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6. Faulty thermocouple (part #8747202083) or
electromagnet ) Unless these 2 parts are at least 8
to 10 years old, it is very unlikely that they are faulty.
Before testing, reconfirm that #2 is absolutely
correct, and that all connections are clean and tight.
To test the thermocouple, disconnect the thermocouple
lead to the ECO. Insert a multi-meter probe on the
thermocouple ECO connection and attach the other meter
lead on the spade connector of the ECO. Light the pilot
flame, and take a reading on the meter. If it reads less
than 24mV, replace the thermocouple. If the reading is
24mV or over the thermocouple is good. To test the electro-
magnet, take another reading across the ECO spade while
the pilot flame is on. The reading should drop to about 15
mV. If it does not and remains unchanged, replace the
electromagnet.
Although the filters can lengthen the cleaning intervals,
they can never completely prevent such clogging. In
consequence the gas jet issuing from the pilot orifice is
reduced and or the air mixture is reduced. The pilot flame
is weak and thus can no longer heat the thermocouple
sufficiently. For cleaning purposes, the air filter screen is
pulled off, washed and blown out. The pilot orifice has
likewise to be cleaned or exchanged. Consult Controlled
Energy or a gas service person.
4. Air in the Gas Line
Note: Normally this is a problem only at the time of initial
installation, after the pipes have been worked on, or after
a propane tank has been allowed to empty, or after the
heater has been shut down for a long time.
Bleed all the air trapped in the gas line. Because of the
very small pilot orifice (especially on LP gas models),
bleeding out all the air could take several minutes. Slide
the gas valve button to pilot position ( ) and depress this
button until all the air has escaped, and the gas has arrived.
During this process, press repeatedly on the piezo ignition
button until the pilot flame has ignited.
PILOT LIGHTS BUT FLAME GOES OUT WHEN
BUTTON IS RELEASED
1. Pilot push button was not pushed in far enough or
was not held in long enough
Once pilot flame has been lighted. Hold button pushed in
for at least 15 seconds to give time for the pilot flame to
properly heat the tip of the thermocouple.
2. Pilot flame improperly aimed or is too weak so it is
not properly heating the tip of the thermocouple.
The Pilot flame should be a sharp blue flame and aimed
at the tip of the thermocouple so that it envelops 10 mm
(3/8 “) of the thermocouple tip. Pilot flame has to be properly
aimed at the thermocouple. See Fig 9.
3. Poor thermocouple connection at the
electromagnet
Note: Electromagnet is part #8707201012 located on the
right side of the gas valve behind the piezo push-button
assembly. Check the tightness of the thermocouple
connection nut at the electromagnet: The Electro-magnet
connection is a large aluminum 17mm hex head nut. The
thermocouple end is a 5 mm brass nut which screws into
the 17 mm nut. Tighten the thermocouple nut snugly but
not too tight.
4. Poor circuit connections at the ECO. (Energy Cut-
Off overheat protection)
Oxidation or looseness of the ECO terminal connections
can result in millivolt current loss through the thermocouple
safety circuit. Clean terminals with very fine sand paper or
an eraser and reconnect ECO leads.
5. Faulty ECO (part #8707206040)
If cleaning the terminals attached to the ECO did not fix
the problem, connect a jumper wire between the two wires
and try to relight the pilot. If the pilot flame now remains
on, replace the ECO. If the flame still goes out when the
button is released, the ECO is not defective. Go to next
step.
BURNERS DO NOT IGNITE WHEN HOT WATER IS
TURNED ON
1. Pilot is not on.
Light the pilot. See lighting instructions.
2. Gas valve button not positioned on Burner Position
Be sure pilot flame is on. Slide gas valve control to burner
position ( ).
3. Cold incoming water connection made to wrong
side of heater
Make sure cold water inlet connection is on the right side
of heater when you are facing heater.
4. Water flow rate at hot water tap is too low.
Note: When the flow control is turned all the way clockwise,
the AquaStar models 125B require 1/2 gallon per minute
flow to activate the burners. This is a flow which would fill
a quart jar in 30 seconds. If the flow control knob is turned
fully counterclockwise, a flow rate of 1.1 gpm is required
to activate the burners.
5. Cold water inlet filter on heater is dirty.
Remove filter and clean. This screen filter is located at
the inlet side of the brass water valve (fig. 12, #28). Check
and clean faucet aerators too.
6. Crossover in household plumbing
The AquaStar burner activates when there is sufficient
water pressure drop in the AquaStar water valve assembly
— i.e. when a hot water faucet is opened. If there is a
crossover in the plumbing, the necessary pressure drop
in the AquaStar will be insufficient, or totally eliminated. A
plumbing crossover can be caused by a bad washer at a
single lever faucet or incorrect plumbing or a mixing valve
in the line, etc. which permits hot and cold water to mix in
the plumbing. The crossover will create a back pressure
in the system preventing the pressure drop in the Aquastar
— i.e. cold water is entering the water heater 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. Open your hot water taps. There
should not be any water flowing. If there is water flowing,
there is a crossover in the plumbing. This is a plumbing
problem, not an Aquastar problem. Please contact your
plumber.