Assessments - 4, GPA: 3.5
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insufficient water flow volume to activate the burners at their minimum flow requirement 2. dirt in the water flow valve causing the valve to malfunction 3. sediment buildup in faucet aerators or shower heads 4. uneven pressures between cold and hot (with single lever faucets) 5. plumbing cross-overs These water related problems can cause the heater to deliver less than its full output, or to shut down completely. SPECIFIC PROBLEMS AND ANSWERS Note: Problems are stated in upper case, bold face. Most common causes for the problems follow in order of likelihood of occurence. For most of the suggested solutions, it will be necessary to take the front cover of the heater off. To do this, pull the knobs off and remove the screws at front bottom corners, then lift and pull the front panel off. It is also advisable to remove the bottom tray: pull off the plastic handle of the manual gas valve and loosen the side panel bottom screws and then pull the tray down. PILOT WILL NOT LIGHT 1. No gas to the AquaStar A. Gas cock on gas line may not be open. B. AquaStar manual shut off valve at base of heater is not open. Turn handle to red flame symbol. 2. In-line AquaStar gas regulator jammed (usually with LP gas) Replace or unjam the regulator. Note: The regulator furnished with the heater is designed for lowgas pressure. Excessive pressure will lock it up. This problem usually happens if the gas pressure between the gas tank and the water heater has not been reduced. See page 3 of your manual for specified gas pressures. To unjam a regulator, remove the nickel size screw plug on the front. Inside you will see another large screw. Draw a line down the threads to mark the location of the screw. Remove the screw and push on the bottom of the hole with the eraser side of a pencil or similar object. This will release the diaphragm. Reinsert the screw and screw it down to the end of the mark you made. 3. Pilot orifice cloggged and/or air screen dirty, or pilot filter is dirty. Clean the pilot orifice and/or pilot filter screen. Disconnect the pilot tube (T) by unscrewing it. Be careful not to misplace the small washers. The diagram on page 19 shows how the parts of the pilot assembly fit together. Natural gas orifices are large enough that you can usually clean them by blowing through them. The LP orifice is so small that it is best to replace it. Never try to enlarge the hole, or use a sharp hard object for cleaning. The pilot gas filter is made from a layered material. If it becomes too dirty, a portion of the filter can be separated and peeled off. The clean portion should be loosely reinserted into the pilot burner brass filter chamber. Be careful when reinstalling the pilot burner to aim the burner so that the smaller right hand pilot flame touches the thermocouple tip. 14 4. Pilot orifice may not be correct for your type of gas. Pilot orifice is stamped: #18 for LP and #35 for NG. 5. Air in the Gas Line Note: Normally this is a problem only at the time of installation if the pipes have been worked on, a propane tank has been allowed to empty, or the heater has been shut down for a long time. Bleed all the air trapped in the gas line. Because of the very small pilot orifice (especially on LP gas models), bleeding out all the air could take several minutes. Hold the pilot push button pushed in until all the air has escaped, and the gas has arrived. PILOT LIGHTS BUT FLAME GOES OUT WHEN BUTTON IS RELEASED 1. Pilot push button was not pushed in far enough or was not held in long enough Push pilot button in, turn it to the left, then push it in all the way. Hold it pushed in for at least 20 seconds to give time for the pilot flame to properly heat the tip of the thermocouple before releasing it. See Lighting Instructions, Page 11. 2. Pilot flame improperly aimed or is too weak so it is not properly heating the tip of the thermocouple The pilot flame has two flames, one aimed at the thermocouple and the other aimed at an angle towards the burners (see pilot flame diagram, Fig. 4, page 13). It is extremely important that the flame directed on the thermocouple head be aimed right at it, and that the pilot flame be a sharp blue flame. If the pilot assembly has been taken apart for cleaning, the pilot flame may no longer be properly aimed. 3. Poor circuit connections at the ECO (Energy Cut-Off) Oxidation or looseness of the ECO screw connections can result in millivolt current loss through the thermocouple safety circuit. Clean terminals with very fine sand paper or an eraser and retighten terminal screws. (See letter V in Fig 2, page 6). 4. Faulty Energy Cut Off (ECO)- Part 34209 If cleaning and retightening the screws on the thermocouple wires attached to the ECO did not fix the problem, test the ECO by disconnecting a wire from one side of it and reconnecting it to the other side so both wires are making good contact. Relight the pilot. If the pilot flame now remains on, replace the ECO. If the flame still goes out when the butto...
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