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INSTALLATION AND OPERATING INSTRUCTIONS
FOR AQ-1 POWER VENT KIT
DESIGNED FOR
BOSCH 425 HN WATER HEATERS
AQUASTAR 125B WATER HEATERS
INCLUDING AQUASTAR MODELS: 125HX • 125BS • 125X • 125BL
TABLE OF CONTENTS
contents with an AQ-1 power vent p.1
mounting gas pressure switch p.2
mounting linear spillage switch p.4
common setup p.6
locating vent hood (clearances) p.7
mounting power vent motor (clearances) p.7
troubleshooting and maintenance p.9
safety interlock test p.10
AQ-1 wiring diagram p.11
v
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AQ-1 Power vent kit Parts included: Spillage Switch Kit 1. 185º F linear spillage switch mounted on an angled bracket and equipped with 36 inch cables connected to one eyelet terminal and one 1/4" quick connect terminal 2. Spillage switch mounting screw 3. Push on male spade connector, replaces eyelet terminal from 36 inch spill switch cable. Vent Hood Kit 1. 4" vent hood: VH1-4 2. Plastic wall anchors (4) 3. Sheet metal screws (4) 4. 5" to 4" vent reducer pipe 5. AQ1FLAPPER back draft accessory
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Before beginning installation review required clearances for Water Heater, IMPORTANT: FREEZE PREVENTION TO HEATER Power Vent Motor and Vent Hood In cold climates the vent hood and power vent mo- tor will not prevent infiltrating cold air to the water heater when not in use. Be sure to install the sup- Power Vent Kit plied backdraft AQ1FLAPPER accessory within the vent hood on the outside of the building. If not used, CAUTION cold air can enter the vent pipe and freeze the heat- ers heat exchang
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ROUTE TUBING TO PRESSURE FIGURE B TAP PORT ON THE HEATER'S BURNER MANIFOLD ROUTE TUBING TO BURNER 125B MODEL SHOWN AREA OR ATMOSPHERIC VENT FIGURE A MANIFOLD TAP PRESSURE TAP-GAUGE PORT (WHERE HEATER'S BURNER MANIFOLD PRESSURE CAN BE MEASURED) INSTRUCTIONS (SEE DIAGRAMS ABOVE) 1. Mount gas pressure switch by securing it to a. Remove the brass pressure tap fitting from the chosen location with a screw in each one the burner manifold of the water heater. This of the four mounting holes. fitting
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Linear Spillage Sensing Switch e. Hand thread the pressure tap fitting into the heater's burner manifold. Use a small amount of an appropriate thread sealant on the This switch provides a means for safety shut down of the male end of the fitting. Over tightening of water heater in the event of flue blockage or power venter the fitting will break it. failure. If hot flue gasses spill from the draft hood diverter, the draft spillage sensing switch will open the pilot safety f. Guide the end of
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1. The ECO is mounted on the lower left outlet water pipe. (See figure C) a. Remove one lead connecting to ECO terminal, it does not matter which one is disconnected. b. Attach 1/4" quick connect terminal end of linear spill switch cable to now exposed terminal of the ECO. c. Remove the eyelet ended terminal from the other spill switch cable. Affix the push on male spade connector, which is provided with the AQ1, to this spill switch cable. d. Connect this male spade connector to the remov
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COMMON SETUP 4" single wall pipe* (galvanized or stainless steel) or 4" B-type vent*. 5" to 4" vent reducer pipe * Single wall vent pipe requires a 6" clearance to combustibles. B-type vent (double wall) requires a 1" clearance to combustibles. Use of B-type vent is not Vent Hood (see freeze prevention permissible downstream outlet side of the fan motor. information on page 2) Any additional vent pipe used between the fan motor and the vent hood must be positive pressure rated with Power vent
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v v NOTE: FOLLOW REQUIREMENTS IN FIGURES F & G ON THIS PAGE BEFORE INSTALLING VENT HOOD, THEN USE TEMPLATE ON PAGE 13 TO CUT HOLE. "The exit terminals of mechanical vent system shall be located not less than 7 feet above grade when located adjacent to a public walkway. The venting system shall CAUTION terminate at least 3 feet above any forced air inlet within 10 Failure to follow these installation feet. The venting system shall terminate at least 4 feet instructions may violate applica
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INSTRUCTIONS (DO NOT BEGIN THESE PROCEDURES UNTIL VENT HOOD HAS BEEN INSTALLED) 1. Remove vibration mounts, nuts and washers 6. Support the vent pipe in accordance with vent from parts bag. Install on power venter as manufacturer's instructions. Vent pipe is not shown in (Figure H). supplied in the power venter package, except for the 5" to 4" reducer vent pipe in the AQ-1. 2. To prevent vibration, securely support power Observe the clearances associated with the venter from ceiling or joist u
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FIGURE I 3. Connect the RED wire from the jacketed cable onto the common terminal of the gas pressure switch. (See Figure I) NOTE: If the distance between the power venter and the gas pressure switch is greater than the length of the cable, splice a section of 2 conductor, PVC sheathed, 105º C thermostat cable to the supplied cable. Make sure that the colored leads remain consistent. TROUBLE-SHOOTING, MAINTENANCE 5. Make sure pressure switch is mounted in such AND TEST PROCEDURES a way that t
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SAFETY INTERLOCK TEST 1. Open the gas supply to the water heater. 5. Perform the operation circuit test and safety circuit check. (See Safety Interlock Test) 2. Remove the vent pipe from the vent connec- tor on the top of the water heater. TROUBLESHOOTING THE POWER VENTER 3. Block the vent connector with sheet metal or 1. Fan Motor runs all the time: Make sure the other noncombustible material. pressure tube that connects to the heater is properly connected to the burner manifold, not 4. Turn
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SAFE TY INTERLOCK DIAGRAM LINEAR LIMIT HEATER SPILLAGE SENSING ECO SWITCH BLACK 185º MANUAL RESET 11
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the pilot holes drilled in step 2. 1. Attach this template to the interior of the wall 4. Using a reciprocating saw, cut a hole through the Vent Hood will be penetrating. the building siding, wall board, etc., following 2. Insure that proposed vent termination clear- the appropriate lines of this template. ances are met before cutting opening through 5. Slide the vent hood through the opening and wall. Using a 1/2" drill bit, drill two pilot holes fasten to exterior wall using provided screws.
