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Fig. 8 - Pilot burner with air screen/ pilot orifice
Fig. 7 - Characteristic Pilot Flame
MAINTENANCE AND SERVICE
Approximately once a year, the AquaStar should be
checked, cleaned and serviced as necessary. To remove
the front cover, first remove the incandescent particle tray,
then pull off the temperature adjustment knob, unscrew
and remove the plastic collar and unscrew the central
screw located at the bottom of the front cover. Pull main
cover out 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 # 8707002497): The water valve on
this heater should be serviced periodically 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. Check that the water inlet
filter (#25 on Figure 10, page 14) is clean.
Pilot Flame: The pilot flame should burn with a clean sharp
blue flame and should resemble the diagram in Fig 7. 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, the orifice may need to be replaced, and or
the air screen or pilot gas filter 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. The position of the Piezo igniter electrode
should be approximately 3 mm (1/8") from the pilot.
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 the incandescent particle tray, pull off the
temperature adjustment knob and unscrew and remove
the knob collar. 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 8). 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. To access the pilot orifice,
remove 2 screws holding pilot assembly in place. Then
loosen compression fittings to expose 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: AquaStars, when operated at
lower temperature settings, tend not to accumulate mineral
buildup. 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.
PILOT ORIFICE
AIR SCREEN
3mm
Correct gap between pilot
burner tip and electrode tip
Piezo Electrode
Air screen filter
10mm
3/8”
Piezo
Electrode
Thermocouple