Bosch 1000P User manual

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CT-13
page 1 of 2
rev 10/06
Bosch Water Heating
340 Mad River Park, Waitsfield, VT 05673
©BBT NORTH AMERICA CORPORATION
Bosch Group
REMOVING AND CLEANING
BURNERS
MODELS: 1000P, 1600P, 1600H,
260PN, 425PN, 425HN
A. Removing pilot assembly
Model 1000P, 1600P, 260PN, 425PN (Fig 1):
1. Shut off gas and water to heater, then remove front
cover.
2. Remove wire clip holding top of pilot tube into
bracket.
3. Move lower end of pilot tube to left to release from
black clip on gas valve. Be sure to catch air screen
attached to base of pilot tube.
4. Pull upwards on upper end of pilot tube to release
from bracket.
5. Remove black clip from bracket to release spark elec-
trode.
6. Gently press down on top of thermocouple to release
it from bracket.
FIGURE 3
FIGURE 4
Model 1600H, 425HN (Fig. 2):
1. Shut off gas and water to heater, then remove front
cover.
2. Remove both pilot bracket screws and pilot shield from
front of burners.
3. Remove pilot assembly from burner bracket. Be sure
to catch air screen secured to base of pilot assembly.
B. Removing burners
1. Remove 2 burner set screws on the right side of the
gas valve. (Fig. 2)
2. Remove four screws from both right and left burner
brackets and set aside. (Fig. 3)
3. Push entire burner assembly up to seperate from the
gas valve.
4. Tilt right side of burners up and slide them out at an
angle to the left. (Fig. 3)
Burner bracket location
(425PN model shown)
FIGURE 2
Pilot shield
Pilot bracket
screws
Burners
Pilot air
screen
1600H, 425HN pilot assembly
1000P, 1600P, 260PN, 425PN pilot assembly
FIGURE 1
Pilot air screen
Pilot wire clip
Burners
Pilot tube
Thermocouple
lead
Pilot air
screen
Burner set
screws

CT-13
page 2 of 2
rev 10/06
Bosch Water Heating
340 Mad River Park, Waitsfield, VT 05673
©BBT NORTH AMERICA CORPORATION
Bosch Group
C. Cleaning burners
1. Use a soft wire brush across burner fins to loosen any
debris and then vacuum out.
2. Check to see that the 18 brass gas injectors in the
rear of the burner assembly are clean. To access,
remove 8 Philips head screws to the left and right of
the two center brass Philips head screws at the rear
of the burner. The burners should separate into two
halves exposing injectors. Blow clean with com-
pressed air or carburetor cleaner and wipe dry with
cloth. Do NOT poke injectors or attempt to clean with
drill bits, wires or other objects. Clean rear venturi
passages with a pipe cleaner and soapy water. Rinse
clean and let dry before reinstalling. Follow instruc-
tions in reverse to reconnect burner halves.
D. Reinstalling burners
1. Reinstall burners into burner area.
2. Reinstall set screws on right side of gas valve and
tighten.
3. Reinstall right and left burner brackets with the four
screws. The brass screws attach to frame.
E. Reinstalling pilot assembly and tube
Models 1000P, 1600P, 260PN, 425PN:
1. Reinsert thermocouple and snap into place. Thermo-
couple tip should sit 1/4” above the burner bed.
2. Put spark electrode into place and attach with clip.
3. Slide upper end of pilot tube into bracket on burner
assembly and reinsert pin.
4. Slide base of pilot tube to the right into clip. Ensure
pilot air screen is installed between pilot tube and pi-
lot orifice.
Models 1600H, 425HN:
1. Slide pilot air screen over pilot tube.
2. Slide pilot assembly into place. Reinsert pilot shield
and secure with screws to the burner assembly.
F. Returning heater to service
Models 1000P, 1600P, 260PN, 425PN:
1. Turn on gas and light pilot. Test for possible gas leaks
where burners connect to the gas valve.
Models 1600H, 425HN:
1. Turn on gas and check for leaks where the burners con-
nect to gas valve by applying leak detecting solution as
you initiate water flow to activate the heater. Allow
enough time to bleed all air in gas line. Bubbles are a
sign of a leak.
All models:
2. If there are bubbles at either connection immediately
shut off water and gas. Loosen the burner set screws
on the right side of gas valve. Remove the burners and
inspect the o-ring. Replace if damaged. Reseat burners
and tighten set screws. Check again for leaks.
3. Replace front cover when complete.
REMOVING AND CLEANING
BURNERS
FIGURE 5
Burners disassembled
Burner fins
Burner venturi passage
Gas injectors