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10
MAINTENANCE AND SERVICE
REVIEW MAINTENANCE TABLE ON THE BACK
OF THIS MANUAL
Approximately once a year, the AquaStar should be checked
and cleaned. To remove the front cover, first remove the
incandescent particle tray, then pull off the temperature
adjustment knob and unscrew and remove the plastic collar.
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 # 8707002534): 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 #26 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 (#28 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.10. If the flame is soft and yellow, the pilot burner orifice
may need to be cleaned or replaced. The pilot flame should
be approximately 2 inches long, extending past the flame
sensor. If the flame is too small, it will not reach the flame
sensor and the burners will not come on.
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.
To access the pilot orifice, remove 2 screws holding pilot
assembly in place. Then loosen compression fittings to
expose pilot orifice.
Fig. 11 - Pilot burner with pilot orifice
Fig. 10 - Characteristic Pilot Flame
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 temperature 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 125X 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,
pull off the temperature adjustment knob and unscrew and
remove the plastic collar. Pull main cover out toward you
and lift up and out.
To clean the pilot burner and/ or the pilot orifice : Turn
off the gas to the unit. Set the On/Off switch to Off (position
0). Remove the cover of the heater. To do so, pull off the
temperature adjustment knob and unscrew and remove
the plastic collar. Pull main cover out toward you and lift
up and out. The pilot orifice should be cleaned or replaced.
Do not enlarge the orifice.
3mm
Correct gap between pilot
burner tip and electrode tip
Piezo Electrode
Flame sensor
Piezo
Electrode