Bosch AQ4 GWH 425 PN, AQ4 GWH 425 HN, AQ4 GWH 1600 H, AQ4 GWH 1600 P User Manual

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Installation manual

AQ4 Horizontal Vent Kit

For Bosch AquaStar Models: GWH 1600 P, GWH 1600 H

For Bosch Pro Tankless Models: GWH 425 PN, GWH 425 HN*

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 or Massachusetts this product must be installed 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.

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

Table of Contents

 

 

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 ......................................................................

10

5.1

Introduction .............................................................................

10

5.2 Power vent motor runs all the time or

 

 

intermittenly without water flow .............................................................................

10

5.3 Pilot will not hold when lit or spark

 

 

automatically with hot water flow .............................................................................

10

5.4

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

10

5.5

Noise when power vent motor is

 

 

running .............................................................................

10

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

11

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

12

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

13

2

AQ4 Manual

Introduction

1 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

3 - 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. 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 as possible.

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 qualified 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.

AQ4 Manual

3

Introduction

1.4 Requirements for installation in

terminal for the horizontally vented gas fueled

Massachusetts

 

heating appliance or equipment. The sign shall

Attention residents of the Commonwealth of

read, in print size no less than one-half (1/2) inch

in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR

Massachusetts:

 

OF ALL OBSTRUCTIONS”.

In the Commonwealth of Massachusetts the

4. INSPECTION. The state or local gas inspector of

following regulation went into effect on 12/30/2005:

the side wall horizontally vented gas fueled

(a) For all side wall horizontally vented gas fueled

equipment shall not approve the installation

equipment installed in every dwelling, building or

unless, upon inspection, the inspector observes

structure used in whole or in part for residential

carbon monoxide detectors and signage installed

purposes, including those owned or operated by the

in accordance with the provisions of 248 CMR

Commonwealth and where the side wall exhaust vent

5.08(2)(a)1 through 4.

termination is less than seven (7) feet above finished

(b) EXEMPTIONS: The following equipment is

grade in the area of the venting, including but not

exempt from 248 CMR 5.08(2)(a)1 through 4:

limited to decks and porches, the following

1. The equipment listed in Chapter 10 entitled

requirements shall be satisfied:

“Equipment Not Required To Be Vented” in the

1. INSTALLATION OF

CARBON MONOXIDE

most current edition of NFPA 54 as adopted by

DETECTORS. At the time of installation of the side

the Board; and

wall horizontal vented gas fueled equipment, the

2. Product approved side wall horizontally vented gas

installing plumber or gasfitter shall observe that

fueled equipment installed in a room or structure

a hard wired carbon monoxide detector with an

separate from the dwelling, building or structure

alarm and battery back-up is installed on the floor

used in whole or in part for residential purposes.

level where the gas equipment is to be installed.

(c) MANUFACTURERS REQUIREMENTS – GAS

In addition, the installing plumber or gasfitter

EQUIPMENT VENTING SYSTEM REQUIRED. When

shall observe that a battery operated or hard wired

the manufacturer of Product Approved side wall

carbon monoxide detector with an alarm is

horizontally mounted gas equipment provides a

installed on each additional level of the dwelling,

venting system design or venting system components

building or structure served by the side wall

with the equipment, the instructions provided by the

horizontal vented gas fueled equipment. It shall

manufacturer for the installation of the equipment

be the responsibility of the property owner to

and the venting shall include:

secure the services

of qualified licensed

1. Detailed instructions for the installation of the

professionals for the installation of hard wired

venting system or the venting system components:

carbon monoxide detectors.

and

a. In the event that the side wall horizontally

2. A complete parts list for the venting system design

vented gas fueled equipment is installed in a

or venting system.

crawl space or an attic, the hard wired

(d)MANUFACTURER REQUIREMENTS – GAS

carbon monoxide detector with alarm and

EQUIPMENT VENTING SYSTEM NOT PROVIDED.

battery back-up may be installed on the next

When the manufacturer of a product approved side

adjacent floor level.

 

wall horizontally vented gas fueled equipment does

b. In the event that the requirements of this

not provide the parts for the venting of flue gases,

subdivision can not be met at the time of

but identifies “special venting systems,” the following

requirements shall be satisfied by the manufacturer:

completion of installation, the owner shall

1. The referenced “special venting system”

have a period of thirty (30) days to comply

instructions shall be included with the appliance

with the above requirements; provided,

or equipment installation instructions; and

however, that during said thirty (30) day

2. The “special venting systems” shall be product

period, a battery operated carbon monoxide

approved by the Board, and the instructions for

detector with an alarm shall be installed.

that system shall include a parts list and detailed

2. APPROVED CARBON MONOXIDE DETECTORS.

installation instructions.

Each carbon monoxide detector as required in

(e) A copy of all installation instructions for all

accordance with the above provisions shall comply

products approved side wall horizontally vented gas

with NFPA 720 and be ANSI/UL 2034 listed and

fueled equipment, all venting instructions, all parts

IAS certified.

 

lists for venting instructions, and/or all venting

3. SIGNAGE. A metal or plastic identification plate

design instructions shall remain with the appliance

shall be permanently mounted to the exterior of

or equipment at the completion of the installation.

the building at a minimum height of eight (8) feet

 

above grade directly in line with the exhaust vent

4

AQ4 Manual

Bosch AQ4 GWH 425 PN, AQ4 GWH 425 HN, AQ4 GWH 1600 H, AQ4 GWH 1600 P User Manual

AQ4 Installation instructions

2 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.

2.2Locating power vent hood and clearances

The maximum vent length from the water heater to the point of termination is 25 feet. 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.Insure 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 flange 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 flapper using the instructions included with flapper.

Fig. 1 External vent hood clearances

AQ4 Manual

5

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