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INSTALLATION AND OPERATING INSTRUCTIONS FOR AUTOMATIC
INSTANTANEOUS TYPE WATER HEATERS FOR USE WITH NATURAL AND
LIQUEFIED PETROLEUM GAS
MODEL 38B LP and NG (Non Modulating)
Suitable for water (potable) heating and space heating
Intended for low flow domestic hot water applications with steady cold water inlet temperatures
WARNING
If the information in this manual is not followed exactly,
a fire or explosion may result causing property
damage, personal injury or death.
FOR YOUR SAFETY
Do not sto
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This well engineered, gas water heater has all the fea- AquaStar 38B LP and 38B 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.: 40,000 Btu/hr water flows through the coils of the heat exchanger in the min.: 20,000 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
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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 devi
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The heater may still operate even when improperly vented. GENERAL RULES TO FOLLOW It will, however, be less efficient and could eventually FOR SAFE OPERATION damage the heater. It could even result in human sickness or death due to oxygen deprivation and carbon monoxide 1. You should follow these instructions when you install poisoning. Follow the guidelines below: your heater. In the United States: The installation must conform with local codes or, in the absence of local codes, 1. Place your
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Appliances located in confined spaces:) The confined Identification labels are found on the shipping box, and on space must be provided with two permanent openings, the rating plate which is located on the right side panel of one commencing within 12 inches of the top and one the cover. Also, each burner orifice is stamped with a num- commencing within 12 inches of the bottom of the ber (79 for LPG and 120 for Natural Gas). enclosure. Each opening must have a minimum free area of one square inch
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WARNING The pressure regulator provided with the heater is adjusted Note: The burners of an instantaneous “on demand” water to deliver the proper gas pressure (as indicated on the heater such as the AquaStar are only on at the time that rating plate and in the manual for altitude up to 2000 feet hot water is actually being used, the venting stack is (660 meters) above sea level. On appliances being therefore cold except for the short durations when hot water installed above 2000 ft (660 meters)
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to no less than 1/2 inch diameter to allow the full flow OPERATING INSTRUCTIONS capacity. Threaded connectors are supplied with this heater for both the hot and cold water fittings. These fittings permit Before proceeding with the operation of the heater make 1/2” NPT connections to be made. Be certain there are no sure that the system is filled with water. loose particles or dirt in the piping. Blow out or flush the Make sure the water heater drain plug is closed. See Figure lines before connec
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LIGHTING INSTRUCTIONS 1. STOP! Read the safety information on the front panel of the heater. 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 front center of the jacket directly below the lighting Fig. 6
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To clean the pilot burner and/ or the pilot orifice : Turn MAINTENANCE AND SERVICE off the gas at the unit. Remove the cover of the heater. To do so, remove the incandescent particle tray, pull off the Approximately once a year, the AquaStar should be temperature adjustment knob and unscrew and remove checked, cleaned and serviced as necessary. To remove the knob collar. Unscrew the central screw located at the the front cover, first remove the incandescent particle tray, bottom of the front co
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button separately until the pilot flame has ignited. TROUBLE SHOOTING PILOT LIGHTS BUT FLAME GOES OUT WHEN Introduction BUTTON IS RELEASED The AquaStar 38 burners are ignited by a water flow valve. Numerous water related problems can cause this water 1. Pilot push button was not pushed in far enough or valve to malfunction such as: Insufficient water flow volume was not held in long enough to activate the burners at its minimum flow requirement; Slide the gas valve button ( ) to pilot position
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BURNERS DO NOT IGNITE WHEN HOT WATER IS PILOT LIGHT GOES OUT DURING OR IMMEDIATELY TURNED ON AFTER HOT WATER HAS BEEN USED 1. Pilot is not on. 1. Gas pressure too low Light the pilot. See lighting instructions. Very low gas pressure may be caused by low delivered gas pressure, a jammed gas regulator or undersized gas 2. Pilot lighting push button not turned to proper lines. If the gas lines are undersized, there may still be the position specified static gas line pressure. However when the water
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heaters, the burners of a tankless water heater must be 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 and 13 respectively for correct gas pressure settings and where gas pressures are taken. 4. Btu input is too low due to insufficient gas supply Make
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Fig. 9 - Diagram of AquaStar 38 B 1 2 5 3 4 6 7 9 8 11 10 1. Heat exchanger 6. Inlet gas pressure test nipple 2. Pilot assembly 7. Gas valve 3. Burner manifold gas 8. Gas control slide pressure test nipple 9. Piezo igniter 4. Pilot gas tubing 10. Temperature adjustment knob 5. Main gas burner 11. Water valve 13
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Fig. 10 - INTERIOR COMPONENTS DIAGRAM AND PARTS LIST
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Fig. 10 INTERIOR COMPONENTS DIAGRAM AND PARTS LIST 38B 1 Cover ¤ 8 705 421 021 2 Temperature adjustment knob ¤ 8 702 000 182 3 Panel back ¤ 8 705 402 170 4 Draft divertor ¤ 8 705 505 361 5 Heat exchanger ¤ 8 705 406 233 6 Overheat sensor (ECO) ¤ 8 707 206 040 7 Hot water pipe ¤ 8 700 703 038 8 Main burner assembly LPG 8 708 120 301 Main burner assembly NG 8 708 120 011 9 Burner assembly washer ¤ 8 710 103 008 10 Piezo electrode ¤ 8 708 107 002 11 Pilot burner assembly ¤ 8 718 105 048 11a Pilot a
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INSTALLATION CHECKLIST GAS LINE SIZE Natural Gas Nominal Iron Pipe Size* 3/8" 1/2" MAXIMUM LENGTH 20' 80' Liquid Propane Semi-rigid Tubing 3/8" 1/2" MAXIMUM LENGTH 10' 60' * Flex tubing greatly reduces capacity and, therefore, is not recommended. Minimum Vent Size* and Height Minimum Diameter Minimum Height** 4 inches 6 feet** * NOTE: Vent size must not be restricted. Installation must comply with national fuel gas code venting requirements for a 40,000 Btu Category I appliance and any applicab
