Instruction/ maintenance manual of the product 80 VPS AquaStar
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W ARNING: If the information in this manual is not followed exactly , a fire or explosion may result causing property damage, personal injury or death. FOR YOUR SAFETY Do not store or use gasoline or other flammable, combustible or corrosive vapors and liquids in the vicinty of this or any other appliance.
2 T ABLE OF CONTENTS Specifications .............................................................................. Page 3 Rules for Safe Operation ............................................................. Page 4-5 General Overview of Aquastar ....
3 AquaStar 80 VP and 80 VP "S" Specifications: Gas input..................................max: 77,500 Btu min: 25,000 Btu W ater Connection........................1/2" sweat fitting H x W x D..........................................27" x 12" x 9" V ent.
4 CAUTION: RULES FOR SAFE OPERA TION If you are using the AquaStar for combined space heating and potable water heating ( see schematic diagram below), all piping and other components connected to the.
5 RULES FOR SAFE OPERA TION 1. Y ou should follow these instructions when you install your heater . In the United States: The installation must con- form with local codes or , in the absence of local codes, the National Fuel Gas Code ANSI Z223.1/ NFP A 54.
6 I. hot water outlet J. thermostat adjustment screw K. gas inlet L. manual gas valve M. cold water inlet screen P. pilot starting button R. water valve venturi piston S. pilot filter X W V T S R P M Z K H J G F D E C B A I Y Fig. 2 Parts of AquaStar 80 L T.
7 LOCA TING YOUR HEA TER FOR SAFE PROPER COMBUSTION Carefully select the location of your new heater . For your safety and for proper heater operation, you must provide an abundant supply of combustion air and install a proper vent. The heater may still operate even when improperly installed.
8 heater . Use the adhesive tape which is included in the package to stick the pattern to the wall. Keep in mind that the heater needs to have cer- tain minimum clearances (See paragraph 7 on this page), and that the heater must be level. Drill four holes into the wall at the studs (16 inches on center) as indicated on the template.
9 3. Connecting the Gas Line In the United States: The installation must con- form with local codes or , in the absence of local codes, the National Fuel Gas Code ANSI Z223. 1/NFP A 54. In Canada: The installation should conform with CGA B149 INST ALLA TION CODES and/or lo- cal installation codes.
10 Sweat your cold water pipe to the AquaStar inlet elbow fitting. NOTE: The inlet filter screen and water flow restrictor can be damaged by heat if the cold water inlet elbow is attached to the AquaStar when it is sweated to the cold water inlet pipe.
11 is lighted. Keep the center knob pressed all the way in for at least 10 seconds after pilot is lighted. Release push knob and turn it clockwise to If pilot goes out, wait 5 minutes before relighting.
12 SETTING THE W A TER TEMPERA TURE The AquaStar 80 water heater contains a flow restrictor set at 3 1/4 gpm. Its purpose is to as- sure that the hot water temperature will always be within a comfortable range regardless of how high one may turn on the hot water faucet or how many faucets may be turned on.
13 valve discharges by itself, a problem exists and service is required. This could be due to a de- fective relief valve or to overheating. Pilot Flame: The pilot flame should burn with a clean sharp blue flame and should resemble Fig.4 below . If the flame is yellow , or if the central button Fig.
14 gas pressure. Excessive pressure will lock it up. This problem usually happens if the gas pressure between the gas tank and the water heater has not been reduced. See page 3 of your manual for specified gas pressures. T o unjam a regulator , remove the nickel size screw plug on the front.
15 3. Poor circuit connections at the ECO (Energy Cut-Off) Oxidation or looseness of the ECO screw con- nections can result in millivolt current loss through the thermocouple safety circuit. Clean terminals with very fine sand paper or an eraser and re- tighten terminal screws.
16 7. W ater valve parts may be dirty or compo- nents damaged. Note: If #4 is OK, skip this. W ater valve and component parts must be totally free of dirt. In hard water areas, mineral depos- its can eventually (3-5 years) corrode water valve parts to a point where they will need replacing.
17 2. W ater flow through the heater is higher than the capacity of the AquaStar to heat it If the AquaStar flow restrictor has been removed, the flow through the heater might be higher than its capacity to heat it. Reduce the flow to a range within which the heater can maintain temperature.
18 5. Cold water is mixing with the hot water between the AquaStar and the outlet Compare water temperature at outlet of AquaStar and at the tap. Check for automatic mixing valve plumbing crossover (see #6 - MAIN BURNERS DO NOT IGNITE WHEN HOT W A TER IS ON).
19 Pilot Burner Hairpin Retaining Clip Thermocouple Retaining Clip Pilot Injector Pilot Filter Housing Gasket Gasket Filter Pilot Tube T o Electromagnet T o E.
20 Thermostat Tubing to Heat Exchanger Calibration Screw Thermostat Piston Assembly Spring Correct height of spring - 5/32" or 4mm Note: Unless setting #8 (145° ± 5, this is scalding hot water) is needed for some rare occa- sion we highly recommend run- ning the heater on setting 4 or 5.
21 PROCEDURE FOR REPLACING A THERMOSTAT Into Left Side of Heat Exchanger 5. Pull down on the thermostat piston assembly to remove it from the gas valve. NOTE: There is a Steel Wedge and an "O" Ring which should come out with the piston assembly.
22 DESCRIPTION OF OPERA TION OF AQUAST AR 80/125 MODELS WATER PATH Cold water entering the Cold Water Inlet passes through a nylon mesh Water Filter Screen (#21) which filters out dirt and debris. Water then passes through the Water Flow Restrictor (#8) which prevents water flow from exceeding 3.
23 DIAGRAMATIC LAYOUT 1 7 . WATER TEMPERATURE PROBE (THERMOSTAT SENSOR) 1 8 . GAS LINE PRESSURE TEST NIPPLE 1 9 . OVERHEAT SENSOR SWITCH 2 0. THERMOSTATIC WATER TEMPERATURE SELECTOR 2 1 . WATER FILTER SCREEN 2 2. GAS PRESSURE TESTING NIPPLE 2 3. VENTURI PISTON 2 4 .
24 SPARE PARTS LIST 38798 - RIGHT SIDE PANEL 38799 - LEFT SIDE PANEL 22527 - TEMPERATURE SELECTOR KNOB 23617 - PANEL RETAINING SCREW 28329 - PILOT STARTER KNOB 36540 - FRONT PANEL 33993 - INCANDESCENT.
25 SPARE PARTS LIST 00839 - PILOT WASHER 00869 - RETAINING NUT FOR GAS INLET FITTING 00910 - RETAINING NUT FOR COLD INLET AND HOT WATER OUTLET 02147 - NG GAS PILOT INJECTOR 02434 - L P GAS PILOT INJEC.
26 VALVE ASSEMBLY COMPONENTS DIAGRAM AQUASTAR 80 22039 - SCREW FOR MANIFOLD CLAMP 22041 - WATER VALVE RETAINING SCREW 22043 - THERMOCOUPLE PUSH BUTTON COVER RETAINING SCREW 22064 - TIGHTENING SCREW FO.
27 INST INST INST INST INST ALLA ALLA ALLA ALLA ALLA TION CHECKLIST TION CHECKLIST TION CHECKLIST TION CHECKLIST TION CHECKLIST Gas Line Size* For installation on well systems, insure that your water pressure is between 30 - 50 psi.
28 GENERAL Controlled Energy Corporation (CEC) will furnish a replacement heat exchanger and will furnish a replacement of any other part, which fails in normal use and service within the applicable periods specified below , in accordance with the terms of this warranty .
An important point after buying a device AquaStar 80 VPS (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought AquaStar 80 VPS yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data AquaStar 80 VPS - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, AquaStar 80 VPS you will learn all the available features of the product, as well as information on its operation. The information that you get AquaStar 80 VPS will certainly help you make a decision on the purchase.
If you already are a holder of AquaStar 80 VPS, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime AquaStar 80 VPS.
However, one of the most important roles played by the user manual is to help in solving problems with AquaStar 80 VPS. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device AquaStar 80 VPS along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
