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Bosch AQUA STAR 2400E LP, Installation And Operating Instructions Manual

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Bosch AQUA STAR 2400E LP Installation And Operating Instructions Manual Download Page 41

6 720 608 263

Electrical diagram

41

7

Electrical diagram

Fig. 44 Electrical scheme

1

Intlet water temperature sensor

2

Ionization sensor

3

Water flow sensor

4

Flue gas limiter

5

Temperature limiter / ECO

6

Gas valve

7

Fan

8

Water valve

9

AC Plug

10

Ignition electrode

11

Display PCB

12

ON/OFF switch

13

Fuse T 2.5A

14

Fuse T 3.15A

15

Terminal block

16

Ground post

17

Outlet water temperature sensor

Summary of Contents for AQUA STAR 2400E LP

Page 1: ...ce 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 In the Commonwealth of Massachusetts this product must be installed by a licensed plumber or gas fitter Upon completion of the installation these instructions should be handed to the user of the appliance for future reference What to ...

Page 2: ...ter during operation 34 6 8 Error code diagnostics 36 7 Electrical diagram 41 8 2400 E Functional scheme 42 9 Interior components diagram and parts list 43 9 1 Interior components 43 9 2 Components diagram 44 9 3 Parts list 45 10 Protecting the environment 46 11 Fifteen Year Limited Warranty 47 1 Warning For your safety Do not store or use gasoline or other flammable combustible or corrosive vapor...

Page 3: ...ith Part 15 of the FCC rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired opera tion Fig 1 ...

Page 4: ...ions Technical data Approved in US Canada Capacity Maximum flow rate 6 35 GPM 24 l min at a 45 F 25 C rise Maximum output 142 968 Btu h 41 8 kW Maximum input 175 000 Btu h 51 2 kW Efficiency in Recovery efficiency 86 5 Min Output 31 131 Btu h 9 1 kW Temperature Control Selection range 100 F 38 C 140 F 60 C Default temperature 122 F 50 C Stability 2 F 1 C Gas Requirement Gas connection inches NPT I...

Page 5: ...elds for covering front cover screws and control panel installer should affix these decals to the front of the unit after installation is complete See Fig 3 Installation manual replacement manuals can be downloaded at www boschhotwater com Product registration card Energy Guide label Please complete and return the enclosed product registration card The 2400 E is not approved or designed for Manufa...

Page 6: ...t supplied with heater during any pressure testing at pressures in excess of Psig 3 5 kPa B 6 Keep water heater area clear and free from combustibles and flammable liquids Do not locate the heater over any material which might burn B 7 Correct gas pressure is critical for the optimum operation of this heater Gas piping must be sized to provide the required pressure at the maximum output of the hea...

Page 7: ...d Minimum installation clearances Fig 4 Dimensions 1 Cover 2 On Off switch 3 Reset button 4 LCD display 5 Program button 6 Temperature buttons Fig 5 Minimum clearances Model 2400 E TOP A 12 FRONT B 1 BACK 0 SIDES 1 FLOOR C 12 Table 1 Minimum clearances ...

Page 8: ...nless steel vent pipe manufacturer Single wall stainless steel AL29 4C vent pipe vent type rated for Category III appliances must be used when exhaust venting this appliance See 3 6 Venting 3 4 Mounting installation B Secure the wall mounting bracket provided with the heater to a wall surface If wall is sheathed with plasterboard it is recommended that two support boards either 1 x4 or 1 2 minimum...

Page 9: ...more stringent Fig 7 Single pipe installation The 2400 E water heater holds cold water in its copper heat exchanger and water valve when not in use Because of this any cold air that comes through the unit s vent pipe could freeze and damage these components This Installation Manual specifies the minimum vertical vent pipe and the amount of combustion air required for this unit When all requirement...

Page 10: ...he outside by horizontal ducts 4000 Btu hr if all air is taken from the outside by direct openings or vertical ducts Or the space must be provided with one permanent opening or duct that is within 12 inches of the ceiling of the enclosure This opening must have a minimum free area of one square inch per 3000 Btu hr if all air is taken from the outside by a direct opening or vertical duct Louvers g...

Page 11: ...nt material will void the manufactures warranty and Danger Do not combination vent this appliance with any other appliance Warning Do not reduce the vent exhaust and combustion pipe sizes and do not common vent with any other vented appliance or stove Warning Failure to vent the exhaust gases to the outside with sealed stainless steel vent pipe AL29 4C may result in dangerous flue gases filling th...

Page 12: ... appliance The unused side must be sealed B Attach the combustion air inlet accessory 8 705 504 115 to the top of the unit position 3 using the 3 screws and gasket provided B Install combustion air pipe over the air inlet acces sory If using flexible piping secure with a clamp position 4 not included Fig 11 Combustion air inlet connection Vent manufacturer Contact information Z flex www z flex com...

Page 13: ...ons where the total vent length is greater than 5 feet Vent installation where any section of the exhaust vent pipe passes through an unconditioned space Note Condensate must be disposed of according to local codes Note Do not install condensate drain in areas where it may freeze 1 Install condensate drain as close to heater as possible 2 Use 3 8 ID high temperature silicone tubing to connect to c...

Page 14: ...h is recom mended on candy cane termination B Exhaust should terminate above and must be a mini mum of 3 feet from must intake termination B The exhaust vent must terminate above the roof sur face with an approved vent cap not less than 3 feet 0 6 m above the highest point where it passes through the roof and at least 2 feet 0 6 m higher than any vertical wall or similar obstruction within 10 feet...

Page 15: ...bserve that a battery oper ated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwell ing building or structure served by the side wall hor izontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a...

Page 16: ...the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instruc tions shall be included with the appliance or equip ment installation instructions and 2 The special venting systems shall be product approved by the Board and the instructions for that system shall include a parts list and detailed installa tion instructions e A copy of all installati...

Page 17: ...From any internal corner 12 in D Above ground or snow pack 12 in Above a paved sidewalk 7 ft E From an opposing wall or structure facing the termination 24 in From the relief valve of a gas regulator 36 in F From a terminator facing a terminator 48 in G Vertically between two exhaust vent terminators on the same wall 60 in H Horizontally between two exhaust vent terminators on the same wall 12 in ...

Page 18: ...nsate drain for vent runs longer than 5 linear feet Note Pitch venting down 1 4 per foot to termination for vent runs less than 5 linear feet Note For horizontal terminations venting must terminate once it penetrates to the outside of the structure There should be no sections of vent pipe exposed to the outdoors Fig 19 Vertical venting installation combustion air piping not shown Fig 20 Vertical v...

Page 19: ...ct for leaks GAS LINE SIZING The gas supply piping should be sized for a maximum draw of 175 000 BTUH Measure the length of gas supply line and use the tables in Fig 22 or the gas line manufacturer s sizing tables to determine the pipe diameter necessary to accommodate the 175 000 BTU demand of the heater If there are more gas drawing appliances on the line size the gas line according to the total...

Page 20: ...ousands of BTU per Hour of Undiluted Liquefied Petroleum Gases at 11 inches Water Column Inlet Pressure Based on a Pressure Drop of 0 5 Inch Water Column Source National Fuel Gas Code NFPA 54 ANSI Z223 1 No Additional Allowance is necessary for an ordinary number of fittings FOR LP GAS Maximum Capacity of Pipe in Thousands of BTU per Hour of Undiluted Petroleum Gases at 11 inches Water Column Inle...

Page 21: ...low maximum water flow B Turn on a high volume of hot water at least 4 gpm and heater will ignite If heater display reverts to P2 open more hot water fixtures to allow sufficient flow Press until P1 reappears on display B Record lowest operating gas pressure reading in table 7 Gas pressures lower than 5 W C for Natural Gas or 11 W C for LPG will result in insufficient degree rise to the hot water ...

Page 22: ...eater B Full port shutoff valves should be installed on both the cold water supply and hot water outlet lines to facilitate servicing the heater see Fig 26 Note If water flow or pressure is low or heater does not ignite check the water inlet filter screen for debris see Chapter 5 1 Connecting the pressure relief valve PRV A listed pressure relief valve supplied with the heater must be installed at...

Page 23: ...and must not be used for actual installation without appropriate engineering and technical advice from a properly licensed professional in the locality where the installation is made Fig 27 Recirculation application 1 Full port isolation valve 2 Circulator 3 Check valve 4 PRV 5 Expansion tank The use of a small electric mini tank water heater 4 6 gallon size should be used for this application and...

Page 24: ...to turn the on off control switch Never use tools Follow these instructions exactly If control switch is jammed close the gas supply and call Bosch Technical Support Attempted forceful repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control s...

Page 25: ...roduce temperatures that are too hot A temperature balance shower valve will automatically mix in cold water to reduce such hot water temperature In the event of any temperature fluctuation with the use of a temperature balance shower valve refer to shower valve manufacturer s instructions for internal adjustment setting Adjustments should be made to the hottest setting in the shower valve Additio...

Page 26: ... the burner input in response to both varying hot water flow rates and or changes in any incoming and outgoing water temperatures Note selected temperature on heater s display will blink until that temperature has been reached Fig 31 Flow temperature chart Note Low flowing fixtures are the leading cause of temperature overshoot To combat this symptom clean aerators and shower heads or replace with...

Page 27: ... order to return heater to normal operation Fig 35 Reset button If the problem persists or error code will not reset contact your installer 4 7 Program button The program button can be used on the appliance and on the remote control Programming Program function Programming actions are similar for both controls appliance control pad and wireless remote control Fig 36 Program button B Press buttons ...

Page 28: ...or soot build up or blockage To access fincoil venting must be removed from flue gas exhaust accessory With venting removed manually hold open damper and inspect fincoil below with a flashlight If there is evidence of soot build up or blockage the heat exchanger should be removed by a professsional and cleaned thoroughly To remove the heat exchanger consult service bulletin TWH G2 22 at www boschh...

Page 29: ...ating pump 11 Make sure there are no leaks and the solution is flowing from the descaling reservoir through the heater and returning to the reservoir 12 Run solution through the heater until the solution returning to the descaling reservoir comes out clear Changing to a fresh solution may be necessary during this process 13 Disconnect all lines and drain all solution from heat exchanger Properly d...

Page 30: ...r readings to those found in Table 10 If CO2 readings are off make adjustments as outlined below Note P1 adjustment will change the P2 reading Con firm the P1 value BEFORE adjusting the P2 level 1 If P1 CO2 level is off B Loosen yellow painted philips screw 1 and cover should rotate down 2 revealing a recessed brass slotted screw Fig 42 B Turning the slotted screw counter clockwise will raise P1 C...

Page 31: ...lockage D Returning to Service 1 Return slotted screw cover to original position 2 Reinstall Torx cover 3 Remove CO2 analyzer probe and reinstall flathead screw with gasket in exhaust collar 4 Install front cover 5 Turn ON OFF switch to the OFF O position and then back to the ON I position 6 Heater is ready for normal operation Final Readings P2 CO2 Reading CO2 P1 CO2 Reading CO2 CO2 level Max CO ...

Page 32: ...in gallons per minute while the unit is flowing water cycle to the 3d mode and press the button A reading of 25 on the display would indicate the heater is reading a flow rate of 2 5 gallons minute 6 Once the information is obtained press the button again to return to the diagnostic mode menu and scroll to addition diagnostic information B To exit the diagnostic mode of the heater use the or butto...

Page 33: ...FF O position and the power supply cord unplugged remove the unit s front cover See Page 5 Fig 3 Check wire connections between the water valve control unit and electrode set See chapter 9 2 for location of these parts 6 3 Water is too hot 1 Selected temperature on the unit is too high To lower output temperature see chapter 4 3 2 Clean inlet filter screen per chapter 5 1 3 Inspect the water path ...

Page 34: ...elow the activation flow rate which shuts off the burners The end result is nothing but cold water coming out of the outlet Follow each step below before proceeding to the next After each step test the hot water flow to see if it remains constant without turning cold 1 Check for restrictions in plumbing outlets which could limit hot water flow and may contribute to heater deactivation For sinks re...

Page 35: ...n Air Requirements 4 Cross contamination Ensure that intake and exhaust terminations maintain required clearances stated in the manual Cross contamination between intake and exhaust may cause unstable burner flames and noise 5 Lack of gas pressure Inadequate gas pressure will cause the fuel to air mixture CO2 to be out of adjustment This will result in unstable burner flames and noise Ensure gas p...

Page 36: ... sensor is firmly clipped on to the hot water copper pipe 2 Sensor may trip if water temperature drops below 36 F Protect heater from freezing condition as any damage due to freezing conditions is not covered under warranty 3 Clean inlet filter screen per chapter 5 1 and clear any debris out of showerheads faucet aerators and whole house filters 4 In areas where water has a high mineral content pe...

Page 37: ...d in chapter 3 6 Long vent lengths venting with more than three elbows blocked vent or combination venting may cause this failure Verify backdraft flapper inside flue gas collector is not stuck shut 4 Ensure intake and exhaust terminations maintain the required clearances stated in the manual Fig 17 and Table 6 on page 17 Cross contamination between intake and exhaust may cause the fan to alter it...

Page 38: ...reezing conditions as any damage resulting from freezing is not covered under warranty 4 Swap cold water temperature sensor with the hot water temperature sensor If the heater produces an A7 error replace cold water temperature sensor E9 Temperature limiter ECO open circuit should reset when cooler temperatures are detected part 8707206204 1 This water heater must be supplied with cold water for d...

Page 39: ...th observations Readings from above gas pressure test will be required EC Ionization failure during operation part 8708107020 1 Verify gas type See Fig 2 corresponds with the type of gas supplied to the heater 2 Verify the three yellow wire connections to the set of electrodes underside of the burner assembly are secure 3 Verify that venting meets specifications per chapter 3 6 Improper venting ma...

Page 40: ...e minimum activation point of 8GPM Measure voltage at the gas valve wire connector The connector should measure 24VDC between the left pair of wires and 24VDC between the right pair of wires when the unit is operating If voltage is not correct contact Bosch Water Heating for further instruction 3 Gas valve may be defective contact Bosch Water Heating for further instruction 8E Electronic noise on ...

Page 41: ...temperature sensor 2 Ionization sensor 3 Water flow sensor 4 Flue gas limiter 5 Temperature limiter ECO 6 Gas valve 7 Fan 8 Water valve 9 AC Plug 10 Ignition electrode 11 Display PCB 12 ON OFF switch 13 Fuse T 2 5A 14 Fuse T 3 15A 15 Terminal block 16 Ground post 17 Outlet water temperature sensor ...

Page 42: ...6 720 608 263 42 2400 E Functional scheme 8 2400 E Functional scheme Fig 45 Functional scheme ...

Page 43: ... 9 1 Interior components Fig 46 Components 1 Cover 2 On Off switch 3 Reset button 4 LCD display 5 Program button 6 Temperature switches 7 Flue gas collector 8 Mixer 9 Heat exchanger 10 Observation window 11 Inlet air duct 12 Control unit 13 Exhaust fan 14 Water valve 15 Gas valve Fig 47 Appliance overview ...

Page 44: ...6 720 608 263 44 Interior components diagram and parts list 9 2 Components diagram Fig 48 Components Diagram ...

Page 45: ...r 8 704 701 062 22 Gas valve 8 707 021 019 23 Gas valve washer 8 700 103 014 24 Remote control optional accessory TSTAT2 25 Control unit 8 707 207 268 26 Ignition cable 8 704 401 220 27 Cables 24V 8 704 401 214 28 Cables 8 704 401 314 29 Power supply cord 8 704 401 221 30 Flue gas limiter 8 700 400 032 31 Flue gas exhaust accessory 8 705 504 137 32 Combustion air inlet accessory 8 705 504 115 33 F...

Page 46: ...fe Contact your city authorities for information about the disposal of recyclable products Saving water resources B Make sure you close all the taps after any use Avoid leaving the taps dripping Repair any leaking tap B Define the temperature you want in the appliance or with the remote control This way you have the precise water flow needed mixing cold water to regulate temperature will increase ...

Page 47: ...rge Shipping costs In addition to supplying the replacement part s BBTNA will provide ground service delivery for these parts Expedited or upgraded shipping will be charged to the customer Service Labor Costs This warranty does not cover any labor costs associated with service removal or re installation of part s All such costs must be borne by the Purchaser Additionally this warranty does not cov...

Page 48: ...cement Parts available from BBT Termotecnologia Portugal S A Estrada de Cacia 3801 856 Aveiro PORTUGAL 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 ...

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