INSTALLATION AND OPERATING INSTRUCTIONS FOR AUTOMATIC

INSTANTANEOUS TYPE WATER HEATERS FOR USE WITH NATURAL AND

LIQUEFIED PETROLEUM GAS
MODEL 125B LP and 125B NG (Flow Modulated)
Suitable for water (potable) heating and space heating
Intended for variable flow applications with steady cold water inlet temperatures. For preheated domestic
hot water, install the 125 BS model. For recirculating applications, install the 125 BL model.

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.

- Installation and service must be performed by a

qualified installer, service agency or the gas supplier.

TABLE OF CONTENTS
6 720 605 297 PT 862 (12.98)

Specifications .................................................... Page 2

WARNING : Improper installation, adjustment, Rules for safe operation .................................... Page 4
alteration, service or maintenance can cause injury Locating the Heater ........................................... Page 5
or property damage. Refer to this manual. For Combustion Air Requirements ........................... Page 5
assistance or additional information consult a Mounting the Heater .......................................... Page 6
qualified installer, service agency or the gas supplier. Venting the Heater ............................................. Page 6
Upon completion of the installation, these instructions Gas Connections ............................................... Page 7
should be handed to the user of the appliance for Water Connections ............................................ Page 8
future reference. Safety before lighting the pilot ............................ Page 8
Lighting instructions ........................................... Page 9
FEATURING: Automatic Variable Power Modulating Gas Setting water temperature ................................. Page 9
Valve Maintenance & Service ...................................... Page 9
Trouble Shooting ............................................. Page 10
Diagram of AquaStar ....................................... Page 13
Components and Parts List ............................. Page 14

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 This well engineered, gas water heater has all the fea- AquaStar 125B LP and 125B NG Specifications
tures a water heater should have:
It operates on the principle of heating water instantaneously
“on demand”. When a hot water faucet is opened, cold Gas Input max.: 117,000 Btu/hr
water flows through the coils of the heat exchanger in the min.: 28,000 Btu/hr
Aquastar. This same flow opens the gas valve, and the
burners are ignited by the pilot flame. The heat exchanger Water Connection 1/2” Thread fitting
coils absorb the heat generated by the burners and trans-
fer heat to the water. When the hot water faucet is shut H x W x D 29 3/4” x 18 1/4” x 8 3/4"
off, the gas valve automatically closes and the burners
turn off. Your hot water faucet is an ignition key to turn on Vent 5”
the water heater, giving you control over your hot water
energy use. Each time you turn off your hot water faucet, Gas Connection 1/2” NPT thread
you also shut off the water heater.
Min. Water Pressure 18 Psi at 4 GPM

FEATURES Max. Water Pressure 150 Psi

- High Quality Materials for Long Working Life. Shipping Weight 42 LB

- Copper heating coils for endless supply of hot water. Net Weight 39 LB

- Burner output proportional to hot water flow demand 1.8 GPM at 90° rise
for maximum energy efficiency.
3.7 GPM at 45° rise
- Safety thermocouple at pilot burner.
Min. Water Flow 1/2 gal/min
- Automatic overheating protection shut-off sensor.
LP GAS Supply Pressure inlet. min. 11” W.C.
- Stainless steel burners with stabilized blue flame. max. 14” W.C.*

- Built-in corrosion resistant draft inducer. LP GAS Manifold pressure 9.0” W.C.**

- Compact space saver: mounts on a wall with two hooks. Natural Gas Pressure inlet min.: 7” W.C.
max.: 14” W.C.*
- Easily removable one-piece cover.
Natural Gas Manifold Pressure 4.2 W.C.**
- Easy one person installation.
* Inlet gas pressure must not exceed this value
- Adjustable water flow restrictor to ensure that water flow
demand will not exceed the heating capacity of the ** For purposes of input adjustment
heater.

- Easy pilot flame lighting with push button piezo ignition.

UNPACKING THE AQUASTAR HEATER

This heater is packed securely. The box includes two water connection fittings, a gas pressure regulator, an incandescent
particle tray, 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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 D861_059

FRONT VIEW SIDE VIEW

MINIMUM INSTALLATION CLEARANCES FROM COMBUSTIBLE AND

NON COMBUSTIBLE MATERIALS FOR ALCOVE INSTALLATIONS

MODEL 125B / 125B LOW

PRESSURE / 125B SOLAR / 125X
TOP (A) 12"
FRONT (B) OPEN
BACK 0"
SIDES 4"
FLOOR (C) 12"
FLUE DIAMETER 5"

AQUASTAR MODELS 125B / 125BL / 125BS / 125X

3

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 If you are using the AquaStar for combined space heating and potable water heating (see
schematic diagram below), all piping and other components connected to the system must
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 do-
mestic, 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
COMBINATION SPACE AND POTABLE WATER HEATING SYSTEM USING THE AQUASTAR
OR ANY OTHER HEAT SOURCE.
Open loop potable water and combination space heating system*
* To be used with a tank, check local codes. May not be permitted in some jurisdictions.

1. Maximum operating temperature of 125B: 140°F

2. Maximum heating capacity: 40°F rise 20°F rise
AquaStar 125B - 80,000 BTU/hr 40,000 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.

GENERAL RULES TO FOLLOW 2. Carefully plan where you install the heater. Correct
FOR SAFE OPERATION combustion air supply and flue pipe installation are very
important. If not installed correctly, fatal accidents can be
1. You should follow these instructions when you install caused by lack of air, carbon monoxide poisoning or fire.
your heater. In the United States: The installation must
conform with local codes or, in the absence of local codes, 3. The place where you install the heater must have
the National Fuel Gas Code ANSI Z223.1/NFPA 54. enough ventilation. The National Fire Codes do not allow
In Canada: The Installation should conform with CGA water heater installation in bathrooms, bedrooms or any
B149.(1,2) INSTALLATION CODES and /or local occupied rooms normally kept closed. See the section
installation codes. below on locating the heater.

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 4. You must vent your heater. See section on Vent Pipe Do not obstruct the flow of combustion and ventilation
Connections, Page 5. air to the appliance. If installed near a clothes dryer it is
very important that the dryer be properly vented. Failure
5. The appliance must be disconnected from the gas to properly vent a dryer could result in a gradual
supply piping system during any pressure testing at accumulation of lint on the water heater fin coils and
pressures in excess of 1/2 Psig (3.5 kPa). burners, leading to a dangerous condition of venting
The appliance must be isolated from the gas supply piping blockage and poor unsafe combustion.
system by closing its individual manual shutoff valve during
any pressure testing of the gas supply piping system at 4. Your hot water lines should be kept short to save energy.
test pressures equal to or less than 1/2 Psig (3.5Kpa). It is always best to have hot water lines insulated. Having
The appliance and its gas connection must be leak tested a floor drain or sink nearby is handy in case you need to
before placing the appliance in operation. drain water from your heater.

6. Keep water heater area clear and free from WARNING: The water in this water heater is cold and
combustibles and flammable liquids. Do not locate the always remains cold except for the times that hot water is
heater over any material which might burn. being used DO NOT INSTALL IN AN AREA WHERE IT
COULD FREEZE.
7. Correct gas pressure is critical for the optimum This heater is neither designed for nor approved for
operation of this heater (see specifications on page 2). outside installation.
Gas piping must be sized to provide the required pressure
at the maximum output of the heater, while all the other WARNING: Flammable materials, gasoline,
gas appliances are in operation. Check with your local gas pressurized containers, or any other items or articles
supplier, and see the section on connecting the gas supply. that are potentially fire hazards must NOT be placed
on or adjacent to the heater. The appliance area must
8. Should overheating occur or the gas supply fail to shut be kept free of all combustible materials, gasoline and
off, turn off the gas supply at the manual gas shut off valve other flammable vapors and liquids.
on the gas line.
COMBUSTION AIR REQUIREMENTS
9. Do not use this appliance if any part has been
underwater. Immediately call a qualified service technician Observe the following instructions concerning combustion
to inspect the appliance and to replace any part of the air.
control system and any gas control which has been
underwater. Appliances located in unconfined spaces:
a) An unconfined space is one whose volume is greater
PROPER LOCATION FOR INSTALLING YOUR than 50 cubic feet per 1000 Btu per hour of the combined
HEATER rating of all appliances installed in the space. That would
be 5850 cubic feet for the AquaStar 125B alone.
Carefully select the location of your new heater. For your b) In unconfined spaces in buildings of conventional frame,
safety and for proper heater operation, you must provide masonry, or metal construction, infiltration is normally
an abundant supply of combustion air and a proper venting adequate to provide air for combustion, ventilation, and
installation. dilution of flue gasses.
The heater may still operate even when improperly vented.
It will, however, be less efficient and could eventually Appliances located in confined spaces:) The confined
damage the heater. It could even result in human sickness space must be provided with two permanent openings,
or death due to oxygen deprivation and carbon monoxide one commencing within 12 inches of the top and one
poisoning. Follow the guidelines below: commencing within 12 inches of the bottom of the
enclosure. Each opening must have a minimum free area
1. Place your heater as close to a vent or chimney as of one square inch per:
possible. - 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
2. National building codes require that you do not install ducts.
this appliance in bathrooms, bedrooms, unvented closet - 4000 Btu/hr if all air is taken from the outside by direct
or any occupied rooms normally kept closed. openings or vertical ducts.
Louvers, grills and screens have a blocking effect. If the
3. Simultaneous operation of other appliances such as effective free area is not known, increase the sizes of your
exhaust fans, ventilation systems clothes dryers, fireplaces openings by 75% if your louvers are wood and by 30% if
or wood stoves could create a vacuum effect in your home your louvers are metal. Refer to the National Fuel Gas
which could cause dangerous combustion by-products to Code for complete information. In buildings of tight
spill back into your home rather than venting to the outside construction all air should be taken from outside.
through the flue. Confirm that your Aquastar is venting
properly when all these other appliances are running. See
section on venting.

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 CLEARANCES The incandescent particle tray (shipped loose in the car-
ton with the water heater) must be attached at the bottom
The Aquastar 125 B is design certified for installation on a of the water heater front cover at the time of installation.
combustible wall and for installation in an alcove with the Use the screws provided. See figure 2
minimum clearances to combustible and non -combustible
construction listed below
A. Top 12 inches ( 305 mm)
B. Front Open
C. Back 0 inches
D. Sides 4 inch (102mm)
E. Bottom 12 inches (306 mm) SCREWS

INCANDESCENT PARTICLE TRAY

Clearance from vent is dependent upon the clearance
rating of the venting material used. For example: type B-1 Fig. 2 - Incandescent Particle Tray Illustration
vent is approved for 1 inch clearance, B-2 vent for 2 inch,
etc. VENTING
Note: Minimum clearance to combustible materials should
Vent pipe connection. WARNING: Do not reduce the
not be less than 6" for single wall flue pipe. Note that this
vent pipe size.
clearance can be reduced if combustible material are
This appliance must be vented to the outside following all
protected as per table VI of the National fuel Gas Code or
local ordinances and specifications for installing a gas
if Type B gas vent is used.
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
MOUNTING INSTALLATION vent size must be 5". Minimum height must be 6 feet,
provided there are no elbows. Termination of vent
The Aquastar 125 B is design certified for mounting on a must be 2 feet above any obstruction within a 10 foot
wall. radius. Consult your gas utility or National Fuel Gas
Do not install this appliance on a carpeted wall or over Code if vent will have elbows or share venting with
floor covering which is combustible, such as carpet. The another appliance. The vent connector should have
heater must be mounted on a wall using appropriate as much vertical rise as possible (minimum 12”) before
anchoring materials. If wall is a stud wall sheathed with any horizontal run. The appliance must be located as
plasterboard, it is recommended that support board(s), close as practicable to a chimney or vent. The vent pipe
either 1x4’s or 1/2" (minimum) plywood first be sections must be secured to each other with sheet metal
attached across a pair of studs and then the heater screws. Keep in mind the minimum clearance from the
should be attached to the support boards. See Fig 1. top of your heater. Remember also that single wall vent
Expansion and contraction of piping due to changing water pipe connectors require a 6 inch clearance from
temperature in the pipes imparts movement to the heater combustibles. National Fuel Gas Code specifies double
which, if mounted directly to a brittle, friable board, such wall — Type “B” — vent pipe be used in cold climates and
as plasterboard, can cause failure of mounting. for gas vents running through attics. We consider double
Before installing the unit, be certain you have the correct wall vent pipe preferable in all circumstances. Any vent
heater for your type of Gas – Propane or Natural Gas. section greater than 45 degrees from vertical is considered
Identification labels are found on the shipping box, and on horizontal. Horizontal sections of vent connectors must
the rating plate which is located on the right side panel of slope upwards at least 1/4 inch for every foot of its
the cover. Also, each burner orifice is stamped with a horizontal length. Keep the horizontal section short and
number (79 for LPG and 120 for Natural Gas). avoid too many elbows.
WARNING
Note: The burners of an instantaneous “on demand” water
heater such as the AquaStar are only on at the time that
WALL STUDS hot water is actually being used, the venting stack is
therefore cold except for the short durations when hot water
13 ¼” is being used, it is therefore very important that the venting
SUPPORT BOARD and air supply be adequate to provide a good positive
draft as soon as the burners turn on. See venting guide
on back page.
The AquaStar 125B instantaneous water heaters have
built-in draft diverters and are designed for indoor
1” X 4” installation only. The draft diverter outlet must be connected
SPACE BOARD to a clear, unobstructed vent of the same size, or larger.
In Canada, CAN/CGA-B149 Installation Code for
detailed requirements
Fig. 1 - Mounting the Heater In U.S.A., ANSI Z223.1 - NFPA 54, national Fuel Gas
Code for detailed requirements.
6

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 The flue connection for the AquaStar 125B is 5 inches. (660 meters) above sea level. On appliances being
However, in Canada, for installations at high altitude (2000- installed above 2000 ft (660 meters) elevation, the inlet
4500 feet above sea level) a six inch flue is required. A 5" gas pressure should be set at installation to the value
by 6" flue adaptor must be affixed to the flue collar of the shown below.
AquaStar with at least two screws. See figure 3
NOTE: The gas pressures specified below refer to
pressures taken at the test pressure nipple on the gas
5” X 6” ADAPTOR inlet pipe just above the regulator (See Fig 4). These
USED ON HIGH ALTITUDE readings should be taken while the heater is operating
at full input — i.e. maximum water flow with the
temperature dial selector turned all the way clockwise.

MAXIMUM INLET GAS FLOW PRESSURE SETTING

Altitude Natural Gas Liquid Propane
inches W.C: inches W.C:
Fig. 3 - Flue Adaptor for High Altitude Installations 0' - 2.000 ft 5.7" 10.5"
WARNING: Failure TO INCREASE THE VENT SIZE TO 2.000 ft - 4.500 ft 4.6" 8.4"
SIX INCHES AND/or assure that the manifold pressure is Above 4.500 ft consult your local gas supplier.
set to proper value listed for applications at high altitudes
will cause unsafe venting, asphyxiation, and will void IAS
GAS LINE SIZE
Certification.
It is strongly recommended that the natural gas pipe line
be 3/4" for the entire distance. If the maximum length is
GAS CONNECTIONS and Gas Regulator above 40 feet, use 1" line. Flexible tubing is NOT
recommended, but if it is to be used, oversize it. With LP
Before connecting the gas supply, check the rating plate gas installation, the recommended sizes are 5/8" up to a
on the right side of the front cover to be sure that the heater maximum of 20 feet distance, 3/4" up to 50 ft distance
is rated for the same gas to which it will be connected. and 7/8" up to 100 feet.
In the United States: The installation must conform with
local codes or, in the absence of local codes, the National National Fuel Gas Code requires that a sediment trap (drip
Fuel Gas Code ANSI Z223.1/NFPA 54. leg) be installed on gas appliances not so equipped. The
In Canada: The Installation should conform with CGA B149 drip leg must be accessible and not subject to freezing
INSTALLATION CODES and /or local installation codes. conditions. Install in accordance with the recommendations
NOTE: The Aquastar 125 B is supplied with a gas of the serving gas supplier.
pressure regulator that must be installed on the heater
before attaching the gas supply line. See figure 4. WARNING: The heater must be disconnected from the
Failure to install the gas regulator as shown in figure gas supply piping system during any pressure testing of
4 will be a violation of IAS certification of the unit. that system at test pressures in excess of 0.5 psig.
The regulator supplied with the heater is preset for The water heater must be isolated from the gas supply
the gas shown on the rating plate to the correct piping system by closing the manual shutoff valve during
pressure. It is an appliance level regulator designed any pressure testing of the gas supply piping system at
for (low inlet) pressure (less than 1/2 Psig or 15” W.C.) test pressures equal to or less than 0.5 psig.
DO NOT connect to an unregulated or high pressure The water heater, including the pressure regulator provided
propane line or to a high pressure commercial natural with it, must not be operated at gas supply pressures in
gas line. excess of 0.5 psig. If overpressure has occurred, such as
GAS INLET PIPE through improper testing of the gas lines or emergency
malfunction of the supply system, the gas valve and
PRESSURE TAP regulator must be checked for safe operation. Make sure
that the regulator vent is protected against blockage. Vent
blockage could occur during ice storms.
When your connections are made, check for gas leaks at
all joints (not just the ones you made). Apply some soapy
PRESSURE REGULATOR
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
Fig. 4 - Installation of Gas Pressure Regulator appropriate fittings to stop leak. Turn the gas on and check
again with a soapy solution. Never test for gas leaks
The pressure regulator provided with the heater is adjusted using a match or flame.
to deliver the proper gas pressure (as indicated on the
rating plate and in the manual for altitude up to 2000 feet

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 WATER CONNECTIONS OPERATING INSTRUCTIONS

Although water piping throughout your structure may be Before proceeding with the operation of the heater make
other than copper, we recommend that copper piping be sure that the system is filled with water.
used for at least three feet before and after the heater Make sure the water heater drain plug is closed. See Figure
(follow local codes if more stringent). Keep water inlet pipe 7 below.
to no less than 1/2 inch diameter to allow the full flow
capacity. Remember that water pressure must be sufficient
to activate the heater when drawing hot water from the
top floor. If the hot and cold connections to the heater are
reversed, the heater will not function. The AquaStar 125B
is provided with two elbow type connectors that must be
connected to the inlet and outlet fittings of the water valve
as shown in Fig 5. These fittings seal to the water valve by
means of a union connection with a washer type gasket at
the joint. No pipe dope or thread tape is to be used at
Fig. 7 - Water heater drain plug
these joints. Be certain there are no loose particles or dirt
in the piping. Blow out or flush the lines before connecting Open the cold water inlet supply to the heater fully.
to the AquaStar. A ball valve should be installed on the Open a hot water faucet to permit the water to fill the heater
cold water feed line to facilitate servicing the heater. and the piping and to eliminate the air trapped in the system
For installation on a private well system, be sure that the Close the hot water faucet after the water flows freely and
water pressure is set between 30 and 50 psi. all the air has escaped from the system. The water heater
is now ready to work

FOR YOUR SAFETY READ BEFORE

LIGHTING THE PILOT

Warning: If you do not follow these instructions exactly, a

fire or explosion may result causing property damage,
personal injury or loss of life

A. This appliance has a piezo-igniter for lighting the pilot

Fig. 5 - Water valve and Elbows water burner. When lighting the pilot, follow these instructions
connectors, top view exactly.
B. BEFORE LIGHTING smell all around the appliance
Connecting the pressure relief valve (PRV) area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
A listed pressure relief valve supplied with the heater must WHAT TO DO IF YOU SMELL GAS
be installed at the time of installation. No valve is to be - Do not try to light any appliance.
placed between the PRV and the heater. No reducing - Do not touch any electric switch; do not use any phone
coupling or other restriction may be installed in the in your building
discharge line. The discharge line must be installed such - Immediately call your gas supplier from a neighbor’s
that it allows complete drainage of both the PRV and the phone. Follow the gas supplier’s instructions.
line. The location of the PRV must be readily accessible - If you cannot reach your gas supplier, call the fire
for servicing or replacement., and be mounted as close to department.
the water heater as possible. See Fig 6. To install the PRV,
a suitable fitting connected to an extension on a “T” fitting C. Use only your hand to push in or turn the gas control
can be sweated to the hot water line. buttons. Never use tools. If a button will not push in, check
to make sure the buttons are being pushed in the proper
sequence. Follow these instructions exactly. If control
button(s) are jammed, close the gas supply and call a
qualified service technician. Attempted forceful repair may
result in a fire or explosion.
D. 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.

Fig. 6 - Pressure Relief Valve

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 LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above on this plate.

2. The Gas valve must be turned off by sliding the gas
valve button to the far left under the OFF ( ) mark.
3. Wait five (5) minutes to clear out any gas. If you smell
gas, STOP! Follow “B” in the safety information above
on this plate. If you don’t smell gas, go to next step.
4. The pilot burner is located behind the peephole in the Fig. 8 - Water Flow Control Knob
front center of the jacket directly below this instruction
plate. What is the best temperature setting? Because AquaStar
5. Slide the gas valve button to the right, under the pilot water heaters deliver endless hot water at the temperature
mark ( ). you have selected, there is no need to produce very hot
6. Fully depress gas valve button and light pilot by pushing water and then mix in cold. It just does not make sense to
“PILOT IGNITER” button ( ). This step may have to overheat water and then mix in cold to cool it off. You cannot
be repeated. run out of hot water with an AquaStar, so set the dial for
7. Observe the pilot flame through the peephole. The gas the temperature you prefer . Note: 105°F is the maximum
valve button should be held down at least 10 seconds recommended for a hot bath. The position you select on
with pilot burning. When the gas valve button is released, the temperature adjustment knob will depend on the
the pilot should continue to burn. temperature of the incoming water (50°F is average in the
U.S.). In warm weather regions where the incoming cold
- If the gas valve button does not pop up when released, water is generally warmer, or during the hot weather
stop and immediately call your service technician or gas months in some other areas a midway setting on the
supplier. temperature adjustment knob would produce a
- If pilot does not stay lit, repeat steps 1 through 7. temperature rise of about 70 ° F, giving an output of
- If pilot will not stay lit after several tries, slide the gas approximately 120°F. At this setting, if it is still necessary,
valve button to the left, under the OFF ( ) mark and call one could mix a small amount of cold water in a shower
service technician or gas supplier. and have a comfortable shower at about 3 gallons/minute.
During the colder months, or in cold climate areas, it might
8. Slide the gas valve button to the right, under the ON be necessary to set the control to the maximum position,
mark ( ). The heater will now fire when water is all the way clockwise to the right.
drawn at a rate greater than the threshold flow rate. If you supply the AquaStar 125B, with preheated water
NOTE: If main burner should fail to ignite, make sure pilot (i.e.) in a solar installation the unit could overheat. It will
is burning. If not, repeat lighting steps 1 through 7. then shut off on safety when the outlet temperature reaches
194°F. For this type of application, purchase a solar model
TO TURN OFF GAS TO APPLIANCE 125 B LPS or 125 B NGS.

Slide the gas valve button to the far left, under the off ( ) MAINTENANCE AND SERVICE
mark and close the gas supply to the heater.
Approximately once a year, the AquaStar should be
SETTING THE WATER TEMPERATURE checked, cleaned and serviced as necessary. To remove
the front cover, first remove the incandescent particle tray,
The AquaStar 125 B LP and 125 B NG water heaters have then pull off the temperature adjustment knob and unscrew
a gas control that modulates burner input in response to and remove the plastic collar. Unscrew the central screw
flow. Its purpose is to ensure that the hot water temperature located at the bottom of the front cover. Pull main cover
will remain steady, although the water flow demand might out toward you and lift up and out. THE FOLLOWING
vary (down to 1/2 gal/minute). To adjust the temperature OPERATIONS SHOULD BE PERFORMED BY A
on your AquaStar, turn on a hot water faucet to its QUALIFIED SERVICE PERSON:
maximum flow. At the water heater, turn the large knob
located beneath the main gas controls on the front of the Vent System: Should be checked annually. Clean and
heater all the way to the right (clockwise). See Fig 8. This repair as needed.
will produce a temperature rise of approximately 90oF at
flow rates between 0.5 and 2.0 gallons per minute. Given Water Valve (Part # 8707002499): The water valve on
that average incoming water temperatures are 50oF, this this heater should be serviced periodically The frequency
heater will produce approximately 140oF water at these will depend on the mineral content of the water and
flow rates. Turning the dial all the way to the left conditions of use or whenever signs of corrosion appear
(counterclockwise) will produce a temperature rise of at the gas and water valve joint. Check that the water inlet
approximately 45oF for flow rates between 1.1 and 3.7 filter (#28 on Figure 12, page 14) is clean.
gallons per minute. It is safest to select a comfortable
temperature and not have to mix in cold water. Pilot Flame: The pilot flame should burn with a clean sharp
blue flame and should resemble the diagram in Fig 9. If
the flame is yellow, or if the pilot knob has to remain
depressed for a long time in order to keep the pilot lighted,

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 the pilot burner and or the pilot burner orifice may need to Main Burner Flames: The main burner flames should be
be cleaned, the orifice may need to be replaced, and or blue, with a more intense blue cone in the center core.
the air screen may need cleaning. The pilot flame should Yellow flames could be a sign of wrong size gas orifices or
envelop approximately 10 mm (3/8") of the tip of the dirty burners, or a blockage on the heat exchangers fins.
thermocouple. If it is too small, the pilot burner must be If some burners have yellow flames while others have good
cleaned. To obtain a spark, the position of the Piezo igniter flames, it is likely that dust, lint or spider webs have partially
electrode should be approximately 3 mm (1/8") from the clogged the burner venturis. To clean the burners, contact
pilot burner tip. a gas service person.
3mm

Mineral Scale Build-up: AquaStars, when operated at

Correct gap between pilot
burner tip and electrode tip
lower temperature settings, tend not to accumulate mineral
buildup. If however, the heater is used at the higher
temperature settings and the water has a high mineral
content, periodic descaling may be necessary. The heating
Piezo Electrode coils should be flushed with a descaling solution. Consult
your dealer or Controlled Energy for instructions.

Air screen filter

TROUBLE SHOOTING

Introduction
The AquaStar 125 burners are activated by a water flow
10mm
3/8”

valve. Numerous water related problems can cause this

water valve to malfunction such as: Insufficient water flow
volume to activate the burners at its minimum flow
requirement; Dirt in the water flow valve causing it to
malfunction; Sediment build-up in faucet aerators, or
shower heads; Uneven pressures between cold and hot.
(with single lever faucets) Plumbing cross overs. These
Thermocouple
water flow related problems can cause the heater to deliver
less than its full output, or to fail to ignite or to shut down
Piezo completely.
Electrode

Fig. 9 - Characteristic Pilot Flame Problems are stated in upper case, bold face. Most
common causes for the problems follow in order of
To clean the pilot burner and/ or the pilot orifice : Turn
likelihood. The suggested solutions require that the cover
off the gas at the unit. Remove the cover of the heater. To
be taken off. To do this, remove incandescent particle tray,
do so, pull off the temperature adjustment knob and
pull off the temperature adjustment knob and unscrew and
unscrew and remove the plastic collar and unscrew the
remove the plastic collar and unscrew the central screw
central screw located at the bottom of the front cover. Pull
located at the bottom of the front cover. Pull main cover
main cover out toward you and lift up and out . Pull the air
out toward you and lift up and out.
screen off, wash it and blow any lint off (See Fig 10). The
pilot orifices should also be cleaned or replaced. Do not
PILOT LIGHT WILL NOT LIGHT
enlarge the orifice. Do not use any wire or sharp object
to clean orifices. Natural gas orifices are large enough
1. No gas to the AquaStar
that you can usually clean them by blowing through them.
A. Gas cock on gas line may not be open.
LP orifices, on the other hand, are too small to clean and
B. Gas valve button has not been moved to “PILOT”
should be replaced. See #3 in Trouble Shooting Section.
position ( ). Slide button to right to PILOT.
To access the pilot orifice, remove 2 screws holding pilot
C. Gas regulator may be shut or damaged.
assembly in place. Then loosen compression fittings to
expose pilot orifice. 2. In-line AquaStar gas regulator jammed (usually on
LP gas)
Replace or unjam the regulator. Note: The regulator
furnished with the heater is designed for low gas pressure.
Excessive pressure will lock it up (propane only). Jamming
AIR SCREEN usually happens if the gas pressure between the gas tank
(propane) and the water heater’s gas regulator has not
been reduced. See page 2 for recommended correct gas
pressure. To unjam a regulator, consult your gas supplier.

3. Pilot orifice clogged and/or air screen dirty, or pilot

gas filter is dirty.
Clogging of the pilot burner can be caused by dust and
PILOT ORIFICE any suspended matter contained in the ambient air.
Fig. 10 - Pilot burner with air screen/ pilot orifice
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 Although the filters can lengthen the cleaning intervals, 6. Faulty thermocouple (part #8747202083) or
they can never completely prevent such clogging. In electromagnet ) Unless these 2 parts are at least 8
consequence the gas jet issuing from the pilot orifice is to 10 years old, it is very unlikely that they are faulty.
reduced and or the air mixture is reduced. The pilot flame Before testing, reconfirm that #2 is absolutely
is weak and thus can no longer heat the thermocouple correct, and that all connections are clean and tight.
sufficiently. For cleaning purposes, the air filter screen is To test the thermocouple, disconnect the thermocouple
pulled off, washed and blown out. The pilot orifice has lead to the ECO. Insert a multi-meter probe on the
likewise to be cleaned or exchanged. Consult Controlled thermocouple ECO connection and attach the other meter
Energy or a gas service person. lead on the spade connector of the ECO. Light the pilot
flame, and take a reading on the meter. If it reads less
4. Air in the Gas Line than 24mV, replace the thermocouple. If the reading is
Note: Normally this is a problem only at the time of initial 24mV or over the thermocouple is good. To test the electro-
installation, after the pipes have been worked on, or after magnet, take another reading across the ECO spade while
a propane tank has been allowed to empty, or after the the pilot flame is on. The reading should drop to about 15
heater has been shut down for a long time. mV. If it does not and remains unchanged, replace the
Bleed all the air trapped in the gas line. Because of the electromagnet.
very small pilot orifice (especially on LP gas models),
bleeding out all the air could take several minutes. Slide BURNERS DO NOT IGNITE WHEN HOT WATER IS
the gas valve button to pilot position ( ) and depress this TURNED ON
button until all the air has escaped, and the gas has arrived.
During this process, press repeatedly on the piezo ignition 1. Pilot is not on.
button until the pilot flame has ignited. Light the pilot. See lighting instructions.

PILOT LIGHTS BUT FLAME GOES OUT WHEN 2. Gas valve button not positioned on Burner Position
BUTTON IS RELEASED Be sure pilot flame is on. Slide gas valve control to burner
position ( ).
1. Pilot push button was not pushed in far enough or
was not held in long enough 3. Cold incoming water connection made to wrong
Once pilot flame has been lighted. Hold button pushed in side of heater
for at least 15 seconds to give time for the pilot flame to Make sure cold water inlet connection is on the right side
properly heat the tip of the thermocouple. of heater when you are facing heater.

2. Pilot flame improperly aimed or is too weak so it is 4. Water flow rate at hot water tap is too low.
not properly heating the tip of the thermocouple. Note: When the flow control is turned all the way clockwise,
The Pilot flame should be a sharp blue flame and aimed the AquaStar models 125B require 1/2 gallon per minute
at the tip of the thermocouple so that it envelops 10 mm flow to activate the burners. This is a flow which would fill
(3/8 “) of the thermocouple tip. Pilot flame has to be properly a quart jar in 30 seconds. If the flow control knob is turned
aimed at the thermocouple. See Fig 9. fully counterclockwise, a flow rate of 1.1 gpm is required
to activate the burners.
3. Poor thermocouple connection at the
electromagnet 5. Cold water inlet filter on heater is dirty.
Note: Electromagnet is part #8707201012 located on the Remove filter and clean. This screen filter is located at
right side of the gas valve behind the piezo push-button the inlet side of the brass water valve (fig. 12, #28). Check
assembly. Check the tightness of the thermocouple and clean faucet aerators too.
connection nut at the electromagnet: The Electro-magnet
connection is a large aluminum 17mm hex head nut. The 6. Crossover in household plumbing
thermocouple end is a 5 mm brass nut which screws into The AquaStar burner activates when there is sufficient
the 17 mm nut. Tighten the thermocouple nut snugly but water pressure drop in the AquaStar water valve assembly
not too tight. — i.e. when a hot water faucet is opened. If there is a
crossover in the plumbing, the necessary pressure drop
4. Poor circuit connections at the ECO. (Energy Cut- in the AquaStar will be insufficient, or totally eliminated. A
Off overheat protection) plumbing crossover can be caused by a bad washer at a
Oxidation or looseness of the ECO terminal connections single lever faucet or incorrect plumbing or a mixing valve
can result in millivolt current loss through the thermocouple in the line, etc. which permits hot and cold water to mix in
safety circuit. Clean terminals with very fine sand paper or the plumbing. The crossover will create a back pressure
an eraser and reconnect ECO leads. in the system preventing the pressure drop in the Aquastar
— i.e. cold water is entering the water heater from both
5. Faulty ECO (part #8707206040) sides and the burners will not come on. To confirm there
If cleaning the terminals attached to the ECO did not fix is no crossover in the plumbing, shut off the cold water
the problem, connect a jumper wire between the two wires supply to the AquaStar. Open your hot water taps. There
and try to relight the pilot. If the pilot flame now remains should not be any water flowing. If there is water flowing,
on, replace the ECO. If the flame still goes out when the there is a crossover in the plumbing. This is a plumbing
button is released, the ECO is not defective. Go to next problem, not an Aquastar problem. Please contact your
step. plumber.
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 7. Water valve parts may be dirty or components 3. Btu input is too low due to insufficient gas pressure
damaged. It is extremely important for a tankless
Water valve and component parts must be totally free of instantaneous water heater to have the right size
dirt. First check that the venturi is free of dirt particles. In gas line to obtain the correct gas pressure
hard water areas, mineral deposits can eventually (3 to 5 See specifications on page 2. Unlike storage tank water
years in hard water areas) corrode the water valve parts heaters, the burners of a tankless water heater must be
to a point where they will need replacing. Any sign of very powerful to heat water instantaneously since they do
moisture or corrosion at the joint of the water valve and this only at the time hot water is actually being used. It is
the gas valve is a sign that the water valve assembly therefore imperative that the gas pressure requirement
components need to be replaced immediately. Note: Water be met exactly. Insufficient gas pressure will directly affect
valve for model 125B is part# 8707002499 for both LP the water temperature at the time of usage. See page 2
and NG models. (Contact service person to clean water for correct gas pressure settings and page 13 for locations
valve or replace if corrosion is present). where gas pressures are taken.
PILOT LIGHT GOES OUT DURING OR IMMEDIATELY
AFTER HOT WATER HAS BEEN USED 4. Btu input is too low due to insufficient gas supply
Make sure your main gas line is fully opened. If using LP
1. Gas pressure too low gas, be sure that the size of the propane tank is adequate
Very low gas pressure may be caused by low delivered to supply the required gas pressure.
gas pressure, a jammed gas regulator or undersized gas
lines. If the gas lines are undersized, there may still be the 5. Cold water is mixing with the hot water between
specified static gas line pressure. However when the water the AquaStar and the outlet
valve opens, and gas enters the burners, the pressure Compare water temperature at outlet of the AquaStar (hold
could drop sharply, causing the pilot flame to go out. Have the AquaStar’s outlet pipe with your hand) and at the tap.
a gas technician confirm the gas pressure both static and If these two are very different, check for mixing valve or
at maximum Btu output. Specifications for your heater are plumbing crossover (see “MAIN BURNERS WILL NOT
on page 2. IGNITE...” paragraph #6). Where automatic “anti-scald”
valves are required by code, lower the temperature setting
2. Pilot may be dirty or weak on the AquaStar as much as possible and balance the
See Page 9 for instructions on pilot maintenance. pressure between cold and hot water after the AquaStar.

3. Burners are not shutting down immediately when 6. Parts in water flow valve are corroded so that the
hot water is turned off gas passage is not fully opening.
Note: If burners don’t shut down immediately when the Contact your service person or Controlled Energy.
hot water is turned off, the heater will overheat and the
ECO will shut-off the gas. Rebuild the water valve assembly
using the repair kit from CEC (part #8 703 406 178). HOT WATER TEMPERATURE FLUCTUATES

WATER IS TOO HOT 1. Unbalanced pressure in waterlines

The added restriction caused by the Aquastar in the hot
1. Temperature Selection too high water system can result in uneven pressures between the
Turn the temperature adjustment knob counter-clockwise cold and the hot. In such cases when mixing cold water at
(to the left) to lower the maximum water temperature. the tap, the lower hot water pressure may be overpowered
Note: This will increase the activation flow rate. by a much higher cold water pressure, which may cause
the Aquastar burners to shut down. Make sure faucet
2. Inlet water temperature is too high (as with solar aerators or shower heads are free of minerals. Do not
preheated water) add any flow restrictor to the shower head.
Note: Only the Model “S” AquaStar should be used if the
inlet water is preheated. 2. Cold water is mixing with the hot water between
the AquaStar and the outlet
3. Reduce inlet gas pressure See #6 under “Burners do Not Ignite When Hot Water
Turned On”.
WATER IS NOT HOT ENOUGH
3. Inlet water pressure is erratic due to inadequate
1. Temperature selection too low. supply water pressure or saturated pressure tank
Change the setting. Turn the temperature adjustment knob on well system
clockwise (to the right). Check the inlet water pressure. On a private well, raise
Note: This will decrease the activation flow rate. minimum pressure setting to 30 psi. Confirm that the
pressure tank is not water logged.
2. Water flow through the heater is higher than the
capacity of the AquaStar to heat it 4. Gas pressure is too low
Reduce the flow demand at the faucet. See flow rates at See page 2 for correct specifications.
specific temperature rises on page 2.

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 Fig. 11 - Diagram of AquaStar 125 B

3
2

5 4
6

8 9

10
11

12

1. Heat exchanger 8. Gas control slide

2. Pilot assembly 9. Piezo igniter
3. Burner manifold gas 10. Water valve
pressure test nipple 11. Temperature adjustment
4. Main gas burner selector
5. Pilot gas tubing 12. Gas inlet gas pressure
6. Gas valve test nipple
7. Pressure tap screw
location

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 Fig. 12 - INTERIOR COMPONENTS DIAGRAM AND PARTS LIST

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 Fig. 12

INTERIOR COMPONENTS DIAGRAM

AND PARTS LIST 125B

1 Cover ¤ 8 705 421 025

2 Plastic collar ¤ 8 700 403 008
3 Temperature adjustment knob ¤ 8 702 000 111
4 Panel back ¤ 8 705 402 164
5 Draft divertor ¤ 8 705 505 354
6 Heat exchanger ¤ 8 705 406 235
7 Hot water pipe ¤ 8 700 705 556
8 Cold water pipe ¤ 8 700 705 294
9 Heat exchanger washer ¤ 8 710 103 045
10 Overheat sensor (ECO) ¤ 8 707 206 040
11 Main burner assembly LPG 8 708 120 296
Main burner assembly NG 8 708 120 298
12 Pilot burner assembly ¤ 8 718 105 048
12a Pilot air screen ¤ 8 700 507 055
13 Piezo electrode ¤ 8 708 107 002
14 Pilot orifice NG 8 708 200 005
“ LPG 8 748 200 173
15 Pilot Tube ¤ 8 700 707 320
16 Thermocouple ¤ 8 747 202 083
17 Burner assembly washer ¤ 8 710 103 060
18 Throttle disc LPG 8 700 100 174
19 Gas valve LPG 8 707 011 463
Gas valve NG 8 707 011 459
20 Gas supply pipe ¤ 8 700 705 552
21 Electromagnet ¤ 8 707 201 012
22 Thermocable ¤ 8 747 202 209
23 Water valve assembly ¤ 8 707 002 499
24 Water valve repair kit ¤ 8 703 406 178
25 Slow ignition valve ¤ 8 708 503 063
26 Water valve diaphragm ¤ 8 700 503 053
27 Water valve selector screw assembly ¤ 8 708 500 251
28 Water inlet filter ¤ 8 700 507 045
29 Water valve venturi ¤ 8 708 205 249
30 Water valve water governor ¤ 8 707 402 013

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 INSTALLATION CHECKLIST

GAS LINE SIZE

Natural Gas
Nominal Iron Pipe Size* 1/2" 3/4" 1"
MAXIMUM LENGTH 10' 40' 150'
Liquid Propane
Semi-rigid Tubing 1/2" 5/8" 3/4" 7/8"
NOT
MAXIMUM LENGTH RECOMMENDED 20' 60' 150'
* Flex tubing greatly reduces capacity and, therefore, is not recommended.

Minimum Vent Size* and Height

Minimum Diameter Minimum Height**

5 inches 6 feet**
* NOTE: Vent size must not be restricted. Installation must comply with national fuel gas code venting requirements
for a 117,000 Btu Category I appliance and any applicable local codes.
** NOTE: Minimum vent height must be 6 feet, provided there are no elbows. Termination of the vent must be 2
feet above any obstruction within a 10 foot radius of vent pipe. 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.

Water Pressure
For installation on well systems, insure that your water pressure is between 30 - 50 psi.

Replacement Parts available from North American Distributor

CONTROLLED ENERGY CORP.
VULCANO Termodomésticos S.A.
340 Mad River Park
Estrada de Cacia
Vermont 05673 (U.S.A.)
3800 Cacia - PORTUGAL
Phone 800-642-3111
Fax (802) 496-6924

WWW.CECHOT.COM techsupport@cechot.com

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