AquaStar 38B LP, 38B NG User Manual
INSTALLATION AND OPERATING INSTRUCTIONS FOR AUTOMATIC
INSTANTANEOUS TYPE WATER HEATERS FOR USE WITH NATURAL AND
LIQUEFIED PETROLEUM GAS
MODEL 38B LP and NG (Non Modulating)
Suitable for water (potable) heating and space heating
Intended for low flow domestic hot water applications with steady cold water inlet temperatures
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
vicinity 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.
WARNING: Improper installation, adjustment,
alteration, service or maintenance can cause injury
or property damage. Refer to this manual. For
assistance or additional information consult a
qualified installer, service agency or the gas supplier .
Upon completion of the installation, these instructions
should be handed to the user of the appliance for
future reference.
6 720 605 293 PT 862 (12.98)
- Installation and service must be performed by a
qualified installer, service agency or the gas supplier .
T ABLE OF CONTENTS
Specifications .................................................... Page 2
Rules for safe operation .................................... Page 4
Locating the Heater ........................................... Page 4
Combustion Air Requirements........................... Page 4
Mounting the Heater ..........................................Page 5
Venting the Heater............................................. Page 5
Gas Connections ............................................... Page 6
Water Connections............................................ Page 6
Safety before lighting the pilot............................ Page 7
Lighting instructions........................................... Page 8
Setting water temperature ................................. Page 8
Maintenance & Service...................................... Page 9
Trouble Shooting ............................................. Page 10
Diagram of AquaStar ....................................... Page 13
Components and Parts List ............................. Page 14
This well engineered, gas water heater has all the features a water heater should have:
It operates on the principle of heating water instantaneously
“on demand”. When a hot water faucet is opened, cold
water flows through the coils of the heat exchanger in the
Aquastar. This same flow opens the gas valve, and the
burners are ignited by the pilot flame. The heat exchanger
coils absorb the heat generated by the burners and transfer heat to the water. When the hot water faucet is shut
off, the gas valve automatically closes and the burners
turn off. Your hot water faucet is an ignition key to turn on
the water heater, giving you control over your hot water
energy use. Each time you turn off your hot water faucet,
you also shut off the water heater .
AquaStar 38B LP and 38B NG Specifications
Gas Input max.: 40,000 Btu/hr
min.: 20,000 Btu/hr
Water Connection 1/2” Thread fitting
H x W x D 25 3/8” x 10 5/8” x 9 1/8"
Vent 4”
Gas Connection 1/2” NPT thread
Min. Water Pressure 13 Psi at 1.3 GPM
FEA TURES
- High Quality Materials for Long Working Life.
- Copper heating coils for endless supply of hot water.
- Safety thermocouple at pilot burner.
- Automatic overheating protection shut-off sensor .
- Stainless steel burners with stabilized blue flame.
- Built-in corrosion resistant draft inducer.
- Compact space saver: mounts on a wall with two hooks.
- Easily removable one-piece cover.
- Easy one person installation.
- Adjustable water flow restrictor to ensure that water flow
demand will not exceed the heating capacity of the
heater.
- Easy pilot flame lighting with push button piezo ignition.
Max. Water Pressure 150 Psi
Shipping Weight 20 LB
Net Weight 18 LB
0.5 GPM at 90° rise
1.3 GPM at 45° rise
Min. Water Flow 1/2 gal/min
LP GAS Pressure inlet. min. 1 1” W.C.
max. 14” W.C.*
LP GAS Manifold pressure 9.0” W.C.**
Natural Gas Pressure inlet min.: 7” W.C.
max.: 14” W.C.*
Natural Gas Manifold Pressure 5.2 W.C.**
* Inlet gas pressure must not exceed this value
** For purposes of input adjustment
UNP ACKING THE AQUASTAR HEATER
This heater is packed securely . The box includes two water connection fittings, a gas pressure regulator, two hooks for
hanging the heater, this manual, a personal letter, a warranty statement and a warranty registration card. Do not lose
this manual, as there is a charge for replacement. Please complete and return the enclosed warranty registration card.
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If you are using the AquaStar for combined space heating and potable water heating
schematic diagram below)
, all piping and other components connected to the system must
(see
be suitable for potable water, (b) toxic chemicals such as those commonly used for boiler
treatment to prevent corrosion and freezing must not be introduced into the system, and
(c) if the space heating requires water temperatures higher than those required for domestic, potable water, a mixing valve or other similar device must be provided to reduce
scald hazard potential, (d) maximum system water temperature must not exceed 140°F
(60°C). DO NOT CONVERT AN EXISTING, CLOSED HOT WATER HEATING SYSTEM TO A
COMBINA TION SPACE AND POTABLE WATER HEATING SYSTEM USING THE AQUASTAR
OR ANY OTHER HEA T SOURCE.
Open loop potable water and combination space heating system*
* T o be used with a tank, check local codes. May not be permitted in some jurisdictions.
Notes
1. Maximum operating temperature of 38B: 140°F
2. Maximum heating capacity: 40°F rise 20°F rise
AquaStar 38B - 30,000 BTU/hr 15,000 BTU/hr
3. System shown is electric storage tank with recirculating supply drawn from the tapping for the lower heating element.
4. Schematic is for illustration and example only and must not be used for actual installation without appropriate
engineering and technical advice from a professional properly licensed in the locality where the installation is made.
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GENERAL RULES TO FOLLOW
FOR SAFE OPERA TION
1. You should follow these instructions when you install
your heater. In the United States: The installation must
conform with local codes or, in the absence of local codes,
the National Fuel Gas Code ANSI Z223.1/NFP A 54.
In Canada: The Installation should conform with CGA
B149.(1,2) INSTALLATION CODES and /or local
installation codes.
2. Carefully plan where you install the heater. Correct
combustion air supply and flue pipe installation are very
important. If not installed correctly , fatal accidents can be
caused by lack of air, carbon monoxide poisoning or fire.
3. The place where you install the heater must have
enough ventilation. The National Fire Codes do not allow
water heater installation in bathrooms, bedrooms or any
occupied rooms normally kept closed. See the section
below on locating the heater.
The heater may still operate even when improperly vented.
It will, however, be less efficient and could eventually
damage the heater. It could even result in human sickness
or death due to oxygen deprivation and carbon monoxide
poisoning. Follow the guidelines below:
1. Place your heater as close to a vent or chimney as
possible.
2. National building codes require that you do not install
this appliance in bathrooms, bedrooms, unvented closet
or any occupied rooms normally kept closed.
3. Simultaneous operation of other appliances such as
exhaust fans, ventilation systems clothes dryers, fireplaces
or wood stoves could create a vacuum effect in your home
which could cause dangerous combustion by-products to
spill back into your home rather than venting to the outside
through the flue. Confirm that your Aquastar is venting
properly when all these other appliances are running. See
section on venting.
4. You must vent your heater. See section on Vent Pipe
Connections, Page 4.
5. The appliance must be disconnected from the gas
supply piping system during any pressure testing at
pressures in excess of 1/2 Psig (3.5 kPa).
The appliance must be isolated from the gas supply piping
system by closing its individual manual shutoff valve during
any pressure testing of the gas supply piping system at
test pressures equal to or less than 1/2 Psig (3.5Kpa).
The appliance and its gas connection must be leak tested
before placing the appliance in operation.
6. Keep water heater area clear and free from
combustibles and flammable liquids. Do not locate the
heater over any material which might burn.
7. Correct gas pressure is critical for the optimum
operation of this heater (see specifications on page 2).
Gas piping must be sized to provide the required pressure
at the maximum output of the heater, while all the other
gas appliances are in operation. Check with your local gas
supplier, and see the section on connecting the gas supply .
8. Should overheating occur or the gas supply fail to shut
off, turn off the gas supply at the manual gas shut off valve
on the gas line.
9. Do not use this appliance if any part has been
underwater. Immediately call a qualified service technician
to inspect the appliance and to replace any part of the
control system and any gas control which has been
underwater.
PROPER LOCA TION FOR INST ALLING YOUR
HEA TER
Carefully select the location of your new heater. For your
safety and for proper heater operation, you must provide
an abundant supply of combustion air and a proper venting
installation.
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Do not obstruct the flow of combustion and ventilation
air to the appliance. If installed near a clothes dryer it is
very important that the dryer be properly vented. Failure
to properly vent a dryer could result in a gradual
accumulation of lint on the water heater fin coils and
burners, leading to a dangerous condition of venting
blockage and poor unsafe combustion.
4. Y our hot water lines should be kept short to save energy .
It is always best to have hot water lines insulated. Having
a floor drain or sink nearby is handy in case you need to
drain water from your heater.
WARNING: The water in this water heater is cold and
always remains cold exept for the times that hot water is
being used DO NOT INST ALL IN AN AREA WHERE IT
COULD FREEZE.
This heater is neither designed for nor approved for
outside installation.
WARNING: Flammable materials, gasoline,
pressurized containers, or any other items or articles
that are potentially fire hazards must NOT be placed
on or adjacent to the heater. The appliance area must
be kept free of all combustible materials, gasoline and
other flammable vapors and liquids.
COMBUSTION AIR REQUIREMENT
Observe the following instructions concerning combustion
air.
Appliances located in unconfined spaces:
a) An unconfined space is one whose volume is greater
than 50 cubic feet per 1000 Btu per hour of the combined
rating of all appliances installed in the space. That would
be 2000 cubic feet for the AquaStar 38B alone.
b) In unconfined spaces in buildings of conventional frame,
masonry, or metal construction, infiltration is normally
adequate to provide air for combustion, ventilation, and
dilution of flue gasses.
Appliances located in confined spaces:) The confined
space must be provided with two permanent openings,
one commencing within 12 inches of the top and one
commencing within 12 inches of the bottom of the
enclosure. Each opening must have a minimum free area
of one square inch per:
- 1000 Btu/hr if all air is taken from inside the building.
- 2000 Btu/hr if all air is taken from the outside by horizontal
ducts.
- 4000 Btu/hr if all air is taken from the outside by direct
openings or vertical ducts.
Louvers, grills and screens have a blocking effect. If the
effective free area is not known, increase the sizes of your
openings by 75% if your louvers are wood and by 30% if
your louvers are metal. Refer to the National Fuel Gas
Code for complete information. In buildings of tight
construction all air should be taken from outside. That
would be 2000 cubic feet for the Aquastar 38B alone.
CLEARANCES
The Aquastar 38 B is design certified for installation on a
combustible wall and for installation in an alcove or closet
with the minimum clearances to combustible and non combustible construction listed below
A. Top 12 inches ( 305 mm)
B. Front 4 inches (102mm)
C. Back 0 inches
D. Sides 4 inch (102mm)
E. Bottom 12 inches (306 mm)
Clearance from vent is dependent upon the clearance
rating of the venting material used. For example: type B-1
vent is approved for 1 inch clearance, B-2 vent for 2 inch,
etc.
Note: Minimum clearance to combustible materials should
not be less than 6" for single wall flue pipe. Note that this
clearance can be reduced if combustible material are
protected as per table VI of the National fuel Gas Code or
if Type B gas vent is used.
MOUNTING INST ALLA TION
The Aquastar 38 B is design certified for mounting on a
wall.
Do not install this appliance on a carpeted wall or over
floor covering which is combustible, such as carpet. The
heater must be mounted on a wall using appropriate
anchoring materials. If wall is a stud wall sheathed with
plasterboard, it is recommended that support board(s),
either 1x4’s or 1/2" (minimum) plywood first be
attached across a pair of studs and then the heater
should be attached to the support boards. See Fig 1.
Expansion and contraction of piping due to changing water
temperature in the pipes imparts movement to the heater
which, if mounted directly to a brittle, friable board, such
as plasterboard, can cause failure of mounting.
Before installing the unit, be certain you have the correct
heater for your type of Gas – Propane or Natural Gas.
Identification labels are found on the shipping box, and on
the rating plate which is located on the right side panel of
the cover. Also, each burner orifice is stamped with a number (79 for LPG and 120 for Natural Gas).
WALL STUDS
5 ½”
SUPPORT BOARD
1” X 4”
SPACE BOARD
Fig. 1 - Mounting the Heater
VENTING
Vent pipe connection. WARNING: Do not reduce the
vent pipe size.
This appliance must be vented to the outside following all
local ordinances and specifications for installing a gas
appliance vent or chimney. The venting system must be
designed and constructed so as to develop a positive flow
adequate to remove flue gasses to the outdoors. Minimum
vent size must be 4". Minimum height must be 6 feet,
provided there are no elbows. Termination of vent
must be 2 feet above any obstruction within a 10 foot
radius. Consult your gas utility or National Fuel Gas
Code if vent will have elbows or share venting with
another appliance. The vent connector should have
as much vertical rise as possible (minimum 12”) before
any horizontal run. The appliance must be located as
close as practicable to a chimney or vent. The vent pipe
sections must be secured to each other with sheet metal
screws. Keep in mind the minimum clearance from the
top of your heater. Remember also that single wall vent
pipe connectors require a 6 inch clearance from
combustibles. National Fuel Gas Code specifies double
wall — Type “B” — vent pipe be used in cold climates and
for gas vents running through attics. We consider double
wall vent pipe preferable in all circumstances. Any vent
section greater than 45 degrees from vertical is considered
horizontal. Horizontal sections of vent connectors must
slope upwards at least 1/4 inch for every foot of its
horizontal length. Keep the horizontal section short and
avoid too many elbows.
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