Bosch Appliances 125X NG Maintenance and Service, Do not enlarge the orifice, Introduction

MAINTENANCE AND SERVICE

REVIEW MAINTENANCE TABLE ON THE BACK OF THIS MANUAL

Approximately once a year, theAquaStar should be checked and cleaned. To remove the front cover, first remove the incandescent particle tray, then pull off the temperature adjustment knob and unscrew and remove the plastic collar. Pull main cover out toward you and lift up and out. THE FOLLOWING OPERATIONS SHOULD BE PERFORMED BY A QUALIFIED SERVICE PERSON:

Vent System: Should be checked annually. Clean and repair as needed.

Water Valve (Part # 8707002534): The water valve on this heater should be serviced periodically. Lubricate component #25 on page 14 with a small amount of silicon, faucet or lithium grease every two years to keep its o rings fresh and pushrod sliding smoothly. Every 3-5 years replace components #25 and #26 on page 14. The frequency will depend on the mineral content of the water and conditions of use or whenever signs of corrosion appear at the gas and water valve joint. Periodically check that the water inlet filter (#28 on page 14) is clean as well.

Pilot Flame: The pilot flame should burn with a clean, sharp, blue flame and should resemble the diagram in Fig.10. If the flame is soft and yellow, the pilot burner orifice may need to be cleaned or replaced. The pilot flame should be approximately 2 inches long, extending past the flame sensor. If the flame is too small, it will not reach the flame sensor and the burners will not come on.

3mm

Correct gap between pilot burner tip and electrode tip

Piezo Electrode

Flame sensor

Piezo

Electrode

Fig. 10 - Characteristic Pilot Flame

To clean the pilot burner and/ or the pilot orifice : Turn off the gas to the unit. Set the On/Off switch to Off (position 0). Remove the cover of the heater. To do so, pull off the temperature adjustment knob and unscrew and remove the plastic collar. Pull main cover out toward you and lift up and out. The pilot orifice should be cleaned or replaced.

Do not enlarge the orifice.

Do not use any wire or sharp object to clean orifices. Natural gas orifices are large enough that you can usually clean them by blowing through them. LP orifices, on the other hand, are too small to clean and should be replaced. To access the pilot orifice, remove 2 screws holding pilot assembly in place. Then loosen compression fittings to expose pilot orifice.

PILOT ORIFICE

Fig. 11 - Pilot burner with pilot orifice

Main Burner Flames: The main burner flames should be blue, with a more intense blue cone in the center core. Yellow flames could be a sign of wrong size gas orifices or dirty burners, or a blockage on the heat exchangers fins. If some burners have yellow flames while others have good flames, it is likely that dust, lint or spider webs have partially clogged the burner venturis. To clean the burners, contact a gas service person.

Mineral Scale Build-up: The AquaStars heater, when operated at lower temperature settings, do not accumulate mineral build-up. If however, the heater is used at the higher temperature settings and the water has a high mineral content, periodic descaling may be necessary. The heating coils should be flushed with a descaling solution. Consult your dealer or Controlled Energy for instructions.

TROUBLE SHOOTING (see maintenance table)

Introduction

The AquaStar 125X burners are activated 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; Sediment build-up in faucet aerators, or shower heads; Uneven pressures between cold and hot. (with single lever faucets) Plumbing cross overs. These water flow related problems can cause the heater to deliver less than its full output, or to fail to ignite or to shut down completely.

Problems are stated in upper case, bold face. Most common causes for the problems follow in order of likelihood. The suggested solutions require that the cover be taken off. To do this, remove incandescent particle tray, pull off the temperature adjustment knob and unscrew and remove the plastic collar. Pull main cover out toward you and lift up and out.

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