Bosch Greentherm 9800 SE 160/199 Manual Download Page 63

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6 720 816 815 (2016/10)

Greentherm 9800 SE 160/199 | SEC 199

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Summary of Contents for Greentherm 9800 SE 160/199

Page 1: ...sistanceoradditionalinforma tion 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 you smell gas Turn off the gas shut off valve Open windows and...

Page 2: ...of the fuses in control unit 37 6 Operating Instructions 37 6 1 For your safety read before operating your water heater 38 6 2 Power 38 6 3 Error code reset 38 6 4 Temperature selection 38 6 5 Information Adjustments menu 40 6 6 Service menu AU Authentication 44 6 7 Factory default settings 44 6 8 Water actuators calibration 44 6 9 Gas type 45 7 Maintenance and service 46 7 1 Annual maintenance 46...

Page 3: ...issioning In the Commonwealth of Massachusetts the water heater must be installed by a licensed plumber Donotinstallthisdeviceinroomswithahighmoisturelevel e g bathrooms saunas Function To ensure that the water heater functions properly follow these installation and maintenance instructions Never close the blow off line of the T P safety valve For safety reasons water may escape during heating If ...

Page 4: ...em has been disconnected from the power supply Risk of scalding at the hot water fixture When the water heater is in operation temperatures in excessof120 F 49 C canoccur Tolimitthetemperature at the tap install a thermostatic DHW mixing valve Water heated for washing the laundry dishes and for other cleaning purposes can cause scalding and permanent injuries Children disable and elderly are at hi...

Page 5: ...ode CSA C22 1 Part 1 DANGER Electric shock Shock hazard line voltage is present Before servicing the water heater unplug power supply cord from outlet Failure to do so could result in severe personal injury or death WARNING Damage to the appliance from over pressure The heater must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures equal ...

Page 6: ... after servicing WARNING System damage If a relief valve discharges periodically this may be due to thermal expansion in a closed water supply system Contact the water supplier or local plumbing inspector on how to correct this situation Do not plug the relief valve WARNING Personal Injury from toxic chemicals Toxic chemicals such as those used for boilertreatment shallnotbeintroduced into the pot...

Page 7: ...agnostics and repair Real time diagnostics for troubleshooting informational purposes Built in freeze prevention Integrated siphon to limit condensate freezing in external condensate pipes Available common vent kits more information at www boschheatingandcooling com Accessories Bosch part Neutralizer Kit 7738001483 Wi Fi module 802 11 b g n 2 4 GHz 1 Source Moritz A R and Henriques F C Jr 1947 Stu...

Page 8: ... Control2 Residential models Selection range F C 100 1203 38 49 100 1203 38 49 Commercial models Selection range F C 100 180 38 82 Default temperature F C 120 49 120 49 Temperature stability4 F C 2 1 2 1 Gas Requirement Gas connection inches Peak load inlet gas pressure5 Propane water column 8 13 8 13 Natural Gas water column 3 5 10 5 3 5 10 5 To assure maximum heat input at maximum vent length mi...

Page 9: ...ge operation A 2 5 2 5 Water protection7 IP X4D X4D 1 Input rating is based on sea level operation and need not be changed for operation up to 2000 ft 610 m elevation For operation atelevationsabove2000ft 610 m inputratingisautomaticallyreduced attherate of4percent US or10 percent Canada for each 1000 ft 305 m above sea level 2 With constant flow 3 Can be reprogrammed to achieve 140 F 60 C 4 Requi...

Page 10: ...al can be downloaded at www boschheatingandcooling com The Greentherm 9800 SE SEC are not approved or designed for Manufactured mobile homes boats or any mobile installation Modular homes are acceptable for installation Use above 10500 ft A S L altitude Applications where inlet water temperature is higher than140 F 60 C forResidentialappliancesor160 F 71 C for Commercial appliances In these applic...

Page 11: ... VENTgasfiredwaterheaterinstallationsinbathrooms bedrooms oranyoccupied roomsnormally keptclosed See chapter 4 6 page 15 4 Youmustcorrectlyventyourheater Seechapter4 6 page 15 on VENTING 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 va...

Page 12: ...6 720 816 815 2016 10 Greentherm 9800 SE 160 199 SEC 199 12 Appliance details 3 5 Dimensions and minimum installation clearances Fig 5 Dimensions ...

Page 13: ...xhaust gases Follow the guidelines below 1 Locate the heater where venting gas and plumbing connections are feasible and convenient 2 Thehotwaterlinesshouldbekeptshortandinsulatedto save energy It is recommended to locate the water heater as close as practical to the most frequently used hot water fixtures Greentherm 9800 SE SEC TOP A 12 FRONT B 1 BACK 0 SIDES 1 FLOOR C 12 Table 4 Required minimum...

Page 14: ...riscoldand alwaysremainscoldexceptforthetimes the burner is on In the event of power outage in conjunction with freezing temperatures the heater should be drained See chapter 7 2 page 47 Winterizing for draining instructions WARNING Flammable materials gasoline pressurized containers or any other items or articles that are potential fire hazards must NOT be placed on or adjacent to the heater The ...

Page 15: ...terial mayresultindangerousfluegasesfilling the structure in which it is installed NOTICE Installations resulting in negative pressure back draft require sealed combustion twin pipe concentric Damage caused from back draft ie freezing is not covered by warranty NOTICE Appliance malfunction Protect the exhaust and inlet from leaves and debris by installing a screen on the end of the termination mes...

Page 16: ...pipe into the exhaust adapter The exhaust pipe must be properly supported and mustbe pitcheda minimum of a inchperfoot back to the appliance This allows the condensate to drain properly Maximum vent lengths and equivalent lengths per table 8 apply Item Material United States Canada Vent or air intake pipe and fitting PP flexible M G Duravent Centrotherm IPEX Thermoplastic vent pipe must be certifi...

Page 17: ... Core PVC CPVC 90 short sweep elbow h h 5 Charlotte Comply with CAN CGA B149 1 ULC S636 2 3 and 4 SCH 40 Solid Core PVC CPVC T terminal w vent screen h h 5 Charlotte Comply with CAN CGA B149 1 ULC S636 2 3 and 4 SCH40 Solid Core PVC CPVC straight pipe h h 1 IPEX 196005 2 by 16 long PVC Concentric termination h h Exhaust 1 5 Intake 20 IPEX 196105 2 by 28 long PVC Concentric termination h h Exhaust ...

Page 18: ...Royal Plumbing Solutions 52SWVKGVS6502 2 GVS 65 Side Wall Vent Termination Kit h Exhaust 0 Intake 5 Manufacturer Manufacturer part number Product description Diagram Horizontal Vertical Equivalent Lengths Ft Duravent M G 810009685 810009713 810009745 2 PP Twin pipe termination 3 PP Twin pipe termination 4 PP Twin pipe termination h Exhaust 2 Intake 2 Duravent M G 810009684 810009712 2 PP Single Ho...

Page 19: ...take 5 Centro therm ICRT3539 3 x 5 Concentric Roof Termination h Exhaust 10 Intake 10 Centro therm ICWT242 2 x 4 Concentric Wall Termination h Exhaust 4 Intake 4 Centro therm ICWT352 3 x 5 Concentric Wall Termination h Exhaust 6 Intake 6 Ecco Manu facturing 190288 2 PP Concentric Terminations Horizontal Wall Terminations h Exhaust 4 Intake 4 Ecco Manu facturing 190388 3 PP Concentric Terminations ...

Page 20: ...The table 8 displays the maximum allowable straight pipe lengths for combustion air and exhaust piping Reduce the maximum allowable pipe length by the equivalent lengths for each elbow used and termination used PROPER GAS PRESSURE The following section assumes the water heaterwillreceivegreaterthanorequalto5 WC In cases of gas pressure below 5 WC andlongventruns thewaterheater soutput power may be...

Page 21: ...from the center line of the terminal E Clearance to unventilated 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 91cm within a height 15ft 4 6m abovethemeter regulator assembly I Clearance to service regulator vent outlet 36 in 91cm J Clearance to nonmechanical air supply inlet to building or th...

Page 22: ...of the terminal E Clearance to unventilated 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 91cm within a height 15 ft 4 6m above the meter regulator assembly I Clearance to service regulator vent outlet 36 in 91cm J Clearance to nonmechanical air supply inlet to building or the combustion air i...

Page 23: ...ust 2 Intake A 12inches 305mm 18in forCanada abovemaximum snow level or at least 24 inches 610 mm whichever is greater B 12 inches 305 mm C 12 inches 305 mm minimum above air intake opening NOTICE Using a single pipe vent in cold climates puts the water heater at risk of freezing asnegativeairpressureiscommon in buildings during cold weather This situation will pull cold air through the heat excha...

Page 24: ...m whichever is greater Fig 15 Horizontal venting system sealed combustion 1 Intake 2 Exhaust Fig 16 Vent and combustion air pipe position of a sealed combustion system 1 Intake 2 Exhaust X At least 1foot 305mm NOTICE Place pipe supports every 5 feet 1525mm of horizontal and vertical run beginning with support near water heater Periodic cleaning of the vent terminal and air intake screens is mandat...

Page 25: ...condensate drain outlet on the water heater and piped for disposal in accordance with local codes To install the condensate drain connect a NPT adapter on the water heater Fig 19 Appliance drain installation 1 Condensate drain connection With Flex Pipe the maximum length is reducedby60 appliesonlytothesection in flex PP Example 10 feet of flex PP is equivalent to 25 feet of rigid PP Flex Pipe acco...

Page 26: ...ithin 12 inches 304 8mm of the top and one commencing within 12 inches 304 8mm of the bottom of the enclosure Each opening must have a minimum free area of one square inch per 1000 BTU hr 292 81 Watts if all air is taken from inside the building 2000 BTU hr 585 62 Watts if allair is takenfromthe outside by horizontal ducts 4000 BTU hr 1171 24 Watts if all air is taken from the outside by direct op...

Page 27: ...ents see chapter 7 4 7 1 Natural gas 4 7 2 Liquid propane gas after gas conversion If gas conversion is needed Natural Gas to Liquid propane gas see section 6 9 The appliances must not be operated if the dynamicgaspressureislessthan3 5 WCor greater than 10 5 WC The appliances must not be operated if the dynamic gas pressure is less than 8 WC or greater than 13 WC DANGER The gas type conversion mus...

Page 28: ...ect for leaks GAS LINE SIZING The gas supply piping for a single heater should be sized for a maximum draw of 199000 BTU hr for Greentherm 9800 SE SEC 199 Measure the length of the gas supply line from the building sgasmaintotheheaterandusethechapter4 8 1and 4 8 2 or the gas line manufacturer s sizing tables to determine the pipe diameter necessary If there are more gas appliances on the line size...

Page 29: ...WC or 138 mbar and a pressure drop of 3 0 W C 7 5 mbar based on 0 60 specific gravity gas Maximum pipe capacity in cubic feet of Natural Gas per hour for gas pressures of 2 0 psig 55 WC or 138 mbar and a pressure drop of 3 0 W C 7 5 mbar based on 0 60 specific gravity gas EHD EquivalentHydraulicDiameter Thegreaterthevalueof EHD the greater the gas capacity of the tubing Initial Supply Pressure of ...

Page 30: ...ginThousandsofBTU hrofUndilutedLiquefied 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 Pipe Sizing Between Single or Second Stage Low Pressure Regulator and Appliance Nominal Iron Pipe inches Internal Diameter inches ...

Page 31: ...e the integrated port to install the PRV see Fig 21 1 Support all piping Fig 21 Plumbing Connections with shutoff valves and Pressure Relief Valve 4 10 Water connections When facing the heater the cold connection is on the top right and the hot connection is on the top left Fig 22 1 Cold connection 2 Hot connection Description Max Levels pH pH 6 5 8 5 TDS total Dissolved Solids mg l or ppm 690 Tot...

Page 32: ... well system with a pressure tank the lowest pressure range setting recommended is 30 45 psi 2 06 3 1bar 4 11 Domestic hot water recirculation with external pump Direct recirculation through the tankless water heater is permissible however theheatexchangerwarrantyisreduced see warranty at www boschheatingandcooling com The following drawing is provided to illustrate one possible recirculation desi...

Page 33: ...re approved for use in combination DHW and space heating applications open loop setup These water heaters are not approved for use in space heating only applications closed loop setup Bosch supports applicationsofcombinationDHWandspaceheatinginanopen loop configuration if plumbed similar to Fig 26 Please see warranty document for additional details Recirculationapplicationshowedinfig 25is for Gree...

Page 34: ... Gas supply 5 Shut off gas valve 6 Thermal expansion tank as required 7 Air purge 8 Cold water supply 9 Check valve 10 Thermostatic mixing valve 11 Thermometer optional 12 DHW outlet 13 Thermostat 14 Air handler 15 Check valve 16 Shutoff valve 17 Circulation pump only required if air handler doesn t includes internal pump 18 Relay only required if air handler doesn t includes internal pump ...

Page 35: ...5 0 5 5 6 0 6 5 7 0 7 5 8 0 8 5 9 0 9 5 10 0 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 Pressure Drop psi Water Flow GPM 6720813634 37 1V 0 4 6 9 2 13 9 18 5 23 1 27 7 32 3 37 0 41 6 46 2 50 8 55 4 60 1 64 7 69 3 73 9 78 5 83 2 87 8 92 4 97 0 101 6 106 3 110 9 115 5 120 1 124 7 129 4 134 0 138 6 Feet of Head ...

Page 36: ...ghten the screw inside test point fitting Depending on the vent length gas pressures below 5 W C for Natural Gas or 8 W C for LPG may result in reduced power outputor possible error codes and must be corrected See Gas Connections chapter 4 8 page 28 Fig 28 Gas pressure test port 1 Gas pressure measuring port 5 Electrical connections 5 1 Electrical power supply The water heater requires an electric...

Page 37: ... the control unit Press the four snaps of the control unit and remove the cover Fig 30 Control Unit Press the four snaps inside the control unit andremove the PCB Check the fuse on the printed circuit board for electrical continuity see fig 31 1 Fig 31 Fuse position 1 Fuse After checking the fuse reinstall all parts in reverse order 6 Operating Instructions Fig 32 Touch control display 1 LCD displ...

Page 38: ...plosion C Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the applianceandtoreplaceanypartofthecontrolsystemandany gas control which has been under water 6 2 Power To turn ON the appliance Touch and hold symbol for more than 3 sec The LCD display shows the selected temperature When the burner is on the display shows symbol Fig 3...

Page 39: ...inking the default set point temperature is saved in memory Selecting the default setpoint temperature In order to select the default setpoint temperature Touch the OK button Display shows the default setpoint temperature which is now the hot water selected setpoint temperature 6 4 2 Solar Mode The water heater will not ignite if the inlet water temperature exceeds the set point temperature minus ...

Page 40: ... NTC current water temperature of the heat exchanger Inlet NTC current temperature of the temperature sensor of the water inlet tube Outlet NTC current temperature of the temperature sensor of the water outlet pipe Fan Speed current fan speed Flow total flow through main valve bypass Output Power current power Ambient NTC current temperature inside cabinet near the fan Exhaust Gas NTC Exhaust gas ...

Page 41: ... the Date Use the symbols or to choose the Date menu Display shows Date menu MM DD YYYY Touch the symbol Use the symbols or to set the month Touch the symbol when month is correct Use the symbols or to set the day Touch the symbol when the day is correct Use the symbols or to set the year Touch the symbol when the year is correct Touch the symbol to exit the Date menu Clock and Date are defined To...

Page 42: ...Touch the symbol to select OFF Recirculation will not be active A2 Vacations Set Vacation time Touch the symbol Display shows Vacation menu Use the symbol to choose On On starts to blink Touch the symbol to define first day of vacation MM DD YYYY Use the symbols or to set the month Touch the symbol when month is correct Use the symbols or to set the day Touch the symbol when day is correct Use the...

Page 43: ...s Access to information adjustments menu Display shows SA Settings Touch the symbol until A9 Units is in the display Touch the symbol Usethesymbols or toselectmeasurementunits Metric C l min Imperial F gal min Touch the symbol after selecting the desired units The selected units blinks display indicates A9 Units AA Display Timeout Fig 42 AA Backlight Control Activationofbrightnesscontrolincreasese...

Page 44: ...Calibration U1 L1 Auto Adjustment U2 L2 Auto Adjustment 6 7 Factory default settings Restore factory values for P1 Max Power Access to menu P1 Max Power Touch symbols or to select Reset Parameters Touch the symbol The display blinks to confirm change Touch the symbol The factory default values for P1 are restored Restore factory values for P2 Max Power Access to menu P2 Min Power Touch symbols or ...

Page 45: ... plate in grey color Fig 44 Gas manifold Remove metal plate and seal The 3 restrictor plates should be pre assembled onto their tray but if loose in box follow installation instructions as shown in fig 45 1 Insert the LP conversion plate in the appropriate location shown in Fig 45 2 Fig 45 Gas conversion kit Tighten the four screws Open the gas supply valve Turn On the appliance The display shows ...

Page 46: ...heexhaustsystemandcombustionairsupplymeets the manufacturer s specifications Pressure Relief Manually open the pressure relief valve to ensure proper operation Inlet Water Filter Verify the inlet water filter screen is clean and undamaged The inlet water filter is located on the top of the appliance at the cold water inlet connection See Fig 23 page 32 Closetheinstallersuppliedwatershutoffvalveand...

Page 47: ...onnection of the heater 7 Empty condensate trap 8 Reconnect the water fittings and return the heater to service when danger of freezing has passed 7 3 Mineral scale build up Periodicdescaling may benecessaryinareaswithhighmineral content in the water Scale buildup in the heat exchanger may result in lower flow rates error codes of A1 and A5 and boiling sounds in the heat exchanger A water softener...

Page 48: ...ater flow hot water demand through the heater to determine if the heater activates with higher flow 5 Clean the inlet water filter screen per chapter 4 10 page 31 6 Inspect the water path for obstructions Make sure all shower heads faucet aerators and whole house filters are clear of debris 7 Check fora plumbing crossover A crossover in the hotand cold plumbing pipes creates back pressure on the w...

Page 49: ...oohighforthe demanded flow rate the water heater will close its motorized water valve reducing the hot water flow rate in an attempt to reach the selected output temperature Loweringtheselectedtemperaturewillallowthemotorized water valve to open up for increased water flow rate 4 Clean the inlet water filter screen as instructed in chapter 7 1 page 46 5 Inspect the water path for obstructions Make...

Page 50: ...be done by a certified gas technician with a calibrated combustion gas analyzer 8 8 Manifold gas pressure Turn Off the appliance Remove the front cover of the appliance see page 10 Fig 47 Pressure head points A Air pressure head in the box B Gas pressure head in the burner C Tee installer supplied Loosen the set screw of the pressure head point B Connect the pressure gauge connection to the test p...

Page 51: ...o P2 open more hot water fixtures to allow sufficient flow and access to P1 menu Touch symbols or to select U1 L1 Auto Adjust NOTICE Before adjusting Gas Air flow turn off any backup appliance example solar to avoid high inlet water temperature Appliance is pre adjusted by default with factory parameters gas air adjustment is required in Natural Gas installations where energy content is less than ...

Page 52: ...ease Wait a few minutes until stabilize Touch symbols or to select U2 L2 Auto Adjust Touch the symbol The appliance will start the auto adjustment of the minimum gas flow Fig 50 L2 gas adjust value Record the L2 gas adjust value in table 23 after check mark symbol appears in the display Touch the symbol to finish the L2 Gas adjust Touch symbols or to select P2 Min Power Touch the symbol to enter P...

Page 53: ...0 ppm min input P2 2 9 3 1 30 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 24 CO2 CO target numbers CO2 range Max CO level measured Greentherm 9800 SE 160 000 BTU Nat Gas ...

Page 54: ...t A2 Tank temperature sensor is not properly installed Temperature sensor fault Check temperature sensor and associated connections 1 2 Check sensor position in the tank pocket Check recirculation sub menu in HMI A3 Flue gas temperature sensor fault Check connections or replace sensor 1 2 A4 Cabinet air temperature sensor fault Check connections or replace sensor 1 2 A5 Primary heat exchanger gas ...

Page 55: ...ure sensor detects high temperature 194 F Let the appliance cool down and try again 1 Check sensor resistance 1 E4 Temperature inside the cabinet is above 194 F Check for flue gas leakage inside the cabinet Let the appliance cool down and try again 1 Check sensor resistance 1 E5 Copper heat exchanger gas temperature sensor detects temperature above 392 F the appliance is locked Descale appliance 1...

Page 56: ...fold shut off valve Main gas shut off valve or gas manifold shut off valve mechanical stuck locked Check main gas shut off valve and gas manifold shut off valve electric circuit FC Buttons touched for more than 30s Release the button DisplayreadsSOLAR but without existence of solar thermal system The hot water temperature selected is lower than the minimum power that the appliance supplies Minimum...

Page 57: ...6 720 816 815 2016 10 Greentherm 9800 SE 160 199 SEC 199 Electrical diagram 57 10 Electrical diagram Fig 51 Electrical diagram ...

Page 58: ...s valve 9 Electrovalve 3 10 Electrovalve 1 11 Electrovalve 2 12 Gas valve Solenoide safety 13 Thermofuse 14 Water flow sensor 15 Exhaust temperature sensor 16 Exhaust temperature sensor Between chambers 17 Water outlet bypass temperature sensor 18 Cabinet temperature sensor 19 Water outlet HC temperature sensor 20 Water inlet temperature sensor 21 Tank temperature sensor 22 Water valve 23 Cascadin...

Page 59: ...ack flow and exhaust gas NTC characteristic 40 22 4 14 32 50 68 86 104 122 140 158 176 194 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 212 230 248 0 1 1 100 RESISTANCE KOHM TEMPERATURE ºF ºC 6720816948 40 1V 10 40 4 32 68 104 140 176 212 284 320 392 428 464 40 20 0 20 40 60 80 100 140 160 200 220 240 248 120 356 180 0 01 0 1 1 10 100 RESISTANCE KOHM TEMPERATURE ºF ºC 6720816948 41 1V ...

Page 60: ...g 54 199 000 Btu components 1 Inlet water filter 2 Air fan 3 Control unit 4 Gas manifold 5 Burner 6 Heat exchanger 7 Condensing unit 8 Main water valve 9 By pass pipe 10 HE drain 11 Power cord 12 Gas connection 13 Condensate drain 14 HE drain 15 Gas valve 16 Condensate trap 17 By pass water valve 18 Ionization sensor 19 Ignition electrodes 20 PRV connection ...

Page 61: ...u components 1 Inlet water filter 2 Air fan 3 Control unit 4 Gas manifold 5 Burner 6 Heat exchanger 7 Condensing unit 8 Main water valve 9 By pass pipe 10 HE drain 11 Power cord 12 Gas connection 13 Condensate drain 14 HE drain 15 Gas valve 16 Condensate trap 17 By pass water valve 18 Ionization sensor 19 Ignition electrodes 20 PRV connection ...

Page 62: ...e precise water flow needed mixing cold water to regulate temperature will increase the water flow with consequent waste of water 14 Installer Checklist to be completed by installer upon installation Serial Number1 1 Serial number is located on the rating plate which is located on the right side of the appliance cabinet ___ ___ ___ ___ ___ ___ ___ ___ Gas Pressure Reading 2 2 See Chapter 4 13 and ...

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