How do i know if the control unit is bad on an aquastar 1600H

If your getting a spark the generator should be ok I would clean the pilot injector and re try

try to check if theres available inverter compatible for your generator...

If there is not a clicking sound, it almost always means the main ignition or control unit (box with red and green lights and wires coming from it) is not getting the supply voltage. The voltage is supplied by a generator that is getting energy from the flow of water (the "hydro generator"). First disconnect the wire connector at the hydogenerator and check the voltage while water is running. The manual says you should read 1.6 VAC (I read 2.5 VAC). Make sure your voltage reader is on AC, not DC. If you have at least something like 1 VAC, then the next thing to check is the "microswitch" that allows the hydro generator voltage to reach the ignition unit. To check it, disconnect the other wire connector that is on the black wire coming from the hydrogenerator that is closer to the ignition unit. Then with the water running, stick a small screwdriver in the male plug side to short the two wires in order to bypass the microswitch (per Bosch tech support instructions). You should now here clicking and see the unit work. This is what happened with me and tech support said I needed to order a new microswitch and gave me a part number and telephone. But don't stop reading here. You can see the microswitch when looking up at the underneath of the unit. It's a small white 1x1 inch box-like shape held by 1 screw. After removing it, I noticed the microswitch had a removable cover (which is strange for a switch) and opened it to discover the internal switch can actually move inside because it "automatically adjusts" itself when it is first put in (it stays more firmly, but not rigidly in place when the cover is on). So you can mess up when putting it in. Don't bump it. It can easily get out of its working range of motion, which is why mine stopped working: it was a bad design to use this type switch in this application. So I slide the internal switch back close to the spring side ("default" position), put the cover back on, carefulyl screwed it in place, and now it works.

The purpose of the mechanical microswitch is to not allow the hydroenerator voltage to the ignition unit unless the "pushrod" has opened the main gas supply. It prevents clicking if there is no supply gas, so it is not needed (you can electrically bypass it with a splice) if everything else is working fine. But don't blame me if you do this and for some reason it ruins the more expensive ignition unit. The microswitch is turned on by the pushrod when the pushrod leaves it's default position. The the pushrod moves only about 2 to 3 mm when you turn on the water. You can see the pushrod when you unscrew the microswitch, and you can watch it move. The problem is that the microswitch mounting is not precise enough for the small pushrod movement and the pushrod's default position can change with age of the diaphragm or change in the grease. So their automatically adjusting microswitch that makes up for lack of precision in design and pushrod movement can stop working when the pushrod changes position. My unit was 2 years old.

Possible flow sensor issue. Check to see if your water pressure fluctuates a lot or is fairly steady. These units are sensitive to the pressure. take care.

Having the same problem with mine. Looking for a replacement generator. Seems that if your water pressure or flow is not adaquate your will have this problem. Get worse over time. I took mine apart and it got better then started doing the same thing again. I turn on several faucets to overcome problem. Still it not good. The 1600H does not appear in the Bosch website parts list models. They do say that a third party does the fulfillment in the notes at bottom on other units...maybe call them

sounds like the generator has packed up. check water flow and clean any filters on the water line. you will need a service agent to check milli volts on generator and power pack

It is a control box issue but now I have to decide if I want to spend $270 to fix or for $299 buy a regular water heater. By my calculations being this is year three, the 15 year life expectancy of this 1600h water heater will cost me $1500 in parts alone.

The manual says to hold a match near the pilot while the ignitor is trying. It says that if the unit lights the pilot orifice may be dirty or clogged. Then the manual says to check the voltage on the igniter. It should be 1.3 volts DC minimum if it is not means the electronic control box is defective.

Let me know the status ...Kevin

Aquastar 1600H NG Natural Gas Tankless Water Heater Bosch AquaStar Model 1600H NG Natural Gas Whole house tankless gas water heater, 117,000 Btu input, natural draft with hydro-generated ignition. Provides endless hot water for one major application at a time . Can replace 40-gallon storage tank water heater. Optional Accessory: Model AQ1- Power vent with built-in... More freeze protection when venting horizontally. Capacity: 1 to 2 Bathrooms Dimensions: 8.75D x 18.25 W x 29.75H Weight: 40 Max GPM @ 45F Rise: 4.2 Energy Factor: NG .80 LP .84 Minimum Input: 28,000 Maximum Input: 117,000 Vent Size: 5 Gas Connection: 3/4 Water Connections: 1/2 Warranty: 12-year warranty on heat exchanger, 2-year on parts Features: Endless hot water Can save up to 50% off utility costs annually Perfect for one major application at a time No standing pilot, hydro generated

I hope this helps!
http://www.boschhotwater.com/HelpfulResources/TechnicalSupport/BoschAquaStarModels/1600HTechSupport/Troubleshoot/tabid/1094/Default.aspx
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