Aquastar 125FX Manual

8/10/2019 Aquastar 125FX Manual

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WARNING: Improper installation,adjustment, alteration, service or maintenance can causeinjury or property damage. Refer to this manual. Forassistance or additional information consult a qualifiedinstaller, service agency or the gas supplier.Upon completion of the installation, these instructionsshould be handed to the user of the appliance for futurereference.

In the Commonwealth of Massachusetts this productmust be installed by a licensed plumber or gas fitter.

FEATURING: Electronic Ignition and Power Venting

INSTALLATION AND OPERATING INSTRUCTIONS FOR AUTOMATICINSTANTANEOUS TYPE WATER HEATER FOR USE WITH NATURAL ANDLIQUEFIED PETROLEUM GAS

MODEL 125FX LP and 125FX NG(Flow Modulated with Electronic Ignition and Power Venting)

Suitable for heating potable water onlyNot approved for space heating purposes

Intended for variable flow applications with steady cold water inlet temperatures

WARNINGIf the information in this manual is not followed exactly. Afire or explosion may result causing property damage,personal injury or death.

FOR YOUR SAFETYDo not store or use gasoline or other flammable,combustible or corrosive vapors and liquids in the vicinityof this or any other appliance.

WHAT TO DO IF YOU SMELL GAS- Close gas valve. Open windows.- 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 neighbors

phone. Follow the gas suppliers 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.

Specifications ............................................. Page 2Rules for safe operation........................... Page 4Locating the Heater .................................. Page 4Combustion Air Requirements ................ Page 5Mounting the Heater ................................. Page 6Venting the Heater .................................... Page 7Gas Connections ....................................Page 10Water Connections .................................Page 12Electrical Connections ................ ........... Page 13Safety before turning on the heater .... Page 14Lighting and Operating instructions .... Page 14Setting water temperature ............... ...... Page 14

Maintenance & Service .............. ............ Page 15Trouble Shooting ............... .............. ......... Page 16Diagram of AquaStar .............................. Page 19Components and Parts List .................. Page 20Warranty ................................................... Page 23

TABLE OF CONTENTS

6

720

606

601

US(

06.0

1)AL


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AquaStar 125FX LP and 125FX NG Specifications

Water Connection 1/2 Thread fitting NPT

H x W x D 29 3/4 x 18 1/4 x 8 3/4"

Vent 4

Gas Connection 1/2 NPT thread

Min. Water Pressure 18 Psi

Max. Water Pressure 150 Psi

Shipping Weight 50.6 LB

Net Weight 44 LB

2.3 GPM at 90rise

4.6 GPM at 45rise

Min. Water Flow 1/2 gal/min

120V/60Hz 1.2 Amps

LP GAS Supply Pressure min. 11 W.C.(before Aquastar regulator) max.14 W.C.*

Required LP GAS pressure at inlettap while Aquastar is operating: 10.5 W.C.

LP GAS Burner Manifold pressure whileAquastar is operating at maximum input: 9.9 W.C.

Natural Gas Supply Pressure min.: 7 W.C.(before Aquastar regulator) max.: 14W.C.*

Required Natural Gas Pressure atinlet tap while Aquastar is operating: 5.7W.C.

Natural Gas Burner Manifold pressure whileAquastar is operating at maximum input: 5.38 W.C.

* Inlet gas pressure before Aquastar regulator must notexceed this value. Pressure may need to be adjusted forhigh altitudes, see page 10.

Principle of Operation:When a hot water faucet is opened, the flow of water throughthe heater causes the gas valve to open. At the same timea microswitch is activated which sends a spark to the pilot.The flame sensor confirms that the pilot has been lightedand allows the first two burners to ignite. The flame sensorconfirms correct activation and all burners ignite. The pilotgoes out. The power exhaust system runs as long as the

burners are on. The heat exchanger coils absorb the heatgenerated by the burners and transfer heat to the water.When the hot water faucet is shut off, the gas valveautomatically closes and the burners turn off, followedimmediately by the exhaust system. Your hot water faucet isan ignition key to turn on the water heater, giving you controlover your hot water energy use. Every time you turn off yourhot water faucet, the energy consumption for hot waterreturns to zero.

FEATURES

- Electronic Pilot Ignition

- On/Off switch to activate system

- Power Venting with safety shutoff

- High Quality Materials for Long Working Life.

- Copper heating coils for endless supply of hot water.

- Burner output proportional to hot water flow demand formaximum energy efficiency.

- Safety flame sensor at pilot burner.

- Automatic overheating protection shut-off sensor.

- Stainless steel burners with stabilized blue flame.

- Built-in corrosion resistant power venter.

- 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 flowdemand will not exceed the heating capacity of the heater.

UNPACKING THE AQUASTAR HEATER

This heater is packed securely. The box includes one water connection fitting, a control knob, a gas pressure regulator, a

pressure relief valve, an incandescent particle tray, two hooks for hanging the heater, an exhaust collar, this manual and awarranty registration card. Do not lose this manual as there is a charge for replacement. Please complete and returnthe enclosed warranty registration card. The FXHOOD horizontal vent terminator is supplied separately from the 125FXwater heaters. There is a set of installation instructions in the FXHOOD box.

AQ125FXNG AQ125FXLPG

max. 130 000 Btu/hr 125 000 Btu/hr

min. 28 000 Btu/hr 28 000 Btu/hrGas input


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MINIMUM INSTALLATION CLEARANCES FROM COMBUSTIBLE AND NONCOMBUSTIBLE MATERIALS FOR ALCOVE OR CLOSET INSTALLATIONS

FRONT VIEW SIDE VIEW

AQUASTAR MODEL 125FX

* On a combustible wall surface the unit should be mounted awayfrom the wall to provide adequate clearance of the vent pipe.

See page 5 for instructions.

TOP (A) 12 "

FRONT (B) 4 "

BACK 0 " *

SIDES 4 "

FLOOR (C) 12 "

VENT DIAMETER 4 "

MODEL 125FX


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GENERAL RULES TO FOLLOWFOR SAFE OPERATION

1. You should follow these instructions when you install yourheater. In the United States: The installation must conformwith local codes or, in the absence of local codes, theNational Fuel Gas Code ANSI Z223.1/NFPA 54.In Canada: The Installation should conform with CGA

B149.(1,2) INSTALLATION CODES and /or local installationcodes.

2. Carefully plan where you install the heater. Correctcombustion air supply and flue pipe installation are veryimportant. If not installed correctly, fatal accidents can becaused by lack of air, carbon monoxide poisoning or fire.

3. The place where you install the heater must haveenough ventilation. The National Fire Codes do not allowgas fired water heater installation in bathrooms,bedrooms or any occupied rooms normally kept closed.See the section below on locating the heater.

4. You must install your heater so that the venting complieswith all requirements. See section on Venting the Heater,pages 7 through 9.

5. The appliance must be disconnected from the gas supplypiping system during any pressure testing at pressures inexcess of 1/2 Psig (3.5 kPa).

The appliance must be isolated from the gas supply pipingduring any pressure testing of the gas supply piping systemat test pressures in excess of 1/2 Psig (3.5Kpa). Theappliance and its gas connection must be leak tested beforeplacing the appliance in operation.

6. Keep water heater area clear and free from combustiblesand flammable liquids. Do not locate the heater over anymaterial that might burn. Do not install heater over carpeting.

7. Correct gas pressure is critical for the optimumoperation of this heater (see specifications on page 2 andchart on page 10). Gas piping must be sized to provide therequired pressure at the maximum output of the heater.Check with your local gas supplier, and see the section onconnecting the gas supply.

8. Should overheating occur or the gas supply fail to shutoff, turn off the gas supply at the manual gas shut off valveon the gas line.

9. Do not use this appliance if any part has been underwater. Immediately call a qualified service technician toinspect the appliance and to replace any part of the controlsystem and any gas control that has been under water.

10. When installed, the appliance must be electricallygrounded in accordance with local codes or, in the absenceof local codes, in accordance with the National ElectricalCodeANSINFPA 70 and/or the CSA 22.1 Electrical Code.

PROPER LOCATION FOR INSTALLING YOURHEATER

Carefully select the location of your new heater. For yoursafety and for proper heater operation, you must provide anabundant supply of combustion air and a proper ventinginstallation.

The heater may still operate even when improperly vented.It will, however, be less efficient and could eventually damagethe heater. It could even result in human sickness or deathdue to oxygen deprivation and carbon monoxide poisoning.Before installing the unit, be certain you have the correctheater for your type of Gas Propane or Natural Gas.Identification labels are found on the shipping box, and onthe 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).

Follow the guidelines below:

1. National building codes require that you do not installthis appliance in bathrooms, bedrooms, unvented closetor any occupied rooms normally kept closed.

2. Simultaneous operation of other appliances such asexhaust fans, ventilation systems, clothes dryers, fireplacesor wood stoves could create a vacuum effect in your homewhich could cause dangerous combustion by-products tospill back into your home rather than venting to the outside

through the flue. Confirm that your Aquastar is ventingproperly when all these other appliances are running. Seepage 6 to test venting performance.

Do not obstruct the flow of combustion air to theappliance.This appliance is power vented and uses roomair. Note: Electrical power is required to operate the powerexhaust. Proper air supply to the appliance is essential.If installed near a clothes dryer it is very important that thedryer be properly vented. Failure to properly vent a dryercould result in a gradual accumulation of lint on the waterheater fin coils and burners, leading to a dangerous conditionof vent blockage and poor, unsafe combustion.

3. Your hot water lines should be kept short to save energy.It is always best to have hot water lines insulated.

WARNING: DO NOT INSTALL IN AN AREA WHEREIT COULD FREEZE. This heater is neither designed fornor approved for outside installation. Drain the heaterentirely if freezing temperatures are anticipated in area whereheater is installed by disconnecting both the inlet and outletwater connections from the heater (disconnect the outletflex line from where it connects to the copper heatexchanger). Additionally, remove the drain plug under thewater valve. See Fig 1.

Fig. 1 - Water heater drain plug

WARNING: Flammable materials, gasoline,

pressurized containers, or any other items or articles thatare potentially fire hazards must NOT be placed on oradjacent to the heater. The appliance area must be keptfree of all combustible materials, gasoline and otherflammable vapors and liquids.


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COMBUSTION AIR REQUIREMENTS

The AquaStar water heater holds cold water in its copperheat exchanger and brass water valve when not in use.Because of this, any cold air that comes in through theunits vent pipe is capable of freezing these components.This Installation Manual specifies the vent lengthrequirements and the amount of combustion air required for

this unit. When all requirements are followed, the unit willoperate properly and safely. However, there may still be arisk of freezing due to negative draft if all the combustionappliances in the area are not being supplied with a sufficientamount of make-up air. A wood stove or furnace can rob themake-up air in the AquaStars vent pipe, leaving the coldinfiltrating air capable of freezing the cold water in theAquaStar heat exchanger. To prevent this the FXHOODhorizontal vent terminator, which is supplied separately withthe water heater, needs to be installed on the end of thehorizontal vent run (see page 7). The FXHOODis a CSAapproved vent terminator for the Aquastar 125FX and has abuilt in back draft flapper.

Observe the following instructions concerning combustionair.

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 combinedrating of all appliances installed in the space. That wouldbe 6500 cubic feet for the AquaStar 125FX alone.

b) In unconfined spaces in buildings of conventional frame,masonry, or metal construction, infiltration is normallyadequate to provide air for combustion, ventilation, anddilution of flue gasses.

Appliances located in confined spaces: The confined spacemust be provided with two permanent openings, onecommencing within 12 inches of the top and onecommencing within 12 inches of the bottom of the enclosure.Each opening must have a minimum free area of one squareinch 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 directopenings or vertical ducts.

Or the confined space must be provided with one permanentopening or duct that is within 12 inches of the ceiling of theenclosure. This opening must have a minimum free area ofone square inch per: 3000 Btu/hr if all air is taken from the outside by a direct

opening or vertical duct.Louvers, grills and screens have a blocking effect. If theeffective free area is not known, assume it is 20 % to 25%of the total opening for wood louvers and 60 % to 75% formetal louvers. Refer to the National Fuel Gas Code for

complete information. In buildings of tight construction allair should be taken from outside.

This product is not approved for manufactured homes(mobile home), recreational vehicles (RV) or boats.Reference ANSI Z21.10.3.This product is neither designed or approved for outsideinstallations.

CLEARANCES

The Aquastar 125FX is design certified for installation on a

combustible wall and for installation in an alcove or closetwith the minimum clearances to combustible and non -combustible construction listed below

A. Top 12 inches (305 mm)B. Front 4 inches (102 mm)C. Back 0 inches*D. Sides 4 inch (102mm)E. Bottom 12 inches (305 mm)

* On a combustible wall surface the unit should be mountedaway from the wall to provide adequate clearance of thevent pipe. Clearance from the vent pipe is dependent uponthe clearance rating of the venting material used. See

VENTING section.

125FX Air Vents(5 X 5 in. each)

Air Vents(10 X 10 in. each) 125FX


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Fig. 3 - Incandescent Particle Tray Illustration

The incandescent particle tray (shipped loose in the cartonwith the water heater) must be attached at the bottom ofthe water heater front cover at the time of installation. Usethe screws provided. See figure 3.

SCREWS

INCANDESCENT PARTICLE TRAY

Fig. 2 - Mounting the Heater

WALL STUDS

1 X 4SPACE BOARD

SUPPORT BOARD

13

MOUNTING INSTALLATION

The Aquastar 125FX is design certified for mounting on awall.Secure the two L shaped hooks, which are provided withheater, to a wall surface. Place them 13 apart as shownin Fig 2.Do not install this appliance on a carpeted wall or over floor

covering which is combustible, such as carpet. The heatermust be mounted on a wall using appropriate anchoringmaterials. If wall is a stud wall sheathed with plasterboard, itis recommended that support board(s) either 1x4s or 1/2"(minimum) plywood first be attached across a pair of studsand then the heater should be attached to the support boards.See Fig 2.NOTE: Additionally the 125FX should be spaced awayfrom any combustible wall surface to provide thenecessary clearance that the venting material specifiesmust be maintained between the vent pipe and acombustible surface. See VENTING section. Also, reviewthe FXHOOD horizontal vent terminator instruction sheet(provided with the FXHOOD) prior to installation.In earthquake-prone zones, BBTNA recommends thatinstallers use a large washer and lag screw through theexisting holes used to hang the heater to affix the upperthird of the heater to the mounting board. To affix the lowerthird of the heater, BBTNA recommends that two new holesbe drilled in the heaters frame, each one 16 inches belowthe top two holes, and that washers and lag screws be usedto secure the lower portion of the heater to a spacing board.Expansion and contraction of piping due to changing watertemperature in the pipes imparts movement to the heaterwhich, if mounted directly to a brittle, friable board, such as

plasterboard, can cause failure of mounting.


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VENTING

WARNING: Do not reduce the vent pipe size anddo not common vent with any other vented appliance orstove.This appliance must be vented horizontally to the outsidewith a sealed 4 single wall vent pipe. The appliances fluegasses are under positive pressure and must travel througha single wall 4 pipe that is sealed gas tight. The 4 singlewall vent pipe can be either stainless steel (AL29-4C) orgalvanized steel with at least 26 gauge. BBTNA recommendsthe use of stainless steel vent pipe (which is equipped withsealing gaskets) for ease of installation and durability. Whenusing galvanized vent pipe a minimum of 4 sheet metalscrews per connection must be installed and all seams mustbe sealed with an approved high temperature siliconesealant. The vent system must be gas tight. See Fig. 4 forsuggested venting installation diagrams.

The 125FX shall not be vented in combination with anyother appliance. This appliance may only be ventedhorizontally with a dedicated sealed single wall vent. The125FX shall not be vented into masonry chimneys or existingvertical vents of any material.

CAUTION:125FX vent system must be installed by a qualifiedagency in accordance with these instructions. If improperlyinstalled a hazardous condition such as explosion or CarbonMonoxide poisoning could result. BBT North America willnot be responsible for improperly installed appliances.

Establish vent clearances that comply with ventmanufacturers specifications. In all cases follow local codes.See table below.

The vent diameter must be 4.The appliance should belocated as close to the point of termination as possible (seeFig. 5 for locating the terminator). The vent system shouldbe as straight and short as possible. The vent pipe must be4 single wall stainless steel (AL29-4C) or galvanized steelpipe of 26 minimum gauge. Maximum vent length is 15feet (4.6 m) with two 90-degree elbows.Subtract 5 feet

from the total vent length for each additional 90-degreeelbow used. No more than four 90-degree elbows may beused. Any short vertical portion of vent pipe used in thevent system shall be considered part of the allowable 15feet (4.6 m) maximum run. Support the vent run at 4 footintervals with overhead hangers. Horizontal sections of ventmust rise for every foot of horizontal length. Any ventsection greater than 45 degrees is considered an elbow.

Note:Single wall pipe should not be used in concealed,unoccupied or unheated locations. Listed thimbles or collarsare necessary to pass through wall partitions. If the ventsystem passes through combustible areas where the ventclearance requirements cannot be maintained, it ispermissible to chase straight sections of sealed 4 inch singlewall vent through 5 inch (or greater) Type-B vent. Thedistance to combustibles using this chase technique is 1inch. Note:Type-B vent should never be used as the actualvent system for the 125FX, as it is not gas tight.

Freeze Warning:

As mentioned on Page 5, negative air pressure in coldclimates will cause a reverse airflow in the vent system thatcan freeze and damage the Aquastar heat exchanger whennot in use. To prevent this the FXHOOD horizontal ventterminator, which was supplied separately with the waterheater, needs to be installed on the end of the horizontalvent run (see page 8). The FXHOODis a CSA approvedvent terminator for the Aquastar 125FX and has a built inback draft flapper.

Flue Gas Sensor:The 125FX is equipped with a Flue Gas Sensor; its mounted

on the left side of the draft diverter (Flue Gas Sensor - #33on page 20). Before leaving the installation site verify properFlue Gas Sensor operation by temporarily blockingtermination outlet. Once blocked then operate the heater,the unit should shut down within 1-3 minutes when the fluegases are blocked. You must reset the electrical power tothe heater after this safety test has been conducted,otherwise the unit will not operate.

Venting Material

Options

Exhaust vent

diameter

Exhaust vent maximum

distance

Vent pipe within an

unenclosed space

Vent pipe within an

enclosed space

Single wall stainless

steel (AL29-4C)

sealed vent pipe

4 inch

15 feet (4.6 m) with two

elbows. Less 5 feet for

each additional elbow.

*See manufacturer's

specifications

*See manufacturer's

specifications

Single wall galvanized

vent pipe (min. 26

gauge and sealed

with high temperature

silicone)

4 inch

15 feet (4.6 m) with two

elbows. Less 5 feet for

each additional elbow.

3 inches NOT PERMISSIBLE

Clearances

from venting

material

The flue gas exhaust temperature on the 125 FX is 356F (180C)

*Stainless steel (AL29-4C) vent pipe manufacturer's are Z-Flex, Protech and Heat Fab. The manufacturer's specified clearances

are identified on the venting material. NOTE: clearance distances are variable depending if the vent pipe is installed in an

enclosed or unenclosed space, the exhaust flue gas temperature and the orientation of the vent pipe.


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Fig 4: Some Venting Guide SuggestionsAn approved side wall vent terminal must be used when the water heater is vented through a sidewall. Locate in accordance with ANSI Z223.1 and local applicable codes. See Fig 5 for restrictionsin location of vent terminal in relation to opening doors and windows, grade, and forced air inlets.Be certain that snow and ice will not interfere with the vent.

Approved Vent Terminal(FXHOOD or other approved terminal)The FXHOOD is design approved with theAquastar 125FX and has a built in back draftflapper to prevent negative air from freezing theAquastar see Fig. 5 for restrictions in locationof vent terminal.

G181_

274

Approved Vent Terminal(FXHOOD or other approved terminal)The FXHOOD is design approved with theAquastar 125FX and has a built in back draft

flapper to prevent negative air from freezing theAquastar see Fig. 5 for restrictions in locationof vent terminal.

4single wall venting only. Usestainless steel (AL29-4C) orgalvanized pipe of 26 minimumgauge must be used. Eachconnection must be properlysealed.

4single wall venting only. Usestainless steel (AL29-4C) orgalvanized pipe of 26 minimumgauge must be used. Eachconnection must be properlysealed.

HORIZONTAL SIDE WALL* Maximum 15 feet with 2 elbows.Deduct 5 feet for each additional elbow.

Installing Flue collarRemove 4 screws from the top of the heater leaving theplate in place. The supplied exhaust collar must be fitted tothis heater before connecting the vent, align the exhaustcollar and tighten with the 4 screws.


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Fig 5: Side wall exit locations for mechanical draft vent terminals

SOFFIT

VENT HOOD

7MINIMUMABOVE

PUBLICWALKWAY

ONEF

OOT

ABOVEG

RADE

3ABO

VEANYF

ORCED

AIRINLETW

ITHIN

10 4M

IN

1MIN

4MIN

4MIN

4MI

N

1MIN

VENT HOOD MUST BEMOUNTED FOUR FEET AWAY

FROM DOORS AND WINDOWS

VENT HOOD MUST

BE MOUNTED FOUR FEET MINIMUMBELOW WINDOWS

VENT HOOD MUST

BE MOUNTED ONE FOOT MINIMUM

ABOVE DOORS AND WINDOWS

The approved vent terminal must be installed so that flue gases will not jeopardize people, overheat combustible structuresor enter into buildings, and so that proper clearances are maintained (See Fig 5).

a) The vent terminal shall not be less than 7 feet above a public walkway.b) The vent terminal shall terminate at least 3 feet above any (mechanical) air inlet within 10 feet.c) The vent terminal shall not be within a 6-foot radius from a gas meter or regulator.d) The vent terminal shall be a minimum of 6 feet from any combustion air inlet.e) The vent terminal shall terminate from an opening window, at least 4 feet below or 4 feet horizontally from the

opening.

f) The vent terminal shall terminate from a door, at least 1 foot above and 4 feet horizontally from the door.g) The vent terminal shall not be less than 3 feet from an adjacent building.h) The vent terminal shall not be less than 1 foot above grade.


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GAS LINE SIZING

The pressure regulator provided with the heater is adjustedto deliver the proper gas pressure (as indicated on the ratingplate and in the manual for altitude up to 2000 feet (660meters) above sea level. On appliances being installed above2000 ft (660 meters) elevation, the inlet gas pressure should

be set at installation to the value shown below.

NOTE: The gas pressures specified below refer topressures taken at the pressure tap on the gas inlet pipejust above the regulator (See Fig 6). These readingsshould be taken while the heater is operating at full input i.e. maximum water flow with the temperature dialselector turned all the way clockwise.

Above 4.500 ft consult your local gas provider.

GAS LINE SIZING

-It is strongly recommended that the Natural Gas pipebe Black Iron pipe the entire distance from the outsidemeter to the inlet of the Aquastar regulator. 1/2 BlackIron pipe up to 10 feet, 3/4 Black Iron pipe up to 40 feetand 1 Black Iron pipe up to 125 feet distances. Flex linetubing is NOT recommended, but if used then oversizeit.-It is strongly recommended that the LP Gas pipe besemi-rigid copper or Black Iron pipe from the outsideregulator to the inlet of the Aquastar regulator. For semi-rigid copper piping: 5/8 up to 20 feet and 3/4 up to 50feet distances. For Black Iron piping: 1/2 up to 30 feetand 3/4 up to 150 feet distances. Flex line tubing is NOTrecommended, but if used then oversize it.THESE FIGURES ARE FOR AQUASTAR SUPPLY ONLY, ALLOTHER APPLIANCES IN THE BUILDING WILL NEED TOBE INCLUDED IN THE PIPE SIZING.

National Fuel Gas Code requires that a sediment trap (drip

leg) be installed on gas appliances not so equipped. Thedrip leg must be accessible and not subject to freezingconditions. Install in accordance with the recommendationsof the serving gas supplier.

WARNING:The heater must be disconnected fromthe gas supply piping system during any pressure testing ofthat system at test pressures in excess of .5 psig.The water heater must be isolated from the gas supply pipingsystem by closing the manual shutoff valve during anypressure testing of the gas supply piping system at testpressures equal to or greater than .5 psig.The water heater, including the pressure regulator providedwith it, must not be operated at gas supply pressures inexcess of .5 psig. If overpressure has occurred, such asthrough improper testing of the gas lines or malfunction ofthe supply system, the gas valve and regulator must bechecked for safe operation.When your connections are made, check for gas leaks atall joints (not just the ones you made). Apply some soapywater to all gas fittings and gas valve. Soap bubbles are asign of a leak.NOTE:Do not apply soap solution to pilot filter screen orpilot orifice area. If you have a leak, shut off the gas. Afterverifying that required gaskets are in place, tighten

appropriate fittings to stop leak. Turn the gas on and checkagain with a soapy solution. Never test for gas leaks usinga match or flame.

GAS PIPING, CONNECTIONS

Before connecting the gas supply, check the rating plate onthe right side of the front cover to be sure that the heater israted for the same gas to which it will be connected.In the United States: The installation must conform withlocal codes or, in the absence of local codes, the NationalFuel Gas Code ANSI Z223.1/NFPA 54.

In Canada: The Installation should conform with CGA B149INSTALLATION CODES and /or local installation codes.

MAXIMUM INLET GAS FLOW PRESSURE SETTING

Altitude Natural Gas Liquid Propane

inches W.C: inches W.C:

0' - 2.000 ft 5.7" 10.5"

2.000 ft - 4.500 ft 4.6" 8.4"

Fig. 6 - Appliance pressure regulator(with directional arrow on reverse side pointing up)

GAS CONNECTIONS

NOTE: The AquaStar 125FX is supplied with a gaspressure regulator that must be installed on the heater

before attaching the gas supply line. See figure 6. Failureto install the gas regulator as shown in figure 6 will be aviolation of CSA certification of the unit. The regulatorsupplied with the heater is preset for the gas shown onthe rating plate to the correct pressure. It is an appliancelevel regulator designed for (low inlet) pressure (lessthan 1/2 Psig or 15 W.C.) DO NOT connect to anunregulated or high pressure propane line or to a highpressure commercial natural gas line.

GAS INLET PIPE

PRESSURE TAP

APPLIANCE PRESSUREREGULATOR(with directional arrow onreverse side pointing upward)

PLASTIC CAP


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FOR NATURAL GAS

Maximum Capacity of pipe in Cubic Feet of Gas per Hour for Gas Pressure of 0.5 Psig or less and a Pressure drop of 0.3in Water Column (0.75mbar).(Based on a 0.60 Specific Gravity Gas) Btu numbers given in thousands.

* EHD = Equivalent Hydraulic Diameter. The greater the value of EHD, the greater thegas capacity of the tubing.

FOR LP GASMaximum Capacity of Pipe in Thousands of BTU per Hour of Undiluted Petroleum Gases (at 11 inches Water Column InletPressure) (Based on a Pressure Drop of 0.5 Inch Water Column).

Follow boxed numbers for piping just one 125FX (example: B.I. Natural Gas pipe for 20 ft (6.1m). will handle 190,000btus (55.7 kWh). For multiple appliances combine the total btu input load and then refer to applicable chart below.

* EHD = Equivalent Hydraulic Diameter. The greater the value ofEHD, the greater the gas capacity of the tubing.

Maximum Capacity of Semi-Rigid (flexible, noncorrugated) Tubing in Thousands of BTU per Hour ofUndiluted Liquefied Petroleum Gases (at 11 inchesWater Column Inlet Pressure).

(Based on a Pressure Drop of 0.5 Inch Water Column)

* Source National Fuel Gas Code NFPA 54, ANSIZ223.1 - No Additional Allowance is necessary for anordinary number of fittings.

Nominal

Iron Length of Black Iron Pipe, Feet

Pipe Internal

Size, Diameter

inches inches 10 20 30 40 50 60 70 80 90 100 125 150 175 200

1/4 0.364 32 22 18 15 14 12 11 11 10 9 8 8 7 6

3/8 0.493 72 49 40 34 30 27 25 23 22 21 18 17 15 14

1/2 0.622 132 92 73 63 56 50 46 43 40 38 34 31 28 26

3/4 0.824 278 190 152 130 115 105 96 90 84 79 72 64 59 55

1 1.049 520 350 285 245 215 195 180 170 160 150 130 120 110 100

1 1/4 1.380 1050 730 590 500 440 400 370 350 320 305 275 250 225 2101 1/2 1.610 1600 1100 890 760 670 610 560 530 490 460 410 380 350 320

2 2.067 3050 2100 1650 1450 1270 1150 1050 990 930 870 780 710 650 610

Tube

size,

inches EHD*

10 20 30 40 50 60

1/2 18 EHD 82 58 47 41 37 34

3/4 23 EHD 161 116 96 83 75 68

1 30 EHD 330 231 188 162 144 131

1 1/4 37 EHD 639 456 374 325 292 267

Length of Flexible Corrugated Stainless Steel Tubing (CSST), Feet

Nominal

Iron Pipe Black Iron Pipe

Size, Length of Pipe, Feet

Inches 10 20 30 40 50 60 70 80 90 100 125 150

1/2 275 189 152 129 114 103 96 89 83 78 69 633/4 567 693 315 267 237 217 196 185 173 162 146 132

1 107 732 590 504 448 409 378 346 322 307 275 252

1 1/4 220 149 121 103 913 834 771 724 677 630 567 511

1 1/2 330 229 185 155 141 127 118 108 102 976 866 787

Tube

size

inches EHD*

10 20 30 40 50 60

1/2 18 EHD 129 91 74 64 58 53

3/4 23 EHD 254 183 151 131 118 107

1 30 EHD 521 365 297 256 227 207

1 1/4 37 EHD 971 661 528 449 397 359

Length of Flexible Corrugated Stainless Steel Tubing (CSST), Feet

Copper

Outside Length of Tubing, Feet

diameter

Inch 10 20 30 40 50 60 70 80 90 100

3/8 39 26 21 19 _ _ _ _ _ _

1/2 92 62 50 41 37 35 31 29 27 26

5/8 199 131 107 90 79 72 67 62 59 55

3/4 329 216 181 145 131 121 112 104 95 90


12/2412 6 720 606 601

Fig.7 - Water valve and water connectors, top view

WATER CONNECTIONS

Install the heater centrally in the building if possible andmake hot water piping runs as short as possible When facingthe heater, the cold water inlet will be on the right and the

hot water outlet on the left..Although water piping throughout your structure may be otherthan copper, we recommend that copper piping be used forat least three feet before and after the heater (follow localcodes if more stringent). Plastics or other PEX type plumbingline materials are not suitable for connecting directly to thewater heater. Keep water inlet pipe to no less than (19.05mm) diameter to allow the full flow capacity. If thecold and hot connections to the heater are reversed, theheater will not function.The 125FX is provided with one flexible type connector thatmust be connected to the cold inlet fitting of the water valve

as shown in Fig. 7. The union end of the flexible connectorshould be attached to the rear inlet port of the water valvewith the supplied washer gasket. No pipe dope or threadtape is to be used at this joint. The flexible hot wateroutlet line is supplied attached to the heater.Be certain there are no loose particles or dirt in the piping.Blow out or flush the lines before connecting to the waterheater. Full port valves should be installed on both the coldwater supply and hot water outlet lines to facilitate servicingthe heater (see Fig. 7). For installation on a private wellsystem with the use of a pressure tank, the lowest pressurerange setting recommended is 30-50 psi (2.07-3.45 bar).

Connecting the pressure relief valve (PRV)

The listed pressure relief valve supplied with the heater mustbe installed at the time of installation. Should a dischargeline be added to the PRV no valve is to be placed betweenthe PRV and the heater. No reducing coupling or otherrestriction may be installed in the discharge line. Thedischarge line must be installed such that it allows completedrainage of both the PRV and the line. The location of thePRV must be readily accessible for servicing or replacementand be mounted as close to the water heater as possible. Toinstall the PRV, a suitable fitting connected to an extensionon a T fitting can be sweated to the hot water line. SeeFig 8.

Fig. 8 - Plumbing and Pressure Relief Valve

PIPE PRV TOAPPROPRIATEDISCHARGE

HOT COLD


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ELECTRICAL CONNECTIONS

WARNING:For safety reasons, disconnect the power supply to the heater before any service or testing is performed.

WARNING: This heater must be electrically grounded in accordance with the most recent edition of the NationalElectrical Code, NFPA 70. In Canada, all electrical wiring to the heater should be in accordance with local codes and the

Canadian Electrical Code, CSA C22.1 Part 1. Do not rely on the gas or water piping to ground the metal parts of theheater.

CAUTION:Label all wires prior to disconnection when servicing controls. Wiring error can cause improper and dangerousoperation. Verify proper operation after servicing.The AquaStar 125FX requires an electrical power supply from 120VAC 60Hz circuit and must be properly grounded.- A means for switching off the 120 VAC power supply must be provided.- The heater is wired as shown in the wiring diagram. (Fig 9).

Fig 9: Wiring Diagram for AQ 125FX

7 - Diaphragm switch8 - ionization probe (flame sensor)

9 - fuse10 - pilot electrode

11 - electric control box12 -power cord13 - exhaust fan

1 - microswitch

2 - On / Off switch3 - temperature limiter

4 - flue gas safety device5 - burner electrovalve6 - pilot electrovalve


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OPERATING INSTRUCTIONS

Before operating the heater, make sure that the system isfilled with water.

Open the cold water inlet supply to the heater fully.Open a hot water faucet to permit the water to fill the heaterand the piping and to eliminate the air trapped in the system

Close the hot water faucet after the water flows freely andall the air has escaped from the system. The water heater isnow ready to operate.

FOR YOUR SAFETY READ BEFOREOPERATING YOUR HOT WATER HEATER

Warning: If you do not follow these instructionsexactly, a fire or explosion may result causing propertydamage, personal injury or loss of life.

A. This appliance is equipped with electronic ignition forlighting the pilot and main burners. When turning the heateron, follow these instructions exactly.B. Before operating the unit, set the On/Off switch to theOn ( ) position. The On/Off switch is located behind theflip-down coverplate on the front panel strip. Smell all aroundthe appliance area for gas. Be sure to smell next to the floorbecause some gas is heavier than air and will settle on thefloor.

WHAT TO DO IF YOU SMELL GAS- Do not try to light any appliance.- Do not touch any electric switch; do not use any phone

in your building.- Immediately call your gas supplier from a neighbors

phone. Follow the gas suppliers instructions.- If you cannot reach your gas supplier, call the firedepartment.

C. Use only your hand to push in the on/off control button.Never use tools. Follow these instructions exactly. If controlbutton is jammed, close the gas supply and call a qualifiedservice technician. Attempted forceful repair may result in afire or explosion.D. Do not use this appliance if any part has been underwater. Immediately call a qualified service technician toinspect the appliance and to replace any part of the controlsystem and any gas control which has been under water.

LIGHTING AND OPERATING INSTRUCTIONS

1. STOP! Read the safety information on the front panel ofthe heater.

2. The gas valve must be turned off by putting the On/Offswitch to position (see fig. 10). Wait five (5) minutesto clear out any gas. If you smell gas, STOP! Follow Bin the safety information above. If you dont smell gas, goto next step.

3. This water heater is equipped with a safety pilot burnerand an automatic ignition control system.

4. Set the ON/OFF switch (flip down cover plate on front

panel strip) marked / to the position. In thisposition the water heater is ready to use.

5. Verify that the power supply to the appliance is turnedon.

To operate the heater, set the ON/OFF switch to position .The switch is located behind the flip down cover plate on thefront panel strip.To shut down the gas to the heater, set the ON/OFF switch to

position

G661_

004

Temperature Adjustment Knob

Decrease temperatureand increase flow

Increases temperatureand decreases flow

Fig. 10 - Principles of Operation

The AquaStar 125FX LP and 125FX NG water heaters have

a gas control that modulates burner input in response toflow. Its purpose is to ensure that the hot water temperaturewill remain steady, although the demand for water flow mightvary (down to 1/2 gal/minute). To adjust the temperature onyour AquaStar, turn on a hot water faucet to its maximumflow. At the AquaStar, turn the large knob located beneaththe main gas controls on the front of the heater all the wayto the right (clockwise). See Fig 11. This will produce atemperature rise of approximately 90F at flow rates between.5 and 2.0 gallons per minute. Given that average incomingwater temperatures are 50F, this heater will produceapproximately 140F water at these flow rates. Turning the

dial all the way to the left (counterclockwise) will produce atemperature rise of approximately 45F for flow rates between1.0 and 4.0 gallons per minute. This will result in a higherflow rate, but at cooler temperatures. Turning the dial tolocations in between will give various temperatures between

6. Turn the hot water faucet on to the minimum flow requiredto activate the heater. The automatic ignition system firstignites the safety pilot burner which then ignites the mainburner in about 4 seconds. The power exhaust will thenactivate.

7. The pilot flame will extinguish 10-30 seconds after theburners come on. The burners will remain on until the hotwater tap is turned off.

NOTE: On a first time installation, existence of air in the gassupply line and in the water line may cause some ignitiondelay. In that case, repeatedly open and close the hot watertap in order to restart the ignition process until all the airhas been purged.

TO TURN OFF GAS TO APPLIANCE

Turn off the manual lever on the gas supply line to the heaterand set the ON/OFF switch to the OFF ( ) position, seeFig. 10.

SETTING THE WATER TEMPERATURE


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Fig. 12 - Characteristic Pilot Flame

Water Valve (Part # 8707002802): The water valve onthis heater should be serviced periodically. Lubricatecomponent #36 on page 22 with a small amount of silicon,faucet or lithium grease every two years to keep its o ringsfresh and pushrod sliding smoothly. Every 3-5 years replacecomponent #36 on page 22. The frequency will depend onthe mineral content of the water and conditions of use orwhenever signs of corrosion appear at the gas and water

valve joint. Periodically check that the water inlet filter (#27on page 22) is clean as well.NOTE: If water valve is removed, be sure to also inspect theo ring seal on the end of the right hand side water pipebefore re-installing. Lubricating the o ring with lithium orfaucet and valve grease is recommended.

Pilot Flame:The pilot flame should burn with a clean, sharp,blue flame and should resemble the diagram in Fig. 12. Ifthe flame is soft and yellow, the pilot burner orifice mayneed to be cleaned or serviced. The pilot flame should beapproximately 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.

Fig. 11 - Temperature Adjustment Knob

140 and 95F at various flow rates between 2.0 and 4.0gallons per minute. The position you select on thetemperature selector dial will depend on the temperature ofthe incoming water (50F is average in the U.S.). In warmweather regions where the incoming cold water is generallywarmer, or during the hot weather months in some otherareas a midway setting on the temperature selector knobwill produce a temperature rise of about 70F, giving an

output of approximately 120F. At this setting, if it is stillnecessary, one could mix a small amount of cold water in ashower and have a comfortable shower at about 3 gallons/minute. During the colder months, or in cold climate areas,it might be necessary to set the control all the way clockwiseto the right for maximum temperature rise.Do not supply the AquaStar 125FX with preheated water.For this type of application, purchase a solar model 125 BLPS or 125 B NGS.If the inlet water temperature to the water heater is verywarm the heater can produce temperatures that may befound to be too hot. A temperature balance shower valvecan automatically mix in cold water to reduce such hot water

temperature, in the event of any temperature instability withthe use of a temperature balance shower valve, refer toshower valve manufactures instructions for internaladjustment setting. Adjustments should be made to thehottest setting in the shower valve. Additionally thetemperature control of the heater can be adjusted to producea more comfortable hot water temperature.

MAINTENANCE AND SERVICE

REVIEW MAINTENANCE TABLE ONTHE BACK OF THIS MANUALApproximately once a year, the AquaStar should be checkedand cleaned. To remove the front cover, first remove theincandescent particle tray, then pull off the temperatureadjustment knob and unscrew and remove the plastic collar.Unscrew the central screw located at the bottom of thefront cover. Pull main cover out toward you and lift up andout. THE FOLLOWING OPERATIONS SHOULD BEPERFORMED BY A QUALIFIED SERVICE PERSON:

Vent System:Should be checked annually. Clean and repairas needed.

To clean the pilot burner and/or the pilot orifice:Turn offthe gas at the unit (Position ). Remove the cover of theheater. To do so, pull off the temperature knob and unscrewand remove the temperature knob collar. Pull main coverout toward you and lift up and out. The pilot orifices shouldalso be cleaned or replaced. Do not enlarge the orifice

(see fig. 13).Do not use any wire or sharp object to cleanorifices. Natural gas orifices are large enough that you canusually clean them by blowing through them. LP orifices, onthe other hand, are too small to clean and should be replaced.See #3 in Trouble Shooting Section. To access the pilotorifice, remove 2 screws holding pilot assembly in place.Then loosen the compression fitting and lift up pilot burnerto expose pilot orifice.

Fig. 13 - Pilot burner with pilot orifice

PILOT ORIFICE

Correct gap between pilotburner tip and electrode tip

Piezo Electrode

Flame sensor

PiezoElectrode


16/2416 6 720 606 601

6. Cross over in water linesTo confirm there is no cross-over in the plumbing, shut offthe cold water supply to the AquaStar water heater andopen a hot water faucet. There should not be any waterflowing at that faucet. Water running is a sign of a plumbingcross-over. Consult your plumber.

7. Microswitch needs to be adjusted or replaced.If you do not hear a click when a tap is opened, the

microswitch needs to be adjusted. See Fig. 15 (#11) forlocation and see Fig. 14 for adjustment. The microswitchmay need to be replaced.

G871_

212

Adjusting screw

Fig. 14 - microswitch adjustment

Main Burner Flames:The main burner flames should beblue, with a more intense blue cone in the center core. Yellowflames could be a sign of wrong size gas orifices or dirtyburners, or a blockage on the heat exchangers fins. If someburners have yellow flames while others have good flames,it is likely that dust, lint or spider webs have partially cloggedthe burner venturis. To clean the burners, contact a gasservice person.

Mineral Scale Build-up:AquaStars, when operated at lowertemperature settings, do not accumulate mineral buildup. Ifhowever, the heater is used at the higher temperaturesettings and the water has a high mineral content, periodicdescaling may be necessary. The heating coils should beflushed with a descaling solution.Consult your dealer or service person.

TROUBLE SHOOTING (see maintenance table)

IntroductionThe AquaStar 125FX pilot and burners are ignited by a waterflow valve. Numerous water related problems can causethis water valve to malfunction such as: Insufficient waterflow volume to activate the burners at its minimum flowrequirement; Dirt in the water flow valve causing it tomalfunction; Sediment build-up in faucet aerators, or showerheads; Uneven pressures between cold and hot with singlelever faucets; Plumbing cross overs. These water flow relatedproblems can cause the heater to deliver less than its fulloutput, or to fail to ignite or to shut down completely.

Problems are stated in upper case, bold face. Most commoncauses for the problems follow in order of likelihood. The

suggested solutions require that the cover be taken off. Todo this, pull off the temperature knob and unscrew andremove the temperature knob collar. Pull main cover outtoward you and lift up and out.

NO SPARK AT THE PILOT

1. On/Off switch is not On (Position ).The On/Off switch is located behind the flipdown coverplate on the front panel strip. See fig. 10.

2. Bad electrical connections.Be certain that all electrical connections are clean, tight,and free of any moisture.

3. Water flow is not sufficient to activate heater.Water flow rate at faucet is below minimum flow needed toactivate heater. When temperature adjustment knob is turnedall the way clockwise, the AquaStar model 125FX requires1/2 gallon per minute flow to activate the heater. As areference, this is a flow which would fill a quart jar in 30seconds. If the temperature adjustment knob is turned fullycounterclockwise, a flow rate of 1.1 gallons/minute is requiredto activate the heater.

4. Bad fuse

Check the viability of the fuse (see Fig 9 (#9) for locationof fuse). Replace if necessary.

5. Water inlet filter is cloggedWater flow is restricted, preventing flow needed to activateheater. Clean water inlet filter screen.

Pilot does not spark with

water flow

Pilot always sparks

without water flow

1 Close water tap 1 Close water tap

2 Remove screw cap and

unscrew till sparking starts

2 Screw in adjusting screw

until it stops sparking

3 Screw in turning one and a

half turns

3 Continue to screw in

turning one and a halfturns more

8. Cold incoming water connection made to wrong sideof heaterMake sure cold water inlet connection is on the right sidewhen you are facing the AquaStar.

9. Water valve parts may be dirty or components damagedFirst check that venturi is free of dirt particles. Water valveand component parts must be totally free of dirt.Mineral deposits can eventually (3-5 years in hard waterareas) corrode the water valve parts to a point where they

will need replacing. Any sign of moisture at the bleed holeis a sign that the water valve needs to be replacedimmediately.

10. Poor circuit connections at the ECO (overheat sensor)or the flue gas safety deviceIgnition sparker will not operate if the electrical circuit isinterrupted. Check that the connections to the ECO aresecure and tighten if necessary.

11. Reset electrical power to heaterIf resetting the electrical power corrected the symptom thenlikely the units Safety Spill switch (Flue gas safety device -

#33 on page 20) had tripped from a flue blockage duringthe previous usage. Inadequate combustion air to the roomarea can also cause the unit to improperly vent. Improperventing or insufficient combustion air must be corrected.Consult a licensed professional to inspect the installation.


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SPARKS APPEAR AT PILOT WHEN HOT WATER TAP ISTURNED ON, BUT PILOT AND BURNERS WILL NOT IGNITE

1. Air in the Gas LineNote:Normally this is a problem only at the time of initialinstallation, after the pipes have been worked on, or after apropane tank has been allowed to empty, or after the heaterhas been shut down for a long time.Bleed all the air trapped in the gas line by turning the hot

water faucet on and off until the air has been cleared fromthe line.

2. No gas to the AquaStarA. Gas cock on gas line may not be openB. Gas regulator may be shut or damaged. Replace or unlockthe regulator. Note:The regulator furnished with the heateris exclusively designed for low gas pressure (less than psig). Excessive pressure will lock it up. Locking usuallyhappens when the gas pressure between the gas tank andthe water heaters gas regulator has not been properlyregulated. See Page 2 for recommended correct gaspressure. To unlock a regulator, consult your gas supplier ora gas technician.

3. Pilot orifice clogged or gas valve is dirtyClogging of the pilot burner can be caused by dust in theair or dirt in the gas. The pilot orifice or gas filter may needto be cleaned or replaced. See Fig. 13.

4. Water valve assembly needs to be checkedIf the pilot orifice is clean, the water valve assembly shouldbe checked. The adjustment screw on the water valve micro-switch may not be tight enough (fig. 14). Remove centralcap beneath micro-switch assembly, carefully loosen theadjustment screw until the pilot light ignites. At that point

retighten the screw one and a half turns. See Fig 14.

5. Pilot electrovalve switch may need to be replaced (seefig 9).Measure millivoltage at pilot electrovalve (see Fig 9).

6. Control Box may need to be replaced (see fig 9).Check wire connections and test operation of control box(see Fig 9).

PILOT SPARKS CONTINUOUSLY WITH NO WATERRUNNING

1. Microswitch needs adjustmentIf no water is running, but pilot electrode continuously sparks,the microswitch screw to the water valve needs adjustment.See Figure 14.

PILOT LIGHTS BUT BURNERS WILL NOT COME ON

1. Confirm the flame sensor is in its proper position. seeFigure 12.

2. Poor circuit connections at the flue gas safety deviceThe burners will not come on if the powered fan exhaust isnot working. Check that the unit is plugged in and that thesensors for the flue gases are secure.

3. Confirm the ECO connections are secure.

4. The Control Box may need to be replaced(see Fig. 9).Check wire connections and test operation of control box(see Fig 9).

5. Burner electrovalve switch may need to be replaced(see Fig. 9).

MAIN BURNERS GO OUT DURING HOT WATER USE

1. Deficient exhaustion of flue gasesCheck that vent is correct and clear of any obstructions,that sensors for flue gases are secure and that electricalconnection has been made. If the heater will not come backon, it will be necessary to turn the electrical supply to theheater off and then on again.

2. Flow rate diminished below activation rateBe certain that water flow is not less than required amountto activate heater.

3. Unbalanced pressure in waterlinesThe added restriction caused by the Aquastar in the hotwater system can result in uneven pressures between thecold and the hot. In such cases when mixing cold water atthe tap, the lower hot water pressure may be overpoweredby a much higher cold water pressure, which may cause theAquastar burners to shut down (deactivate). Make sure faucetaerators or shower heads are free of minerals. Do not addany flow restrictor to the shower head.

Typically this deactivation symptom is a result of the hotwater being too hot to use comfortably. Warm inlet watergenerally causes this. Lowering the control knob setting

and/or reducing the inlet gas supply to the heater shouldcorrect this deactivation symptom.

4. ECO (overheat sensor) tripped due to overheatingDo not feed preheated water to this water heater.

5. Minimum inlet pressure on well pressure tank isinadequate

Check the inlet water pressure. For installation on a privatewell system with the use of a pressure tank, the lowestpressure range setting recommended is 30-50 psi (2.07-3.45 bar).


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WATER IS TOO HOT

1. Temperature Selection too highTurn the temperature adjustment knob counter-clockwise(to the left) to lower the maximum water temperature.Note: This will increase the activation flow rate.

2. Inlet water temperature is very warm (60-75F)Reduce inlet gas supply to lower the heaters degree rise.

Note:Only the Model 125BS should be used if the inletwater is preheated.NOTE: Only the model 125B LPS or 125B NGS should beused if the inlet water is preheated.

3. Inlet filter screen is clogged, restricting flowRemove screen and clean it.

WATER IS NOT HOT ENOUGH

1. Temperature selection is set too low.Change the setting. Turn the temperature selector knobclockwise (to the right). Note: this will decrease theactivation flow rate.

2. Gas pressure is insufficientIt is extremely important for a tankless instantaneouswater heater to have the right size gas line to obtain thecorrect gas pressure. See specifications on page 2. Unlikestorage tank water heaters, the burners of a tankless waterheater must be very powerful to heat water instantaneouslysince they do this only at the time hot water is actuallybeing used. It is therefore imperative that the gas pressurerequirement be met exactly. Insufficient gas pressure willdirectly affect the water temperature at the time of usage.

See page 2 for correct gas pressure settings and see page11 for proper gas line sizing.

3. Gas supply is insufficientMake sure your main gas line is fully opened. If using LPgas, be sure that the size of the propane tank is adequate tosupply the required gas pressure. See gas pipe sizing charton page 11.

4. Cold water is mixing with the hot water between theAquaStar and the outlet

Compare water temperature at outlet of the AquaStar (holdthe AquaStars outlet pipe with your hand) and at the tap.

If these two are very different, check for mixing valve orplumbing crossover (see NO SPARK AT THE PILOTparagraph 4). Where automatic anti-scald valves arerequired by code, lower the temperature setting on theAquaStar as much as possible and balance the pressurebetween cold and hot water after the AquaStar.

5. Parts in water valve are dirty or damaged, which will

prevent the gas valve from being fully opened.

If the internal water valve parts are damaged from waterquality or use, or there is evident corrosion where the watervalve and gas valve connect, then immediate service is

needed. See step 9 under the problem NO SPARK AT THEPILOT. White vinegar should be applied first to any corrosionbefore the loosening of screws.

HOT WATER TEMPERATURE FLUCTUATES / UNITDEACTIVATED

1. Unbalanced pressure in waterlinesThe added restriction caused by the Aquastar in the hotwater system can result in uneven pressures between thecold and the hot. In such cases when mixing cold water atthe tap, the lower hot water pressure may be overpoweredby a much higher cold water pressure, which may cause the

Aquastar burners to shut down (deactivate). Make sure faucetaerators or shower heads are free of minerals.Do not add any flow restrictor to the shower head.

Typically this deactivation symptom is a result of the hotwater being too hot to use comfortably. Warm inlet watergenerally causes this. Lowering the control knob settingand/or reducing the inlet gas supply to the heater shouldcorrect this deactivation symptom.

2. Temperature balance valvesIf the inlet water temperature to the water heater is verywarm the heater can produce temperatures that may befound to be too hot. A temperature balance shower valve

can automatically mix in cold water to reduce such hot watertemperature, in the event of any temperature instability withthe use of a temperature balance shower valve, refer toshower valve manufactures instructions for internaladjustment setting. Adjustments should be made to thehottest setting in the shower valve. Additionally thetemperature control of the heater can be adjusted to producea more comfortable hot water temperature.

See SETTING THE WATER TEMPERATURE section.

3. Cold water is mixing with the hot water between theAquaStar and the outletSee #4 under NO SPARK AT THE PILOT.

4. Inlet water pressure is erratic due to inadequate supplywater pressure or saturated pressure tank on wellsystemCheck the inlet water pressure. For installation on a privatewell system with the use of a pressure tank, the lowestpressure range setting recommended is 30-50 psi (2.07-3.45 bar). Confirm that the pressure tank is not water logged.

5. Gas pressure is too lowSee page 2 for correct specifications.

EXHAUST FAN DOES NOT OPERATE

1. Check the fuse (see fig 9)

2. Check all electrical connections

3. Check adjustment of microswitch (see Fig. 14)

FAN CIRCULATES WHEN HOT WATER IS SHUTOFF

1. Check adjustment of microswitch (see Fig. 14)

FAN OPERATES WITHOUT WATER FLOW

1. Unplug the heater and first check that all electrical andelectronic connections in the heater are clean and tight.

2. Check adjustment of microswitch (see Fig. 14).

3. Control box may need to be replaced (see Fig 9). Check wireconnections and test operation of control box (see Fig 9).


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Fig. 15 - Diagram of AquaStar 125FX

1. Heat exchanger2. Pilot assembly3. Burner manifold gas

pressure test nipple4. Main gas burner5. Pilot gas tubing6. Gas valve

7. electric control box8. Power cord9. on/off switch

10. Temperature adjustment selector11. Microswitch12. Gas inlet gas pressure test nipple13. Exhaust Fan14. Flexible hot outlet

5

11

1

4

9

10

12

2

6

8

7

13

3

14

6 720 606 601-12.1AL


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Fig. 16- INTERIOR COMPONENTS DIAGRAM AND PARTS LIST


21/24216 720 606 601

Fig. 16

INTERIOR COMPONENTS DIAGRAMAND PARTS LIST 125FX

1 Cover 8 705 421 7752 Temperature adjustment knob 8 702 000 1113 Temperature adjustment collar 8 700 403 0084 Draft diverter 8 705 505 4515 Heat exchanger 8 705 406 2356 Overheat sensor (ECO) 8 707 206 0407 Main burner 8 708 120 298 NG7 Main burner 8 708 120 296 LPG8 Burner assembly washer 8 710 103 060

10 Pilot burner 8 718 105 051 NG10 Pilot burner 8 708 105 491 LPG

11 Piezo electrode 8 708 107 00612 Pilot injector 8 708 200 069 NG12 Pilot injector 8 708 200 312 LPG13 Pilot tube 8 700 707 34914 Washer pilot tube 8 700 103 17315 Gas valve 8 707 011 949 NG15 Gas valve 8 707 011 950 LPG16 Diaphragm switch 8 708 504 021 NG16 Diaphragm switch 8 708 504 049 LPG17 Pilot electrovalve 8 708 501 24918 Burner electrovalve 8 708 501 25019 Cold water pipe 8 700 705 627

20 Exhaust fan assembly 8 707 204 02321 Exhaust fan cable 8 704 401 16822 Outlet flex hose 8 700 703 13923 Washer 8 700 103 65824 Water valve 8 707 006 36125 Water valve cover 8 705 500 10126 Diaphragm 8 700 503 09227 Water inlet filter 8 700 507 00128 Water valve selector screw 8 708 500 28929 Volumetric water governor 8 705 705 02130 Venturi 8 708 205 27931 Electric control box 8 707 207 106

32 Fuse T2,5A 1 904 521 34233 Flue Gas Sensor 8 707 206 30534 Microswitch 8 707 200 00735 Set of cables 8 704 401 17036 Pushrod 8 700 306 11437 Washer connection gasket 8 710 103 04338 Water elbow fitting 8 700 703 11439 Connecting pipe hot 8 700 715 17840 Water valve set screw 8 703 401 05141 Washer 8 710 103 04542 Flame sensor 8 708 107 00743 Exhaust pipe union 8 705 504 093


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Fig. 17- Flow chart of Aquastar 125 FX


23/24236 720 606 601

LIMITED WARRANTY

Aquastar

GeneralAquastar water heaters are warranted by the Manufacturer(BOSCH) through BBTNorth America. BBTNorth America(BBTNA) will furnish a replacement heat exchanger and willfurnish a replacement of any other part which fails in normaluse and service within the applicable periods specifiedbelow, in accordance with the terms of this warranty. TheBBTNA replacement will be warranted for the unexpiredportion of the original warranty. This warranty will be validonly for water heaters in possession of the original purchaseras recorded on the warranty card.

The heat exchangerIf the heat exchanger fails within twelve (12) years after theoriginal installation and operation BBTNA will furnish areplacement heat exchanger. However, if the water heateris installed in other than a single family dwelling this heatexchanger warranty is limited to two (2) years from date oforiginal installation and operation.

ExceptionsThis warranty will not apply:1. to defects or malfunctions resulting from failure to properly

install, operate or maintain the unit in accordance with

the printed instructions provided;2.to damage or abuse, accident, neglect or freezing and

other acts of nature;3. to damage resulting from operation with either the flame

sensor rod or overheat sensor removed;4. to failure of the heat exchanger resulting from the

operation of the water heater in a corrosive atmosphereor at water temperatures exceeding the maximum rating,or if the water heater is not supplied with potable water;

5. to defects or damage cause by any attachmentor modification, including any energy-saving device.

All other partsIf any other part fails within two (2) years after originalinstallation and operation, BBTNA will furnish a replacementpart free of charge.

Shipping costsIn addition to supplying the replacement part(s), BBTNAwill provide ground service delivery for these parts. Expeditedor upgraded shipping will be charged to the customer.

Service labor costsThis warranty does not cover any labor costs associatedwith service, removal or re-installation of part(s). All suchcosts must be borne by the Purchaser. Additionally, thiswarranty does not cover any labor costs associated withservice, removal or re-installation of the original water heateror a replaced water heater.

NOTE : the water heater must be free of damaging scaledeposits and not subject to gas pressures greater than thoseshown on the rating plate, which must not be altered, defacedor removed.

How to Make a ClaimAny claim for warranty parts should be made to your localdealer, distributor or to BBTNA. If BBTNA, please contactthe Technical Support Department:

BBTNORTH AMERICA340 Mad River ParkWaitsfield, VT 05673Phone: 800-642-3111www.boschhotwater.com

In most cases, the dealer or distributor will be able to promptlyhonor your claim and subsequently notify BBTNA. However,all replacements are made subject to validation by BBTNAof in-warranty coverage. The damaged or defective itemmust be made available in exchange for the replacement.

MiscellaneousNo one is authorized to make any other warranties on behalfof BBTNA. It is expressly understood that the replacementwarranty of BBTNA shall be in lieu of any and all otherwarranties, express or implied, including warranties ofmerchantability or fitness for a particular use or purpose,and further that BBTNA shall not be liable for any loss ordamage directly or indirectly arising from the use of the hotwater heater, or for any consequential damages arising fromsuch use (including damages from water leakage). BBTNAsole liability with respect to any defect shall be for thereplacement of the defective part(s). Some states do notallow such limitations and exclusions, so the above may notapply to you.This warranty gives specific legal rights. You may also haveother rights which vary from state to state.


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Installer Checklist, to be performed by installer upon installation

Serial Number ___ ___ ___ ___ ___ ___ ___ ___ (8 digit serial number is located on rating plate on right side panel)

Gas Pressure Reading Static__________ Operating__________

Building Water Pressure __________ Range if on Well system __________

Installing Company _____________________________________________

Installer name _____________________________________________

Address _____________________________________________

Phone _____________________________________________

Installation manual should be left with the owner after the installation is tested and completed

61egapeesELBATECNANETNIAM

RAEYYREVE SRAEY2YREVE SRAEY5-3YREVE

EVLAVRETAWETACIRBUL

EVLAVRETAWDLIUBER

NEERCSRETLIFRETAWTCEPSNI

YLBMESSATOLIPTCEPSNI

YLBMESSATNEVTCEPSNI

RENRUBNIAMTCEPSNI

VULCANO Termodomsticos S.A.Estrada de Cacia

3801 - 856 Aveiro - PORTUGAL

Replacement Parts available from:

BBTNORTH AMERICABosch Group

Bosch Water Heating340 Mad River Park

Waitsfield, VT 05673Phone 800-642-3111Fax (802) 496-6924www.boschhotwater.com

Documents

Aquastar 125FX Manual