input is too low due to insufficient gas pressure
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.
It is extremely important for a tankless instantaneous
water heater to have the right size gas line to obtain
the correct gas pressure
Note: Water valve for model 125BL is part # 8707002478 See specifications on page 2. Unlike storage tank water
for both LP and NG models. (Contact service person to heaters, the burners of a tankless water heater must be
clean water valve or replace if corrosion is present).
PILOT LIGHT GOES OUT DURING OR AFTER USE
1. Gas pressure too low
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
Very low gas pressure may be caused by low delivered for correct gas pressure settings.
gas pressure, a jammed gas regulator or undersized gas
lines. If the gas lines are undersized, there may still be the 5. Btu input is too low due to insufficient gas supply
specified static gas line pressure. However when the water Make sure your main gas line is fully opened. If using LP
valve opens,and gas enters the burners, the pressure could gas, be sure that the size of the propane tank is adequate
drop sharply, causing the pilot flame to go out. Have a gas to supply the required gas pressure.
technician confirm the gas pressure both static and at
maximum Btu output. Specifications for your heater are on 6. Cold water is mixing with the hot water between
page 2.
the AquaStar and the outlet
2. Pilot may be dirty or weak
See Page 9 for instructions on pilot maintenance.
Compare water temperature at outlet of theAquaStar (hold
theAquaStar’s outlet pipe with your hand) and at the tap. If
these two are very different, check for mixing valve or
3. Burners are not shutting down immediately when plumbing crossover (see “MAIN BURNERS WILL NOT
hot water is turned off or when a circulator pump IGNITE...” paragraph #5).
has stopped operating
Note: If burners don’t shut down immediately when the hot 7. Parts in water flow valve are corroded so that the
water is turned off, the heater will overheat and the ECO
gas passage is not fully opening
will shut-off the gas. Rebuild the water valve assembly using Contact your service person or Controlled Energy.
the repair kit from CEC (part#8 703 406 214).
HOT WATER TEMPERATURE FLUCTUATES
4. Temperature controls are set too high
If unit is plumbed in a recirculating loop system insure that 1. Cold water is mixing with the hot water between
the aquastat or relay for the primary circulator pump is set
for no hotter than 140°F. This is necessary to prevent pilot
the AquaStar and the outlet (if not being used with
a circulator pump)
outage due to overheating. The temperature slide control See #5 under “Burners do Not Ignite When Hot Water Turned
on the 125BL may also need to be lowered to prevent On”.
overheating.
2. Storage in tank (recirculating system) has not fully
recovered
WATER IS TOO HOT
Storage capacity in tank is inadequate. Increasing tank
size, setting slide control higher for a fast recovery or adding
a second 125BL for even a faster recovery is suggested.
1. Gas flow is higher than necessary.
Move gas control slide to the left.
3. Insufficient gas pressure
2. Temperature (aquastat) control is set too high
Note required gas pressures (page 2) and consult gas ser-
vice person.
If unit is plumbed in a recirculating loop system the aquastat
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Fig. 10 - Diagram of AquaStar 125 BL
1
3
2
5
8
4
6
7
9
10
11
7. Gas control slide
8. Piezo igniter
9. Location of pressure tap
nipple
1. Heat exchanger
2. Pilot assembly
3. Burner manifold gas
pressure test nipple
4. Pilot gas tubing
5. Main gas burner
6. Gas valve
10. Water valve
11.
Gas inlet gas pressure
test nipple
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Fig. 11 - INTERIOR COMPONENTS DIAGRAM AND PARTS LIST
14
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Fig. 11
INTERIOR COMPONENTS DIAGRAM
AND PARTS LIST 125BL
1
Cover
Cap cover
Water connection gasket
Draft divertor
Heat exchanger
Hot water pipe
Cold water pipe
¤
¤
8 705 421 031
8 703 304 011
8 710 103 043
8 705 505 354
8 705 406 235
8 700 705 431
8 700 705 294
8 710 103 045
8 707 206 017
8 708 120 296
8 708 120 298
8 708 105 337
8 700 507 055
8 708 107 002
8 708 200 005
8 748 200 173
8 710 707 166
8 747 202 083
8 710 103 060
8 700 100 174
8 707 011 460
8 707 011 464
8 700 705 464
8 747 201 094
8 700 103 144
8 700 507 051
8 747 202 078
8 707 002 478
8 703 406 214
8 700 503 043
8 708 503 060
8 703 404 098
8 700 205 050
8 708 500 230
8 708 205 248
8 700 507 059
8 700 703 114
2
3
¤
¤
4
5
¤
6
¤
7
¤
8
Heat exchanger washer
Overheat sensor (ECO)
Main burner assembly
Main burner assembly
Pilot burner assembly
Pilot filter screen
Piezo electrode
¤
9
¤
10
LPG
NG
¤
11
11a
12
13
¤
¤
NG
LPG
¤
¤
¤
Pilot orifice
“
14
15
16
17
18
Pilot Tube
Thermocouple
Burner assembly washer
Throttle disc
LPG
NG
LPG
¤
Gas valve
Gas valve
Gas supply pipe
Electromagnet
Electromagnet washer
Gas filter
Thermocable
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
¤
¤
¤
¤
Water valve assembly
Water valve repair kit
Water valve diaphragm
Slow ignition valve
Water valve setting screw
O ring setting screw
Water valve piston assembly
Water valve venturi
Water inlet filter
¤
¤
¤
¤
¤
¤
¤
¤
¤
Water elbow fitting
¤
15
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INSTALLATION CHECKLIST
GAS LINE SIZE
Natural Gas
Nominal Iron Pipe Size*
1/2"
10'
3/4"
40'
1"
MAXIMUM LENGTH
150'
Liquid Propane
Semi-rigid Tubing
1/2"
NOT
RECOMMENDED
5/8"
20'
3/4"
60'
7/8"
150'
MAXIMUM LENGTH
* Flex tubing greatly reduces capacity and, therefore, is not recommended.
Minimum Vent Size* and Height
Minimum Diameter
Minimum Height**
5 inches
6 feet**
* NOTE: Vent size must not be restricted. Installation must comply with national fuel gas code venting requirements
for a 117,000 Btu Category I appliance and any applicable local codes.
** NOTE: Minimum vent height must be 6 feet, provided there are no elbows. Termination of the vent must be 2
feet above any obstruction within a 10 foot radius of vent pipe. 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.
MAINTENANCE TABLE see pages 9 & 10
EVERY YEAR
EVERY 2 YEARS EVERY 3-5 YEARS
LUBRICATE WATER VALVE
REBUILD WATER VALVE
†
†
INSPECT WATER FILTER SCREEN
INSPECT PILOT ASSEMBLY
INSPECT VENT ASSEMBLY
INSPECT MAIN BURNER
†
†
†
†
Replacement Parts available from North American
Distributor
CONTROLLED ENERGY CORP.
340 Mad River Park
VULCANO Termodomésticos S.A.
Estrada de Cacia
3801 - 856 Aveiro - PORTUGAL
Waitsfield, Vermont 05673
Phone 800-642-3111
Fax (802) 496-6924
Recycled paper
©2001ControlledEnergyCorporation,Waitsfield,VT
allrightsreserved
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