INSTALLATION AND OPERATING INSTRUCTIONS FOR AUTOMATIC
INSTANTANEOUS TYPE WATER HEATERS FOR USE WITH NATURAL AND
LIQUEFIED PETROLEUM GAS
MODEL 125HX LP and 125HX NG
(Flow Modulated with Electronic Ignition)
Suitable for heating potable water only
Not approved for space heating purposes
Intended for variable flow applications with steady cold water inlet temperatures.
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 4
CombustionAir Requirements ............................ Page 5
Mounting the Heater ........................................... Page 5
WARNING: Improper installation,
Venting the Heater ............................................. Page 6
adjustment, alteration, service or maintenance can Gas Connections ............................................... Page 7
cause injury or property damage. Refer to this manual. Gas Piping ......................................................... Page 8
For assistance or additional information consult a Water Connections ............................................ Page 9
qualified installer, service agency or the gas supplier. Safety before turning on the heater ..................... Page 9
Upon completion of the installation, these instructions Operating instructions ...................................... Page 10
should be handed to the user of the appliance for Setting water temperature ................................ Page 10
future reference.
In the Commonwealth of Massachusetts this product
must be installed by a licensed plumber.
Maintenance & Service......................................Page 11
Trouble Shooting ...............................................Page 11
Electrical Diagram ............................................ Page 13
Diagram ofAquaStar......................................... Page 15
FEATURING: Automatic Variable Power Modulating Gas Interior components diagram ............................ Page 16
Valve and power generated Electronic Ignition Parts List ......................................................... Page 17
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FRONT VIEW
SIDE VIEW
MINIMUM INSTALLATION CLEARANCES FROM COMBUSTIBLE AND NON
COMBUSTIBLE MATERIALS FOR ALCOVE OR CLOSET INSTALLATIONS
MODEL 125 HX
TOP (A)
12"
4"
FRONT (B)
BACK
0"
SIDES
4"
FLOOR (C)
VENT DIAMETER
12" *
5"
* Some local codes require 18” in garage installations
AQUASTAR MODEL 125HX
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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:
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, in the absence of local codes,
the National Fuel Gas CodeANSI Z223.1/NFPA54.
In Canada: The Installation should conform with CGA
1. Place your heater as close to a vent or chimney as
possible.
B149.(1,2) INSTALLATION CODES and /or local installation 2. National building codes require that you do not install
codes.
this appliance in bathrooms, bedrooms or any occupied
rooms normally kept closed.
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. 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.
3. The place where you install the heater must have enough
ventilation. The National Fire Codes do not allow gas fired
water heater installation in bathrooms, bedrooms or any
occupied rooms normally kept closed. See the section below
on locating the heater.
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.
4. You must vent your heater. See section on VENTING,
Page 6.
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 more than 1/2 Psig (3.5Kpa).
The appliance and its gas connection must be leak tested
before placing the appliance in operation.
4. Your hot water lines should be kept short to save energy.
It is always best to have hot water lines insulated.
WARNING: The water in this water heater is cold
and always remains cold except 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.
6. Keep water heater area clear and free from combustibles
and flammable liquids. Do not locate the heater over any
material which might burn.
Drain the heater entirely if freezing temperatures are
anticipated in area where heater is installed by
disconnecting both the inlet and outlet water
connections from the heater (disconnect the outlet flex
line from where it connects to the copper heat
exchanger). Additionally remove the drain plug under
the water valve. See Fig. 0.
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 system and any gas control which has been
underwater.
Fig. 0 - Water heater drain plug
PROPER LOCATION FOR INSTALLING
YOUR HEATER
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.
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.
4
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This product is not approved for manufactured homes Louvers, grills and screens have a blocking effect. If the
(mobile home), recreational vehicles (RV) or boats. effective free area is not known, increase the sizes of your
Reference ANSI Z21.10.3.
openings by 75% if your louvers are wood and by 30% if
This product is neither designed or approved for 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.
outside installations.
COMBUSTION AIR REQUIREMENTS
CLEARANCES
The AquaStar water heater holds cold water in its copper
heat exchanger and 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.
TheAquastar 125 HX 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 (306 mm)
B. Front 4 inches (102 mm)
C. Back 0 inches
D. Sides 4 inch (102mm)
E. Bottom 12 inches (306 mm)
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.
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.
MOUNTING INSTALLATION
Observe the following instructions concerning combustion
air.
TheAquastar 125 HX 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 shown in
Fig 1.
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 5850 cubic feet for theAquaStar 125HX 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.
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.
Appliances located in confined spaces:
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.
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 (79 for LPG and 120 for Natural
Gas).
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 provided with one permanent
opening or 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:
- 3000 Btu/hr if all air is taken from the outside by a direct
opening or vertical duct.
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at least 1/4 inch for every foot of its horizontal length. Keep
the horizontal section short and avoid too many elbows.
WALL STUDS
To check the draft:
Close all doors and windows to the outside.
13 ¼”
Turn on all appliances that force air out of the building.
These include all exhaust/ventilation fans, furnaces, clothes
dryers, wood burning stoves, etc.
SUPPORT BOARD
Open all doors between the AquaStar and these other
appliances.
With the control knob set fully clockwise and strong hot
water flow rate, run the unit for at least 10 minutes. The
125HX is equipped with a Flue Gas Sensor; it’s mounted
on the right side of the draft diverter (Flue Gas Sensor #34
on page 17). If the main burners shut off during this test it
is because the Flue Gas Sensor has detected inadequate
venting. 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, which is all a
result of negative air flow. Additional combustion air and/or
improved venting will be necessary to correct this.
1” X 4”
SPACE BOARD
Fig. 1 - Mounting the Heater
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
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.
SCREWS
INCANDESCENT PARTICLE TRAY
Fig. 2 - Incandescent Particle Tray Illustration
VENTING
TheAquaStar 125HX 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
Vent pipe connection. WARNING: Do not reduce
the vent pipe 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 5". 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 the vent pipe. Consult your gas
utility or National Gas Fuel 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.
Optional powervent (Model AQ-1) is available in order to
sidewall vent. In the Commonwealth of Massachusetts:
Powervented applications must utilize proof-of-draft
safety interlock device. 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.
In U.S.A., ANSI Z223.1 - NFPA 54, National Fuel Gas
Code for detailed requirements.
The vent connection for the AquaStar 125HX is 5 inches.
However, in CANADA, for installations at high altitude (2000-
4500 feet above sea level) a six inch vent is required. A5"
by 6" vent adaptor must be affixed to the vent collar of the
AquaStar with at least two screws. See figure 3.
WARNING: Failure TO INCREASETHE 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.
5” X 6”ADAPTOR
USED ON HIGHALTITUDE
Fig. 3 - Vent Adaptor for High Altitude Canadian
Installations
Horizontal sections of vent connectors must slope upwards
6
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GAS CONNECTIONS and Gas Regulator
GAS LINE SIZING
NOTE: The Aquastar 125 HX is supplied with a gas -It is strongly recommended that the Natural Gas pipe
pressure regulator that must be installed on the heater be Black Iron pipe the entire distance from the outside
before attaching the gas supply line. See figure 4. meter to the inlet of the Aquastar regulator. 1/2” Black
Failure to install the gas regulator as shown in figure Iron pipe up to 10 feet, 3/4” Black Iron pipe up to 40
4 will be a violation of CSA certification of the unit. feet and 1” Black Iron pipe up to 150 feet distances.
The regulator supplied with the heater is preset for Flex line tubing is NOT recommended, but if used
the gas shown on the rating plate to the correct then oversize it.
pressure. It is an appliance level regulator designed -It is strongly recommended that the LP Gas pipe be
for (low inlet) pressure (less than 1/2 Psig or 15” W.C.) semi-rigid copper or Black Iron pipe from the outside
DO NOT connect to an unregulated or high pressure regulator to the inlet of the Aquastar regulator. For
propane line or to a high pressure commercial natural semi-rigid copper piping: 5/8” up to 20 feet and 3/4”
gas line.
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.
GAS INLET PIPE
PRESSURE TAP
THESE FIGURESARE FORAQUASTAR SUPPLY ONLY,
ALL OTHER APPLIANCES IN THE BUILDING WILL NEED
TO BE INCLUDED IN THE PIPE SIZING.
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.
PLASTIC VENT CAP
PRESSUREREGULATOR
(with directional arrow on
reverse side pointing
upward)
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 more 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 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.
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 the pilot 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 a soapy
solution. Never test for gas leaks using a match or
flame.
Fig. 4 - Installation of 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 pressure tap on the gas inlet
pipe just above the regulator (See Fig 4). 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
Altitude
Natural Gas
inches W.C:
5.7"
Liquid Propane
inches W.C:
10.5"
0' - 2.000 ft
2.000 ft - 4.500 ft
4.6"
8.4"
Above 4.500 ft consult your local gas provider.
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GAS PIPING, 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 CodeANSI Z223.1/NFPA54.
In Canada: The Installation should conform with CGAB149 INSTALLATION CODES and /or local installation codes.
GAS LINE SIZING
The gas supply piping should be sized according to the Applicable Plumbing Code for a maximum draw of 117,000 BTUH. First
determine the effective length of the gas supply line by measuring the actual length of piping, and then adding 5 ft. for every elbow
or “T” to the actual length. Use the charts below to determine the pipe diameter necessary to accommodate the BTU demand
of the unit. If there are more gas drawing appliances on the line, size according to the maximum amount of BTU demand.
FOR NATURAL GAS
Maximum Capacity of pipe in Cubic Feet of Gas per Hour
for Gas Pressure of 0.5 Psig or less and a Pressure drop of
0.3 in Water Column.
(Based on a 0.60 Specific Gravity Gas) Btu numbers given
in thousands.
Follow boxed numbers for piping just oneAquastar 125HX
(example: 3/4” B.I. Natural Gas pipe for 30 ft. will handle
152,000 btu’s). For multiple appliances combine the total
btu input load and then refer to applicable chart below.
Nominal
Iron
Length of Black Iron Pipe, Feet
Pipe
Internal
Size, Diameter
inches inches
10
20
30
40
50
60
70
80
90
100
125
150
175
200
1/4
3/8
1/2
0.364
0.493
0.622
32
72
22
49
92
18
40
73
15
34
63
14
30
56
12
27
50
11
25
46
11
23
43
10
22
40
9
8
8
7
6
21
38
18
34
17
31
15
28
14
26
132
3/4
1
0.824
1.049
278
520
190
350
152
285
130
245
115 105
215 195
96
90
84
79
72
64
59
55
180
170
160
150
130
120
110
100
1 1/4
1 1/2
2
1.380
1.610
2.067
2.469
3.068
4.026
1050
1600
3050
4800
8500
730
590
890
500
760
440 400
670 610
370
560
350
530
320
490
930
305
460
870
275
410
780
250
380
710
225
350
650
210
320
610
1100
2100 1650 1450
3300 2700 2300
5900 4700 4100
1270 1150 1050 990
2 1/2
3
2000 1850 1700 1600 1500 1400 1250
3600 3250 3000 2800 2600 2500 2200
1130 1050 980
2000 1850 1700
4
17,500 12,000 9,700 8,300 7,400 6,80 6,200 5,800 5,400 5,100 4,500 4,100 3,800 3500
Nominal
FOR LP GAS
Iron Pipe
Size,
Black Iron Pipe
Length of Pipe, Feet
Maximum Capacity of Pipe in Thousands of
BTU per Hour of Undiluted Petroleum Gases
(at 11 inches Water Column Inlet Pressure)
(Based on a Pressure Drop of 0.5 Inch Water
Column).
Inches
10 20 30
40 50 60 70 80 90 100 125 150
1/2
275 189 152 129 114 103 96 89 83
78
69
63
3/4
1
567 693 315 267 237 217 196 185 173 162 146 132
107 732 590 504 448 409 378 346 322 307 275 252
1 1/4 220 149 121 103 913 834 771 724 677 630 567 511
1 1/2 330 229 185 155 141 127 118 108 102 976 866 787
2
622 433 346 299 264 239 220 204 192 1811 1606 1496
Copper
Outside
Diameter,
Inch
Length of Tubing, Feet
Maximum Capacity of Semi-Rigid
10 20
39 26
92 62
30
21
50
40
19
41
50
_
60 70 80 90 100
Tubing in Thousands of BTU per Hour of
Undiluted Liquified Petroleum Gases (at 11
inches Water Column Inlet Pressure)
3/8
1/2
_
_
_
_
_
37
79
35 31 29 27 26
72 67 62 59 55
121 112 104 95 90
187 164 155 146 138
(Based on a Pressure Drop of 0.5 Inch Water
Column)
5/8 199 131 107 90
3/4 329 216 181 145 131
7/8 501 346 277 233 198
* Source National Fuel Gas Code NFPA54,ANSI Z223.1.
8
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The discharge line must be installed such that it allows
complete drainage of both the PRV and the line.
WATER CONNECTIONS
When facing the heater, the cold water inlet is on your right
and the hot water outlet is on your left.
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.
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 125HX is provided
with one flexible type connector that must be connected to
the inlet fitting of the water valve as shown in Fig 5. ½”
Copper or brass fittings work best when connected to the
connectors. See Fig 6. The flexible type connector seals
to the water valve by means of a union connection with a
washer type gasket at the joint. No pipe dope or thread
Support all piping.
tape is to be used at this joint.
This fitting 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.
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.
FOR YOUR SAFETY READ BEFORE
OPERATING YOUR HOT WATER HEATER
Warning: If you do not follow these instructions exactly,
a fire or explosion may result causing property
damage, personal injury or loss of life.
A. This appliance is equipped with electronic ignition for
lighting the pilot and main burners. When turning the heater
on, follow these instructions exactly.
Fig. 5 - Water valve - top view
SWEATEDASSEMBLY
THREADEDASSEMBLY
B. Before operating the unit, set the On/Off switch to the
1/2” FLEX
On (
) position. The On/Off switch is located behind
the flip-down coverplate on the front panel strip. 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.
1/2” FLEX
WHAT TO DO IF YOU SMELL GAS
- Do not try to light any appliance.
- 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 the on/off control button.
Never use tools. Follow these instructions exactly. If control
button is 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.
PIPE PRV TO
APPROPRIATE
DISCHARGE
PIPE PRV TO
APPROPRIATE
DISCHARGE
Fig. 6 - Plumbing connections for the Aquastar
125HX
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.
6 720 606 804 (02.10)
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LIGHTING AND OPERATING INSTRUCTIONS
1. STOP! Read the safety information above on this label.
2. The gas valve must be shut off by putting the ON/OFF
switch to position “
”. Wait five (5) minutes to clear
out any gas. If you smell gas, STOP! Follow “B” in the
safety information above. If you do not smell gas, go to
the next step.
Fig. 8 - Temperature Adjustment Knob
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.). In warm weather regions where the
incoming cold water is generally warmer, or during the hot
weather months in some other areas a midway setting on
the temperature adjustment knob would produce a
temperature rise of about 70°F, giving an output of
approximately 120°F. At this setting, if it is still necessary,
one could mix a small amount of cold water in a shower
and have a comfortable shower at about 3 gallons/minute.
During the colder months, or in cold climate areas, it might
be necessary to set the control to the maximum position,
all the way clockwise to the right.
3. This water heater is equipped with a safety pilot burner
and an automatic ignition control system.
4. Set the ON/OFF switch (flip down cover plate on front
panel strip) to the “
” position. In this position, the
water heater is ready to use.
5. If the red LED indicator light is flashing, this is a warning
that the water pressure is not enough to ignite the main
burner.
6. Turn the hot water faucet on to the minimum flow rate
required to activate the heater. The automatic ignition
system first ignites the safety pilot burner which then
ignites the main burner in about 4 seconds.
7. The green LED indicator is on when the main burner is
If you supply the AquaStar 125HX, with preheated water
(i.e.) in a solar installation the unit could overheat. It will
then shut off on safety when the outlet temperature reaches
194°F. For this type of application, purchase a solar model
125B LPS or 125B NGS.
on.
8. The pilot flame will extinguish 10-30 seconds after the
burners come on. The burners will remain on until the
hot water tap is turned off.
NOTE: On a first time initial installation, existence of air in
the gas supply line and in the water line may cause some
ignition delay. In that case, repeatedly open and close the
hot water tap in order to restart the ignition process until
all the air has been purged.
To start and to shut down
the appliance press the
button “ ”.
The switch is located
behind the flip down
cover plate on the front
panel strip.
TO TURN OFF GAS TO APPLIANCE
- on
- off
Turn off the manual lever on the gas supply line to the
heater and set the ON/OFF switch to the OFF (
position. See Fig 9.
)
SETTING THE WATER TEMPERATURE
Green light on = main
burner on.
The AquaStar 125 HX LP and 125 HX NG water heaters
have a gas control that modulates burner input in response
to flow. Its purpose is to ensure that the hot water
temperature will remain steady, although the water flow
demand might vary (down to 1/2 gal/minute). To adjust the
temperature on your AquaStar, turn on a hot water faucet
to its maximum flow. At the water heater, turn the large
knob located beneath the main gas control on the front of
the heater all the way to the right (clockwise). See Fig 8.
This will produce a temperature rise of approximately 90°F
at flow rates between 0.5 and 2.0 gallons per minute. Given
that average incoming water temperatures are 50°F, this
heater will produce approximately 140°F water at these
flow rates. Turning the dial all the way to the left
(counterclockwise) will produce a temperature rise of
approximately 45°F for flow rates between 1.1 and 3.7
gallons per minute. It is safest to select a comfortable
temperature and not have to mix in cold water.
Green light off = main
burner off.
If the red light is flashing,
that means the water
flow is not enough to
ignite the burner.
Temperature Adjustment Knob
Decrease
temperature and
increase flow
Increases temperature
and decreases flow
Fig. 9 - Principles of Operation
10
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To clean the pilot burner and/ or the pilot orifice : Turn
off the gas to the unit. Set the On/Off switch to Off (position
). Remove the cover of the heater. To do so, pull off
the temperature adjustment knob and unscrew and remove
MAINTENANCE AND SERVICE
REVIEW MAINTENANCE TABLE ON THE BACK OF THIS
MANUAL.
Approximately once a year, theAquaStar should be checked the plastic collar. Pull main cover out toward you and lift up
and cleaned. To remove the front cover, first remove the and out. The pilot orifice should be cleaned or replaced. Do
incandescent particle tray, then pull off the temperature not enlarge the orifice.
adjustment knob and unscrew and remove the plastic collar. Do not use any wire or sharp object to clean orifices. Natural
Pull main cover out toward you and lift up and out. THE gas orifices are large enough that you can usually clean
FOLLOWING OPERATIONS SHOULD BE PERFORMED them by blowing through them. LP orifices, on the other
BYAQUALIFIED SERVICE PERSON:
hand, are too small to clean and should be replaced.
To access the pilot orifice, remove 2 screws holding pilot
assembly in place. Then loosen compression fittings to
expose pilot orifice.
Vent System: Should be checked annually. Clean and
repair as needed.
Water Valve (Part # 8707002649): The water valve on this
heater should be serviced periodically. Lubricate component
36 on page 16 with a small amount of silicon, faucet or
lithium grease every two years to keep its o rings fresh and
pushrod sliding smoothly. Every 3-5 years replace
component 36 on page 16. 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 (#27
on page 16) is clean as well. NOTE: If water valve is removed,
be sure to also inspect the o ring seal on the end of the
right hand side water pipe before re-installing. Lubricating
the o ring with lithium or faucet and valve grease is
recommended.
PILOT ORIFICE
Fig. 11 - Pilot burner with pilot orifice
(Pilot assembly shown without pilot hood)
Pilot Flame: The pilot flame should burn with a clean,
sharp, blue flame and should resemble the diagram in
Fig.10. If the flame is soft and yellow, the pilot burner orifice
may need to be cleaned or replaced. The pilot flame should
be approximately 2 inches long, extending past the flame
sensor. If the flame is too small, it will not reach the flame
sensor and the burners will not come on.
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.
3mm
Correct gap between pilot
burner tip and electrode tip
Mineral Scale Build-up: The AquaStar heater, when
operated at lower temperature settings, does 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. The descaling is done only to the heat
exchanger. The chemicals will damage the hydro-generator
and other parts. Consult your dealer or Controlled Energy
for instructions.
Piezo Electrode
TROUBLE SHOOTING
Introduction
The AquaStar 125HX 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.
Flame sensor
Piezo
Fig. 10 - Characteristic Pilot Flame
(Pilot assembly shown without pilot hood)
6 720 606 804 (02.10)
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Problems are stated in upper case, bold face. Most common SPARK APPEARS AT PILOT WHEN HOT WATER TAP
causes for the problems follow in order of likelihood. The TURNED ON, BUT PILOT AND BURNERS WILL NOT
suggested solutions require that the cover be taken off. To IGNITE
do this, remove incandescent particle tray, pull off the
temperature adjustment knob and unscrew and remove the 1. Air in the Gas Line
plastic collar. Pull main cover out toward you and lift up Normally this is a problem at time of initial installation,
after the pipes have been worked on, or after a gas supply
line has been allowed to empty. Bleed the air trapped in
the gas line by turning the hot water faucet on and off until
the air has been cleared from the line.
and out.
NO SPARK AT THE PILOT
1. On/Off switch is not ”On” (Position
The On/Off switch is located behind the flipdown cover plate
on the front panel strip. See fig. 9.
).
2. No gas to the AquaStar
A. Gas cock on gas line may not be open
B. Gas regulator may be shut or damaged. Replace or
unlock the regulator. Note: The regulator furnished with the
heater is exclusively designed for low gas pressure.
Excessive pressure will lock it up. Locking usually happens
when using propane gas if the gas pressure between the
gas tank and the water heater’s gas regulator has not been
reduced. See Page 2 for recommended correct gas
pressure. To unlock a regulator, consult your gas supplier
or call CEC.
2. Cross over in water lines
To confirm there is no cross-over in the plumbing, shut off
the cold water supply to the AquaStar and open all hot
water faucets. There should not be any water flowing at
any faucets. Water running is a sign of a plumbing cross-
over. Consult your plumber.
3. Water flow is not sufficient to activate heater.
Water flow rate at faucet is below minimum flow needed to
activate heater. When temperature adjustment knob is
turned all the way clockwise, the AquaStar model 125HX
requires 1/2 gallon per minute flow to activate the heater.
As a reference, this is a flow which would fill a quart jar in
30 seconds. If the temperature adjustment knob is turned
fully counterclockwise, a flow rate of 1.1 gallons/minute is
required to activate the heater.
3. Pilot orifice or gas valve is dirty
Clogging of the pilot burner can be caused by dust in the
air or dirt in the gas. The pilot orifice or gas filter may need
to be cleaned or replaced.
4. Pilot electrovalve switch may need to be replaced
(See Fig 13).
Call CEC.
The red LED light (located behind the coverplate on the
front panel) flashes when the water flow is not enough.
5. Electronic Control Box may need to be replaced
(See Fig 13).
Call CEC.
4. Water inlet filter is clogged
Water flow is restricted, preventing needed flow to activate
heater. Clean water inlet filter screen.
5. 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.
6. Water valve parts may be dirty or components
damaged
First check that venturi is free of dirt particles. Water valve
and component parts must be totally free of dirt. In hard
water areas, mineral deposits can eventually (3-5 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 components need to be serviced
immediately.
7. Poor circuit connections at the ECO (overheat
sensor) or the flue gas safety device
Ignition sparker will not operate if the electrical circuit is
interrupted. Check that the connections to the ECO and
Flue Gas Safety Device are secure and tighten if necessary.
If the Aquastar is Powervented, check spill switch reset
12
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PILOT LIGHTS BUT BURNERS WILL NOT COME ON
5. Flue gas safety device tripped
Ventilate the room and re-ignite the appliance 10 minutes
1. Confirm water valve assembly is working properly. later. If it happens again, contact your service person or
Controlled Energy..
2. Confirm the flame sensor is in its proper position.
WATER IS TOO HOT
3. Confirm the burner electrovalve switch is
functioning properly.
1. Temperature Selection too high
Call CEC
Turn the temperature adjustment knob counter-clockwise
(to the left) to lower the maximum water temperature.
4. The Electronic Control Box (Fig. 13) may need to Note: This will increase the activation flow rate.
be replaced.
Call CEC.
2. Inlet water temperature is too hot (as with solar
preheated water or high ground water
temperatures)
Decrease gas pressure. Note: Only the Model “S”
AquaStar should be used if the inlet water is preheated.
WATER IS NOT HOT ENOUGH
1. Temperature selection too low.
Change the setting. Turn the temperature adjustment knob
clockwise (to the right).
Note: This will decrease the activation flow rate.
2. 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 page 2
for correct gas pressure settings and fig. 4 for locations
where gas pressures are taken.
Fig. 13 - Electrical wiring diagram
8
9
electronic control box
LED failure indicator
LED indicator main
burner operation
on/off switch
hydro-generator
1
2
3
4
5
6
7
burner electrovalve
gas control valve
pilot electrovalve
flame sensor
10
11
12
13
pilot electrode
overheat sensor
temperature limiter
flue gas safety device
MAIN BURNERS GO OUT DURING HOT WATER USE
1. Flow rate diminished below activation rate
3. 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.
2. Unbalanced pressure in the water lines
4. Cold water is mixing with the hot water between
the AquaStar and the outlet
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 and showerheads are free of minerals and dirt.
Do not add any flow restrictor to the shower head.
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 “NO SPARK AT THE PILOT”
paragraph #4). Where automatic “anti-scald” valves are
required by code, lower the temperature setting on the
AquaStar as much as possible and balance the pressure
between cold and hot water after the AquaStar.
3. Minimum inlet pressure on well is inadequate
Check the inlet water pressure. On a private well, raise the
minimum pressure setting to 30 psi. Confirm that the
pressure tank is not water logged.
5. Parts in water flow valve are corroded so that the
gas passage is not fully opening.
Contact your service person or Controlled Energy.
4. ECO (overheat sensor) tripped due to overheating
re-ignite the appliance 10 minutes later. If it happens again,
contact your service person or Controlled Energy.
6 720 606 804 (02.10)
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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 #4 under “NO SPARK AT THE PILOT”.
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. Gas pressure is too low
See page 2 for correct specifications.
14
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Fig. 14 - Diagram of AquaStar 125 HX
1
3
2
4
5
6
7
8
10
9
12
11
6
720 606 804-10.1AL
1. Heat exchanger
7. on/off switch
2. Pilot assembly
8. LED operation indicator
9. Water valve
10. Temperature adjustment selector
11. Gas inlet gas pressure test nipple
12. Hose
3. Burner manifold gas
pressure test nipple
4. Main gas burner
5. Pilot gas tubing
6. LED failure indicator
6 720 606 804 (02.10)
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Fig. 15 - INTERIOR COMPONENTS DIAGRAM AND PARTS LIST
16
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Fig. 15
INTERIOR COMPONENTS DIAGRAM
AND PARTS LIST 125HX
1
2
3
4
5
7
7
8
9
Cover
8 705 421 752
Temperature adjustment knob
Temperature adjustment collar
Draft diverter
Heat exchanger
Main burner
Main burner
Burner assembly washer
Throttle disc
Pilot burner
Pilot burner
Piezo electrode
Pilot orifice
Pilot orifice
8 702 000 111
8 700 403 008
8 705 505 354
8 705 406 235
8 708 120 298 NG
8 708 120 296 LP
8 710 103 060
8 700 100 174 LP
8 708 105 491 LP
8 708 105 337 NG
8 718 107 067
8 708 200 069 NG
8 708 200 312 LP
8 700 707 370
8 700 103 173
8 707 011 917 NG
8 707 011 945 LP
8 708 504 021 NG
8 708 504 049 LP
8 708 501 249
8 708 501 250
8 700 205 023
8 707 406 043
8 700 705 947
8 700 703 139
8 700 103 658
8 707 002 649
8 705 500 101
8 700 503 053
8 700 507 001
8 708 500 289
8 705 705 009
8 708 205 279
8 707 207 085
8 704 404 040
8 704 404 039
8 707 206 345
8 704 404 038
8 700 306 114
8 700 205 120
8 700 205 119
8 710 103 043
8 700 703 114
8 707 206 040
8 700 715 178
8 710 103 045
10
10
11
12
12
13
14
15
15
16
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
Pilot tube
Washer pilot tube
Gas valve
Gas valve
Diaphragm switch
Diaphragm switch
Pilot electrovalve
Burner electrovalve
O-ring
Hydro-generator
Cold water pipe
Outlet flex hose
Washer
Water valve
Water valve cover
Diaphragm
Water inlet filter
Water valve selector screw
Volumetric water governor
Venturi
Electronic control box
Flame sensor cable
Electrode cable
Flue Gas Sensor
Set of cables
Pushrod
O-ring
O-ring
Water connection gasket
Water elbow fitting
Overheat sensor (ECO)
Connecting pipe hot
Washer
6 720 606 804 (02.10)
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18
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6 720 606 804 (02.10)
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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 obstructionwithin a 10 foot radius of vent pipe. Consult your gas utility or National Gas Fuel 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 the minimum pressure tank setting is between 30-50 psi.
MAINTENANCE TABLE see page11
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
© 2001 Controlled Energy Corporation,
Waitsfield, VT all rights reserved
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Recycled paper
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