Bosch Aquastar GWH 1600 H N User manual

MODEL GWH 1600 H
INDOOR MODEL
Hydro-generated ignition
Suitable for heating potable water only
Not approved for space heating or preheated water applications
GWH 1600 H N - Natural Gas
GWH 1600 H L - Liquefied Petroleum (LP) Gas
6 720 608 032 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.

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Index
Index
1 Warning 2
2 Appliance details 3
2.1 GWH 1600 H specifications (Technical data) 3
2.2 Unpacking the GWH 1600 H 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 8
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
4.1 For 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 16
4.5 Power adjustment 16
4.6 Purge the appliance 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 No spark at pilot with water flow 19
6.3 Spark appears when hot water is turned on, but pilot and
burners will not ignite 19
6.4 Pilot light, but burners will not come on. 20
6.5 Main burners go out during hot water use 20
6.6 Hot water temperature fluctuates at tap 21
6.7 Water is too hot 21
6.8 Water is not hot enough 22
6.9 Burners ignite without water flow 22
6.10 Low hot water pressure 22
6.11 Noise when heater is running 22
6.12 Burners do not burn cleanly, yellow flames
when operating 23
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
1 Warning
Fig. 1
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.

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Appliance details
3
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
Gas Requirement
Gas connection (inches) - ¾” 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) - 5”
• Minimum height (feet) - 6’ with no elbows
• Vertical termination
• Sidewall termination only with AQ4 power vent kit.
Water
• Hot water connection (inches) - ½” NPT
• Cold water connection (inches) - ½” NPT
• Water valve material: Polymer (PPS) (Polypropylene
Sulfid)
• Minimum water flow: 0.6 gallon/minute (2.2 l/m)
• Minimum recommended water pressure: 30 PSI
(2.07 bar)
• Connections:
– Bottom of heater
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.
LP Gas
Safety devices
• Flame failure device (ionization flame rod sensor)
• Pressure relief valve (supplied with heater)
• Over heat prevention (temperature limiter).
Water resistant
IP X4.

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Appliance details
2.2 Unpacking the GWH 1600 H 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
ASerial 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 1600 H 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 bathroom, bedroom 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.
2.3 General 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.
i
BOSCH is constantly improving its
products, therefore specifications are
subject to change without prior notice.

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Appliance details
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2.4 Dimensions and installation clearances
Fig. 3 Dimensions in Inches and (mm)
4Heat exchanger
5Burner
10 Temperature control
11 Water valve
20 Gas connection
23 Igniter unit
26 Output control
34 LED indicator for burner status
36 Front cover
37 Hole for fixing to wall
38 Exhaust pipe to wall
39 Draught diverter with flue gas monitor
40 Gas valve
49 Observation window
51 On/Off switch
110 LED failure indicator
Fig. 4 Minimum clearances
Model GWH 1600 H
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 1600 H
A16.73” (425)
B25.75” (655)
C13.15” (334)
D5.11” (130)
E21.25” (540)
F2.55” (65)
G1.18” (30)
H3/4”
Table 1 Dimensions in inches (mm)