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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.
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
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.
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.
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.
PILOT ORIFICE
AIR SCREEN
10mm
3/8”
Piezo
Electrode
Thermocouple
Fig. 8 - Characteristic Pilot Flame
3mm
Correct gap between pilot
burner tip and piezo electrode
tip
Piezo Electrode
Air screen filter
toward you and lift up and out. THE FOLLOWING
OPERATIONS SHOULD BE PERFORMED BY A
QUALIFIED SERVICE PERSON:
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
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 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
be approximately 3 mm (1/8") from the pilot burner tip.
To access the pilot orifice, remove 2 screws holding pilot
assembly in place. Then loosen compression fittings to
expose pilot orifice.