AquaStar 125X, 125BS, 125BL User Manual
INSTALLATION AND OPERATING INSTRUCTIONS
FOR AQ-1 POWER VENT KIT
DESIGNED FOR
BOSCH 425 HN WATER HEATERS
AQUASTAR 125B WATER HEATERS
INCLUDING AQUAST AR MODELS: 125HX • 125BS • 125X • 125BL
TABLE OF CONTENTS
contents with an AQ-1 power vent p.1
mounting gas pressure switch p.2
mounting linear spillage switch p.4
common setup p.6
locating vent hood (clearances) p.7
mounting power vent motor (clearances) p.7
troubleshooting and maintenance p.9
safety interlock test p.10
AQ-1 wiring diagram p.1 1
vent hood template p.12
8504077 rev . B 10.03
AQ-1Power vent kit
Parts included:
Spillage Switch Kit
1. 185º F linear spillage switch mounted on an
angled bracket and equipped with 36 inch
cables connected to one eyelet terminal
and one 1/4" quick connect terminal
2. Spillage switch mounting screw
3. Push on male spade connector, replaces
eyelet terminal from 36 inch spill switch cable.
Vent Hood Kit
1. 4" vent hood: VH1-4
2. Plastic wall anchors (4)
3. Sheet metal screws (4)
4. 5" to 4" vent reducer pipe
5. AQ1FLAPPER back draft accessory
Vibration Mount Packet
1. Vibration mounts (2) with nuts and washers
2. Brackets (2) with nuts and washers
Gas Pressure Switch Packet
1. Gas pressure switch
2. Self-tapping mounting screws (4)
3. Manifold pressure tap fitting with 1/4" compression nut and sleeve
4. 1/4" by 40" aluminum tubing (2)
Power Vent Kit
1. Power venter (HSUL-1 Series containing
integrated 24v control circuit) including 25
foot control cable with 1/4" quick connect
ends and an HPN 6 foot power cord
2. Nylon ties
1
Before beginning installation review
required clearances for Water Heater ,
Power Vent Motor and V ent Hood
Power Vent Kit
CAUTION
1. Failure to install, maintain and/or operate the
Power Venter in accordance with
manufacturer's instruction may result in
conditions which can produce bodily injury and
property damage.
IMPORT ANT : FREEZE PREVENTION TO HEA TER
In cold climates the vent hood and power vent motor will not prevent infiltrating cold air to the water
heater when not in use. Be sure to install the supplied backdraft AQ1FLAPPER accessory within the
vent hood on the outside of the building. If not used,
cold air can enter the vent pipe and freeze the heaters heat exchanger when not in use. Such damage
is not covered under the water heater's warranty.
2. The Power Venter must be installed by a
qualified installer in accordance with all local
codes or, in their absence, in accordance with
the National Fuel Gas Code (ANSI
Z223.1NFPA #54), the National Electric Code
and The Occupational Health and Safety Act
(OSHA) as applicable.
3. The Power venter motor shaft must be
mounted horizontally to prevent motor bearing
wear.
4. Disconnect power supply when making wiring
connections or when working around the fan
blade and motor. Failure to do so may result
in severe personal injury and equipment
damage.
5. Make certain the power source is adequate for
the fan motor requirements. Do not add the
power venter to a circuit where the total load
is unknown.
AQ-1 Motor is 200 watts- 1.66 amps @ 120vac
Bosch-Aquastar
1. Follow installation and operating instructions
manual supplied with the water heater.
2. Before mounting water heater to wall, check
its minimum clearance requirements.
Gas Pressure Switch
Remove the gas pressure switch from the bag in the
carton and the brass 1/4" compression nut fitting which
is meant for the burner manifold tap on the heater , not
the inlet tap on the heater's gas inlet pipe (see p. 3,
Fig B). Also remove the four self-t apping screws and
the two sections of 1/4" diameter aluminum tubing from
the master carton.
The gas pressure switch must be mounted in such a
way that the diaphragm is oriented vertically and the
aluminum tubing pieces can easily reach the manifold
pressure test nipple and the burner respectively.
It must not be mounted inside the heater. See
Figure E p.6
When mounting the Gas Pressure Switch: We
recommend mounting the gas pressure switch vertically
against a wall on the lower left side of the water heater .
See Figure E p.6. Because the cabinet cover is three
sided we do not recommend screwing the gas pressure
switch to the left side of it. Instead, mount the gas
pressure switch vertically against a wall on the lower left
side of the water heater. Inst alled in this manner all
necessary connections will be within reach and there
will be minimal interference when servicing.
3. When using an AQ-1 the maximum
horizontal distance from the water heater to the
power vent motor is 100 feet. Subtract 10 feet
for each added elbow. Inst all power vent
motor as close to the termination as
possible to maintain the water heater's
optimal efficiency.
2
FIGURE A
ROUTE TUBING TO PRESSURE
PORT ON THE
TAP
HEATER
ROUTE
AREA
'S BURNER MANIFOLD
TUBING TO BURNER
OR ATMOSPHERIC VENT
FIGURE B
125B MODEL SHOWN
PRESSURE TAP-GAUGE POR T
(WHERE HEATER'S BURNER
MANIFOLD
MEASURED
PRESSURE CAN BE
)
INSTRUCTIONS (SEE DIAGRAMS ABOVE)
1. Mount gas pressure switch by securing it to
the chosen location with a screw in each one
of the four mounting holes.
2. Use a tube cutter to make a clean cut (not
crimped) at each end of the two lengths of the
1/4" aluminum tubing. One tube must be long
enough to reach from the fitting marked
"connect to gas valve" to the pressure tap port
on the heater's burner manifold (Not to the
inlet gas pressure port of the water heater
since there will be constant gas pressure
there). The tube must be long enough to enter
the bottom of the water heater front cover and
attach to the burner manifold without difficulty
(See Figure B). The second tube must be long
enough to reach from the gas pressure switch
to the burner area, but not in the pilot flame
area. Allow enough slack for very gradual
bends.
(See Figure A for gas pressure switch ports).
MANIFOLD
TAP
a. Remove the brass pressure tap fitting from
the burner manifold of the water heater. This
fitting will not be required for reuse.
b. Bend one 1/4" aluminum tubing so that it
will run from the gas pressure switch to where
the fitting attaches to the burner manifold.
Make gradual bends - do not crimp the tube.
c. Do not connect to burner manifold, first
assemble the 1/8" NPT male by 1/4"
compression fitting with nut and sleeve to
this end of the aluminum tube. Tighten the
fitting and nut with two wrenches.
d. Separate the joint just made in step 3.c.
3. ATTENTION - Failure to follow the next series
of instructions may result in breaking a part.
3
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