Bosch 125HX LP User Manual

INSTALLATION AND OPERATING INSTRUCTIONS FOR AUTOMATIC
INSTANTANEOUS TYPE WATER HEATERS FOR USE WITH NATURAL AND
LIQUEFIED PETROLEUM GAS
MODEL 125HX LP and 125HX NG
(Flow Modulated with Electronic Ignition)
Suitable for heating potable water only
Not approved for space heating purposes
Intended for variable flow 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 store or use gasoline or other flammable, combustible or corrosive vapors and liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
- 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.
WARNING: 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.
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Upon completion of the installation, these instructions should be handed to the user of the appliance for future reference. In the Commonwealth of Massachusetts this product must be installed by a licensed plumber.
FEA TURING: Automatic V ariable Power Modulating Gas V alve and power generated Electronic Ignition
T ABLE OF CONTENTS
Specifications .................................................... Page 2
Rules for safe operation .................................... Page 4
Locating the Heater ............................................ Page 4
Combustion Air Requirements ............................ Page 5
Mounting the Heater........................................... Page 5
Venting the Heater ............................................. Page 6
Gas Connections ............................................... Page 7
Gas Piping ......................................................... Page 8
Water Connections ............................................ Page 9
Safety before turning on the heater..................... Page 9
Operating instructions ...................................... Page 10
Setting water temperature ................................ Page 10
Maintenance & Service......................................Page 1 1
Trouble Shooting ...............................................Page 1 1
Electrical Diagram............................................ Page 13
Diagram of AquaS tar......................................... Page 14
Interior components diagram ............................ Page 16
Parts List ......................................................... Page 17
Principle of Operation:
When a hot water faucet is opened, the water flow through the heater causes the gas valve to open. At the same time the hydro-generator activates the electronics which sends a spark to the pilot. The flame sensor confirms the pilot has been lighted and allows the first two burners to come on. The flame sensor confirms correct activation and all burners come on. The pilot goes off. The heat exchanger coils absorb the heat generated by the burners and transfer heat to the water. When the hot water faucet is shut of f, the gas valve automatically closes and the burners turn off. Y our hot water faucet is an ignition key to activate the water heater, giving you control over your hot water energy use. Every time you turn off your hot water faucet, the energy consumption of your hot water returns to zero.
AquaStar 125HX LP and 125HX NG Specifications
Gas Input max.: 117,000 Btu/hr
min.: 28,000 Btu/hr
Water Connection ½” Thread fitting NPT
H x W x D 29 3/4” x 18 1/4” x 8 3/4" Vent 5” Gas Connection 1/2” NPT thread Min. Water Pressure 18 Psi at 4 GPM
FEATURES
- Electronic Pilot Ignition driven by hydro-generator
- High Quality Materials for Long Working Life.
- Copper heating coils for endless supply of hot water.
- Burner output proportional to hot water flow demand for maximum energy efficiency .
- Safety flame sensor at pilot burner.
- Automatic overheating protection shut-off sensor .
- T emperature limiter .
- Flue gas safety device.
- St ainless steel burners with stabilized blue flame.
- Built-in corrosion resistant draft inducer .
- Compact space saver: mounts on a wall with two hooks.
- Easily removable one-piece cover.
- Easy one person installation.
Max. Water Pressure 150 Psi Shipping Weight 43 LB Net Weight 40 LB
1.8 GPM at 90° rise
3.7 GPM at 45° rise Min. Water Flow 1/2 gal/min LP GAS Supply Pressure
(before Aquastar regulator) min. 1 1” W.C.
max. 14” W.C.*
Required LP GAS Pressure at inlet tap while Aquast ar is operating: 10.5” W.C.
LP GAS Burner Manifold pressure while Aquastar is operating at maximum input: 9.0” W.C.
Natural Gas Supply Pressure (before Aquastar regulator) min.: 7” W.C.
max.: 14” W.C.*
- Adjustable water flow restrictor to ensure that water flow demand will not exceed the heating capacity of the heater.
- On/Off Switch to activate system.
- Red LED indicator flashes with low water pressure.
- Green LED indicator main burner condition.
BOSCH is constantly improving our products, therefore specifications are subject to change without prior notice.
Required Natural Gas Pressure at inlet tap while Aquast ar is operating: 5.7” W.C.
Natural Gas Burner Manifold Pressure while Aquastar is operating at maximum input: 4.2” W.C.
* Inlet gas pressure before Aquastar regulator must not exceed this value. Pressure may need to be adjusted for high altitudes, see page 7.
UNPACKING THE AQUASTAR HEATER
This heater is packed securely . The box includes two water connection fittings, a control knob, a gas pressure regulator , a pressure relief valve, an incandescent particle tray , two hooks for hanging the heater , this manual, a personal letter , a warranty statement and a warranty registration card. Do not lose this manual, as there is a charge for replacement. Please complete and return the enclosed warranty registration card.
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FRONT VIEW SIDE VIEW
MINIMUM INST ALLATION CLEARANCES FROM COMBUSTIBLE AND NON COMBUSTIBLE MATERIALS FOR ALCOVE OR CLOSET INSTALLATIONS
MODEL 125 HX
TOP (A) 12" FRONT (B) 4" BACK 0" SIDES 4" FLOOR (C) 12" * VENT DIAMETER 5"
* Some local codes require 18” in garage installations
AQUASTAR MODEL 125HX
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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/NFP A 54. In Canada: The Installation should conform with CGA B149.(1,2) INST ALLATION CODES and /or local installation codes.
2. Carefully plan where you install the heater. Correct
combustion air supply and flue pipe installation are very important. If not installed correctly, fatal accidents can be caused by lack of air, carbon monoxide poisoning or fire.
3. The place where you install the heater must have enough
ventilation. The National Fire Codes do not allow gas fired water heater installation in bathrooms, bedrooms or any occupied rooms normally kept closed. See the section below on locating the heater.
The heater may still operate even when improperly vented. It will, however, be less ef ficient and could eventually damage the heater. It could even result in human sickness or death due to oxygen deprivation and carbon monoxide poisoning. Follow the guidelines below:
1. Place your heater as close to a vent or chimney as possible.
2. National building codes require that you do not install this appliance in bathrooms, bedrooms or any occupied rooms normally kept closed.
3. Simultaneous operation of other appliances such as exhaust fans, ventilation systems clothes dryers, fireplaces or wood stoves could create a vacuum effect in your home which could cause dangerous combustion by-products to spill back into your home rather than venting to the outside through the flue. Confirm that your Aquastar is venting properly when all these other appliances are running. See section on venting.
4. You must vent your heater . See section on VENTING,
Page 6.
5. The appliance must be disconnected from the gas supply
piping system during any pressure testing at pressures in excess of 1/2 Psig (3.5 kPa). The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or more than 1/2 Psig (3.5Kpa). The appliance and its gas connection must be leak tested before placing the appliance in operation.
6. Keep water heater area clear and free from combustibles
and flammable liquids. Do not locate the heater over any material which might burn.
7. Correct gas pressure is critical for the optimum
operation of this heater (see specifications on page 2). 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 the section on connecting the gas supply .
8. 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.
Do not obstruct the flow of combustion and ventilation air to the appliance. If installed near a clothes dryer it is
very important that the dryer be properly vented. Failure to properly vent a dryer could result in a gradual accumulation of lint on the water heater fin coils and burners, leading to a dangerous condition of vent blockage and poor unsafe combustion.
4. Y our hot water lines should be kept short to save energy . It is always best to have hot water lines insulated.
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. This heater is neither designed for nor approved for outside installation. Drain the heater entirely if freezing temperatures are anticipated in area where heater is installed by disconnecting both the inlet and outlet elbow connections at the rear of heater. The water exp ansion may damage the hydro-generator. Additionally remove the drain plug under the water valve. See Fig. 0.
WA TER VAL VE
TO HEAT EXCHANGER
9. 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
FROM HEAT EXCHANGER
control system and any gas control which has been underwater.
DRAIN PLUG
Fig. 0 - Water heater drain plug
PROPER LOCATION FOR INSTALLING YOUR HEATER
WARNING: Flammable materials, gasoline, pressurized containers, or any other items or articles that are potentially fire hazards must NOT be placed
Carefully select the location of your new heater. For your safety and for proper heater operation, you must provide an abundant supply of combustion air and a proper venting
on or adjacent to the heater. The appliance area must be kept free of all combustible materials, gasoline and other flammable vapors and liquids.
installation.
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This product is not approved for manufactured homes (mobile home), recreational vehicles (RV) or boats. Reference ANSI Z21.10.3. This product is neither designed or approved for
outside installations.
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 in 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. The vent pipe must not be restricted and its 6 foot minimum height (provided there are no elbows) must terminate 2 feet above any obstruction within a 10 foot radius. 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 AquaS tar’s vent pipe, leaving the cold infiltrating air capable of freezing the cold water in the AquaS tar heat exchanger. More make up air is the solution. Follow the instructions on venting and checking adequacy of make up air. 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 AquaS tar 125HX alone.
b) In unconfined spaces in buildings of conventional frame,
masonry, or metal construction, infiltration is normally adequate to provide air for combustion, ventilation, and dilution of flue gasses.
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 75% if your louvers are wood and by 30% 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.
CLEARANCES
The Aquastar 125 HX is design certified for inst allation on a combustible wall and for installation in an alcove or closet with the minimum clearances to combustible and non ­combustible construction listed below
A. Top 12 inches (306 mm) B. Front 4 inches (102 mm) C. Back 0 inches D. Sides 4 inch (102mm)
E. Bottom 12 inches (306 mm) Clearance from vent is dependent upon the clearance rating of the venting material used. For example: type B-1 vent is approved for 1 inch clearance.
Note: Minimum clearance to combustible materials should not be less than 6" for single wall flue pipe. Note that this clearance can be reduced if combustible material are protected as per table VI of the National fuel Gas Code or if Type B gas vent is used.
MOUNTING INST ALLATION
The Aquastar 125 HX is design certified for mounting on a wall. Secure the two L shaped hooks provided with the heater to a wall surface. Place them 13 ¼ inches apart as shown in Fig 1. Do not install this appliance on a carpeted wall or over floor covering which is combustible, such as carpet. 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 1.
Expansion and contraction of piping due to changing water temperature in the pipes imparts movement to the heater which, if mounted directly to a brittle, friable board, such as plasterboard, can cause failure of mounting. In earthquake-prone zones, CEC recommends that installers use a large washer and lag screw through the existing holes used to hang the heater to affix the upper third of the heater to the mounting board. T o affix the lower third of the heater, CEC recommends that two new holes be drilled in the heater’s frame, each one 16 inches below the top two holes, and that washers and lag screws be used to secure the lower portion of the heater to a spacing board.
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. Also, each burner orifice is stamped with a number (79 for LPG and 120 for Natural Gas).
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at least 1/4 inch for every foot of its horizontal length. Keep the horizontal section short and avoid too many elbows.
WALL STUDS
13 ¼”
SUPPORT BOARD
1” X 4”
SPACE BOARD
Fig. 1 - Mounting the Heater
The incandescent particle tray (shipped loose in the carton with the water heater) must be attached at the bottom of the water heater front cover at the time of installation. Use the screws provided. See figure 2
SCREWS
INCANDESCENT PARTICLE TRAY
Fig. 2 - Incandescent Particle Tray Illustration
VENTING
Vent pipe connection. W ARNING: Do not reduce
the vent pipe size.
This appliance must be vented to the outside following all local ordinances and specifications for installing a gas appliance vent or chimney. The venting system must be designed and constructed so as to develop a positive flow adequate to remove flue gasses to the outdoors. Minimum
vent size must be 5". Minimum vent height must be 6 feet, provided there are no elbows. Termination of the vent must be 2 feet above any obstruction within a 10 foot radius of the vent pipe. Consult your gas utility or National Gas Fuel Code if vent will have elbows or share venting with another appliance. The vent connector should have as much vertical rise as possible (minimum 12”) before any horizontal run.
Optional powervent available in order to sidewall vent. Contact your local dealer . The appliance must be located as close as practicable to a chimney or vent. The vent pipe sections must be secured to each other with sheet metal screws. Keep in mind the minimum clearance from the top of your heater. Remember also that single wall vent pipe connectors require a 6 inch clearance from combustibles. National Fuel Gas Code specifies double wall — T ype “B” — vent pipe be used in cold climates and for gas vents running through attics. We consider double wall vent pipe preferable in all circumstances. Any vent section greater than 45 degrees from vertical is considered horizontal. Horizontal sections of vent connectors must slope upwards
T o check the draf t:
Close all doors and windows to the outside. Turn on all appliances that force air out of the building. These include all exhaust/ventilation fans, furnaces, clothes dryers, wood burning stoves, etc. Open all doors between the AquaStar and these other appliances. Run the unit for at least 10 minutes. Then hold an ordinary mirror at the side above the front shell. Any flue gases backdrafting will cause the mirror to fog. This is a serious health hazard and must be corrected. Poor venting can result in soot building up inside the heater, overheating of the heater and freezing of the heat exchanger in a freezing environment. The mirror will remain clear with a properly functioning draft.
WARNING
Note: The burners of an instantaneous “on demand” water
heater such as the AquaStar are only on at the time that hot water is actually being used, the vent pipe is therefore cold except for the short durations when hot water is being used, it is therefore very important that the venting and air supply be adequate to provide a good positive draft as soon as the burners turn on. See venting guide on back page. The AquaS tar 125HX instantaneous water heaters have built­in draft diverters and are designed for indoor installation only. The draft diverter outlet must be connected to a clear , unobstructed vent of the same size, or larger.
In Canada, CAN/CGA-B149 Installation Code for detailed requirements In U.S.A., ANSI Z223.1 - NFPA 54, national Fuel Gas Code for detailed requirements.
The vent connection for the AquaStar 125HX is 5 inches. However, in CANADA, for installations at high altitude (2000- 4500 feet above sea level) a six inch vent is required. A 5" by 6" vent adaptor must be affixed to the vent collar of the AquaStar with at least two screws. See figure 3.
WARNING: Failure TO INCREASE THE VENT SIZE
TO SIX INCHES AND/or assure that the manifold pressure is set to proper value listed for applications at high altitudes will cause unsafe venting, asphyxiation, and will void CSA Certification.
5” X 6” ADAPTOR
USED ON HIGH ALTITUDE
Fig. 3 - Vent Adaptor for High Altitude Canadian
Installations
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