AquaStar AQ4 User Manual

Installation manual

AQ4 Horizontal Vent Kit

For Bosch AquaStar Models: GWH 1600 P, GWH 1600 H For Bosch ProTankless Models: GWH 425 PN, GWH 425 HN*

WARNING: If the information in this manual is not followed

exactly, a re or explosion may result causing property damage, personal injury or death. Do not store or use gasoline or other ammable vapor and liquids in the vicinity of this or any other appliance.

BTC715003301A

Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualied installer, service agency or the gas supplier.

In the Commonwealth of Massachusetts this product

must be installed by a licensed plumber or gas tter.

Upon completion of the installation, these instructions should be handed to the user of the appliance for future reference.

* The GWH 425 HN has been redesigned. This vent kit is not compatible with the older version (identied by a white cover). Use the AQ1 horizontal vent kit with the older version.

Table of Contents

1 Introduction ......................................................................... 3

1.1 Parts included ................................................................................ 3

1.2 Warnings ................................................................................ 3

1.3 Preparation ................................................................................ 3

1.4 Requirements for installation in

Massachusetts ................................................................................ 4

2 AQ4 Installation instructions ......................................................................... 5

2.1 Introduction ................................................................................ 5

2.2 Locating power vent hood and

clearances ................................................................................ 5

2.3 Power vent hood ................................................................................ 5

2.4 Power vent motor ................................................................................ 6

2.5 Vent piping ................................................................................ 7

2.6 Linear safety spillage switch ................................................................................ 7

2.7 Flow switch ................................................................................ 8

3 Operation ......................................................................... 9

3.1 First time start up ................................................................................ 9

4 Maintenance ......................................................................... 9

5 Troubleshooting ......................................................................... 9

5.1 Introduction ................................................................................ 9

5.2 Power vent motor runs all the time or

intermittently without water ow ................................................................................ 9

5.3 Pilot will not hold when lit or spark

automatically with hot water ow .............................................................................. 10

5.4 Sparks but pilot will not light

5.5 Pilot goes out during hot water use .............................................................................. 10

5.6 Noise when power vent motor is

running .............................................................................. 10

6 One Year Limited Warranty ....................................................................... 11

7 Wiring diagram ....................................................................... 12

8 Vent hood template ....................................................................... 13

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1 Introduction

Introduction

1.1 Parts included

Vent Hood Kit

• 1 - 4” vent hood: VH1-4

• 4 - Exterior screws

• 1 - 5” to 4” vent reducer pipe

• 1 - AQ4FLAPPER back draft accessory

Vibration Mount Packet

• 2 - Vibration mounts with nuts and washers

• 2 - Brackets with nuts and washers

Flow Switch Packet

• 1 - Flow switch

• 4 - Replacement pipes (See chapter 2.7)

• 2 - Pipe clips

• 1 - Molex connector cable

• 1 - Heat exchanger bushing

Power vent motor

• 1 - Power vent motor (HSUL-1 Series containing integrated 24v control circuit) including 25 foot control cable with wire nuts and an HPN 6-foot power cord

• 5 - Nylon ties

Warning: Failure to install AQ4FLAPPER properly may allow freezing air to come in contact with the water heater’s heat exchanger and cause the heat exchanger to burst. Such damage is not covered under the water heater’s warranty.

1.3 Preparation

1. Follow installation and operating instructions manual supplied with the water heater.

2. Before mounting water heater to wall, check its minimum clearance requirements.

3. When using an AQ4 the maximum vent length from the water heater to the point of termination is 25 feet with one elbow. Subtract 5 feet for each additional 90° elbow (up to two additional elbows allowed.)

4. Install power vent motor as close to the vent hood

1.2 Warnings

1. Failure to install, maintain and/or operate the power vent in accordance with manufacturer’s

instructions may result in conditions which can

produce bodily injury and property damage.

2. The power vent must be installed by a qualied

installer in accordance with all local codes or, in

their absence, in accordance with the National Fuel Gas Code (ANSI Z223.1 NFPA #54), the National Electric Code, the Canadian Electrical Code (C22.1), Canadian Gas Code (CSA B149.1) and The Occupational Health and Safety Act (OSHA) as applicable.

3. The power vent 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 vent to a circuit where the total load is unknown.

AQ4 Motor is 200 watts- 1.66 amps @ 120vac.

6. Locate the outlet receptacle as close to the vent motor as possible. Do not use an extension cord.

3AQ4 Manual

Introduction

as possible.

1.4 Requirements for installation in

Massachusetts

Attention residents of the Commonwealth of Massachusetts:

In the Commonwealth of Massachusetts the following regulation went into effect on 12/30/2005: (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by

the Commonwealth and where the side wall exhaust

vent termination is less than seven (7) feet above nished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satised:

1. IN S TA L LATION OF C ARBON MONOX I D E DETECTORS. At the time of installation of the side wall horizontally vented gas-fueled equipment, the installing plumber or gastter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the oor level where the gas equipment is to be installed. In addition, the installing plumber or gastter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontally vented gas-fueled equipment. It shall be the responsibility of the property owner to secure the services of qualied licensed professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the side wall horizontally

vented gas-fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent oor level.

b. In the event that the requirements of this

subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certied.

3. SIGNAGE. A metal or plastic identication plate shall be permanently mounted to the exterior of

4 AQ4 Manual

the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR

5.08(2)(a)1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2. Product approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

the manufacturer of Product Approved side wall horizontally mounted gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for the installation of the equipment and the venting shall include:

1. Detailed instructions for the installation of the venting system or the venting system components:

and

2. A complete parts list for the venting system design or venting system.

(d )M AN UFACTURER RE QU IR EM ENTS – GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.

When the manufacturer of a product approved side wall horizontally vented gas fueled equipment does not provide the parts for the venting of ue gases, but identies “special venting systems,” the following requirements shall be satised by the

manufacturer:

1. The referen ced “spe cia l venti ng system” instructions shall be included with the appliance or equipment installation instructions; and

2. The “special venting systems” shall be product approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all products approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

2 AQ4 Installation instructions

AQ4 Installation instructions

2.1 Introduction

Please follow these instructions. Failure to follow

instructions may result in:

· Damage, injury or death

· Improper operation

· Loss of warranty If you are unable to perform the tasks required to install the water heater and this accessory properly, please contact a locally licensed plumber, HVAC contractor or gas technician. Please contact Bosch Water Heating with any questions.

2.2 Locating power vent hood and

clearances

The maximum vent length from the water heater to the point of termination is 25 feet with one elbow. If using more than one 90° elbow, subtract 5 feet off the maximum vent length for each additional elbow used. Maximum of three elbows allowed.

The power vent motor must be installed as close as possible to the VH1-4 vent hood.

Clearances

The vent system must terminate so that proper clearances from the center of the vent hood (Fig.

1) are maintained as cited in the National Fuel Gas Code, ANSI Z223.1 and CSA B149.1 in Canada:

“The vent terminal shall also not be installed closer than 3 feet from the inside corner of an L-shaped structure, or less than 1 foot above grade or anticipated snow pack level.”

Also:

“The exit terminals of mechanical vent system shall be located not less than 7 feet above grade when located adjacent to a public walkway. The venting system shall terminate at least 3 feet above any forced air inlet within 10 feet. The venting system shall terminate at least 4 feet below, 4 feet horizontally from or 1 foot above any door, window or gravity air inlet into any building.”

2.3 Power vent hood

1. Attach the mounting template (on page 13) to the interior wall that the vent hood will be penetrating.

2. Ensure that the proposed vent termination clearances are met (Chapter 2.2) before cutting opening through wall. Using a 1/2” drill bit, drill two pilot holes where noted on the template. The drill bit must be long enough to penetrate to the building exterior.

3. Attach the template to the outside of the building aligning the pilot holes on the template with the pilot holes drilled in step 2.

4. Using a reciprocating saw, cut a hole through the building siding, wall board, etc., following the appropriate lines of the template.

5. Apply a bead of exterior-rated caulk to the vent hood ange to seal at the exterior of building.

6. Slide the vent hood through the opening and fasten to exterior wall using screws provided.

7. Install backdraft apper using the instructions included with apper.

Fig. 1 External vent hood clearances

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