Bosch AQ4 Installation Manual Download Page 10

10

AQ4 Manual

4 Maintenance

The vent system must be inspected at regular 3-month 

intervals. Points of inspection are as follows:

1.  Screened opening of the vent hood should be free 

from foreign material and cleaned as necessary.

2.  Check  all  vent  system  connections  for  leakage 

and reseal where needed with high temperature 

silicone sealant. If any vent pipe component shows 

signs of deterioration, replace immediately.

3.  Inspect  for  proper  closure  of  the  back  draft 

flapper.  If  the  flapper  does  not  properly  close, 

there is a risk of freezing air coming across the 

heat exchanger which may cause the pipes inside 

to freeze and burst.  This condition is not covered 

by the water heater warranty.  See Fig. 11A for a 

properly closed back draft flapper.

4.  Conduct  safety  interlock  test  and  operation  of 

back draft flapper once a year (Chapter 3.1.3).

Maintenance

Fig. 11B Improperly closed back draft flapper

Fig. 11A Properly closed back draft flapper

5 Troubleshooting

5.1 Introduction

Many  of  the  questions  customers  ask  regarding 

operation of this unit can be answered by following 

the  troubleshooting  steps  outlined  below.    Visit 

our  website  at  www.boschhotwater.com  for  more 

detailed troubleshooting.  For best results, perform 

each step before proceeding to the next.  

5.2 Power vent motor runs all the time or 

intermittently without water flow

1.  The power vent motor is flow switch activated.  

If  the  internal  paddle  inside  the  flow  switch  is 

jammed, it may constantly send a signal to turn on 

the fan. Shut off water supply to heater and drain. 

Remove flow switch from water heater piping by 

removing clips on both ends.  Flush water through 

both ends of flow switch to free up internal paddle 

and clear debris.  After flushing, shake flow switch 

up and down. The internal paddle should be heard 

moving freely back and forth. 

2.  Large  amounts  of  water  demand  can  create 

pressure  drops  throughout  the  plumbing.  This 

may allow for movement of the power vent flow 

switch and activate the fan.  Activated sprinkler 

systems or flushed toilets are common causes for 

this symptom. Consult a plumbing professional 

to correct unintentional water flow through the 

heater.

3.  In buildings with excessively high water pressure, 

a condition known as “water hammer” may exist.  

This condition is caused by a combination of high 

water pressure and the abrupt closing of a faucet 

valve or internal washer/toilet valve.  This instant 

change in flow results in an instant change in the 

internal pressures in the pipe, which then sends 

a  shock  wave  through  the  pipe.  This  physical 

shock will shake, rattle or cause a loud bang in the 

plumbing which is referred to as “water hammer.” 

Such a shock wave may cause movement of the 

power vent flow switch which will activate the fan.  

Consult a plumbing professional for the use of a 

pressure reducing valve, expansion tank or water 

hammer arrestor to combat this condition.

Summary of Contents for AQ4

Page 1: ...iance 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 Massachusetts this product must be installed by a licensed plumber or gas fitter Upon completion of the installation these instructions shoul...

Page 2: ...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 10 5 Troubleshooting 10 5 1 Introduction 10 5 2 Power vent motor runs all the time or intermittently without water flow 10 5 3 Pilot will not hold when lit or spark automatically with hot water flow 11 5 4 Sparks but pilot will not light 5 5 Pilot goes out during hot water use ...

Page 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 ...

Page 4: ...g 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 DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment ...

Page 5: ...en located adjacent to a public walkway The venting system shall terminate at least 3 feet above any forced air inlet within 10 feet The venting system shall terminate at least 4 feet below 4 feet horizontally from or 1 foot above any door window or gravity air inlet into any building 2 3 Power vent hood 1 Attach the mounting template on page 14 to the interior wall that the vent hood will be pene...

Page 6: ...r sleeve of the vent hood Fig 4 Use the four pre punched holes in the outlet collar of the power vent motor as a guide to drill diameter holes into the vent pipe Fasten power vent motor outlet to the vent hood inlet using sheet metal screws Seal the connection with high temperature silicone sealant Note Any additional vent pipe used between the power vent motor and the vent hood will be under posi...

Page 7: ... the draft spillage sensing switch will open the pilot safety circuit and shut off all gas to the water heater The switch is normally closed and opens at temperatures greater than 185º F It has a manual reset button Mounting the linear safety spillage switch 1 Attach the spillage switch to the top left of the heater s draft diverter using the existing hole and the included mounting screw Fig 6 2 L...

Page 8: ...lled install before proceeding Open hot water tap to relieve water pressure if water is already connected 2 Remove and save clip on lower right side of hydrogenerator 3 Remove and save pin from front right side of water valve using a flat head screwdriver Fig 8 4 Remove copper pipe and set aside 5 Find and connect the black flow switch to the pipes shown in Fig 9B Note There are two pipes included...

Page 9: ...structions in water heater installation manual 3 1 3 Draft test 1 Operate the water heater by running hot water Check for proper combustion and ensure there is no spillage by holding an recently extinguished match or other visible smoke source in front of the draft divertor The smoke from the extinguished match should be quickly sucked into the opening and up the exhaust venting If the smoke is bl...

Page 10: ... 1 The power vent motor is flow switch activated If the internal paddle inside the flow switch is jammed it may constantly send a signal to turn on the fan Shut off water supply to heater and drain Remove flow switch from water heater piping by removing clips on both ends Flush water through both ends of flow switch to free up internal paddle and clear debris After flushing shake flow switch up an...

Page 11: ...ut during hot water use 1 Inspect entire vent system for blockage or obstruction Ensure the back draft flapper installed on the power vent hood swings freely 2 Verify power vent fan operates with water flow If not verify wire connection from flow switch to fan motor Clean cold water inlet filter and verify flow rate through the water heater is adequate enough to activate the flow switch If flow ra...

Page 12: ...ranty does not cover any labor costs associated with service removal or re installation of part s All such costs must be borne by the Purchaser Additionally this warranty does not cover any labor costs associated with service removal or re installation of the original vent kit or a replaced vent kit How to Make a Claim Any claim for warranty parts should be made to your local dealer distributor or...

Page 13: ...VDC RED 115VAC BLACK BLACK BLACK BLACK WHITE WHITE WHITE GREEN GREEN 115 1 60 PLUG TIMER RELAY POWER VENT MOTOR YELLOW WIRE NUT WIRE NUT C NO NC YELLOW RED TIMER RELAY 2 1 BLUE Wiring Diagram 7 Wiring diagram Fig 12 Fan wiring diagram Fig 13 Safety circuit wiring diagram 425HN and 1600H wiring 425PN and 1600P wiring ...

Page 14: ...l the vent hood will be penetrating 2 Verify that wall penetration will not come in contact with concealed wiring or plumbing Using a 1 2 drill bit drill two pilot holes where noted on the template The drill bit must be long enough to penetrate to the building exterior 3 Attach the template to the building exterior aligning the pilot holes on the template with the pilot holes drilled in step 2 4 U...

Page 15: ...15 AQ4 Manual Notes ...

Page 16: ...BTC 718003301 C Bosch Thermotechnology Corp 50 Wentworth Avenue Londonderry NH 03053 Tel 1 866 642 3198 Fax 1 603 584 1681 www bosch climate us ...

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