Bosch Appliances Water Heater 125B LPL User Manual

INSTALLATION AND OPERATING INSTRUCTIONS FOR AUTOMATIC  
INSTANTANEOUS TYPE WATER HEATERS FOR USE WITH NATURAL AND  
LIQUEFIED PETROLEUM GAS  
MODEL 125B LPL and 125B NGL (Non-Modulated)  
Suitable for heating potable water  
Certified for space heating in combination with potable water only  
Not certified for space heating only. Intended for either recirculation to storage or cold water inlet flow that  
is non-varying. For variable flow, install the 125 B or the 125 X 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  
Specifications .................................................... Page 2  
Rules for safe operation ...................................... Page 4  
Locating the Heater ............................................ Page 5  
CombustionAir Requirements ............................ Page 5  
Mounting the Heater ........................................... Page 6  
Venting the Heater ............................................. Page 6  
Gas Connections ............................................... Page 7  
Water Connections ............................................ Page 8  
Safety before lighting the pilot ............................ Page 9  
WARNING: Improper installation,  
adjustment, alteration, service or maintenance can  
cause injury or property damage. Refer to this manual.  
For assistance or additional information consult a  
qualified installer, service agency or the gas supplier.  
Upon completion of the installation, these instructions  
should be handed to the user of the appliance for  
future reference.  
Lighting instructions ........................................... Page 9  
About Water Temperature .................................. Page 9  
Warning: If you do not follow these instructions exactly, a  
Maintenance & Service....................................... Page 9  
fire or explosion may result causing property damage,  
Trouble Shooting .............................................. Page 10  
personal injury or loss of life  
Diagram ofAquaStar......................................... Page 13  
Components and Parts List .............................. Page 14  
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FRONT VIEW  
SIDE VIEW  
MINIMUM INSTALLATION CLEARANCES FROM COMBUSTIBLEAND NON  
COMBUSTIBLE MATERIALS FOR ALCOVE OR CLOSET INSTALLATIONS  
MODEL 125BL  
TOP (A)  
12"  
4"  
FRONT (B)  
BACK  
0"  
SIDES  
4"  
FLOOR (C)  
FLUE DIAMETER  
12" *  
5"  
* Some local codes require 18” in garage installations  
AQUASTAR MODEL 125BL  
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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.  
Notes  
1. Maximum to tank water temperature from 125 BL 140°F  
2. Maximum heating capacity:  
40°F rise  
20°F rise  
AquaStar 125BL -  
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. If circulation flow to the Aquastar 125BL is restricted, it may be  
necessary to adjust the temperature slide control to prevent  
overheating.  
*Pipe PRV to appropriate discharge  
**Tempering valve is required when tank water temperature is over  
130 F.  
5. 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  
FOR SAFE OPERATION  
occupied rooms normally kept closed. See the section below  
on locating the heater.  
1. You should follow these instructions when you install 4. You must vent your heater. See section on VENTING,  
your heater. In the United States: The installation must Page 6.  
conform with local codes or, in the absence of local codes,  
5. The appliance must be disconnected from the gas supply  
piping system during any pressure testing at pressures in  
excess of 1/2 Psig (3.5 kPa).  
The appliance must be isolated from the gas supply piping  
system by closing its individual manual shutoff valve during  
the National Fuel Gas CodeANSI Z223.1/NFPA54.  
In Canada: The Installation should conform with CGA  
B149.(1,2) INSTALLATION CODES and/or local installation  
codes.  
2. Carefully plan where you install the heater. Correct any pressure testing of the gas supply piping system at  
combustion air supply and flue pipe installation are very test pressures equal to or less than 1/2 Psig (3.5kPa).  
important. If not installed correctly, fatal accidents can be The appliance and its gas connection must be leak tested  
caused by lack of air, carbon monoxide poisoning or fire.  
before placing the appliance in operation.  
3. The place where you install the heater must have enough 6. Keep water heater area clear and free from combustibles  
ventilation. The National Fire Codes do not allow gas fired and flammable liquids. Do not locate the heater over any  
water heater installation in bathrooms, bedrooms or any material which might burn.  
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7. Correct gas pressure is critical for the optimum  
WARNING: The water in this water heater is cold  
operation of this heater (see specifications on page 2). Gas and always remains cold except for the times that hot  
piping must be sized to provide the required pressure at water is being used DO NOT INSTALL IN AN AREA  
the maximum output of the heater, while all the other gas WHERE IT COULD FREEZE.  
appliances are in operation. Check with your local gas This heater is neither designed for nor approved for  
supplier, and see the section on connecting the gas supply. outside installation.  
Drain the heater entirely if freezing temperatures are  
8. Should overheating occur or the gas supply fail to shut anticipated in area where heater is installed by  
off, turn off the gas supply at the manual gas shut off valve disconnecting both the inlet and outlet elbow connections  
on the gas line.  
at the rear of heater. Additionally remove the drain plug  
under the water valve. See Fig 0.  
9. Do not use this appliance if any part has been  
underwater. Immediately call a qualified service technician  
to inspect the appliance and to replace any part of the  
control system and any gas control which has been  
underwater.  
PROPER LOCATION FOR INSTALLING  
YOUR HEATER  
Fig. 0 - Water heater drain plug  
Carefully select the location of your new heater. For your  
safety and for proper heater operation, you must provide an  
abundant supply of combustion air and a proper venting  
installation.  
The heater may still operate even when improperly vented.  
It will, however, be less efficient and could eventually damage  
the heater. It could even result in human sickness or death  
due to oxygen deprivation and carbon monoxide poisoning.  
Follow the guidelines below:  
WARNING: Flammable materials, gasoline,  
pressurized containers, or any other items or articles  
that are potentially fire hazards must NOT be placed  
on or adjacent to the heater. The appliance area must  
be kept free of all combustible materials, gasoline  
and other flammable vapors and liquids.  
COMBUSTION AIR REQUIREMENTS  
1. Place your heater as close to a vent or chimney as  
possible.  
The AquaStar water heater holds cold water in its copper  
heat exchanger and brass water valve when not in use.  
Because of this, any cold air that comes in through the  
unit’s vent pipe is capable of freezing these components.  
This Installation Manual specifies the minimum vertical vent  
pipe and the amount of combustion air required for this  
unit. The vent pipe must not be restricted and its 6 foot  
minimum height (provided there are no elbows) must  
terminate 2 feet above any obstruction within a 10 foot  
radius.  
When all requirements are followed, the unit will operate  
properly and safely. However, there may still be a risk of  
freezing due to negative draft if all the combustion appliances  
in the area are not being supplied with a sufficient amount  
of make-up air. Awood stove or furnace can rob the make-  
up air in theAquaStar’s vent pipe, leaving the cold infiltrating  
air capable of freezing the cold water in theAquaStar heat  
exchanger. More make up air is the solution. Follow the  
instructions on venting and checking adequacy of make up  
air. A HVAC specialist should be used to design solutions  
for providing more make-up air if necessary.  
2. National building codes require that you do not install  
this appliance in bathrooms, bedrooms, unvented closet or  
any occupied rooms normally kept closed.  
3. Simultaneous operation of other appliances such as  
exhaust fans, ventilation systems clothes dryers, fireplaces  
or wood stoves could create a vacuum effect in your home  
which could cause dangerous combustion by-products to  
spill back into your home rather than venting to the outside  
through the flue. Confirm that your Aquastar is venting  
properly when all these other appliances are running. See  
section on venting.  
Do not obstruct the flow of combustion and ventilation  
air to the appliance. If installed near a clothes dryer it is  
very important that the dryer be properly vented. Failure to  
properly vent a dryer could result in a gradual accumulation  
of lint on the water heater fin coils and burners, leading to a  
dangerous condition of vent blockage and poor unsafe  
combustion.  
Observe the following instructions concerning combustion  
air.  
Appliances located in unconfined spaces:  
4. Your hot water lines should be kept short to save energy.  
It is always best to have hot water lines insulated.  
a) An unconfined space is one whose volume is greater  
than 50 cubic feet per 1000 Btu per hour of the combined  
rating of all appliances installed in the space. That would  
be 5850 cubic feet for theAquaStar 125BL alone.  
b) In unconfined spaces in buildings of conventional frame,  
masonry, or metal construction, infiltration is normally  
adequate to provide air for combustion, ventilation, and  
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  
outside installations.  
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dilution of flue gases.  
which, if mounted directly to a brittle, friable board, such  
Appliances located in confined spaces:) The confined space  
must be provided with two permanent openings, one  
commencing within 12 inches of the top and one  
commencing within 12 inches of the bottom of the  
enclosure. Each opening must have a minimum free area  
of one square inch per:  
- 1000 Btu/hr if all air is taken from inside the building.  
- 2000 Btu/hr if all air is taken from the outside by horizontal  
ducts.  
- 4000 Btu/hr if all air is taken from the outside by direct  
openings or vertical ducts.  
Or the confined space must be providedwith one permanent  
openingor duct that is within 12 inches of the ceiling of the  
enclosure. This opening must have a minimum free area of  
one square inch per:  
as plasterboard, can cause failure of mounting.  
In earthquake-prone zones, CEC recommends that  
installers use a large washer and lag screw through the  
existing holes used to hang the heater to affix the upper  
third of the heater to the mounting board. To affix the lower  
third of the heater, CEC recommends that two new holes  
be drilled in the heater’s frame, each one 16 inches below  
the top two holes, and that washers and lag screws be  
used to secure the lower portion of the heater to a spacing  
board.  
Before installing the unit, be certain you have the correct  
heater for your type of Gas – Propane or Natural Gas.  
Identification labels are found on the shipping box, and on  
the rating plate which is located on the right side panel of  
the cover.Also, each burner orifice is stamped with a number  
- 3000 Btu/hr if all air is taken from the outside by a direct  
opening or vertical duct.  
(79 for LPG and 120 for Natural Gas).  
Louvers, grills and screens have a blocking effect. If the  
effective free area is not known, increase the sizes of your  
openings by 75% if your louvers are wood and by 30% if  
your louvers are metal. Refer to the National Fuel Gas Code  
for complete information. In buildings of tight construction  
all air should be taken from outside.  
WALL STUDS  
13 ¼”  
SUPPORT BOARD  
CLEARANCES  
TheAquastar 125 BLis design certified for installation on a  
combustible wall and for installation in an alcove or closet  
with the minimum clearances to combustible and non -  
combustible construction listed below  
A. Top 12 inches (306 mm)  
1” X 4”  
SPACE BOARD  
Fig. 1 - Mounting the Heater  
B. Front 4 inches (102 mm)  
C. Back 0 inches  
D. Sides 4 inches (102mm)  
E. Bottom 12 inches (306 mm)  
The incandescent particle tray (shipped loose in the carton  
with the water heater) must be attached at the bottom of  
the water heater front cover at the time of installation. Use  
the screws provided. See figure 2  
Clearance from vent is dependent upon the clearance rating  
of the venting material used. For example: type B-1 vent is  
approved for 1 inch clearance.  
Note: Minimum clearance to combustible materials should  
not be less than 6" for single wall flue pipe. Note that this  
clearance can be reduced if combustible material are  
protected as per table VI of the National fuel Gas Code or if  
Type B gas vent is used.  
SCREWS  
INCANDESCENT PARTICLE TRAY  
MOUNTING INSTALLATION  
Fig. 2 - Incandescent Particle Tray Illustration  
TheAquastar 125 BL is design certified for mounting on a  
wall. Secure the two L shaped hooks provided with the  
heater to a wall surface. Place them 13 ¼ inches apart as  
VENTING  
Vent pipe connection. WARNING: Do not reduce  
the vent pipe size.  
shown in Fig 1.  
Do not install this appliance on a carpeted wall or over floor  
covering which is combustible, such as carpet. The heater  
must be mounted on a wall using appropriate anchoring  
materials. If wall is a stud wall sheathed with plasterboard,  
it is recommended that support board(s), either 1x4’s  
or 1/2" (minimum) plywood first be attached across a  
pair of studs and then the heater should be attached  
to the support boards. See Fig 1.  
This appliance must be vented to the outside following all  
local ordinances and specifications for installing a gas  
appliance vent or chimney. The venting system must be  
designed and constructed so as to develop a positive flow  
adequate to remove flue gasses to the outdoors. Minimum  
vent size must be 5". Minimum height must be 6 feet,  
provided there are no elbows. Termination of vent  
must be 2 feet above any obstruction within a 10 foot  
radius. Consult your gas utility or National Gas Fuel  
Expansion and contraction of piping due to changing water  
temperature in the pipes imparts movement to the heater  
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Code if vent will have elbows or share venting with  
another appliance.  
5” X 6” ADAPTOR  
The vent connector should have as much vertical rise  
as possible (minimum 12”) before any horizontal run.  
Optional powervent available in order to sidewall vent.  
Contact your local dealer. The appliance must be located  
as close as practicable to a chimney or vent. The vent pipe  
sections must be secured to each other with sheet metal  
screws. Keep in mind the minimum clearance from the top  
of your heater. Remember also that single wall vent pipe  
connectors require a 6 inch clearance from combustibles.  
National Fuel Gas Code specifies double wall — Type “B”  
— vent pipe be used in cold climates and for gas vents  
running through attics. We consider double wall vent pipe  
preferable in all circumstances. Any vent section greater  
than 45 degrees from vertical is considered horizontal.  
Horizontal sections of vent connectors must slope upwards  
at least 1/4 inch for every foot of its horizontal length. Keep  
the horizontal section short and avoid too many elbows.  
Optional power vent available in order to sidewall vent.  
Contact your local dealer.  
USED ON HIGH ALTITUDE  
Fig. 3 - Flue Adaptor for High Altitude Canadian  
Installations  
WARNING: Failure TO INCREASE THE VENT SIZE  
TO SIX INCHESAND/or assure that the manifold pressure  
is set to proper value listed for applications at high altitudes  
will cause unsafe venting, asphyxiation, and will void CSA  
Certification.  
GAS CONNECTIONS and Gas Regulator  
To check the draft:  
Before connecting the gas supply, check the rating plate  
on the right side of the front cover to be sure that the heater  
is rated for the same gas to which it will be connected.  
In the United States: The installation must conform with  
local codes or, in the absence of local codes, the National  
Fuel Gas Code ANSI Z223.1/NFPA 54.  
In Canada: The Installation should conform with CGA B149  
INSTALLATION CODES and /or local installation codes.  
NOTE: The Aquastar 125 BL is supplied with a gas  
pressure regulator that must be installed on the heater  
before attaching the gas supply line. See figure 4.  
Failure to install the gas regulator as shown in figure  
4 will be a violation of CSA certification of the unit.  
The regulator supplied with the heater is preset for  
the gas shown on the rating plate to the correct  
pressure. It is an appliance level regulator designed  
for (low inlet) pressure (less than 1/2 Psig or 15” W.C.)  
DO NOT connect to an unregulated or high pressure  
propane line or to a high pressure commercial natural  
gas line.  
Close all doors and windows to the outside.  
Turn on all appliances that force air out of the building.  
These include all exhaust/ventilation fans, furnaces, clothes  
dryers, wood burning stoves, etc.  
Open all doors between theAquaStar and these other ap-  
pliances.  
Run the unit for at least 10 minutes. Then hold an ordinary  
mirror at the side above the front shell. Any flue gases  
backdrafting will cause the mirror to fog. This is a serious  
health hazard and must be corrected. Poor venting can  
result in soot building up inside the heater, overheating of  
the heater and freezing of the heat exchanger in a freezing  
environment.  
The mirror will remain clear with a properly functioning draft.  
WARNING  
Note: The burners of an instantaneous “on demand” water  
heater such as the AquaStar are only on at the time that  
hot water is actually being used, the vent pipe is therefore  
cold except for the short durations when hot water is being  
used, it is therefore very important that the venting and air  
supply be adequate to provide a good positive draft as soon  
as the burners turn on. See venting guide on back page.  
GAS INLET PIPE  
PRESSURE TAP  
TheAquaStar 125BLinstantaneous water heaters have built-  
in draft diverters and are designed for indoor installation  
only. The draft diverter outlet must be connected to a clear,  
unobstructed vent of the same size, or larger.  
PLASTIC VENT CAP  
PRESSUREREGULATOR  
(with directional arrow on  
reverse side pointing  
upward)  
In Canada, CAN/CGA-B149 Installation Code for detailed  
requirements  
In U.S.A., ANSI Z223.1 - NFPA 54, national Fuel Gas  
Code for detailed requirements.  
Fig. 4 - Installation of Gas Pressure Regulator  
The flue connection for the AquaStar 125BL is 5 inches.  
However, in CANADA, for installations at high altitude (2000-  
4500 feet above sea level) a six inch flue is required. A 5"  
by 6" flue adaptor must be affixed to the flue collar of the  
The pressure regulator provided with the heater is adjusted  
to deliver the proper gas pressure (as indicated on the rating  
plate and in the manual for altitude up to 2000 feet (660  
meters) above sea level. On appliances being installed  
above 2000 ft (660 meters) elevation, the inlet gas pressure  
should be set at installation to the value shown below.  
AquaStar with at least two screws. See figure 3.  
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NOTE: The gas pressures specified below refer to NOTE: Do not apply soap solution to pilot filter screen or  
pressures taken at the test pressure nipple on the gas pilot orifice area. If you have a leak, shut off the gas. After  
inlet pipe just above the regulator (See Fig 4). These verifying that required gaskets are in place, tighten  
readings should be taken while the heater is operating appropriate fittings to stop leak. Turn the gas on and check  
at full input — i.e. with the gas control positioned all again with a soapy solution. Never test for gas leaks using  
the way to the right.  
a match or flame.  
MAXIMUM INLET GAS FLOW PRESSURE SETTING  
WATER CONNECTIONS  
When facing the heater, the cold water inlet is on your right  
and the hot water outlet is on your left.  
Altitude  
Natural Gas  
inches W.C:  
5.7"  
Liquid Propane  
inches W.C:  
10.5"  
Although water piping throughout your structure may be  
other than copper, we recommend that copper piping be  
used for at least three feet before and after the heater (follow  
local codes if more stringent). Keep water inlet pipe 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 125BL is provided  
with two flexible type connectors that must be connected  
to the inlet and outlet fittings of the water valve as shown in  
Figs 5 and 6. ½” Galvanized or brass fittings work best  
when connected to the connectors. See Fig 6. These  
connectors 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 these joints. Be certain  
there are no loose particles or dirt in the piping. Blow out or  
flush the lines before connecting to theAquaStar. Full port  
valves should be installed on both the cold water feed line  
and the hot water outlet line to facilitate servicing the heater.  
For installation on a private well system, be sure that the  
water pressure is set between 30 and 50 psi.  
0' - 2.000 ft  
2.000 ft - 4.500 ft  
4.6"  
8.4"  
Above 4.500 ft consult your local gas supplier.  
GAS LINE SIZING  
-It is strongly recommended that the Natural Gas pipe  
be Black Iron pipe the entire distance from the outside  
meter to the inlet of theAquastar regulator. 1/2” Black  
Iron pipe up to 10 feet, 3/4” Black Iron pipe up to 40  
feet and 1” Black Iron pipe up to 150 feet distances.  
Flex line tubing is NOT recommended, but if used  
then oversize it.  
-It is strongly recommended that the LP Gas pipe be  
semi-rigid copper or Black Iron pipe from the outside  
regulator to the inlet of the Aquastar regulator. For  
semi-rigid copper piping: 5/8” up to 20 feet and 3/4”  
up to 60 feet distances. For Black Iron piping: 1/2” up  
to 45 feet and 3/4” up to 160 feet distances. Flex line  
tubing is NOT recommended, but if used then oversize  
it.  
WASHER  
THESE FIGURESARE FORAQUASTAR SUPPLY ONLY,  
ALL OTHER APPLIANCES IN THE BUILDING WILL NEED  
TO BE INCLUDED IN THE PIPE SIZING.  
WATER FILTER  
WATER VALVE  
National Fuel Gas Code requires that a sediment trap (drip  
leg) be installed on gas appliances not so equipped. The  
drip leg must be accessible and not subject to freezing  
conditions. Install in accordance with the recommendations  
of the serving gas supplier.  
FLEX  
CONNECTORS  
WASHER  
WARNING: The heater must be disconnected from  
the gas supply piping system during any pressure testing  
of that system at test pressures in excess of 0.5 psig.  
The water heater must be isolated from the gas supply  
piping system by closing the manual shutoff valve during  
any pressure testing of the gas supply piping system at  
test pressures equal to or less than 0.5 psig.  
Fig. 5 - Water valve and water  
connectors, top view  
SWEATEDASSEMBLY  
THREADEDASSEMBLY  
The water heater, including the pressure regulator provided  
with it, must not be operated at gas supply pressures in  
excess of 0.5 psig. If overpressure has occurred, such as  
through improper testing of the gas lines or malfunction of  
the supply system, the gas valve and 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  
water to all gas fittings and gas valve. Soap bubbles are  
a sign of a leak.  
1/2” FLEX  
1/2” FLEX  
PIPE PRV TO  
APPROPRIATE  
DISCHARGE  
PIPE PRV TO  
APPROPRIATE  
DISCHARGE  
Fig. 6-Plumbing connections for the Aquastar 125BL  
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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.  
Connecting the pressure relief valve (PRV)  
A listed pressure relief valve supplied with the heater must  
be installed at the time of installation. No valve is to be  
placed between the PRV and the heater. No reducing  
coupling or other restriction may be installed in the discharge  
line.  
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.  
The discharge line must be installed such that it allows  
complete drainage of both the PRV and the line.  
The location of the PRV must be readily accessible for  
servicing or replacement., and be mounted as close to the  
water heater as possible. See Fig 7.  
To install the PRV, a suitable fitting connected to an  
extension on a Tfitting can be sweated to the hot water  
line.  
LIGHTING INSTRUCTIONS (as seen on front  
cover of heater)  
1. STOP! Read the safety information above on this plate.  
2. The gas valve must be turned off by depressing the gas  
valve off button ( ).  
3. Wait five (5) minutes to clear out any gas. If you smell  
gas, STOP! Follow Bin the safety information above  
on this plate. If you dont smell gas, go to the next step.  
4. The pilot burner is located behind the peephole in the  
front center of the jacket directly below this instruction  
plate.  
5. Depress PILOT button ( ) and light pilot by pushing  
PILOT INGITER button (  
repeated.  
). This may have to be  
6. Observe the pilot flame through the peephole. The pilot  
button ( ) should be held down at least 10 seconds  
Fig. 7 - Pressure Relief Valve  
OPERATING INSTRUCTIONS  
Before proceeding with the operation of the heater make  
sure that the system is filled with water.  
Open the cold water inlet supply to the heater fully.  
Open a hot water faucet to permit the water to fill the heater  
and the piping and to eliminate the air trapped in the system  
Close the hot water faucet after the water flows freely and  
all the air has escaped from the system. The water heater  
is now ready to operate.  
with pilot burning. When the pilot button is released the  
pilot should continue to burn.  
- If the gas valve button does not pop up when released,  
stop and immediately call your service technician or gas  
supplier.  
- If pilot does not stay lit, repeat steps 1 through 6.  
- If pilot will not stay lit after several tries, depress the OFF  
button (  
supplier.  
), and call your service technician or gas  
FOR YOUR SAFETY READ BEFORE  
LIGHTING THE PILOT  
7. When lit, depress the ON button (  
). The heater will  
now fire when water is drawn at a rate greater than the  
threshold flow rate.  
Warning: If you do not follow these instructions  
exactly, a fire or explosion may result causing property  
damage, personal injury or loss of life  
NOTE: If main burner should fail to ignite, make sure  
pilot is burning. If not, repeat lighting steps 1 through 6.  
A. This appliance has a piezo-igniter for lighting the pilot  
burner. When lighting the pilot, follow these instructions  
exactly.  
B. BEFORE LIGHTING smell all around the appliance area  
for gas. Be sure to smell next to the floor because some  
gas is heavier than air and will settle on the floor.  
TO TURN OFF GAS TO APPLIANCE  
Depress the OFF button ( ) and close the gas supply to  
the heater.  
INFORMATION ABOUT WATER TEMPERATURE  
WHAT TO DO IF YOU SMELL GAS  
- Do not try to light any appliance.  
The AquaStar 125B LPL and 125B NGL water heaters  
produce a 90°F temperature rise at 1.8 gallons per minute.  
As the flow rate is increased above 1.8, gallons per minute,  
the temperature will decrease.  
- 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 fire  
department.  
C. Use only your hand to push in or turn the gas control  
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.  
MAINTENANCE AND SERVICE  
(see maintenance table on back of manual)  
Approximately once a year, theAquaStar should be checked  
and cleaned. To remove the front cover, first remove the  
incandescent particle tray, then unscrew the central screw  
located at the bottom of the front cover. Pull main cover out  
9
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toward you and lift up and out. THE FOLLOWING To access the pilot orifice, remove 2 screws holding pilot  
OPERATIONS SHOULD BE PERFORMED BY A assembly in place. Then loosen compression fittings to  
QUALIFIED SERVICE PERSON:  
expose pilot orifice.  
Vent System: Should be checked annually. Clean and repair  
as needed.  
Water Valve (Part # 8707002478): The water valve on this  
heater should be serviced periodically. Lubricate component  
#25 on page 14 with a small amount of silicon, faucet or  
AIR SCREEN  
lithium grease every two years to keep its o rings fresh and  
pushrod sliding smoothly. Every 3-5 years replace  
components #25 and #27 on page 14. The frequency will  
depend on the mineral content of the water and conditions  
of use or whenever signs of corrosion appear at the gas  
and water valve joint. Periodically check that the water inlet  
filter (#32 on page 14) is clean as well.  
PILOT ORIFICE  
Pilot Flame: The pilot flame should burn with a clean sharp  
blue flame and should resemble the diagram in Fig 8. 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, the pilot  
burner and or the pilot burner orifice may need to be cleaned  
(NG), the orifice may need to be replaced(LP), and or the  
air screen may need cleaning. The pilot flame should envelop  
approximately 10 mm (3/8") of the tip of the thermocouple.  
If it is too small, the pilot burner must be cleaned. To obtain  
a spark, the position of the Piezo igniter electrode should  
Fig. 9 - Pilot burner with air screen/ pilot orifice  
Main Burner Flames: The main burner flames should be  
blue, with a more intense blue cone in the center core.  
Yellow flames could be a sign of wrong size gas orifices or  
dirty burners, or a blockage on the heat exchangers fins. If  
some burners have yellow flames while others have good  
flames, it is likely that dust, lint or spider webs have partially  
clogged the burner venturis. To clean the burners contact a  
gas service person  
be approximately 3 mm (1/8") from the pilot burner tip.  
3mm  
Mineral Scale Build-up: The AquaStars heater, when  
operated at lower temperatures settings, do not accumulate  
mineral build-up. If however, the heater is used at the higher  
temperature settings and the water has a high mineral  
content, periodic descaling may be necessary. The heating  
coils should be flushed with a descaling solution. Consult  
your dealer or Controlled Energy for instructions.  
Correct gap between pilot  
burner tip and piezo electrode  
tip  
Piezo Electrode  
Air screen filter  
TROUBLE SHOOTING (see maintenance table)  
Introduction  
The AquaStar 125 BL burners are activated by a water flow  
valve. Numerous water related problems can cause this  
water valve to malfunction such as: Insufficient water flow  
volume to activate the burners at its minimum flow  
requirement; Dirt in the water flow valve causing it to  
malfunction; Sediment build-up in faucet aerators, or shower  
heads; Uneven pressures between cold and hot. (with single  
lever faucets) Plumbing cross overs. These water flow  
related problems can cause the heater to deliver less than  
its full output, or to fail to ignite or to shut down completely.  
Problems are stated in upper case, bold face. Most common  
causes for the problems follow in order of likelihood. The  
suggested solutions require that the cover be taken off. To  
do this, remove incandescent particle tray and unscrew  
the central screw located at the bottom of the front cover.  
Pull main cover out toward you and lift up and out.  
Thermocouple  
Piezo  
Electrode  
Fig. 8 - Characteristic Pilot Flame  
To clean the pilot burner and/ or the pilot orifice : Turn  
off the gas at the unit. Remove the cover of the heater. To  
do so, remove incandescent particle tray and unscrew the  
central screw located at the bottom of the front cover. Pull  
main cover out toward you and lift up and out. Pull the air  
screen off, wash it and blow any lint off (See Fig 9). The  
pilot orifices should also be cleaned or replaced. Do not  
enlarge the orifice. Do not use any wire or sharp object  
to clean orifices. Natural gas orifices are large enough  
that you can usually clean them by blowing through them.  
LP orifices, on the other hand, are too small to clean and  
should be replaced. See #3 in Trouble Shooting Section.  
PILOT LIGHT WILL NOT LIGHT  
1. No gas to the AquaStar  
A. Gas cock on gas line may not be open.  
B. Gas valve button has not been pushed in on PILOT”  
position.  
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C. Gas regulator may be shut or damaged.  
Tighten the thermocouple nut snugly but not too tight.  
2. In-line AquaStar gas regulator jammed (usually on 4. Poor circuit connections at the ECO. (Energy Cut-  
LP gas)  
Off overheat protection)  
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).  
Oxidation or looseness of the ECO terminal connections  
can result in millivolt current loss through the thermocouple  
safety circuit. Clean terminals with very fine sand paper or  
Jamming usually happens if the gas pressure between the an eraser and reconnect ECO leads.  
gas tank (propane) and the water heaters gas regulator  
has not been reduced. See page 2 for recommended correct 5. Faulty ECO (part #8707206017)  
gas pressure.  
If cleaning the terminals attached to the ECO did not fix  
the problem, connect a jumper wire between the two wires  
3. Pilot orifice clogged and/or air screen dirty, or pilot and try to relight the pilot. If the pilot flame now remains  
gas filter is dirty. on, replace the ECO. If the flame still goes out when the  
Clogging of the pilot burner can be caused by dust and any button is released, the ECO is not defective. Go to next  
suspended matter contained in the ambient air. Although step.  
the filters can lengthen the cleaning intervals, they can never  
completely prevent such clogging. In consequence the gas 6. Faulty thermocouple (part #8747202083) or  
jet issuing from the pilot orifice is reduced and or the air  
mixture is reduced. The pilot flame is weak and thus can  
no longer heat the thermocouple sufficiently. For cleaning  
purposes, the air filter screen is pulled off, washed and  
blown out. The pilot orifice has likewise to be cleaned or  
electromagnet) Unless these 2 parts are at least 8  
to 10 years old, it is very unlikely that they are  
faulty. Before testing, reconfirm that #2 is absolutely  
correct, and that all connections are clean and  
tight.  
exchanged. To clean the pilot consult a gas service person Consult a gas service person to test and change the  
.
thermocouple.  
4. Air in the Gas Line  
BURNERS DO NOT IGNITE WHEN HOT WATER IS  
Note: Normally this is a problem only at the time of initial TURNED ON OR WHEN A CIRCULATOR PUMP IS  
installation, after the pipes have been worked on, or after a OPERATING  
propane tank has been allowed to empty, or after the heater  
has been shut down for a long time.  
1. Pilot is not on.  
Bleed all the air trapped in the gas line. Because of the Light the pilot. See lighting instructions.  
very small pilot orifice (especially on LP gas models),  
bleeding out all the air could take several minutes. Depress 2. Gas valve button not positioned on Burner Position  
Be sure once the pilot flame is on, that after a 15 to 20  
the pilot button ( ) until all the air has escaped, and the  
gas has arrived. During this process, press repeatedely on  
the piezo ignition button until the pilot flame has ignited.  
second wait, the main burner button (  
the way in.  
) is pushed all  
PILOT LIGHTS BUT FLAME GOES OUT WHEN BUTTON  
IS RELEASED  
3. Water flow rate at hot water tap is too low.  
Note: The AquaStar models 125BL require 1.8 gallon per  
minute flow to activate the burners. This is a flow which  
would fill a quart jar in 8 seconds.  
1. Pilot push button was not pushed in far enough or  
was not held in long enough  
Once pilot flame has been lighted. Hold button pushed in  
for at least 15 seconds to give time for the pilot flame to  
properly heat the tip of the thermocouple.  
4 . Cold water inlet filter on heater is dirty.  
Remove filter and clean. This screen filter is located at the  
inlet side of the brass water valve (fig 11, #32). Check and  
clean faucet aerators too.  
2. Pilot flame improperly aimed or is too weak so it  
is not properly heating the tip of the thermocouple.  
The Pilot flame should be a sharp blue flame and aimed at  
the tip of the thermocouple so that it envelops 10 mm (3/8  
) of the thermocouple tip. Pilot flame has to be properly  
aimed at the thermocouple. See Fig 8.  
5. Inadequate pump used on a recirculating loop  
If unit is plumbed in a recirculating loop system verify that  
the primary circulator pump is sized properly. GF 26-96,  
Taco 009 or equivalent is required. See diagram on page 4.  
6. Crossover in household plumbing  
3. Poor thermocouple connection at the  
electromagnet  
TheAquaStar burner activates when there is sufficient water  
pressure drop in theAquaStar water valve assembly ie.  
when a hot water faucet is opened. If there is a crossover in  
the plumbing, the necessary pressure drop in theAquaStar  
will be insufficient, or totally eliminated. A plumbing  
crossover can be caused by a bad washer at a single lever  
faucet or incorrect plumbing or a mixing valve in the line,  
etc. which permits hot and cold water to mix in the  
plumbing. The crossover will create a back pressure in the  
Note: Electromagnet is part #8707201094 located on the  
right side of the gas valve behind the piezo pushbutton  
assembly. Check the tightness of the thermocouple  
connection nut at the electromagnet: The Electro-magnet  
connection is a large aluminum 17mm hex head nut. The  
thermocouple end is a 5 mm brass nut which screws into  
the 17 mm nut.  
11  
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system preventing the pressure drop in the Aquastar (i.e. temperature relay for the primary circulator pump is possibly  
cold water is entering the water heater from both sides and set too high.  
the burners will not come on).  
To confirm there is no crossover in the plumbing, shut off WATER IS NOT HOT ENOUGH  
the cold water supply to theAquaStar. Open your hot water  
taps.  
1. Water flow rate is too high.  
There should not be any water flowing. If there is water Decrease the flow rate.  
flowing, there is a crossover in the plumbing. This is a  
plumbing problem, not anAquastar problem. Please contact 2. Gas flow is not optimal  
your plumber.  
Move gas control slide to the right.  
7. Water valve parts may be dirty or components  
damaged.  
3. Temperature (aquastat) control is set too low  
First check that the venturi is free from dirt particles.  
If unit is plumbed in a recirculating loop system the aquastat  
Water valve and component parts must be totally free of temperature relay for the primary circulator pump is possibly  
dirt. In hard water areas, mineral deposits can eventually set too low.  
(3 to 5 years in hard water areas) corrode the water valve  
parts to a point where they will need replacing. Any sign of 4. Btu input is too low due to insufficient gas pressure  
moisture or corrosion at the joint of the water valve and the  
gas valve is a sign that the water valve assembly  
components need to be replaced immediately.  
It is extremely important for a tankless instantaneous  
water heater to have the right size gas line to obtain  
the correct gas pressure  
Note: Water valve for model 125BL is part # 8707002478 See specifications on page 2. Unlike storage tank water  
for both LP and NG models. (Contact service person to heaters, the burners of a tankless water heater must be  
clean water valve or replace if corrosion is present).  
PILOT LIGHT GOES OUT DURING OR AFTER USE  
1. Gas pressure too low  
very powerful to heat water instantaneously since they do  
this only at the time hot water is actually being used. It is  
therefore imperative that the gas pressure requirement be  
met exactly. Insufficient gas pressure will directly affect  
the water temperature at the time of usage. See pages 2  
Very low gas pressure may be caused by low delivered for correct gas pressure settings.  
gas pressure, a jammed gas regulator or undersized gas  
lines. If the gas lines are undersized, there may still be the 5. Btu input is too low due to insufficient gas supply  
specified static gas line pressure. However when the water Make sure your main gas line is fully opened. If using LP  
valve opens,and gas enters the burners, the pressure could gas, be sure that the size of the propane tank is adequate  
drop sharply, causing the pilot flame to go out. Have a gas to supply the required gas pressure.  
technician confirm the gas pressure both static and at  
maximum Btu output. Specifications for your heater are on 6. Cold water is mixing with the hot water between  
page 2.  
the AquaStar and the outlet  
2. Pilot may be dirty or weak  
See Page 9 for instructions on pilot maintenance.  
Compare water temperature at outlet of theAquaStar (hold  
theAquaStars outlet pipe with your hand) and at the tap. If  
these two are very different, check for mixing valve or  
3. Burners are not shutting down immediately when plumbing crossover (see MAIN BURNERS WILL NOT  
hot water is turned off or when a circulator pump IGNITE...paragraph #5).  
has stopped operating  
Note: If burners dont shut down immediately when the hot 7. Parts in water flow valve are corroded so that the  
water is turned off, the heater will overheat and the ECO  
gas passage is not fully opening  
will shut-off the gas. Rebuild the water valve assembly using Contact your service person or Controlled Energy.  
the repair kit from CEC (part#8 703 406 214).  
HOT WATER TEMPERATURE FLUCTUATES  
4. Temperature controls are set too high  
If unit is plumbed in a recirculating loop system insure that 1. Cold water is mixing with the hot water between  
the aquastat or relay for the primary circulator pump is set  
for no hotter than 140°F. This is necessary to prevent pilot  
the AquaStar and the outlet (if not being used with  
a circulator pump)  
outage due to overheating. The temperature slide control See #5 under Burners do Not Ignite When Hot Water Turned  
on the 125BL may also need to be lowered to prevent On.  
overheating.  
2. Storage in tank (recirculating system) has not fully  
recovered  
WATER IS TOO HOT  
Storage capacity in tank is inadequate. Increasing tank  
size, setting slide control higher for a fast recovery or adding  
a second 125BL for even a faster recovery is suggested.  
1. Gas flow is higher than necessary.  
Move gas control slide to the left.  
3. Insufficient gas pressure  
2. Temperature (aquastat) control is set too high  
Note required gas pressures (page 2) and consult gas ser-  
vice person.  
If unit is plumbed in a recirculating loop system the aquastat  
12  
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Fig. 10 - Diagram of AquaStar 125 BL  
1
3
2
5
8
4
6
7
9
10  
11  
7. Gas control slide  
8. Piezo igniter  
9. Location of pressure tap  
nipple  
1. Heat exchanger  
2. Pilot assembly  
3. Burner manifold gas  
pressure test nipple  
4. Pilot gas tubing  
5. Main gas burner  
6. Gas valve  
10. Water valve  
11.  
Gas inlet gas pressure  
test nipple  
13  
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Fig. 11 - INTERIOR COMPONENTS DIAGRAM AND PARTS LIST  
14  
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Fig. 11  
INTERIOR COMPONENTS DIAGRAM  
AND PARTS LIST 125BL  
1
Cover  
Cap cover  
Water connection gasket  
Draft divertor  
Heat exchanger  
Hot water pipe  
Cold water pipe  
¤
¤
8 705 421 031  
8 703 304 011  
8 710 103 043  
8 705 505 354  
8 705 406 235  
8 700 705 431  
8 700 705 294  
8 710 103 045  
8 707 206 017  
8 708 120 296  
8 708 120 298  
8 708 105 337  
8 700 507 055  
8 708 107 002  
8 708 200 005  
8 748 200 173  
8 710 707 166  
8 747 202 083  
8 710 103 060  
8 700 100 174  
8 707 011 460  
8 707 011 464  
8 700 705 464  
8 747 201 094  
8 700 103 144  
8 700 507 051  
8 747 202 078  
8 707 002 478  
8 703 406 214  
8 700 503 043  
8 708 503 060  
8 703 404 098  
8 700 205 050  
8 708 500 230  
8 708 205 248  
8 700 507 059  
8 700 703 114  
2
3
¤
¤
4
5
¤
6
¤
7
¤
8
Heat exchanger washer  
Overheat sensor (ECO)  
Main burner assembly  
Main burner assembly  
Pilot burner assembly  
Pilot filter screen  
Piezo electrode  
¤
9
¤
10  
LPG  
NG  
¤
11  
11a  
12  
13  
¤
¤
NG  
LPG  
¤
¤
¤
Pilot orifice  
14  
15  
16  
17  
18  
Pilot Tube  
Thermocouple  
Burner assembly washer  
Throttle disc  
LPG  
NG  
LPG  
¤
Gas valve  
Gas valve  
Gas supply pipe  
Electromagnet  
Electromagnet washer  
Gas filter  
Thermocable  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
¤
¤
¤
¤
Water valve assembly  
Water valve repair kit  
Water valve diaphragm  
Slow ignition valve  
Water valve setting screw  
O ring setting screw  
Water valve piston assembly  
Water valve venturi  
Water inlet filter  
¤
¤
¤
¤
¤
¤
¤
¤
¤
Water elbow fitting  
¤
15  
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INSTALLATION CHECKLIST  
GAS LINE SIZE  
Natural Gas  
Nominal Iron Pipe Size*  
1/2"  
10'  
3/4"  
40'  
1"  
MAXIMUM LENGTH  
150'  
Liquid Propane  
Semi-rigid Tubing  
1/2"  
NOT  
RECOMMENDED  
5/8"  
20'  
3/4"  
60'  
7/8"  
150'  
MAXIMUM LENGTH  
* 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.  
MAINTENANCE TABLE see pages 9 & 10  
EVERY YEAR  
EVERY 2 YEARS EVERY 3-5 YEARS  
LUBRICATE WATER VALVE  
REBUILD WATER VALVE  
INSPECT WATER FILTER SCREEN  
INSPECT PILOT ASSEMBLY  
INSPECT VENT ASSEMBLY  
INSPECT MAIN BURNER  
Replacement Parts available from North American  
Distributor  
CONTROLLED ENERGY CORP.  
340 Mad River Park  
VULCANO Termodomésticos S.A.  
Estrada de Cacia  
3801 - 856 Aveiro - PORTUGAL  
Waitsfield, Vermont 05673  
Phone 800-642-3111  
Fax (802) 496-6924  
Recycled paper  
©2001ControlledEnergyCorporation,Waitsfield,VT  
allrightsreserved  
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