AquaStar 80 VP, 80 VPS User Manual

INSTALLATION AND OPERATING INSTRUCTIONS FOR AUTOMATIC INSTANTANEOUS TYPE WATER HEATERS FOR USE WITH NATURAL AND LIQUEFIED PETROLEUM GAS

MODEL 80 VP AND MODEL 80VPS

Suitable for water (potable) heating and space heating

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 vicinty 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.

- Installation and service must be performed by 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. *REPLACEMENT MANUAL MUST BE PURCHASED

FEA TURING: Variable Power - Modulating Gas V alve - Thermostatic Control with Temperature Dial Selector

TABLE OF CONTENTS

Specifications ..............................................................................Page 3

Rules for Safe Operation.............................................................Page 4-5

General Overview of Aquastar ....................................................Page 6

Locating the Heater for Safe Proper Combustion........................Page 7

Installation ...................................................................................Page 8

Connecting Gas and Water Lines & Pressure Relief Valve .........Page 9-10

Vent Pipe Connection..................................................................Page 10

Safety Before Lighting.................................................................Page 11

Lighting Instructions ....................................................................Page 11

Setting Water Temperature..........................................................Page 12

Maintenance & Service ...............................................................Page 12-14

Trouble Shooting.........................................................................Page 14-18

Cleaning Pilot Assembly..............................................................Page 19

Calibration and Thermostat Test..................................................Page 20-21

Description of Operation and Parts Layout Diagrams .................Page 22-26

Gas Line Size, Vent Size & Height Guide Lines..........................Page 27

This well engineered, tankless gas water heater has all the features a water heater should have:

The instantaneous principle of heating water is very simple. Cold water enters the heater when a hot water faucet is opened. This flow of water causes the gas valve to open. Gas flows to the burners and is ignited by the pilot flame. The heat exchanger then absorbs the heat generated by the burners and transfers it to the cold water as it travels through the heat exchanger. When the hot water is turned off, the gas valve automatically closes and the burners shut off. Your hot water faucet is an ignition key for hot water . You now have complete control over your hot water energy use. [See pages 22-26 for detailed Description of Operation and Parts Layout Diagrams].

FEATURES

• Automatic thermostatic control for steady hot water temperature. Burner output is proportional to water flow for maximum energy efficiency .

• Automatic thermostatic control for steady hot water temperature.

• Safety thermocouple at pilot and burner.

• Automatic Energy Cut-Off mechanism.

• Built-in gas shut-off valve.

• Stainless steel burners with stabilized blue flame.

• Built-in corrosion resistant draft inducer.

• Long working life insured by heavy-duty

high quality materials.

• Compact space saver: mounts on wall

with four screws.

• Easy installation.

• 2.2 gpm (removable) flow restrictor to

ensure water flow will never exceed heater capacity .

AquaStar 80 VP and 80 VP "S" Specifications:

Gas input..................................max: 77,500 Btu

Water Connection........................1/2" sweat fitting

H x W x D..........................................27" x 12" x 9"

Vent.......................................................................4"

Gas Connection...........................3/4" NPT thread

Min. Water Pressure....................................15 Psi

Max. Water Pressure................................150 Psi

Shipping Weight..............................................33 lb

Net Weight......................................................27 lb

GPM at 90ºF rise...........................................1.32*

GPM at 45ºF rise...........................................2.64*

Min. Water Flow ....................................3/4 gal/min

LP GAS Pressure inlet...............min.: 10"W.C.***

LP GAS Manifold pressure....................8.9" W.C.

Natural Gas Pressure inlet..........min.: 4.7"W.C.***

Natural Gas Manifold Pressure...............3.2"W.C.

min: 25,000 Btu

max.: 14"W.C.**

* Figured on a 55ºF cold inlet temperature ** Inlet gas pressure must not exceed this value ***For purposes of input adjustment

SETTING THE INLET GAS PRESSURE FOR HIGH ALTITUDES

The pressure regulator provided with the heater is set to deliver the proper gas pressure (as indicated on the rating plate and in the manual) for altitude up to 2500 feet (758 meters) above sea level. On appliances being installed above 2500 ft/ 758 m elevation, the inlet gas pressure should be reset at installation to the value shown below for the altitude of the installation.

NOTE: The gas pressures specified below refer to pressures taken at the test pressure nipple on the manual gas valve as shown in fig.3 page 9. These readings should be taken while the heater is operating at full output --i.e. maximum water flow with the temperature setting on #8.

MAXIMUM INLET GAS FLOW PRESSURE SETTING

AL TITUDE NATURAL GAS LIQUID PROPA NE

inches W.C. inches W.C.

0' - 2,500 FT / 758 M 3.90" 9.75" 2,500 ft - 4,000ft / 758m - 1212m 3.00" 7.35"

CAUTION: RULES FOR SAFE OPERATION

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. DO NOT CONVERT AN EXISTING, CLOSED HOT WATER HEA TING SYSTEM TO A COMBINATION SPACE AND POTABLE WATER HEATING SYSTEM USING THE AQUASTAR OR ANY OTHER HEAT SOURCE.

Cold

Water

Hot

Water

Out

Pressure

Relief V alve

Boiler Drain

Full Port Ball V alve

Pump (Grundfos UP26-99BF , T aco 001 1B or equivalent)

Dip Tube

Secondary Pump

Aquastat Sensor

Radiant Floor, Low T emperature Fan Coil Units, Baseboard Heaters, Indirect Water Heater , Snow Melt, or Root-zone Grid

Fig. 1 Schematic Diagram of Combination Potable Water and Space Heating System

Room Thermostat

RULES FOR SAFE OPERA TION

1. Y ou 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/ NFPA 54. In Canada: The installation should conform with CGA B149.(1,2) INST ALLA TION 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 a gas appliance is not installed correctly , fatal accidents can result from 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 on Pages 7-8 on Locating the Heater.

4. Y ou must vent your heater. See section on V ent Pipe Connection, Page 10, paragraph 6 and V enting Guide on page 27.

6. Keep water heater area clear and free from

combustibles and flammable liquids. Do not locate the heater over any material which might burn, such as carpet.

7. Correct gas pressure is critical for the optimum

operation of this heater (see specifications on page 3). Gas piping must be sized to provide the required pressure at the maximum output of the heater. Check with your local gas supplier, and see gas line size requirements on page 27.

8. As a precaution, shut off your heater if you plan

to be away for several days.

9. Should overheating occur and the gas supply

fail to shut off, turn off the manual gas control valve to the appliance.

10. See instructions on setting the water tempera-

ture, page 12.

11. Do not use this appliance if any part has been

under water. 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 under water.

5. The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at pressures in excess of 1/2 psig (3.5kPa).

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

Fig. 2 Parts of AquaStar 80

C E

A. hanging frame and back

support

B. thermostatic sensor C. heat exchanger D. thermocouple E. burners F. burner manifold G. gas pressure testing nipple H. temperature selector knob

I. hot water outlet J. thermostat adjustment screw K. gas inlet L. manual gas valve M. cold water inlet screen P. pilot starting button R. water valve venturi piston

S. pilot filter

PMZK

T. pilot V. overheat shut off sensor W. draft hood X. rating plate-serial #

& gas type, etc.

Y. incandescent particles tray Z. gas pressure testing nipple

or gas valve

LOCATING YOUR HEATER FOR SAFE PROPER COMBUSTION

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 install a proper vent. The heater may still operate even when improperly installed. However, an improper installation will be less efficient and may damage the heater. Improper installation can even result in human sickness or death due to oxygen deprivation and carbon monoxide poisoning. Follow the guidelines below:

1. Y ou must not install this appliance in bathrooms, bedrooms, unvented closets or any occupied rooms normally kept closed.

2. Simultaneous operation of appliances such as exhaust fans, ventilation systems, clothes dryers, fireplaces or wood stoves may create a vacuum effect in your home. This can cause dangerous combustion by-products to spill back into your home rather than venting to the outside through the flue.

3. A simple test for proper ventilation is to inroduce smoke (as from a candle) near the louvers on the front of the heater. Have all appliances mentioned in the above paragraph operating at the same time. Have all doors and windows to the outside shut. If the heater does not suck the smoke into the louvers while the heater is operating, you need to supply additional combustion air to the heater and/or improve the vent system.

4. Observe the following instructions concerning additional combustion air .

Appliances located in unconfined spaces:

a) An unconfined space is one in which the 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 6250 cubic feet for the AquaStar 125 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 shall 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 shall have a minimum free area of one square inch per:

-1,000 Btu/hr if all air is taken from inside the building.

-2,000 Btu/hr if all air is taken from the outside by horizontal ducts.

-4,000 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, assume 20% to 25% for wood louvers and 60% to 75% for metal louvers. Refer to the National Fuel Gas Code for complete information. In buildings of tight construction, all air should be taken from outside.

5. Place your heater as close to a vent or chim-

ney as possible. Y our hot water lines should be kept short to save energy. It is always best to have hot water lines insulated.

6. Having a floor drain or sink nearby is handy in

case you need to drain water from your heater.

7. Place the heater in a location where water

leaks will do NO DAMAGE to adjacent areas or lower floors. CONTROLLED ENERGY CORP IS NOT RESPONSIBLE FOR WATER DAMAGE.

8. For alcove installation, maintain the following minimum clearances from all construction for servicing and proper operations:

Alcove Closet A. Top 6 inches 12 inches B. Front OPEN 6 inches C. Back 0 inches 0 inches D. Sides 1 inch 1 inch (Left side 6" for service) E. Floor 6 inches* 12 inches* F. Flue 6 inches 6 inches (single wall only)

*Do not install over floor covering which is combustible, such as carpet.

Minimum clearance to combustible materials should not be less than 6" for single wall flue pipe. Note that this can be reduced if combustible materials are protected as per table VI of the National Fuel Gas Code or if Type B gas vent is used. (Follow the minimum clearances for the vent type. We recommend the use of T ype B gas vent.

9. WARNING: THIS WATER HEATER DOES NOT STORE ANY HOT W ATER. DO NOT INSTALL IN AN AREA WHERE IT COULD FREEZE. This heater is neither designed for nor approved for outside installation.

10. The heater must be level before you begin

the piping.

INST ALLA TION

Before installing the unit, be certain your heater is for your type of gas - Propane or Natural Gas. Identification labels for type of gas are found on the shipping box, on the right side panel and on the rating plate which is located in upper part of draft hood seen by removing front panel (See "X" Fig. 2, page 6). Also, each gas orifice is stamped with a number (75 for LPG and 1 15 for Natural Gas).

1. Hanging the heater on the wall Place the paper pattern or template (supplied with heater) on the wall where you plan to hang your

heater. Use the adhesive tape which is included in the package to stick the pattern to the wall. Keep in mind that the heater needs to have certain minimum clearances (See paragraph 7 on this page), and that the heater must be level. Drill four holes into the wall at the studs (16 inches on center) as indicated on the template. Use a 1/8 inch drill if screws are to go directly into wood or 1/4 inch if plastic anchors are to be used.

WARNING: Be sure to remove the paper template before hanging the heater on the wall.

After the paper template is removed, insert the mounting screws into the two upper holes. Leave 1/2 inch between the wall and the screw head, in order to have enough space for your unit to slip over. The bottom screws will secure the Water and Gas Connecting Strip Assembly to the wall. Next remove the front panel. T o do this, remove the temperature selector knob (H) and the pilot starting button by pulling them out. Unscrew the screws under each front corner. Lift the panel up and pull out. At this point, you can either screw the two large screws to fasten the Water and Gas Connecting Strip Assembly to the wall using the pre-drilled holes and connect your pipes directly to the water heater, or you can remove the heater from the Water and Gas Connecting Strip Assembly in order to connect the piping, and then reconnect the heater later. If you decide to connect the pipes directly , skip the next section and go to #3, "Connecting the Gas Line."

2. T o Disconnect Heater From the Water and Gas Connecting Strip Assembly (Optional)

Refer to figure 3 (following page). Unscrew each brass union nut at the three points marked in figure 3. Be careful not to lose the washers. Remove your heater from the Water and Gas Connecting Strip. Now you can make your water and gas connections as explained in the following sections. When all connections have been made, re-hang the heater on the upper screws and reconnect the brass union nuts making certain that the washers are properly in place.

Fig. 3 T o Disconnect Heater From Wall Hanging Strip

3. Connecting the Gas Line

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 INSTALLATION CODES and/or local installation codes. IMPORT ANT An appliance gas pressure regulator has been supplied with this unit. This regulator must be installed on the gas line within 6 feet of the heater. National Fuel Gas Code requires that a sediment trap be installed on gas appliances not so equipped. The 3/4" NPT gas inlet elbow fitting supplied with the heater connects to the manual gas shutoff valve with a washer gasket. No pipe dope or thread tape should be used at this joint. The 3/4" NPT side of the fitting has a hex shoulder to help you avoid twisting the elbow and requires pipe dope or thread tape to make its seal. The 3/4" size is the minimum for use with Natural Gas and must not be reduced. Propane gas line size requirements are less than those for Natural Gas. Provided the propane gas line is less than 20 feet and serves only the AquaStar, it can be reduced to 5/8". When threading the gas pressure regulator to the gas piping, the indicator arrow on the regulator must be pointed in the direction of gas flow.

NOTE: The regulator supplied with the heater is an appliance level regulator designed for low inlet pressure (less than 1/2 LB or 15"W.C.). DO NOT connect to an unregulated or high pressure propane line.

When your connections are made, check for gas leaks at all joints (not just ones you made). Apply some soapy water to all gas fittings and gas valve.

Soap bubbles are a sign of a leak. NOTE: Do not apply soap solution to pilot filter

screen or pilot orifice area. If you have a leak, shut off the gas. After verifying that required gaskets are in place, tighten appropriate fittings to stop leak. Turn the gas on and check again with a soapy solution. Never test for gas leaks using a match or flame.

4. Connecting the water lines

Although water piping throughout your structure may be other than copper , copper piping should be used for at least three feet before and after the heater (follow local codes if more stringent). Keep water inlet pipe to at least 1/2 inch diameter to allow the full flow capacity. Remember that piping and water pressure must allow sufficient flow to activate the heater when drawing hot water from the top floor. If the hot and cold connections are reversed, the heater will not function.

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