AquaStar GWH 1600 P User Manual

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MODEL GWH 1600 P

INDOOR MODEL

Standing pilot Suitable for heating potable water only Not approved for space heating or preheated water applications

MODEL GWH 1600 P NG - Natural Gas MODEL GWH 1600 P LP - Liquefied Petroleum (LP) Gas

Warning: If the information in this manual is not

followed exactly, a fire or explosion may result causing property damage, personal injury or death. Do not store or use gasoline or other flammable vapor and liquids in the vicinity of this or any other appliance. 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. In the Commonwealth of Massachusettes the installation must be performed by a licensed plumber or gas fitter. Upon completion of the installation, these instructions should be handed to the user of the appliance for future reference.

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What to do if you smell gas

•

Open windows

• Close gas valve.

• 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.

Index

1 Warning 2

2 Appliance details 3

2.1 GWH 1600 P specifications (Technical data) 3

2.2 Unpacking the GWH 1600 P heater 4

2.3 General rules to follow for safe operation 4

2.4 Dimensions and installation clearances 5

3 Installation instructions 6

3.1 Introduction 6

3.2 Proper location for installing your heater 6

3.3 Heater placement and clearances 6

3.4 Mounting Heater 7

3.5 Combustion air requirements 8

3.6 Venting 9

3.7 Gas piping & connections 11

3.8 Measuring gas pressure 13

3.9 Water connections 13

3.10 Recirculation application 14

4 Operation instructions 14

4.1 For your safety read before operating your water heater 14

4.2 Lighting instructions 15

4.3 To turn off appliance 15

4.4 Setting the water temperature 15

4.5 Draining water from heater 16

1 Warning

Warning: The heater must be isolated

from the gas supply piping system during any pressure testing of that system at test pressures equal to or more than 0.5 psig.

Caution: Any changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.

5 Maintenance and service 17

5.1 Maintenance intervals 17

5.2 Water valve 17

5.3 Pilot 17

5.4 Main burners 18

5.5 Vent assembly 18

5.6 Mineral scale build-up 18

6 Troubleshooting 19

6.1 Introduction 19

6.2 Pilot does not light 19

6.3 Pilot lights, but goes out when button released 19

6.4 Pilot goes out during or after hot water use 19

6.5 Burners do not light with water flow 20

6.6 Hot water temperature fluctuates at tap 20

6.7 Water is too hot 21

6.8 Water is not hot enough 21

6.9 Burners ignite without hot water flow 21

6.10 Low hot water pressure 21

6.11 Noise when heater is running 21

6.12 Burners do not operate cleanly; yellow flames when operating 22

7 Protecting the environment 23

8 Interior components and diagram parts list 24

8.1 Interior components 24

8.2 Components diagram 25

8.3 Parts list 26

Fig. 1

9 Twelve Year Limited Warranty 27

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2 Appliance details

Appliance details

2.1 GWH 1600 P specifications (Technical data)

Approved in US/Canada

Capacity

GWH 1600 P: 4.3 GPM

Maximum output

GWH 1600 P: 91 525 Btu/hr

Maximum input

GWH 1600 P: 117 000 Btu/hr

Efficiency in %

Recovery efficiency 78%

Min. Output

GWH 1600 P: 23 906 Btu/hr

Gas Requirement

Gas connection (inches) - ¾” NPT

Inlet gas pressure under maximum operation*

• Propane: 10.5” - 14” water column

• Natural Gas: 5.7” - 14” water column.

* To measure Gas Pressure, see Measuring Gas Pressure, chapter 3.8.

Dimensions

• Depth (in): 8.66” (220 mm)

• Width (in): 18.11” (460 mm)

• Height (in): 25.79” (655 mm)

• Weight: 35 pounds (16 kg).

Gas types

Natural Gas. LP Gas

Safety devices

• Flame failure device (ionization thermocouple)

• Pressure relief valve (supplied with heater)

• Over heat prevention (temperature limiter).

Water resistant

IP X4.

Venting

• Natural Draft

• Vent diameter (inches) - 5”

• Minimum height (feet) - 6’ with no elbows

• Vertical termination

• Sidewall termination only with AQ4 power vent kit.

Water

• Hot water connection (inches) - ½” NPT

• Cold water connection (inches) - ½” NPT

• Water valve material: Polymer (PPS) (Polypropylene

Sulfid)

• Minimum water flow: 0.5 gallon/minute (1.9 l/m)

• Minimum recommended water pressure: 30 PSI

(2.07 bar)

• Connections:

– Bottom of heater

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Appliance details

2.2 Unpacking the GWH 1600 P heater

This heater is packed securely.

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.

Fig. 2 Rating plate

A Serial number B Type of gas

The box includes:

• Pressure relief valve

• Mounting screws

• Product registration card

• Installation manual

• Incandescent particle tray.

Do not lose this manual, there is a charge for a replacement.

Please complete and return the enclosed product registration card.

The GWH 1600 P is not approved or designed for:

• Manufactured (mobile) homes, RV's or boats

• Heating or other recirculating/pumping applications*

• Solar/preheat backup or high temperature booster use

• Installation in a bathroom.

* This includes domestic hot water circulator pump loop systems that may be installed in home hot water system prior to installing this unit. An approved recirculation design can be found in chapter 3.10.

2.3 General rules to follow for safe operation

• 1. You should follow these instructions when you

install your heater. 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.(1,2) INSTALLATION CODES and /or local installation codes

• 2. Carefully plan where you install the heater. Proper

clearances must be followed

• 3. The appliance must be isolated from the gas

supply piping system by closing its individual manual gas shutoff valve (not supplied with heater) during any pressure testing at pressures in excess of ½ Psig (3.5 kPa). The appliance and its gas connection must be leak tested before placing the appliance in operation.

• 4. Keep water heater area clear and free from

combustibles and flammable liquids. Do not locate the heater over any material which might burn.

• 5. Correct gas pressure is critical for the optimum

operation of this heater. Gas piping must be sized to provide the required pressure at the maximum output of the heater, while all the other gas appliances are in operation. Check with your local gas supplier, and see chapter 3.7 and 3.8 to verify proper gas line sizing.

• 6. Should overheating occur or the gas supply fail to

shut off, turn off the gas supply at the manual gas shut off valve, on the gas line. Note: manual gas shutoff valve is not supplied with the heater

• 7. 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.

BOSCH is constantly improving its products, therefore specifications are subject to change without prior notice.

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2.4 Dimensions and installation clearances

Model GWH 1600

TOP (A)

12 inches (306 mm)

FRONT (B)

4 inches (100 mm)

BACK

0 inches

SIDES

4 inches (100 mm)

BOTTOM (C)

12 inches (306 mm)

Appliance details

Fig. 3 Dimensions in Inches and (mm)

4 Heat exchanger 5 Burner 10 Temperature control 11 Water valve 20 Gas connection 26 Output control 36 Front cover 37 Hole for fixing to wall 38 Exhaust pipe to connector 39 Draft diverter with flue gas monitor 40 Gas valve 49 Observation window 102 Piezo

Dimensions

inches (mm)

GWH 1600 P

A 16.73” (425)

B 25.75” (655)

C 13.15” (334)

D 5.11” (130)

E 21.25” (540)

F 2.55” (65)

G 1.18” (30)

H 3/4”

Table 1 Dimensions in inches (mm)

Fig. 4 Minimum clearances

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Installation instructions

3 Installation instructions

3.1 Introduction

Please follow these instructions. Failure to follow instructions may result in:

B Damage or injury. B Improper operation. B Loss of warranty.

If you are unable to perform the tasks required to install this heater properly, please contact a locally licensed plumber or gas technician. Please contact Bosch Water Heating with any questions.

3.2 Proper location for installing your heater

Carefully select the location of the water heater. For your safety and for proper heater operation, you must provide combustion air to the heater and a proper exhaust vent system. Follow the guidelines below:

B 1. Locate the heater where venting, gas and

plumbing connections are feasible and convenient.

B 2. The hot water lines should be kept short to save

energy. Centrally locating the water heater is best. It is always best to have hot water lines insulated.

Warning: The heater must be isolated from the gas supply piping system during any pressure testing of that system at test pressures equal to or more than 0.5 psig.

Warning: Place the heater in a location where water leaks will do NO DAMAGE to adjacent areas.

3.3 Heater placement and clearances

The GWH 1600 P is design certified for installation on a combustible wall (see 3.4 Mounting installation) provided the floor covering below the heater is noncombustible. For installations in an alcove or closet, maintain the minimum clearances to combustible and non-combustible materials listed below. See also Fig. 4.

A. Top 12 inches (306 mm) B. Front 4 inches (100 mm) C. Back 0 inches D. Sides 4 inches (100 mm) E. Bottom 12 inches (306 mm)

Warning: The water in this water heater is cold and always remains cold except for the times that hot water is being used. DO NOT INSTALL IN AN AREA WHERE IT COULD FREEZE. Drain the heater entirely if freezing temperatures are anticipated in area where heater is installed. See chapter

4.5 for draining instructions. To prevent any freeze damage, introduce short bursts of compressed air (20-40psi) through these connections to remove the residual water in the horizontal pipes and water valve.

Warning: Flammable materials, gasoline, pressurized containers, or any other items or articles that are potential 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.

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3.4 Mounting Heater

Incandescent particle tray

Screws

Warning: before starting installation: B check that there are no loose parts

inside the appliance

B ensure that gas pipe, gas valve, and

burner have no damage and are properly fitted.

B Read chapter 2.2 to verify proper gas

type and to check all parts are included in box.

Front cover should be removed in order to inspect components visually (see instructions below).

Remove cover and inspect.

B Remove the temperature control. B Remove the outer case by pulling it forwards and

then lifting upwards, see Fig. 6.

B Ensure that the flue terminal is clear. B After inspection, replace front cover.

Installation instructions

Fig. 6 Remove front cover

Install incandescent particle tray.

B Install incandenscent particle tray using screws

provided as shown in Fig. 5.

Fig. 5 Incandescent particle tray illustration

Mounting heater.

The GWH 1600 P wall.

Warning:

B Do not install this appliance on a

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. 7.

B Secure the two included L shaped hooks to wall

studs or support board 13 1/4” apart. (See Fig. 7).

B Hang heater on two L shaped hooks. (See Fig. 8).

is design certified for mounting on a

carpeted wall.

Fig. 7 Support board

Fig. 8 Secure heater to wall

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Installation instructions

3.5 Combustion air requirements

The AquaStar water heater holds cold water in its copper heat exchanger and water valve when not in use. Because of this, any cold air that comes down 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. 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. A wood stove or furnace can rob the makeup air in the AquaStar's vent pipe, leaving the cold infiltrating air capable of freezing the cold water in the AquaStar heat exchanger. More make up air is the solution. Supplying more combustion air for all combustion appliances is the solution. A HVAC specialist should be used to design solutions for providing more make-up air if necessary. Observe the following instructions concerning combustion air.

Appliances located in unconfined spaces: 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 the AquaStar GWH 1600 P alone.

b) Installations in structures that have been tightly constructed (air infiltration rate of 0.40 ACH or less) must be provided for combustion air per the National Fuel Gas Code. Consult a HVAC specialist if your air infiltration rate is questionable.

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 provided with one permanent opening or 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:

• 3000 Btu/hr if all air is taken from the outside by a

direct opening or vertical duct.

Louvers, grills and screens have a blocking effect. If the effective free area is not known, increase the sizes of your openings by 400% if your louvers are wood and by 135% 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.

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Installation instructions

LISTED VENT CAP

MINIMUM 6 FEET (1.8M)

LISTED GAS VENT

ESTABLISH A ONE

FOOT RISE BEFORE

ANY ELBOWS

5” X 6” ADAPTOR

USED ON HIGH

ALTITUDE

3.6 Venting

Danger: Do not reduce the vent pipe

size. Do not put an elbow directly on top of heater. Failure to follow venting requirements may cause deadly exhaust gases to enter living space.

B Minimum vent pipe diameter: 5 inches B Minimum vertical vent height: 6 feet, with no elbows B Establish 12 inch rise before any elbow

The heater must be vented to the outside following all local ordinances and specifications for installing a gas appliance vent or chimney. The heater must be located as close as practicable to a vertically rising chimney or vent that has a listed vent cap at its termination point. The venting system must be designed and constructed so as to develop a positive flow adequate to remove flue gasses to the outdoors. Consult the National Fuel Gas Code if the vent will have elbows or share venting with another natural draft appliance.

Warning: Do not combination vent with a mechanically vented appliance.

B All gas vent sections must be secured to each other

with sheet metal screws and be properly supported.

Horizontal runs:

Any gas vent section that is greater than 45 degrees from the vertical is considered horizontal. Horizontal sections must slope upwards at least ¼ inch for every foot of its horizontal length and be properly supported. Keep the horizontal section short and avoid too many elbows. The maximum horizontal run allowed is half of the total vertical vent height; horizontal vent connectors and elbows are not to be considered in the total gas vent height.

Vent termination:

The gas vent constructed of double wall Type B gas vent must terminate above the roof surface with a listed vent cap at a height that's in accordance with Fig. 11 and table 2, provided they are at least 8 feet (2.4 m) from a vertical wall or similar obstruction. All other gas vents that are not able to terminate within the minimum specified height allowed must terminate not less than 2 feet (0.6 m) above the highest point where it's passed through the roof and at least 2 feet (0.6 m) higher than any vertical wall or similar obstruction within 10 feet (3.1 m).

3.6.1 Horizontal venting

A power vent, with a proof-of-draft safety interlock device, is required and is available for sidewall venting. Contact your dealer. In the Commonwealth of Massachusetts power vented applications must utilize proof-of-draft safety interlock device.

3.6.2 Vertical venting

B A 5 inch diameter gas vent constructed of double

B An approved gas vent connector must be attached

B The minimum vertical gas vent height allowed is 6

Warning: Horizontally venting to a vertically constructed vent stack along an outside wall of a building is not permissible.

Warning: Horizontally venting to a sidewall vent terminator (without power vent) is not permissible.

wall Type B gas vent is recommended. A 6 inch vent is required in elevations greater than 2000 feet, see Fig. 10. Under no circumstances should the vent pipe be reduced in size.

to the top of the water heater and rise vertically at least 12" before entering into an approved gas vent connector elbow.

feet; horizontal vent connectors and elbows are not to be considered in the total gas vent height.

Fig. 9 Flat roof

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Fig. 10 Vent Adaptor for High Altitude Installations

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