Bosch GWH 1000 User Manual

MODEL GWH 1000 P

INDOOR MODEL

Standing pilot

Suitable for heating potable water only

Not approved for space heating or preheated water applications

MODEL GWH 1000 P NG - Natural Gas

MODEL GWH 1000 P LP - Liquefied Petroleum (LP) Gas

6 720 608 124 US (06.05) AL

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.

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

Index

1	Warning	2
2	Appliance details	3
2.1	GWH 1000 P specifications (Technical data)	3
2.2	Unpacking the GWH 1000 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

4.1For 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
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 is 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	22

6.12Burners 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
9	Twelve Year Limited Warranty	27

1Warning

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.

Fig. 1

2	6 720 608 124

Appliance details

2Appliance details

2.1GWH 1000 P specifications (Technical data)

Approved in US/Canada

Capacity

GWH 1000 P: 2.6 GPM

Maximum output

GWH 1000 P: 58 400 Btu/hr

Maximum input

GWH 1000 P: 74 900 Btu/hr

Efficiency in %

Recovery efficiency 78%

Min. Output

GWH 1000 P: 23 906 Btu/hr

Gas Requirement

Gas connection (inches) - ½” 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.

Venting

•Natural Draft

•Vent diameter (inches) - 4”

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

•Vertical termination.

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: 13 PSI (0.9bar)

•Connections:

– Bottom of heater

Dimensions

•Depth (in): 8.66” (220 mm)

•Width (in): 12.20” (310 mm)

•Height (in): 22.83” (580 mm)

•Weight: 26 pounds (12 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.

6 720 608 124

3

Appliance details

2.2Unpacking the GWH 1000 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

BType 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 1000 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 or other occupied rooms normally kept closed.

* 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.

2.3General 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

iproducts, therefore specifications are subject to change without prior notice.

4	6 720 608 124

Appliance details

2.4Dimensions and installation clearances

Fig. 3 Dimensions in Inches and (mm)

4Heat exchanger

5Burner

10Temperature control

11Water valve

20 Gas connection

26 Output control

36Front cover

37Hole for fixing to wall

38Exhaust pipe to connector

39Draft diverter with flue gas monitor

40Gas valve

49 Observation window

102 Piezo

	Model GWH 1000
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)

Dimensions inches

(mm)

GWH 1000 P

A

12.20”

(310)

B

22.83”

(580)

C

9” (228)

D

4” (100)

E

20.71”

(526)

F

2.36”

(60)

G

1” (25)

H

1/2”

Table 1 Dimensions in inches (mm)

Fig. 4 Minimum clearances

6 720 608 124

5

Installation instructions

3Installation instructions

3.1Introduction

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

BDamage or injury.

BImproper operation.

BLoss 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.

3.2Proper 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.

B2. 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 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 freeze damage from residual water in the heater, 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.

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.

3.3Heater placement and clearances

The GWH 1000 P is design certified for installation on a combustible wall (see 3.4 Mounting installation) provided the wall is not covered with carpet or other fabric material. 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)

6	6 720 608 124

Installation instructions

3.4Mounting Heater

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.

i	Front cover should be removed in order to
	inspect components visually	(see
	instructions below).
Remove cover and inspect.		Fig. 6 Remove front cover

BRemove the temperature control.

BRemove the outer case by pulling it forwards and then lifting upwards.

BEnsure that the flue terminal is clear.

B After inspection, replace front cover.

Install incandescent particle tray.

B Install incandenscent particle tray using screws provided as shown in Fig. 5.

Screws Incandescent particle tray

Fig. 5 Incandescent particle tray illustration

Mounting heater.

The GWH 1000 P is design certified for mounting on a wall.

Warning:

B Do not install this appliance on a carpeted wall.

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.

BSecure the two included L shaped hooks to wall studs or support board 13 1/4” apart. (See Fig. 7).

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

Fig. 7 Support board

Fig. 8 Secure heater to wall

6 720 608 124

7

Installation instructions

3.5Combustion 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 building or structure are not being supplied with a sufficient amount of make-up air. A wood stove or furnace can pull outside air down through the Aquastar's vent pipe and across the heat exchanger tubing. If the air is cold enough, the heat exchanger is at risk of freezing and bursting. Supplying more combustion air for all combustion appliances is the solution. Follow the instruction on venting and checking the adequacy of make up air. A HVAC specialist should be consulted on how to provide more combustion 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 1000 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.

8	6 720 608 124

Installation instructions

3.6Venting

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 dangerous exhaust gases to enter living space.

BMinimum vent pipe diameter: 4 inches

BMinimum vertical vent height: 6 feet, with no elbows

BEstablish 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.

3.6.1Horizontal venting

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 is not permissible.

3.6.2Vertical venting

BA 4 inch diameter gas vent constructed of double wall Type B gas vent is recommended. Under no circumstances should the vent pipe be reduced in size.

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

BThe minimum vertical gas vent height allowed is 6 feet; horizontal vent connectors and elbows are not to be considered in the total gas vent height.

BAll 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. 10 and table 2, provided it is 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).

LISTED VENT CAP

MINIMUM 6

FEET (1.8M)

LISTED GAS VENT

ESTABLISH A ONE

FOOT RISE BEFORE

ANY ELBOWS

Fig. 9 Flat roof

6 720 608 124

9