AquaStar 170 VP manual

W ARNING: If the information in this manual is not followed exactly , a fire or explosion may result causing property damage, personal injury or death. FOR YOUR SAFETY Do not store or use gasoline or other flammable, combustible or corrosive vapors and liquids in the vicinty of this or any other appliance. WHA T TO DO IF YOU SMELL GAS • Do not tr[...]

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

3 AquaStar 170 VP Specifications: SETTING THE INLET GAS PRESSURE FOR HIGH AL TITUDES The pressure regulator provided with the heater is set to deliver the proper gas pressure (as indicated on the rating plate and in the manual) for altitude up to 2500 feet (758 meters) above sea level. On appliances being installed above 2500 ft/ 758 m elevation, t[...]

4 CAUTION: RULES FOR SAFE OPERA TION If you are using the AquaStar for combined space heating and potable water heating ( see schematic diagram below), all piping and other components connected to the system must be suitable for potable water , (b) toxic chemicals such as those commonly used for boiler treatment to prevent corrosion and freezing mu[...]

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

6 Fig. 2 Parts of AquaStar 170 A. Hanging frame and back support B. Thermostatic sensor C. Heat exchanger D. Thermocouple E. Burners F. Burner manifold G. Manifold Gas pressure testing nipple H. T emperature selector knob I. Hot water outlet J. Thermostat adjustment screw K. Gas Inlet L. Manual gas valve M. Cold water inlet P. Pilot starting button[...]

7 LOCA TING YOUR HEA TER FOR SAFE PROPER COMBUSTION Carefully select the location of your new heater . For your safety and for proper heater operation, you must provide an abundant supply of combustion air and install a proper vent. The heater may still operate even when improperly installed. However , an improper installation will be less efficien[...]

8 8. This heater is not approved for closet instal- lation. For alcove installation, maintain the fol- lowing minimum clearances from all construc- tion for servicing and proper operations: Alcove A. T op 12 inches B. Front OPEN C. Back 0 inches D. Sides 6 inches (Left side 10" for ease of service) E. Floor 12 inches* F . Flue 6 inches (single[...]

9 The location of the relief valve must be readily accessible for servicing or replacement. T o ac- commodate the pressure relief valve, a suitable fitting connected to an extension of a "T" fitting can be sweated to the line. Make the T-fitting extension long enough to ensure that the tem- perature probe does not interfere with the wa- t[...]

10 Therefore, when operating at less than full output, the heater does not have its full heating capacity to warm the flue pipes to create a natural draft. Most gas appliances have longer duty cycles than are typical of instantaneous heaters. For many gas appliances, it is con- sidered sufficient if the appliance can overcome a downdraft within the[...]

11 LIGHTING INSTRUCTIONS 1. STOP! Read the safety information above. 2. Push in gas control handle slightly and turn clockwise to "RED DOT" posi- tion. 3. W ait five (5) minutes to clear out any gas. If you smell gas, STOP! Follow "B" in the safety information on previous page. If you don't smell gas, go to next step. 4. T [...]

12 SETTING THE W A TER TEMPERA TURE The AquaStar 170 water heater contains a flow restrictor set at 4 1/4 gpm. Its purpose is to assure that the hot water temperature will al- ways be within a comfortable range regardless of how high one may turn on the hot water fau- cet or how many faucets may be turned on. Y our AquaStar model 170 also has an au[...]

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 cen- tral button Fig.2 (P) has to remain depressed for a long time in [...]

14 Letter references, e.g. "L" in this section refer to Fig. 2 on page 6. Introduction: The flow of gas to the AquaStar burners is triggered by a water flow valve. Numerous water related problems can cause this water flow valve to malfunction such as: 1. Insufficient water flow volume to activate the burners at their minimum flow requirem[...]

15 4. Pilot orifice may not be correct for your type of gas. Pilot orifice is stamped: #15 for LP and #27 for NG. 5. Air in the Gas Line Note: Normally this is a problem only at the time of installation if the pipes have been worked on,a propane tank has been allowed to empty , or the heater has been shut down for a long time. Bleed all the air tra[...]

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 to- tally free of dirt. In hard water areas, mineral deposits can eventually (3-5 years) corrode water valve parts to a point where they will need replacing. Note: there is a small bleed hole under the gas valve at t[...]

17 3. Burners are not shutting down immedi- ately when hot water is turned off If burners don't shut off immediately when hot water is turned off, the heater will overheat and the ECO will shut off the gas. Replace both parts in the water valve assembly (part #38475, 33071). (See Letter R, Fig 2, page 6). W A TER IS TOO HOT 1. T emperature set[...]

18 6. Parts in water flow valve (#3841 1) are cor- roded The gas valve will not open fully if water valve parts are corroded. Replace both parts in wa- ter valve (#38475, 33071). HOT W A TER TEMPERA TURE FLUCTUA TES 1. T emperature setting is too high Setting the temperature too high will make it necessary to add a great deal of cold water to make [...]

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

20 1. T urn AquaStar temperature setting to #8. This is all the way to the right, clockwise. 2. T urn on a hot water tap at the flow which will turn the AquaStar burners on. If the heater is working correctly , this minimum activation flow will be 3/4 of a gallon a minute, for Model 125/80 and 1.1 for Model 170. This is a flow that can fill up a qu[...]

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

22 Before the water leaves the AquaStar, it passes two energy CutOff Switches (ECO-#19). These are safety devices which cause other gas controls to shut off all the gas if the Heat Exchanger overheats. GAS FLOW PATH The appliance Gas Regulator (#23) at the inlet to the heater ensures that gas pressure fluctuations don’t over-pressure the heater. [...]

23 DIAGRAMATIC LAYOUT 18. GAS LINE PRESSURE TEST NIPPLE 19. OVERHEAT SENSOR SWITCH 20. THERMOSTATIC WATER TEMPERATURE SELECTOR 21. WATER FILTER SCREEN 22. GAS PRESSURE TESTING NIPPLE 23. WATER DIAPHRAGM ASSEMBLY 24. GAS REGULATOR 25. PUSH ROD ASSEMBLY 26. DOMESTIC HOT WATER (DWH) SENSOR 95° C 10. PILOT LIGHT ORIFICE 11. PILOT LIGHT GAS FILTER 12. [...]

24 HOUSING COMPONENTS DIAGRAM AQUASTAR 170 00134 - WASHER 01302 - HAIRPIN SPRING CLIP 08493 - FRONT PANEL RETAINING SCREW 22348 - SCREW 22527 - TEMPERATURE SELECTOR KNOB 23617 - PANEL RETAINING SCREWS 28329 - THERMOCOUPLE ACTIVATING KNOB 29297 - CROSS-BAR FIXING SCREW 29411 - FRONT PANEL EMBELISHER 38294 - CASE FRONT PANEL LM170 38452 - CASE SIDE P[...]

25 INTERIOR COMPONENTS DIAGRAM AQUASTAR 170 SP ARE PARTS LIST AQUAST AR 170VP 00869 NUT 01302 T .C. RET AINING CLIP LM170 05964 GASKET 20849 DOMESTIC HOT WA TER THERMOST A T 22040 SCREW 22343 RET AINING SCREW 22345 FIXING SCREW 22348 SCREW 22349 FIXING SCREW 23617 SCREW 23989 THERMOCOUPLE LM170 25775 RUBBER GASKET 25776 RUBBER GASKET 26674 WA TER F[...]

26 VALVE ASSEMBLY COMPONENTS DIAGRAM AQUASTAR 170 SP ARE PARTS LIST AQUAST AR 170VP 00341 WA TER V AL VE CENTERING TUBE 02071 RUBBER GASKET 08501 MANIFOLD GAS INJECTOR N.G. Ø 1.25 20772 CORK GASKET 20775 MAIN GAS V AL VE COVER LPG 20883 MAGNETIC HEAD + GASKET 20897 CORK GASKET 20971 MAGNETIC HEAD FIXING NUT 22039 SCREW 22041 SCREW 22043 SCREW 2204[...]

27 INST INST INST INST INST ALLA ALLA ALLA ALLA ALLA TION CHECKLIST TION CHECKLIST TION CHECKLIST TION CHECKLIST TION CHECKLIST Gas Line Size* For installation on well systems, insure that your water pressure is between 30 - 50 psi. Semi-rigid T ubing 1/2" 5/8" 3/4" 7/8" Liquid Propane Natural Gas Model 80 25" 100' 150[...]

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