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AQ4 Horizontal Vent Kit 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
WARNING
WARNING
WARNING
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. 2
AQ4 Manual
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 3
AQ4 Manual
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
1.2 Warnings
1. Failure to install, maintain and/or operate the
power vent in accordance with manufacturers
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.
W
W
W
W
War
ar
ar
ar
arning:
ning:
ning:
ning:
ning: Failure to install AQ4FLAPPER
properly may allow freezing air to come in
contact with the water heaters heat
exchanger and cause the heat exchanger
to burst. Such damage is not covered
under the water heaters 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.
Introduction 4
AQ4 Manual
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 finished
grade in the area of the venting, including but not
limited to decks and porches, the following
requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE
DETECTORS. At the time of installation of the side
wall horizontal vented gas fueled equipment, the
installing plumber or gasfitter shall observe that
a hard wired carbon monoxide detector with an
alarm and battery back-up is installed on the floor
level where the gas equipment is to be installed.
In addition, the installing plumber or gasfitter
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
horizontal vented gas fueled equipment. It shall
be the responsibility of the property owner to
secure the services of qualified 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 floor 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 certified.
3. SIGNAGE. A metal or plastic identification plate
shall be permanently mounted to the exterior of
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 D