Bosch Evolution 500 Instruction Manual Download

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6 720 680 223

Interior components diagram and parts list

12.2 Components diagram

12.2.1 Group 1

Fig. 66 Components Diagram

6720902973.AA JF

Item

Description

Reference

Front cover

8 705 431 369

Cover shield

8 705 506 749

Trade mark badge

8 701 103 140

Cover screw

8 703 401 170

Combustion cover

8 700 506 300

Combustion cover gasket

8 704 701 084

Observation window

8 705 600 003

Holding bracket

8 708 104 103

Screw

8 703 403 012

Table 21

Combustion cover clip

8 701 201 032

Grommet set

8 710 203 039

Exhaust accessory

8 705 504 151

Gasket exhaust

8 700 103 710

Inlet air cover

8 708 006 022

Inlet air gasket

8 700 103 166

Inlet air accessory

8 705 504 154

Mounting bracket

8 701 309 164

Item

Description

Reference

Table 21

Summary of Contents for Evolution 500

Page 1: ... 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 do if ...

Page 2: ...ety read before operating your water heater 30 5 3 Power 30 5 4 Temperature selection 30 5 5 Use of optional remote control accessory part no TSTAT2 31 5 6 Operation 31 5 7 Reset button 31 5 8 Program button 31 5 9 Locked condition 31 6 Maintenance and service 32 6 1 Annual maintenance 32 6 2 Winterizing for seasonal use 32 6 3 Mineral scale build up 33 6 4 Adjusting CO2 carbon dioxide 33 6 5 Prog...

Page 3: ...eater must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures equal to or more than 0 5 psig Warning The appliance should be located in an area where leakage of the heater or connections will not result in damage to the area adjacent to the appliance or to lower floors of the structure When such locations cannot be avoided it is recommend...

Page 4: ...operate with the appliance TSTAT2 Cascading kit TLINK Outdoor kit BSHTOK Gas conversion kit 8719002176 Vertical vent kit ESVVT Concentric vent air intake kit ESHCK Horizontal vent kit AQ3ES1 Stainless steel bird screen L2594 fits into a 3 PCV fitting Intake vent Warning The anti freeze kit is designed to provide protection for the water heater down to approximately 5 F for short term conditions on...

Page 5: ... Minimum recommended water pressure 30 PSI 2 07 bar Minimum recommended well pressure 40 PSI 2 75 bar see chapter 3 9 Connections Bottom of heater Combustion NOx 40 Ng J Nanograms of NOx calculated as NO2 per Joule of heat output CO 250 ppm measured CO2 level set from factory see chapter 6 4 Dimensions Depth in 11 286 mm Width in 17 7 8 452 mm Height in 30 775 mm Weight 67 pounds 30 5 kg Gas types...

Page 6: ...l can be downloaded at www boschhotwater com Product registration card Energy Guide label Please complete and return the enclosed product registration card The water heater is not approved or designed for Manufactured mobile homes boats or any mobile installation modular homes are acceptable for installation Use above 8000 ft A S L altitude see page 18 Outdoor installation without installation of ...

Page 7: ...r heater See chapter 3 3 on VENTING B 5 The appliance and its gas connection must be leak tested before placing the appliance in operation The appliance must be isolated from the gas supply piping system by closing its individual manual gas shutoff valve not 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 combus...

Page 8: ...ower ON or stand by LED 5 LCD display 6 Up button 7 Down button Fig 7 Minimum clearances Note For servicing access a 2ft clearance to front cover is recommended 6720608158 04 2AL 2 3 1 6 5 7 4 reset P 5 30 17 7 8 5 11 2 6 2 16 5 5 2 16 4 1 16 6 5 16 1 16 5 16 Model Evolution 500 TOP A 12 FRONT B 1 BACK 0 SIDES 1 FLOOR C 12 Table 1 Minimum clearances ...

Page 9: ...ent pipe AL29 4C may result in dangerous flue gases filling the structure in which it is installed Warning Do not mix vent pipe or joining methods from different manufacturers Warning Approved terminators must be used for inlet and exhaust vent sys tems to prevent rain from entering the appliance Failure to do so may result in damage to the appliance This failure is not covered under the manufactu...

Page 10: ...enting must terminate once it penetrates to the outside of the structure There must be no sections of vent pipe exposed to the outdoors other than the termination Note Listed thimbles or collars are necessary where venting passes through wall and ceiling partitions If the vent system passes through combustible areas where the vent clearance requirements cannot be maintained it is permissible to ch...

Page 11: ...ion air and exhaust piping with consideration to the number of elbows used Step 1 Total the number of 90 elbows and 45 elbows used on the exhaust piping Step 2 Use this value in the table to determine the maximum straight exhaust pipe length allowed Step 3 Total the number of 90 elbows and 45 elbows used on the combustion air piping Step 4 Use this value in the table to determine the maximum strai...

Page 12: ...nventilated soffit F Clearance to outside corner G Clearance to inside corner H Clearance to each side of center line extended above meter regulator assembly 36 in within a height 15 feet above meter regulator assembly I Clearance to service regulator vent outlet 36 in J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other application 36 in 12 in K Clea...

Page 13: ...entilated soffit F Clearance to outside corner G Clearance to inside corner H Clearance to each side of center line extended above meter regulator assembly 36 in within a height 15 feet above meter regulator assembly I Clearance to service regulator vent outlet 36 in J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other application 36 in 4 feet below o...

Page 14: ...ure There must be no sections of vent pipe exposed to the outdoors Fig 14 Horizontal venting installation concentric penetration Fig 15 Horizontal twin pipe penetration Below are approved examples of vertical venting installations Important Note Pitch horizontal runs down toward the heater 1 4 per foot Fig 16 Vertical venting installation single pipe pene tration Warning for non freezing climates ...

Page 15: ...over the accessory NOTE The appliance has the option to mount the combustion air inlet acces sory on the top right or on the top left side of the heater The combustion air inlet that is not used must be kept sealed Fig 20 B Ensure that exhaust vent pipe is fully inserted in collar to enable proper connection CHIMNEY MORTAR HANGER STRAP HORIZONTAL RUN 1 4 RISE FT ELBOW APPLIANCE MAY BE INSULATED IF...

Page 16: ...the high temperature silicone tubing with vinyl tubing PVC or CPVC pipe Do not reduce the internal diameter at any point 5 Dispose of condensate according to local codes Fig 21 Condensate drain installation combustion air piping not shown 3 Venting Z flex ProTech Heat Fab 90 Condensate Drain Tee 2SVEVWCF03 FST3 FSDF3 93PPLSTEE Horizontal Condensate Drain 2SVEDWCF03 FSHDT3 9321 Condensate Drain Tub...

Page 17: ... and enter those values in the intake section of table 10 B Add line 4 from Exhaust to line 4 of Intake and enter result in line 5 This is the total equivalent vent length Example Exhaust 7 3 straight sections 1 1 straight section Total straight pipe length 22 2 90 elbow Intake 5 3 straight sections Total straight pipe length 15 1 90 elbows Example Note Do not count terminals and first elbow used ...

Page 18: ...setting will appear on the display B Press or to choose the fan speed suitable with your installation see Table 12 B Press and hold 5 sec Program button until the display flashes then the selected value is memo rized Natural Gas Liquid propane Altitude above sea level Total equivalent vent length1 Minimum power fan speed P2 Maximum power fan speed P1 Maximum power fan speed P1 0 2000 ft 0 610 m 5 ...

Page 19: ... minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall ...

Page 20: ...eater s vent pipe allowing the cold incoming air to freeze the cold water in the heat exchanger Supplying more combustion air for all combustion appliances is the solution A HVAC specialist should be consulted to design solutions for providing more combustion air Observe the following guidelines Installations in structures that have been tightly constructed air infiltration rate of 0 40 ACH or les...

Page 21: ... minimum plywood first be attached across a pair of studs see Fig 24 B Secure the wall mounting bracket provided with the heater to the wall surface The heater must be kept level on the wall surface see Fig 25 B Hang the appliance on the bracket see Fig 26 Fig 24 Distance between support boards Warning The water in this water heater is cold and always remains cold except for the times the burner i...

Page 22: ...red for any appliance connector is B Undersized flexible appliance connectors not permitted B National Fuel Gas Code requires that a sediment trap drip leg be installed on gas appliances not so equipped The drip leg must be accessible and not subject to freezing conditions Install in accordance with the recommendations of the serving gas sup plier see Fig 27 Fig 27 Gas connection drip leg Warning ...

Page 23: ...ne the pipe diameter necessary to accommodate the 195 000 BTU demand of the heater If there are more gas appliances on the line size the gas line according to the total maximum amount of BTU input rating for all appliances Note Undersizing the gas line may result in diminished hot water flow rate and temperature See chapter 3 12 page 26 for the procedure to confirm gas pressure Proper gas pressure...

Page 24: ...lack iron Pipe Feet Pipe Internal Size Diameter inches inches 10 20 30 40 50 60 70 80 90 100 125 150 175 200 1 4 0 364 32 22 18 15 14 12 11 11 10 9 8 8 7 6 3 8 0 493 72 49 40 34 30 27 25 23 22 21 18 17 15 14 1 2 0 622 132 92 73 63 56 50 46 43 40 38 34 31 28 26 3 4 0 824 278 190 152 130 115 105 96 90 84 79 72 64 59 55 1 1 049 520 350 285 245 215 195 180 170 160 150 130 120 110 100 1 1 4 1 380 1050 ...

Page 25: ...tank the lowest pressure range setting recommended is 40 60 psi 2 75 and 4 15 bar 3 10 Water quality Water quality can have an impact on appliance longevity and may not be covered under the manufacturer s warranty For water analysis data call your local water department or if on a well have well water analyzed periodically If water quality exceeds one or more of the values specified below Bosch re...

Page 26: ...d for actual installation without appropriate engineering and technical advice from a properly licensed professional in the locality where the installation is made Fig 32 Recirculation application 1 Full port isolation valve 2 Circulator pump 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 designed so t...

Page 27: ...cient flow Press until P1 reappears on display B Operate all other gas appliances on the same gas piping system at maximum output B Record lowest operating gas pressure reading in table 15 Gas pressures lower than 3 5 W C for Natural Gas or 8 W C for LPG will result in insufficient degree rise to the hot water being used reduced hot water volume possible error code faults and must be corrected See...

Page 28: ... of the control unit Fig 36 B Pull control unit free to access and remove the six screws from the back cover of the control unit see Fig 37 pos 2 B Check the fuses in the printed circuit board see Fig 37 pos 3 Fig 37 Location of fuses B After verifying the fuses mount all parts in reverse order Warning For safety reasons disconnect the power supply cord to the heater before any service or testing ...

Page 29: ...4 LCD display 5 Up button 6 Down button 7 LED Power On indicator or Stand by 5 1 LCD Display functions Fig 39 Power bar indicator Fig 40 Temperature indicator Fig 41 Error indicator Fig 42 Lock indicator Fig 43 Flame indicator Fig 44 Remote control Warning Do not use any cleaning or corrosive agent to clean the window ...

Page 30: ...ce press the On Off button Fig 45 Off B To shut down the appliance press the On Off button again 5 4 Temperature selection To select output water temperature B Press buttons or in order to reach desired temperature Fig 46 Setting the water temperature The desired temperature of the hot water can be adjusted on the front control panel of the heater The water heater has an electronically controlled ...

Page 31: ...et button If the problem persists contact your installer 5 8 Program button Program button can be used on the appliance and in the remote control Programming Program function Programming actions are similar for both controls appliance control pad and wireless remote control Fig 51 Program key Memorizing selected temperature B Press buttons or to select temperature to be memorized B Hold Program bu...

Page 32: ...y has a high mineral content see Table 13 page 25 the heat exchanger should be periodically flushed with a descaling solution Scale build up will shorten the life of the water heater and damage resulting from scale is not covered under warranty Refer to section 6 3 for detailed instructions on descaling the heat exchanger Heat exchanger fin coils Inspect heat exchanger fincoil for soot build up or...

Page 33: ...utlet of the circulating pump installer supplied to the inlet water fitting on the water heater see Fig 54 6 Using another line B connect to the water outlet fitting on the water heater Route the other end of this line into a descaling reservoir 7 Using a 3rd line C from the descaling reservoir connect to the inlet side of circulating pump Install a filter on the end of this line in the descaling ...

Page 34: ...2 reading Confirm 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 57 B Turning the slotted screw counter clockwise will raise P1 CO2 levels and clockwise will lower P1 CO2 levels Adjustments to the slotted screw will also change P2 CO2 levels B After bringing the ...

Page 35: ...1 250 ppm min input P2 2 3 2 6 60 ppm LP Gas max input P1 8 7 9 3 250 ppm min input P2 2 7 3 0 60 ppm Values above are for climate controlled conditions Inputs such as gas pressure heating value of the gas humidity and temperature of combustion air all impact CO and CO2 values Changes in these inputs can result in different CO and CO2 values on the same appliance Table 17 CO2 CO target numbers 672...

Page 36: ...ent P1 Maximum Power NG 48 LP 46 21 NG 50 LP 49 see chapter 3 12 page 26 note reducing P1 values below maximum will reduce maximum power of the appliance P2 Minimum Power 7 7 20 see chapter 3 3 6 page 17 P3 Remote Con trols installed _0 _0 6 see chapter 5 5 page 31 P4 Access to Diag nostic Mode E 0d 10f see chapter 6 6 page 37 P5 Cascade Mode NO NO CC contact Bosch for details P6 Temperature Unit ...

Page 37: ...it 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 8 Once the information is obtained press the button again to return to the diagnostic mode menu and scroll to addition diagnostic information 9 To exit the diagnostic mode of the heater use the or button until the display reads E 10 Pre...

Page 38: ...s are common causes of plumbing crossovers 8 With the ON OFF switch turned to OFF O position and the power supply cord unplugged remove the unit s front cover See Page 6 Fig 3 Check wire connections between the water valve control unit and electrode set See chapter 12 1 page 49 for location of these parts 7 3 Water is too hot 1 Selected temperature on the unit is set too high To lower output tempe...

Page 39: ...water heater such as a clogged inlet filter screen can result in unequal pressures between the cold and hot water lines In such cases when mixing in the higher pressure cold water at the tap the lower pressure hot water can be overpowered This will shut down the burners because the hot water flow rate fell below the minimum flow rate required for activation Verify inlet filter screen is clean and ...

Page 40: ...se Ensure gas pressure is in accordance with specifications in section 3 12 page 26 Measuring Gas Pressure A gas pressure reading is needed to proceed further Contact your original installer or a local certified gas technician to obtain this reading 6 Verify proper CO2 readings per chapter 6 4 page 33 CO2 adjustments must be done by a certified gas technician with a calibrated combustion gas analy...

Page 41: ...ot correct 1 Check P7 mode water heater requires setting NC 2 Check jumper and connection on sensor at upper right hand corner of heat exchanger 3 Measure jumper resistance must be 115 125 ohms Backflow temperature sensor defect happens if sensor is disconnected or short circuit 1 Check backflow temperature sensor connection and resistance See Fig 62 page 47 and Fig 64 page 49 2 Replace backflow t...

Page 42: ... fan to alter its rotational speed 5 Check gas pressure Low gas pressure may cause the fan to change its speed to meet desired temperature 6 Possible defective control unit call Bosch Water Heating for further instructions No rotational speed sensor signal from primary fan 1 Disconnect power supply cord and check wire connections on back side of primary fan and the two connectors on the control bo...

Page 43: ...ry fan connections are disconnected 3 Check venting specifications are met Long vent lengths venting with more than three elbows blocked vent or combination venting may cause this failure 4 Check sensor resistance see Fig 62 page 47 Overheat sensor ECO open circuit should reset when cooler temperatures are detected 1 Disconnect power supply cord and check wire connections on overheat sensor top ri...

Page 44: ...the lower front of the heat exchanger are secure 3 Check venting specifications are met Improper venting may cause unstable burner flames and loss of flame ionization 4 Check that the minimum power fan speed has been adjusted to the proper value See page 18 5 Check gas pressure see section 3 12 page 26 6 Check and adjust CO2 readings see section 6 4 page 33 Ionization error at standby 1 Loose conn...

Page 45: ...er flow sensor 8 Flue gas limiter 9 Heat exchanger overheat sensor ECO 10 Gas valve 11 Jumper resistance 12 Water valve 13 Primary fan 14 ON OFF switch 15 Secondary fan 16 AC plug 17 Main connection 18 Ignition electrodes 19 Ground post 20 Antifreeze kit connection 21 Fuse 22 Fuse 20 1 16 1 JP5 JP6 JP7 JP8 JP2 M PS M M E FS T 104 C T 220 F T 110 C T 230 F Casc input Casc output 2 1 4 5 6 7 9 10 11...

Page 46: ... 29 30 31 32 33 34 35 36 37 Resistance Kohm Temp ºF 0 5 10 15 2 0 2 5 3 0 3 5 4 0 4 5 50 55 6 0 6 5 70 75 8 0 8 5 9 0 9 5 10 0 10 5 110 Temp ºC Inlet temperature sensor characteristics 3 2 3 7 4 2 4 7 52 57 6 2 6 7 72 77 8 2 8 7 9 2 9 7 10 2 10 7 112 117 12 2 12 7 13 2 13 7 14 2 14 7 152 157 16 2 16 7 172 177 18 2 18 7 19 2 19 7 2 0 2 2 0 7 2 12 2 17 2 2 2 2 2 7 2 3 2 2 3 7 2 4 2 2 4 7 0 1 2 3 4 5...

Page 47: ... 7 18 2 18 7 19 2 19 7 2 0 2 2 0 7 2 12 2 17 2 2 2 2 2 7 2 3 2 2 3 7 2 4 2 2 4 7 2 5 2 2 5 7 2 6 2 2 6 7 2 7 2 2 7 7 2 8 2 2 8 7 2 9 2 2 9 7 3 0 2 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Resistance Kohm Temp ºF 0 5 10 15 2 0 2 5 3 0 3 5 4 0 4 5 50 55 6 0 6 5 70 75 8 0 8 5 9 0 9 5 10 0 10 5 110 115 12 0 12 5 13 0 13 5 14 0 14 5 150 155...

Page 48: ...6 720 680 223 48 Evolution 500 Functional scheme 11 Evolution 500 Functional scheme Fig 63 Functional scheme ...

Page 49: ... Flame sensor 4 Primary fan Mixer 5 Outlet temperature sensor 6 LCD display 7 On Off button 8 Reset button 9 Program key 10 Flue gas limiter 11 Heat exchanger overheat sensor ECO 12 Ignition electrodes 13 Observation window 14 Backflow temperature sensor 15 Secondary air fan 16 Gas valve 17 Water valve with engine and temperature sensor 18 Control unit 19 Up button 20 Down button 21 LED ...

Page 50: ...6 720 680 223 50 Interior components diagram and parts list Fig 65 Appliance overview ...

Page 51: ...0 4 Cover screw 8 703 401 170 5 Combustion cover 8 700 506 300 6 Combustion cover gasket 8 704 701 084 7 Observation window 8 705 600 003 8 Holding bracket 8 708 104 103 9 Screw 8 703 403 012 Table 21 10 Combustion cover clip 8 701 201 032 11 Grommet set 8 710 203 039 12 Exhaust accessory 8 705 504 151 13 Gasket exhaust 8 700 103 710 14 Inlet air cover 8 708 006 022 15 Inlet air gasket 8 700 103 1...

Page 52: ...e 1 Heat exchanger 8 705 406 422 2 Heat exchanger top gasket 8 704 701 052 3 Flue gas collector 8 705 700 153 4 Overheat sensor ECO 8 707 206 204 5 Heat exchanger bottom gasket 8 704 701 054 Table 22 6 Site window 8 701 000 401 7 Ignition group 8 701 302 249 8 Heat exchanger O ring 8 700 205 147 9 Rubber grommet 8 710 303 027 Item Description Reference Table 22 ...

Page 53: ...low temperature sensor 8 707 206 459 5 Washer 8 704 701 097 6 Fan mount nut 2 915 011 006 7 Secondary fan NG 8 707 204 094 7 Secondary fan LPG 8 707 204 072 8 Screw 8 703 403 012 9 Gas Air Mixer 8 705 700 170 Table 23 10 Air duct O ring 8 700 205 149 11 Venturi 8 700 306 226 12 O ring 8 700 205 224 13 Mixer Fan gasket 8 704 701 059 14 Screw 2 910 642 150 15 Plate gasket 8 701 004 049 16 Air supply...

Page 54: ... tapping 8 703 404 219 3 Washer 8 700 203 041 4 Pressure balance tube 8 700 703 136 5 Pressure balance nut 8 703 300 041 6 Gas supply pipe 8 700 715 389 7 Gas valve washer 8 700 103 014 Table 24 8 Gas filter 8 700 507 002 9 Gasket 8 704 701 085 10 Gas Fan connector 8 705 202 140 11 Washer 8 704 701 062 12 Regulation screw 8 703 404 220 13 O ring 8 700 205 009 14 Screw 2 910 149 181 Item Descriptio...

Page 55: ...4 Pipe connection clip 8 701 201 028 5 Hot water pipe 8 700 715 469 6 Temperature sensor 8 700 400 015 7 Outlet fitting 8 703 305 349 8 Inlet Outlet washer 8 710 103 045 9 Wireform spring 8 701 300 025 Table 25 10 Inlet fitting with filter 8 703 305 356 11 O ring 8 700 205 157 12 Watervalve clip 8 716 102 607 13 Water filter 8 700 507 059 14 Washer 8 700 103 764 15 O ring 8 700 205 231 Item Descri...

Page 56: ...les 8 704 401 371 5 Power supply cord 8 704 401 378 6 Fan cables 8 704 401 347 7 Wire harness 8 704 401 348 8 Jumper 8 704 401 376 Table 26 9 Electrode cables 8 704 401 346 10 Flue gas limiter 8 700 400 032 11 Cascading kit optional 7 709 003 617 12 Freeze prevention kit 7 709 003 665 13 Remote control optional 8 707 207 153 14 Shaped seal optional 8 700 201 012 15 Screw optional 8 703 401 109 16 ...

Page 57: ...ronment Packing The packing box may be fully recycled as confirmed by the recycling symbol Components Many parts in the heater can be fully recycled in the end of the product life Contact your city authorities for information about the disposal of recyclable products ...

Page 58: ...ized unsoftened water supply All Other Parts If any other part fails within five 5 years after original installation and operation Bosch Thermotechnology Corp will furnish a replacement part free of charge 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 warr...

Page 59: ...6 720 680 223 Limited Warranty 59 ...

Page 60: ...is located on rating plate on right side panel Gas Pressure Reading Static__________ Operating__________ Building Water Pressure __________ Range if on Well system __________ Installing Company _____________________________________________ Installer name _____________________________________________ Address _____________________________________________ Phone _______________________________________...

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Bosch Evolution 500, Instruction Manual

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