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Bosch NG Installation And Operating Instructions Manual

Automatic instantaneous type water heaters for use with natural and liquefied petroleum gas
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I NSTALLATION AND OPERATI NG I NSTR UCTIONS FOR AUTOMATIC
INSTANTANEOUS TYPE WATER HEATERS FOR USE WITH NATURAL AND
LIQUEFIED PETROLEUM GAS
Intended for low flow domestic hot water applications with steady cold water inlet temperatures
WARNING
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.
Upon completion of the installation, these instructions
should be handed to the user of the appliance for future
reference.
In the Commonwealth of Massachusetts this product
must be installed by a licensed plumber or gas fitter.
MODEL 38B LP and NG
Suitable for heating potable water only
Not approved for space heating purposes
:
Improper
installation,
WARNING
If the information in this manual is not followed exactly, a
fire or explosion may result causing property damage,
personal injury or death.
FOR YOUR SAFETY
Do not store or use gasoline or other flammable,
combustible or corrosive vapors and liquids in the vicinity
of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
- 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.

TABLE OF CONTENTS

Specifications ................................................................. Page 2
Rules for safe operation ............................................... Page 4
Locating the Heater ...................................................... Page 4
Combustion Air Requirements .................................... Page 5
Mounting the Heater ..................................................... Page 5
Venting the Heater ........................................................ Page 7
Gas Connections .......................................................... Page 9
Water Connections .................................................... Page 10
Safety before lighting the pilot ................................ Page 11
Lighting instructions ................................................... Page 11
Setting water temperature ........................................ Page 12
Maintenance & Service ............................................. Page 12
Trouble Shooting ......................................................... Page 13
Diagram of AquaStar ................................................. Page 16
Components and Parts List ...................................... Page 19
Warranty ....................................................................... Page 21

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Table of Contents
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  • Page 1: Table Of Contents

    I NSTALLATION AND OPERATI NG I NSTR UCTIONS FOR AUTOMATIC INSTANTANEOUS TYPE WATER HEATERS FOR USE WITH NATURAL AND LIQUEFIED PETROLEUM GAS Suitable for heating potable water only Not approved for space heating purposes Intended for low flow domestic hot water applications with steady cold water inlet temperatures...
  • Page 2: Specifications

    It operates on the principle of heating water instantaneously “on demand”. When a hot water faucet is opened, cold water flows through the coils of the heat exchanger in the Aquastar. This same flow opens the gas valve, and the burners are ignited by the pilot flame.
  • Page 3 MINIMUM INSTALLATION CLEARANCES FROM COMBUSTIBLE AND NON COMBUSTIBLE MATERIALS 6 720 606 446 TOP (A) FRONT (B) BACK SIDES FLOOR (C) VENT DIAMETER AQUASTAR MODEL 38B SIDE VIEW MODEL 38B 12 " 4 " 0 " 4 " 12 " 4 "...
  • Page 4: Rules For Safe Operation

    Confirm that your Aquastar is venting properly when all these other appliances are running. See section on venting.
  • Page 5: Combustion Air Requirements

    A wood stove or furnace can rob the make- up air in the AquaStar’s vent pipe, leaving the cold infiltrating air capable of freezing the cold water in the AquaStar heat exchanger.
  • Page 6 50 cubic feet per 1000 Btu per hour of the combined rating of all appliances installed in the space. That would be 2000 cubic feet for the AquaStar 38B alone. b) In unconfined spaces in buildings of conventional frame,...
  • Page 7: Venting The Heater

    VENTING Vent pipe connection. WARNING: Do not reduce the vent pipe size. The heater must be vented to the outside following all local ordinances and specifications for installing a gas appliance vent or chimney. The heater must be located as close as practicable to a vertically rising chimney or vent that has a listed vent cap at its termination point.
  • Page 8 : Masonry chimneys shall be built and installed in accordance with NFPS 211 or local codes. A MASONRY CHIMNEY minimum 4” 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.
  • Page 9: Gas Connections

    WARNING Note: The burners of an instantaneous “on demand” water heater such as the AquaStar are only on at the time that hot water is actually being used, the vent pipe is therefore cold except for the short durations when hot water is being...
  • Page 10: Water Connections

    MAXIMUM INLET GAS FLOW PRESSURE SETTING Altitude Natural Gas inches W.C: 0' - 2.000 ft 5.7" 2.000 ft - 4.500 ft 4.6" Above 4.500 ft consult your local gas supplier. National Fuel Gas Code requires that a sediment trap (drip leg) be installed on gas appliances not so equipped.
  • Page 11: Safety Before Lighting The Pilot

    Fig. 4 - Pressure Relief Valve OPERATING INSTRUCTIONS Before proceeding with the operation of the heater make sure that the system is filled with water. Fig. 5 - Water Piping Open the cold water inlet supply to the heater fully. Open a hot water faucet to permit the water to fill the heater and the piping and to eliminate the air trapped in the system Close the hot water faucet after the water flows freely and...
  • Page 12: Setting Water Temperature

    The position you select on the temperature adjustment knob will depend on the temperature of the incoming water (50°F is average in the U.S.). If you plan to supply the AquaStar 38 B, with preheated water (i.e.) solar installation, the unit could overheat.
  • Page 13: Trouble Shooting

    (see maintenance table on back) Introduction The AquaStar 38 burners are ignited by a water flow valve. Numerous water related problems can cause this water valve to malfunction such as: Insufficient water flow volume to activate the burners at its minimum flow requirement; Dirt in the water flow valve causing it to malfunction;...
  • Page 14 The crossover will create a back pressure in the system preventing the pressure drop in the Aquastar (i.e. cold water is entering the water heater from both sides and the burners will not come on).
  • Page 15 AquaStar and the outlet Compare water temperature at outlet of the AquaStar (hold the AquaStar’s outlet pipe with your hand) and at the tap. If these two are very different, check for mixing valve or plumbing crossover (see “BURNERS DO NOT IGNITE WHEN HOT WATER IS TURNED ON”...
  • Page 16: Diagram Of Aquastar

    Heat exchanger Pilot assembly Burner manifold gas pressure test nipple Pilot gas tubing Main gas burner Fig. 9 - Diagram of AquaStar 38 B Inlet gas pressure test nipple Gas valve Gas control slide Piezo igniter Temperature adjustment knob Water valve...
  • Page 17 6 720 606 446...
  • Page 18 Fig. 10 - INTERIOR COMPONENTS DIAGRAM AND PARTS LIST 6 720 606 446...
  • Page 19: Components And Parts List

    Cover Temperature adjustment knob Draft divertor Heat exchanger Overheat sensor (ECO) Hot water pipe Main burner assembly Main burner assembly Burner assembly washer Piezo electrode Pilot burner assembly Pilot air screen Pilot orifice “ Pilot Tube Thermocouple Gas valve Gas valve Electromagnet Thermocable Water valve assembly...
  • Page 20 - Flow chart of Aquastar 38 B Fig. 11 6 720 606 446...
  • Page 21: Warranty

    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.
  • Page 22 6 720 606 446...
  • Page 23 6 720 606 446...
  • Page 24 Replacement Parts available from: BBT NORTH AMERICA Bosch Group Bosch Water Heating 340 Mad River Park Waitsfield, VT 05673 Phone 800-642-3111 Fax (802) 496-6924 www.boschhotwater.com techsupport@boschhotwater.com Recycled paper † † † † & † † Bosch Heating System Co. Foschan Guangdong C.

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Aquastar 38b lpAquastar 38b ng