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AquaStar 80 VP Install And Operation Instructions

AquaStar 80 VP Install And Operation Instructions

Suitable for water (potable) heating and space heating

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I N S TA L L AT I O N A N D O P E R AT I N G I N S T R U C T I O N S
F O R A U T O M AT I C I N S TA N TA N E O U S T Y P E WAT E R H E AT E R S
F O R U S E W I T H N AT U R A L A N D L I Q U E F I E D P E T R O L E U M G A S
Suitable for water (potable) heating and space heating
Upon completion of the installation, these instructions should be handed to the user of the appliance for
future reference.
FEATURING:
Variable Power - Modulating Gas Valve - Thermostatic Control with Temperature Dial Selector
MODEL 80 VP AND MODEL 80VPS
*REPLACEMENT MANUAL MUST BE PURCHASED
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 vicinty 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.

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Summary of Contents for AquaStar 80 VP

  • Page 1 F O R U S E W I T H N AT U R A L A N D L I Q U E F I E D P E T R O L E U M G A S MODEL 80 VP AND MODEL 80VPS...
  • Page 2: Table Of Contents

    Specifications ... Page Rules for Safe Operation ... Page General Overview of Aquastar ... Page Locating the Heater for Safe Proper Combustion... Page Installation ... Page Connecting Gas and Water Lines & Pressure Relief Valve ... Page Vent Pipe Connection ... Page Safety Before Lighting ...
  • Page 3 AquaStar 80 VP and 80 VP "S" Specifications: SETTING THE INLET GAS PRESSURE FOR HIGH ALTITUDES 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.
  • Page 4 CAUTION: RULES FOR SAFE OPERATION 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...
  • Page 5: Rules For Safe Operation

    RULES FOR SAFE OPERATION 6. Keep water heater area clear and free from combustibles and flammable liquids. Do not lo- cate the heater over any material which might burn, such as carpet.
  • Page 6 D. thermocouple E. burners F. burner manifold G. gas pressure testing nipple H. temperature selector knob Fig. 2 Parts of AquaStar 80 hot water outlet J. thermostat adjustment screw K. gas inlet L. manual gas valve M. cold water inlet screen P.
  • Page 7 1000 Btu per hour of the combined rating of all appliances installed in the space. That would be 6250 cubic feet for the AquaStar 125 alone. b) In unconfined spaces in buildings of conventional frame, masonry, or metal construction, infiltration is normally ad- equate to provide air for combustion, ven- tilation, and dilution of flue gasses.
  • Page 8: Installation

    Connecting Strip Assembly to the wall using the pre-drilled holes and connect your pipes directly to the water heater, or you can remove the heater from the Water and Gas Connecting Strip Assem- bly in order to connect the piping, and then re- connect the heater later.
  • Page 9 Natural Gas. Provided the propane gas line is less than 20 feet and serves only the AquaStar, it can be reduced to 5/8". When threading the gas pressure regulator to the gas piping, the indicator arrow on the regulator must be pointed in the direction of gas flow.
  • Page 10: Vent Pipe Connection

    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.
  • Page 11: Lighting Instructions

    Check that manual gas valve handle is on "RED FLAME" position. Push in center PILOT LIGHTING knob on the front of the AquaStar and twist counterclockwise .Push knob all the way in and hold it in. While holding knob in, light the pilot with a match through pilot viewing open ing in front of the heater.
  • Page 12 Water Valve Spring Loaded Piston (part #34542). of cold water to cool it off. Remember you can- not run out of hot water with an AquaStar, so set the dial for the (exact) temperature that you need. Note: 105ºF is the maximum recommended for a hot bath.
  • Page 13 Do not ob- struct the flow of combustion air and ventilation air. If installed near a dryer, make sure the dryer is properly vented, and that the AquaStar vents properly when the dryer is operating. Fig 5. Characteristic Burner Flame Pattern...
  • Page 14 PILOT WILL NOT LIGHT 1. No gas to the AquaStar A. Gas cock on gas line may not be open. B. AquaStar manual shut off valve at base of heater is not open. Turn handle to red flame sym- bol.
  • Page 15 4. Pilot orifice may not be correct for your type of gas. Pilot orifice is stamped: #18 for LP and #35 for 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.
  • Page 16 The crossover will create a back pres- sure in the system preventing the pressure drop in the AquaStar - i.e. cold water is entering the water valve from both sides and the burners will not come on. To confirm there is no crossover in the plumbing, shut off the cold water supply to the AquaStar.
  • Page 17: Setting Water Temperature

    AquaStar can be set for the exact temperature needed and give endless hot water without need for mixing in cold water. We rec- ommend setting the temperature selector dial on #4 or #5.
  • Page 18 3. Cold water is mixing with the hot water between the AquaStar and the outlet Compare water temperature at outlet of the AquaStar with the temperature at the tap. If dif- ferent, check for automatic mixing valve or plumb- ing crossover (see #6, MAIN BURNERS WILL NOT IGNITE) Where automatic "anti-scald"...
  • Page 19: Cleaning Pilot Assembly

    CLEANING THE PILOT ASSEMBLY AquaStar models 80/125/170 A. Removing Pilot 1.Hold Gas Pilot Filter Housing in place with one wrench. 2. Unscrew Pilot Tube nut with second 3.Save the little white Gasket for reassembly. 4. Pivot the tube to the left (loosen base fitting if needed).
  • Page 20: Calibration And Thermostat Test

    1. Turn AquaStar temperature setting to #8. This is all the way to the right, clockwise. 2. Turn 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.
  • Page 21 PROCEDURE FOR REPLACING A THERMOSTAT TO REMOVE THERMOSTAT: A. Your replacement thermostat comes as part of a kit. The kit includes additional replacement components to ensure a successful installation. When removing the old thermostat be certain to remove all its components ("O" Ring, and Steel Wedge) prior to installing the replacement thermostat.
  • Page 22 25,000 /125,000 Btu's (Model 125) and 25,000/77,500 (Model 80). Special “S” version heaters have the ability to further modulate gas flow so that the effective output approaches This permits the AquaStar 80/125 vpS to work effectively and safely with pre-heated water.
  • Page 23 DIAGRAMATIC LAYOUT 1 . HEAT EXCHANGER 2. BURNERS 3. WATER FLOW RESTRICTOR 4. FLOW IGNITION DEVICE (LPG ONLY) 5. THERMOSTATIC GAS FLOW MODULATOR 6. GAS FLOW VALVE (THERMOSTATIC CON- TROLLED) 7. GAS FLOW VALVE (WATER FLOW CONTROLLED) 8. COLD WATER INLET AND BUILT IN FLOW CONTROL (REMOVABLE) 9.
  • Page 24 HOUSING COMPONENTS DIAGRAM AQUASTAR 80 SPARE PARTS LIST 38798 - RIGHT SIDE PANEL 38799 - LEFT SIDE PANEL 22527 - TEMPERATURE SELECTOR KNOB 38798 23617 - PANEL RETAINING SCREW 28329 - PILOT STARTER KNOB 38799 36540 - FRONT PANEL 33993 - INCANDESCENT...
  • Page 25 INTERIOR COMPONENTS DIAGRAM AQUASTAR 80 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 - LP GAS PILOT INJECTOR...
  • Page 26 VALVE ASSEMBLY COMPONENTS DIAGRAM AQUASTAR 80 37613 37614 SPARE PARTS LIST 02071 - MANUAL GAS VALVE GASKET 02103 - INJECTORS - NG 20596 - WATER VALVE COVER 20597 - WATER VALVE HOUSING 20772 - CORK GASKET 20775 - REGULATOR COVER...
  • Page 27 INST INST ALLA ALLA INST ALLA ALLA TION CHECKLIST INST INST ALLA Nominal Iron Pipe Size* Model 80 Semi-rigid Tubing Model *Flex tubing greatly reduces capacity and, therefore, is not recommended. Minimum Vent Size* and Height Model Min. Diameter *WARNING: Vent size must not be restricted. Installation must comply with national and local codes.
  • Page 28 CEC will furnish a replacement part free of charge. SHIPPING COSTS In addition to supplying the replacement part (s), CEC will pay transportation costs for these parts to a convenient delivery point near you selected by CEC, such as a local AQUASTAR dealer or distributor.

This manual is also suitable for:

80 vps