MODEL GWH 1600 H INDOOR MODEL Hydro-generated ignition Suitable for heating potable water only Not approved for space heating or preheated water applications 6 720 608 032 US (06.05) AL GWH 1600 H N - Natural Gas GWH 1600 H L - 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.
Index Index 1 Warning 2 2 2.1 2.2 2.3 2.4 Appliance details GWH 1600 H specifications (Technical data) Unpacking the GWH 1600 H heater General rules to follow for safe operation Dimensions and installation clearances 3 3 4 4 5 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.
Appliance details 2 Appliance details 2.1 GWH 1600 H specifications (Technical data) Approved in US/Canada Capacity GWH 1600 H: 4.36 GPM Maximum output GWH 1600 H: 91,525 Btu/hr Maximum input GWH 1600 H: 117,000 Btu/hr Efficiency in % Recovery efficiency 80% Min. Output GWH 1600 H: 23,906 Btu/hr Dimensions • Depth (in): 8.66” (220 mm) • Width (in): 16.73” (425 mm) • Height (in): 25.79” (655 mm) • Weight: 35 pounds (16 kg). Gas types Natural Gas.
Appliance details 2.2 Unpacking the GWH 1600 H heater 2.3 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. General rules to follow for safe operation 1. You should follow these instructions when you install your heater.
Appliance details 2.4 Fig. 3 4 5 10 11 20 23 26 34 36 37 38 39 40 49 51 110 Dimensions and installation clearances Dimensions in Inches and (mm) Heat exchanger Burner Temperature control Water valve Gas connection Igniter unit Output control LED indicator for burner status Front cover Hole for fixing to wall Exhaust pipe to wall Draught diverter with flue gas monitor Gas valve Observation window On/Off switch LED failure indicator Dimensions inches (mm) GWH 1600 H A 16.73” (425) B 25.
Installation instructions 3 Installation instructions 3.1 Introduction 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. Please follow these instructions. Failure to follow instructions may result in: B Damage or injury. B Improper operation. B Loss of warranty.
Installation instructions 3.4 Mounting 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 Fig. 7 Support board Fig.
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.
Installation instructions 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.
Installation instructions Masonry chimney Masonry chimneys shall be built and installed in accordance with NFPS 211 or local codes. A minimum 5" diameter gas vent pipe (metal double wall Type B), or an approved clay flue liner or a listed chimney lining system must be used when venting into a naturally drafting, internal masonry chimney. 6 inch is required in elevations greater than 2000 feet, see Fig. 10.
Installation instructions 3.7 Gas piping & connections Before connecting the gas supply, check the rating plate on the right side of the heater to be sure that the heater is rated for the same gas to which it will be connected. 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 to CGA B149 INSTALLATION CODES and/or local installation codes.
Installation instructions FOR NATURAL GAS Maximum Capacity of pipe in Cubic Feet of Gas per Hour for Gas Pressure of 0.5 Psig or less and a Pressure drop of 0.3 in Water Column (0.75mbar).(Based on a 0.60 Specific Gravity Gas) Btu numbers given in thousands. Copper tubing is prohibited for use with Natural Gas in the Commonwealth of Massachusetts and not recommended elsewhere. Follow boxed numbers for piping just one GWH 1600 H (example: ¾” B.I. Natural Gas pipe for 20 ft (6.1m).
Installation instructions 3.8 Measuring gas pressure Connecting manometer B Shut off gas. B Remove front cover and locate inlet gas pressure measuring point on the right side, see Fig. 15. B Loosen screw from test point on the right side and connect manometer tube on test point. or suitably rated stainless steel flex line piping be used for at least three feet before and after the heater (follow local codes if more stringent).
Operation instructions 3.10 Recirculation application Since recirculation through the heater is not permissible, the following drawing is provided to outline a proper recirculation application using the Aquastar water heater with an Ariston minitank. This schematic is for illustration only and must not be used for actual installation without appropriate engineering and technical advice from a professional properly licensed in locality where the installation is made. 4 Operation instructions 4.
Operation instructions 4.2 Lighting instructions B 1. STOP! Read the previous safety information. 4.3 To turn off appliance B Set the ON/OFF switch to the position OFF . B 2. The gas valve must be shut off by putting the ON/ OFF switch to position OFF . Wait five (5) minutes to clear out any gas. If you smell gas, STOP! Follow “B” in chapter 4.1. If you do not smell gas, go to the next step. B 3. This water heater is equipped with a safety pilot burner and an automatic ignition control system. B 4.
Operation instructions 4.4 Setting the water temperature The GWH 1600 H has a gas control that modulates burner input in response to flow. Its purpose is to ensure that the hot water temperature will remain steady, although the water flow demand might vary. The output temperature can be adjusted with either the temperature adjustment knob or the gas control knob. 4.5 Power adjustment Less power. Lower water temperature.
Maintenance and service 5 Maintenance and service 5.1 Maintenance intervals Warning: Failure to perform recommended maintenance may result in complete failure of the unit over time. The warranty does not cover failures due to improper or insufficient maintenance. The GWH 1600 H requires periodic maintenance. The below time maintenance intervals should keep the unit operating for many years.
Maintenance and service 5.4 Main burners The main burner flames should be blue, with a more intense blue cone in the center core. Yellow flames could be a sign of wrong size gas orifices or dirty burners, a blockage on the heat exchangers fins. If some burners have yellow flames while others have blue flames, it is likely that dust, lint or spider webs have partially clogged the burner venturis. To clean the burners, contact a gas service person. 5.
Troubleshooting 6 Troubleshooting 6.1 Introduction Many of the questions customers ask regarding operation of this unit can be answered by following the troubleshooting steps as outlined below. Visit our web site at www.boschhotwater.com for more detailed troubleshooting. For best results, perform each step before proceeding to the next. The suggested solutions may require that the cover be taken off (See chapter 3.4). 6.2 No spark at pilot with water flow • 1.
Troubleshooting • 5. Confirm wire connection to the pilot electro valve is secure. See Components Diagram for location. Inspect terminals for corrosion. To clean terminals, remove the spade connectors and clean with a pencil eraser • 6. Open a hot water faucet. While sparking, hold a flame from a lit match or lighter in the pilot area. If the pilot successfully lights, the pilot orifice may be dirty or clogged. See chapter 5.3 on how to clean the pilot read 1.6VAC on the burner electro valve.
Troubleshooting • 4. Hot water is very hot out of the tap, requiring a lot of cold water to be added with it in order to attain a useable hot water temperature. The addition of too much cold will overpower and slow the flow within the tankless heater, decreasing it below activation point, which shuts off the burners. The end result is nothing but cold water coming out of the outlet. Reduce the need for cold water mixed by turning the power adjustment knob clockwise for lower hot water temperatures.
Troubleshooting • 3. Inlet water is preheated. This model does not have a thermostat and will not modulate flame height in order to prevent overheating. It is designed for a cold water feed only. Replumb the heater with cold water to the inlet. • 4. Increase flow rate. Restrictions in the water path can slow the flow of water through the heater, resulting in very hot outlet temperatures. Restrictive showerheads and faucet aerators should be cleaned out or upgraded with less restrictive ones.
Protecting the environment in the water path can slow water flow through the heat exchanger causing it to boil and make noise 7 Protecting the environment • 3. If the water has a high mineral content, the heat exchanger may be scaled internally. This restricts the water path, causing the water to boil resulting in noise and overheating. To descale the heat exchanger, consult service bulletins on www.boschhotwater.com. Components 6.
Interior components and diagram parts list 8 Interior components and diagram parts list 8.1 Interior components Fig.
Interior components and diagram parts list 8.2 Components diagram 7 6 8 10 36 40 33 39 42 24 35 15 18 20 19 16 17 13 14 11 43 12 21 44 23 25 22 26 2 24 28 3 27 9 1 4 37 29 5 30 38 34 41 32 6720608032-07.1 JF Fig.
Interior components and diagram parts list 8.3 Parts list Item Description Reference 1 Front cover 8 705 431 242 0 2 Shield 8 705 506 814 0 3 Control cover 8 705 506 813 0 4 Temp.
Twelve Year Limited Warranty 9 Twelve Year Limited Warranty General Aquastar water heaters are warranted by the Manufacturer (BOSCH) through BBT North America. BBT North America (BBTNA) will furnish a replacement heat exchanger and will furnish a replacement of any other part which fails in normal use and service within the applicable periods specified below, in accordance with the terms of this warranty. The BBTNA replacement will be warranted for the unexpired portion of the original warranty.
Installer Checklist, to be performed by installer upon installation Serial Number ___ ___ ___ ___ ___ ___ ___ ___ (8 digit serial number is located on rating plate on right side panel) Gas Pressure Reading* Static__________ Operating__________ Building Water Pressure __________ Range if on Well system __________ Average Winter Temperature __________ Average Summer Temperature __________ Installing Company _____________________________________________ Installer name ____________________________