Instantaneous gas water heater Models W 325 K..T1 W 400 K..T2 · Installation · Operation · Maintenance The Bosch instantaneous water heater is a high efficiency, space saving answer to your water heating needs. All Bosch instantaneous water heaters heat water only as required; noenergy is lost maintaining a large voluma of water at elevated temperatures as in tanktype storage water heaters. Suitable for heating potable water. Certified for space heating in combination with potable water only. Not certified for heating only. READ INSTRUCTIONS CAREFULLY BEFORE INSTALLING NOTICE TO INSTALLER: Please leave this manual with the owner or affix adjacent to appliance. WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. - 6 720 601 783 CA (03.11) AL - ASTRAVAN DISTRIBUTORS, LTD. 123 Charles Street North Vancouver, B.C. V7H 1S1 Phone Canada: (604) 929-5488 Phone USA: (206) 860-8448 Web Site: www.astravan.com - Do not store or use gasoline or other flammable 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 agency or the gas supplier. Note: In case of problems please contact your salesman or installer DIMENSIONS Figure 1 Maximum hydrostatic water pressure ­ 1.03 Mpa (150 p.s.i.) Maximum recommend working pressure ­ 0.69 Mpa (100 p.s.i.) Minimum working pressure ­ 0.0138 Mpa (2 p.s.i.) at 2 Litres/min. (0.5 U.S. Gallons/min) free discharge Minimum recommended inlet water pressure for use with showers 30 p.s.i.g. Dimensions in Milimetres (inches) Model W325 W400 A 400 17 1/4" 440 17 1/4" Model Type of gas Natural Propane W325 Natural Propane W400 Natural Propane W400 Natural Propane high** (2,000 - 4,500 ft.) 30.85 kW ( 105,000Btu/hr) 0.82 diam. 16 standard (0 - 2,000 ft.) 34.28 kW (117,000Btu/hr) 0.82 diam. 1.25 diam. 16 16 high** (2,000 - 4,500 ft.) 26.37kW (90,000Btu/hr) 25.05 kW (85,000Btu/hr) 0.79 diam. 1.25 diam. 14 16 B 755 29 3/4" 770 30 1/4" C 250 9 3/4" 250 9 3/4" Altitude standard (0 - 2,000 ft.) D 155 6" 155 6" E 85 3 1/4" 85 3 1/4" Input 29.30kW (100,000Btu/hr) 27.83 kW (95,000Btu/hr) F 130 5" 130 5" G 410 16 1/8" 410 16 1/8" H 320 12 5/8" 320 12 5/8" Main Burner orifices Size, mm 1.25 diam. 0.79 diam. 1.25 diam. Qt. 14 14 14 W325 * The wall bracket is only required for the WR 325 K ... when mounted directly to combustible construction. The WR 400 K... T2 may be mounted directly to combustible construction. ** The high altitude ratings listed are Canadian Gas Association high altitude ratings and are only valid in Canada. In the U.S., the National Fuel Gas Code, ANSI Z223.1/NFPA 54, recommends for high altitude installations above 2,000 feet, that the input rate be reduced 4% for each 1,000 feet above sea level. ­ See page 8. 2 FORWARD This design complies with CAN1-4.3-77 and ANS1Z21.10.3b 1994 as an instantaneous gas water heater. In addition the unit complies with CAN1-2.17-M80 for use at high altitude, 2.000-4.500 feet above sea level. Installation, operation and maintenance information is provided in this manual. Installation and operation instrution should be thoroughly reviewed before proceeding with installation of the BOSCH instantaneous gas water heater. The BOSCH instantaneous gas water heater is designedto operate on natural or propane gas; however, make sure that gas onwhich heater is to operate is to operate is the same as specified on the heater's model/rating plate. In addition to these instructions, the water heater shall be installed in accordance with CAN1-B149 Installation Code (in Canada) or ANSI Z223-1/NFFA 54 National fuel Gas Code (in U.S.) and/or local installation codes. These shall be carefully folowed in all cases. INSTALLATION INSTRUCTIONS Note: Proper plumbling, venting, gas connections and an adequate supply of combustion air are required for safe and reliable operatrion. Ability equivalent to that of a licensed tradesman in the field involved is required for installation and/or servicing of these heaters. AIR REQUIREMENTS For safe operation ,sufficient air for combustion, ventilation and dilution of flue gases must be available. An insufficient supply of air will result in a yellow luminous burner flame, causing carboning or sooting of the heat exchanger. In unconfined spaces, in buildings of normal construction, infiltration normally is adequate to provide air for combustion, ventilation and dilution of flue gases. However, a confined space must be provided with two permanent openings to provide combustion and ventilation air to the appliance. Each opening shall have a free area of one square inch per 1000 BTU/Hr* of total input rating os all appliances in the enlosure.One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure. * SPECIAL NOTE When the W 400 K... T2 is installed in a confined space of minimum size the openings described above must be increased to a size of 1 ½ square inches per 1000 BTU/Hr. In other words, for the W400 K..T2 installed in a minimum sized confined space the two openings that are to be made in the enclosure within 12 inches of the top and 12 inches of the bottom must each have a minimum free area of, (11/ 2") x (117) = 175.5 square inches. LOCATION Before installation the BOSCH instantaneous gas water heater consideration must be given to proper location. Location should be as close to a chimney or gas vent as practicable, in an area with an adequate air supply and as centralized with the piping system as possible. The heater should not not be located in area where it will be subject to freezing. The heater should be located in an area where leakage of the heater or its connections will not result in damage to the area adjacent to the heater or to lower floors of the structure. In order to prevent corrosion, make sure that the combustion air kept free of aggressive substances. Subtances that especially contribute to corrosion are halogenated hydrocarbons (e.g. chlorine and fluorine), which are contained in solvents, paint, adhesives, propellant gases, various house hold cleaners, etc. Take precautionary measures as necessary. If plastic pipes are used , a 1.5 m metal connection must be provided on the cold and hot sides. Note: When such loctions cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the water heater. The pan must not restrict combustion air flow. 3 For either confined or unconfined space in a building of tight construction with inadequate infiltration, air must be drawn from the outdoors or from spaces that freely communicate the outdoors. Two permanent openings located as indicated above are to be provided as follows: 1. When communicating with outdoor directly, or by means of vertical ducts, each opening shall have a free area of not less than one square inch per 4000 BTU/Hr of total input of all appliances in the space. 2. When communicating with outdoors by means of horizontal ducts, each opening shall have a free area of not less than one square inch per 2000 BTU/Hr of total input of all appliances in the space. For detailed reqirements see in Canada, CAN 1-B 149 Installation Codes in U.S., ANSI Z223.1/NFPA 54 National Fuel Gas Code. MOUTING The W 325 K.. and W 400 K.. are design certified for mounting to a wall. A wall bracket, see figure 1 is provided with the W 325 K.. and must be used when the heater mounted on a combustible wall. Heaters may not be installed directly on a carpeted wall. The heater, or the wall bracket, must be mounted to the wall using appropriate anchoring materials. WARNING Failure to use the wall bracket with the W 325 K... when installing the unit on combustible construction will cause an unsafe condition and possible fire. In addition, failure to use the wall bracket when installing the W 325 K... on combustible construction will be in violation of A.G.A. and C.G.A. certification of the unit. Note: If wall is a stud wall sheethed with plasterboard it is recommended that support board(s), either 1 x 4's or ½ (minimum) plywood first be attached across a pair of studs and then heater, in the case of the W 400 K..., or the wall bracket, in the case of the W 325 K..., be attached to the support boards. See figure 2. WARNING 1. Flammable materials, gasoline, pressurized containers, or any other items or articles that are potentially fire hazards must never be placed on or adjacant to the heater. The appliance area must be kept free of all combustible materials, gasoline and other flammable vapors and liquids. 2. Do not obstruct the flow of combuston and ventilation air to the appliance. CLEARENCE In Canada The W 325 and the W 400 are design certified for installation on a combustible wall (for the W 325 the wall bracket supplied with the unit must be used for mounting to combustible construction), and for installation in an alcove or closet with minimum clearances to 0 mm from back, 102 mm (4 inches) from sides, 305 mm (12 inches) from top and bottom, and 102 mm (4 inches) from front. A minimum of 305 mm (12 inches) shall be allowed for maintenance of serviceable parts. Clearence from vent is dependant upon the clearence rating of the venting material used; that is, type B-1 vent is approved for 1 inch clearence, B-2 vent for 2 inch, etc. In United States The W 325 and the W 400 are design certified for installation on a combustible wall (for the W 325 the wall bracket supplied with the unit must be used for mounting to combustible construction), and for installation in an alcove with minimum clearences to combustible construction of 0 mm from back, 102 mm (4 inches) from sides, 305 mm (12 inches) from top and bottom. In addition, the WR 325 has also been design certified for closet installation with minimum clearences to combustible construction of 0 mm from back, 102 mm (4 inches ) from sides, 305 mm (12 inches) from top and bottom, and 102 (4 inches) from front. A minimum of 305 mm (12 inches) shall be allowed for maintenance of serviceable parts.Clearence from vent is dependent upon the clearence rating of the venting material used, that is, type B-1 vent is approved for 1 inch clearence, B-2 vent for 2 inch, etc. WALL STUDS WALL BRACKET Figure 2 1" X 4" SUPPORT BOARDS Expansion and contraction of piping due to changing water temperature in pipes imparts movement to heater which, if mounted directly to a brittle, friable board such as plasterboard can cause failure of mounting. 4 DRIP TRAY If the water heater is being mounted above a floor of combustible construction, the drip tray ( shipped loose in the water heater) must be attached to the bottom of front cover of the water heater at time of installation. The drip tray should be attached to the front cover, using screws provided, as shown in figure 3. Failure to use drip tray when installing unit above a floor of combustible construction will cause an unsafe condition and possible fire and will be in violation of A.G.A. and C.G.A. sertification of the unit. For high altitude use the adaptor must be installed as shown in figure 4, without alternation, before connecting the six inch flue to the unit. The adaptor must be secured to the draft diverter outlet with a minimum of two screws. Also, in Canada, the gas pressure regulator supplied with the water heater is factory preset to deliver gas to the water at the proper pressure settting for high altitude operation, see PRESSURE REGULATION section of this manual. WARNING Failure to increase vent size on W 400 to six inches and/or to assure that manifold pressure is set to proper value listed on rating plate for applications at altitudes in range 2,000 to 4,500 ft. above sea level will cause unsafe venting, asphyxiation, and voids C.G.A. certification. WATER CONNECTIONS The W series instantaneous water heatrs are provided with two S-bend water connectors/adaptors that must be connected to inlet and oulet and outlet connections on water valve assembly, see figure 1 and figure 5 below. DRIP TRAY Figure 3 VENTING The BOSCH instantaneous water heaters have builtin draft diverters and are designed for indoor installation only. The draft diverter outlet must be connected to a clear, unobstructed vent of the same size, or lerger, refer to: In Canada, CAN1-B149 Installation Code for detailed requirements. In U.S.A., ANSI Z223.1/NFPA 54 ­ National Fuel Gas Code for detailed requirements. Water valve and S-bends, top view Figure 5 The purpose of the S-bend water connectors/adaptors is to provide threaded water connections tha ...