Bosch Appliances 2400E NG manual

MO DE L 24 0 0E NG and 24 0 0E LP - I N D OO R M OD E L T emperat ure Modulated wit h Elec tronic Ignit ion Suit able for heating pot able wat er only Not approved for spac e heating purpose s (Intended for variable flow applications) 2400 E NG - Natural Gas 2400 E LP - Liquefied Petroleum (LP) Gas 6 720 608 263 US (06.11 ) JS Warning: If the infor[...]

6 720 608 263 2 Index Index 1W a r n i n g 2 2 Appliance details 4 2.1 Features 4 2.2 2400 E Specific ations (Technical data) 4 2.3 Dimensions and Minimum installa tion clearances 6 2.4 General rules to follow for safe o peration 7 2.5 Proper location for in stalling your heater 7 2.6 Clearance s 8 2.7 Mounting installation 8 2.8 Combustion air req[...]

6 720 608 263 Warning 3 What to do if you smell gas • Close gas valve. Open wi ndows. • Do not try to light any appliance. • Do not touch any electri cal switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructi ons. • If you cannot reach your gas s[...]

6 720 608 263 4 Appliance details 2 Appliance details 2.1 Features Parts • Touch Pa d interface co ntrol • High power pre-mix compact burner with low Nox emissions • Modulating Gas Valve with constant gas:air ratio control • Modulating water valve for improved comfort and temperature control. Safety • Flame sensor (ionizat ion) rod • Ov[...]

6 720 608 263 Appliance details 5 Combustion •N O x ≤ 55 ppm •C O ≤ 250 ppm •C O 2 level set from factory, see chapter 9. Dimensions • Depth (in): 8 ½” (220 mm ) • Width (in): 15 ¾” (400 mm) • Height (in): 23 ½” (600 mm) • Weight: 47 pounds (21 kg). Gas types Natural Gas. LP Gas. Converting the gas type can onl y be done [...]

6 720 608 263 6 Appliance details 2.3 Dimensions and 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” VENT DIAMETER 3” Table 1 Minimum clearances[...]

6 720 608 263 Appliance details 7 2.4 General rules to follow for safe operation B 1. You should follow these instruct ions when you install your heater. In the United States: The installation must conform with local codes or, in t he absence of local c odes, the National Fuel Gas Code ANSI Z223.1/NFPA 54. In Canada: The Installati on should confor[...]

6 720 608 263 8 Appliance details 2.6 Clearances The 2400 E is design certified for installation on a combustible wall (see 2.7 Mounting installation) provided the floor covering below the heater is noncombustible. For instal lations in an alc ove or closet, maintain the minimum clearanc es to combustible and non-combustible materials listed below.[...]

6 720 608 263 Appliance details 9 construction, infiltration air i s normally adequate to provide air for combustion. • Appliances located in confined spaces: The confined space must be provided with two permanent openings, one commencing within 12 inches (304.8mm) of the top and one commencing within 12 inches (304.8mm) of the bottom of the encl[...]

6 720 608 263 10 Appliance details The appliance should be loca ted as close to the point of termination as possible. The maximum vent le ngth is 26 feet (8 m) with one 90 degree elbow. Subtract 2½ feet from the total vent length for each additional 90° elbow used (a maximum of three 90° el bows are permitted in the total vent length), or subtra[...]

6 720 608 263 Appliance details 11 Note: reduce 2½ ft for each 90° elbow us ed after the first one, reduce 1 ¼ ft for each 45° elbow. Vent Safety System The 2400 E will shut down if inadequate exhaust venting is detected or a lack of combust ion air is provided to the unit; see troubleshooting sec tion on page 24. See error code to confirm erro[...]

6 720 608 263 12 Appliance details 2.9.1 Venting options Installing this water heater as a room sealed (TWIN PIPE SYSTEM) is the recommended method. Contact BBTNA or dealer for available vent termination k its and vent materials for th is water heater. Room sealed installation (TWIN PIPE SYSTEM) Fig. 12 Combustion air p ipe: ≤ 26 ft (8 m) Exhaust[...]

6 720 608 263 Appliance details 13 Recommended exhaust vent terminator position Fig. 16 * Subject to local codes and anticipated snow level ** Other equipment that operates with a mechanical air inlet may require greate r distan ces, reference manufacturer's in structio ns Ref. Description Minimum distance A Directly below an opening; ope rabl[...]

6 720 608 263 14 Appliance details Supporting the exhaust vent system Fig. 17 Horizontal side wall venting inst allation (combustion air piping not being shown) Fig. 18 Abov e the roof clearance requirements from rain cap (combust ion air piping not being shown) B A condensate drain tube must be attached to the exhaust collar of the heater for all [...]

6 720 608 263 Appliance details 15 Fig. 20 Vertical venting installation - Masonr y Chimney (combustion air piping not being shown) A condensate drain tube must be attached to the exhaust collar of the heater for all ven t type applications, see page 11. 2.10 Gas piping & connections Before connecting the gas supply , check the rating plate on [...]

6 720 608 263 16 Appliance details FOR NA TU RAL GAS Maximum Capacity of pipe in Cubic Feet of Gas per Hour for Gas Pressure of 0.5 Psig or less and a Pre ssure drop of 0.3 in Water Column (0.75mbar).(Based on a 0.60 Sp ecific Gravity Gas) Btu num bers given in thousands. Fig. 22 Follow boxed numbers for piping just one 2400 E (example : ¾” B.I [...]

6 720 608 263 Appliance details 17 2.11 Gas line sizing B It is strongly recomme nded that the Natu ral Gas pipe be Black Iron pipe the entire di stance from the outside meter to the inlet of the gas connection. ¾” Black Iron pipe up to 20 feet (6.1m) and 1” Black Iron pipe up to 70 feet (21.34m) distances . Flex line is NOT recommended, but i[...]

6 720 608 263 18 Appliance details HIGH ALTITUDE OPERATION 2.13 Water connections When facing the heater, the ¾” cold water inlet is on the bottom right and the hot water outlet is on the bottom left. Install the heater cen trally in the building if possible and make hot water piping runs as short as possible . Fig. 25 B THE USE OF A UNION WHEN [...]

6 720 608 263 Appliance details 19 2.14 Electrical connections The 2400 E requires an electri cal power supply from a 120VAC 60Hz circuit and must be properly grounded. A means for switching of f the 120VAC power supply must be provided. The heater is wi red as shown in the wiring diagram (chapter 6, Fig. 37). 2.15 Operating instructions B Before p[...]

6 720 608 263 20 Appliance details When the heater is in operation you will hear its power vent fan and burner operating. Upon turning off the hot water flow the power vent fan will continue to operate for up to 60 seconds to exhaust all fl ue gases. The power vents fan speed is variable depending on the rate of hot water used and the burner output[...]

6 720 608 263 Operation instructions 21 3 Operation instructions Fig. 27 1 On/Off switch 2 Reset button 3 Program Key 4 Increasing temperature s elector 5 Decreasing temperature sele ctor 6 LCD display 3.1 Power On B T o start the appliance switc h the button to position ( I ). LCD display the default te mperature - temperature factory setting 122?[...]

6 720 608 263 22 Operation instructions Setting the water temperature The desired temperature of the hot water can be adjusted on the front control panel of the heater. The 2400 E has an electronically controlled gas valve that modulates the burner in put in response to both varying hot water flow rates and/or cha nges in any i ncoming and outgoing[...]

6 720 608 263 Operation instructions 23 3.3 Use of remote control accessory Fig. 31 Remote control The wireless remote control accessory and the temperature selector butt ons on the front of the water heater operate identicall y. Contact your distributor or BBTNA to order if the remote control accessory is preferred. Modification of the water heate[...]

6 720 608 263 24 Maintenance and service 4 Maintenance and service The unit should be checked once a year by a gas technician. If repairs are neede d, the repairs should be done by a gas technician To remove front cover B Remove plastic decals on front panel (Page 5, Fig. 3). B Loosen the two Philips head screws locate d behind decals. B Lift front[...]

6 720 608 263 Troubleshooting 25 Test by following 4t h bullet under BURNERS DO NOT IGNITE WHEN HOT WATER IS TURNED ON. LOW WATER FLOW/PRESSURE • Too many hot water applications are bein g used simultaneously or too much flow is being demanded The 2400 E will effectively support two 2.0-2.5 gpm shower heads simultaneously or multiple sink applica[...]

6 720 608 263 26 Troubleshooting Display Cause Solution E9 Temperature limiter opened circuit (overheat). Trips at 220F (104C). Check connections.* Check heat exchanger condition.* EA No ionization during safety time (safety time out). Note: appliance makes 3 igniti on attempts before entering error mode “EA”. Check gas pressure.* Check that ga[...]

6 720 608 263 Electric al diagra m 27 6 Electrical diagram Fig. 37 Electrical scheme 1 Intlet water temperature sensor 2 Ionization sensor 3 Water flow sensor 4 Over heat protection 5 Temperature li miter 6 Gas valve 7 Fan 8 Water valve 9 AC Plug 10 Ignition electrode 11 Display PCB 12 ON /OFF switch 13 Fu se T 2,5A 14 Fu se T 3,15A 15 Te rminal bl[...]

6 720 608 263 28 2400 E Functional scheme 7 2400 E Functional scheme Fig. 38 Functional scheme[...]

6 720 608 263 Interior components diagram and parts list 29 8 Interior components diagram and parts list 8.1 Interior components Fig. 39 Components 1 Cover 2 On/Off switch 3 Reset button 4 LCD display 5 Program button 6 Temperatur e switches 7 Flue gas collector 8 Mixer 9 Heat exchang er 10 Obse rvation window 11 Inlet air duct 12 Control unit 13 E[...]

6 720 608 263 30 Interior components diagram and par ts list 8.2 Components diagram Fig. 41 Components Diagram[...]

6 720 608 263 Interior components diagram and parts list 31 8.3 Parts list Item Description Reference 1 Front cover 8 7 05 42 1 9 1 5 2 Shield 8 7 05 506 706 3 Heat exc hanger 8 7 05 406 285 4 Heat exchanger top gasket 8 7 04 70 1 052 5 Clip 8 7 1 6 1 02 607 6 Heat exchanger bottom gasket 8 7 04 70 1 0 54 7 O-ring 8 7 00 205 1 4 7 8 Temperature sen[...]

6 720 608 263 32 Special ad justment for measurin g and adjusting CO2 levels 9 Special adjustment for measuring and adjusting CO 2 levels The CO 2 can only be adjusted by a certified gas technician with a calibrated CO 2 analyzer. Static Gas Pressure: “ WC P1 Operating Pressure: “ WC The P1 minimum operating pressure is 5" WC for Natural G[...]

6 720 608 263 Special adjustment for measur ing and adjusting CO2 levels 33 D. Returning to Service: 1. Return slotted cover to original position. 2. Reinstall Torx cover. 3. Remove CO 2 analyze r probe a nd reinsta ll flat head screw in exhaust collar. 4. Turn ON/OFF switch to the OFF (O) positio n and then back to the ON (I) position. 5. Heater i[...]

6 720 608 263 34 Protecting the environment 10 Protecting the environment Packing The packing box may be ful ly recycled as confirmed by the recycling s ymbol . Components Many parts in the heate r can be fully re cycled in the end of the product life. Cont act your city auth orities for information about the disposal of recyclable products. Saving[...]

6 720 608 263 Twelve Year Limited Warranty 35 11 Twelve Year Limited Warranty General Aquastar w ater heaters are warranted by the Manufacturer (BOSCH) through BBT North America. BBT North America (BBTNA) will furnish a replacement heat exchanger and will furnish a replacement of any other part which fails in normal us e and service within the appl[...]

Recycled paper © 2006 BB T NOR TH A M E RICA, W aitsfield, VT all rights reser ved Replacement Parts available from : VU L CAN O T ermodomésticos S.A . Estrada de C acia 380 1 - 8 56 Aveiro - PO RTU GAL 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[...]