Bosch Appliances GWH 2400 ES NG manual

MO DE L G WH 24 0 0 E S NG and G WH 24 0 0 E S LP - IN DOOR MODE 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) GWH 2400 ES NG - Natural Gas GWH 2400 ES LP - Liquefied Petroleum (LP) Gas 6 720 608 782 US (20 08.01) A[...]

6 720 608 782 2 Index Index 1W a r n i n g 3 2 Appliance details 4 2.1 Features 4 2.2 GWH 2400 ES Specifications (Technical data) 4 2.3 Unpacking the GWH 2400 ES heater 5 2.4 General rules to follow for safe operation 6 2.5 Dimensions and Minimum installation clearances 7 3 Installation instructions 8 3.1 Tools required for installation 8 3.2 Intro[...]

6 720 608 782 Warning 3 1 Warning For your safety Do not store or use gasoline or other flammable, combustible or corrosive vapors and liquids in the vicinity of this or any other appliance. FCC: This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: (1) This device may not cause h armful interfere[...]

6 720 608 782 4 Appliance details 2 Appliance details 2.1 Features Parts • Key Pad interface control • 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. High quality material s for long working life • Co[...]

6 720 608 782 Appliance details 5 Call Bosch Water Heating through Bosch thermotechnology corporation for conversion instructions. Voltage 120 V AC (60 Hz) nominal Amperage Idle - 40 mA Operation - ≤ 2.5 A Noise 45 - 65 db (A) Safety devices • Flame failure device (ionization flame rod se nsor) • Pressure relief valve (supplied with heater) ?[...]

6 720 608 782 6 Appliance details To remove front cover B Loosen the two Philips head screws located on bottom rear of cover (see Fig. 3). Fig. 3 Loosen the two screws B Lift front cover panel upw ard and remove. Fig. 4 Removing the front cover To remove combustion cover (service only) B Open the four clips and remove the combustion cover see Fig. [...]

6 720 608 782 Appliance details 7 2.5 Dimensions and Minimum installation clearances Fig. 6 Dimensions 1 On/Off button 2 Reset button 3 Program key 4 Power ON or stand-by LED 5 LCD display 6 Up button 7 Down button Fig. 7 M inimum clearances Note: For servicing access, a 2ft clearance to front cover is recommended. Model GWH 2400 ES TOP (A) 12” F[...]

6 720 608 782 8 Installation instructions 3 Installation instructions 3.1 Tools required for installation • Philips head screwdriver • Flat head scre wdriver • Adjustable wrench • Level • Thermometer • Standard plumbing tools •M a n o m e t e r • Drill • Pipe wrench • Adjustable pliers • Pipe fitting t ools • Hacksaw with me[...]

6 720 608 782 Installation instructions 9 upwards towards termination ¼" for every foot of horizontal length, to prevent the pooling of condensate, and be supported at 4 foot intervals with overhead hangers. Exception: horizontal run between last elbow and termination must pitch down to termination 1/4" per foot. Note: For horizontal ter[...]

6 720 608 782 10 Installation instructions Recommended exhaust vent terminator position Fig. 10 * Subject to local co des an d anticipated snow level ** Other equipment th at operates with a mec hanical air in let may require greater distances, referen ce manufacturer's instructio ns NOTE: terminating exha ust vent under a deck is not permitte[...]

6 720 608 782 Installation instructions 11 Venting configuration examples Fig. 11 Horizontal side wall venting installatio n (combustion air p iping not shown) Important: Note: Pitch horizontal runs down toward the heater, except horizontal run between last elbow and termination which must slope down to termination 1/4" per foot. Note: For hor[...]

6 720 608 782 12 Installation instructions 3.3.2 Con densate drain requirements A condensate drain must be installed under the followin g conditions : • All vert ical terminating vent installa tions • Horizontal terminating vent installations where the total equivalent exhau st vent lengt h is greater than 10 feet. See table 17, page 33. • Ve[...]

6 720 608 782 Installation instructions 13 Fig. 18 Open combustion instal lation (SINGLE PIPE SYSTEM) Not recommended in cold cl imate areas, see chapter 3.4, page 15. Fig. 19 Connecting a one piece 90 degree elbow pi pe to the combustion air inlet adapto r is required. This w ill prevent debris or objects from fall ing into the appliance. The exha[...]

6 720 608 782 14 Installation instructions 3.3.3 Vent connection s B Attach the flue gas exhaust accessory (8 705 504 151) to the top of the unit (position 1) using th e 4 screws and gasket provided. Fully insert stainless steel vent pipe 1.5” minimum into the accessory and tighten the c lamp (position 2). Fig. 20 B Attach the combustion air inle[...]

6 720 608 782 Installation instructions 15 signage installed in accordan ce with the provisions of 248 CMR 5.08(2)(a)1 through 4. (b) EXEMPTIONS: The followi ng equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1. The equipment listed in Chapter 10 entitl ed "Equipment Not Required To Be Vente d" in the most current edition of NFPA [...]

6 720 608 782 16 Installation instructions below for providing ade quate combustion air for the water heater as well as any other appliances that may consume air in the space. Always follow local codes if they are more stringent. This Installation Manual speci fies the minimum exhaust vent length (Fig. 8, page 9) and the amount of combustion air re[...]

6 720 608 782 Installation instructions 17 If wall is sheathed with plaster or drywall, it is recommended that two support boa rds, either 1”x4” or 1/2" (minimum) plywood first be attached across a pair of studs, see Fig. 22. B Secure the wall mounting brac ket provided wit h the heater to the wall surface. The heat er must be kept level o[...]

6 720 608 782 18 Installation instructions INSTALLATION CODES and/ or local installation codes. GAS CONNECTIONS B Install a manual gas shut off valve on the gas su pply line within easy reach of the appliance . B Install a union when connectin g gas supply. B The minimum internal diameter required for any appliance connector is ¾”. B Undersized [...]

6 720 608 782 Installation instructions 19 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 Pressure drop of 0.3” in Water Column (0.75mbar).(Based on a 0.60 Specific Gravity Gas) Btu numbers given in thousands. Fig. 27 Follow boxed numbers for piping just one GWH 2400 ES ( e xamp[...]

6 720 608 782 20 Installation instructions 3.9 Water connections B When facing the heater, the ¾” cold connecti on is on the bottom right and the hot connect ion is on the bottom left. Centrally locating the wat er heater is recommended to keep hot water distribution ti mes even throughout the structure. Fig. 28 B The use of unions when conn ect[...]

6 720 608 782 Installation instructions 21 Connecting the pressure relief valve (P RV) A listed pressure relief valve su pplied with the heater must be installed at the time of install ation. No valve is to be placed between the PRV and the heater. No reducing coupling or other restriction may be installed in the discharge line. The discharge l ine[...]

6 720 608 782 22 Installation instructions 3.12 Measu ring gas pressure Confirm gas pressure u pon installation . Connecting manometer B Shut off gas supply at installer supplied shutoff valve for this water heater. B Remove front cover an d locate in let gas pressure measuring point (see Fig. 32). B Loosen screw inside left test point fitting (do [...]

6 720 608 782 Electrical connections 23 4 Electrical connections 4.1 Electrical power supply The GWH 2400 ES requires an electrical power supply from a 120VAC / 60Hz circuit (with a dedicated outlet) and must be properly grounded. The heater is wi red as shown in the wiring diagram (chapter 9, Fig. 58). Fig. 33 Connecting power supply cord 1 Power [...]

6 720 608 782 24 Operation instructions 5 Operation instructions Fig. 36 1 On/Off button 2 Reset button 3 Program Key 4 LCD display 5 Up button 6 Down button 7 LED - Power On indicator or Stand-by 5.1 LCD Display functions Fig. 37 Power bar indicator Fig. 38 Temperature indicator Fig. 39 Error indicator Fig. 40 Lock indicator Fig. 41 Flame indicato[...]

6 720 608 782 Operation instructions 25 5.2 For your safety read before operating your water heater A. This appliance is equipped wi th electronic igniti on for lighting the main burner. When turning the heater on, follow these instructions exactl y. B. Before operat ing the unit, pr ess the On/Off button. WHA T T O DO I F Y O U S M ELL GAS B Do no[...]

6 720 608 782 26 Operation instructions 5.5 Use of optional remote control accessory (part no. TSTAT2) Fig. 45 Remote control The wireless remote control accessory (Fig. 70, component 13) and the temperatur e selector buttons on the front of the water heater operate identicall y. Contact your distributor to order the remote control accessory. Modif[...]

6 720 608 782 Maintenanc e and service 27 6 Maintenance and service The unit should be checked once a ye ar by a gas technician. If repairs are needed, the repairs should be done by a g as technician . 6.1 Annual maintenance (To remove front cover, see page 6.) Venting System • Venting system - inspe ct inside of flue pipe for any blockage or res[...]

6 720 608 782 28 Maintenance and service such as anti-freeze is not permitted as they may cause damage to the water heater's internal components. 1. Press ON/OFF switch on the water heat er to turn OFF the heater and unplug power supply cord. The display should be blank. 2. Shut off gas supply to heater. 3. Shut off the water supply to the wat[...]

6 720 608 782 Maintenanc e and service 29 adjusting CO 2 until pressure i s at or above these level s, but not to exceed 10.5” WC for Natural Gas and 13” WC for Propane. A. Once Gas Pressure is adequate B Press ON/OFF button to turn off the heater. B Remove brass flat head sc rew on the exhaust collar as seen in Fig. 53. B Insert CO 2 analyzer [...]

6 720 608 782 30 Maintenance and service Final Readings P2 CO 2 Reading: % CO 2 P1 CO 2 Reading: % CO 2 Fig. 55 Adjusting P1 CO 2 level Fig. 56 Adjusting P2 CO 2 level CO 2 range (%) Max. CO level (measured) Nat. Gas max. input P1 6.9 % - 7.5 % < 250 ppm min. input P2 2.3 % - 2.6 % < 60 ppm LP Gas max. input P1 8.1 % - 8.7 % < 250 ppm min.[...]

6 720 608 782 Maintenanc e and service 31 6.5 Program values This section describes detai ls on programming the appliance. For most applications the factory default values will robust and stable operation. On ly adjust the factory settings if the install ation requires changes as indicated in the appropriate section of thi s manual. Refer to chapte[...]

6 720 608 782 32 Maintenance and service 6.6 Control board diagnostics 1. Turn on/off switch on water heater to off ( O) position. 2. Press and hold the program ( ) button while turning the on/off switch to the on (I) position. The display will cycle through a startup procedure including the software version. 3. Release the ' ' button whe[...]

6 720 608 782 Maintenanc e and service 33 6.7 Fan speed adjustment Installation adjustment: Fl ue pipe length setting for minim um pow er - P2. After installing the GWH 2400 ES, the minimum power fan speed must be selected to compensat e for variation in vent pipe length. Total vent length calculation B Determine the total l ength of all straight s[...]

6 720 608 782 34 Maintenance and service To select fan speed: B Press ON/OFF button into OFF. B Press and hold "Program" button and press ON/OFF button to turn appliance ON. Fig. 57 B As soon as '188' is di splayed, release "Progr am" button , and the display should read P2. B Press or to choose the fan speed suitable [...]

6 720 608 782 Troubleshooting 35 7T r o u b l e s h o o t i n g 7.1 Introduction Many of the questions customers ask regarding operation of this unit can be answered by following the troubleshooting steps as outlined bel ow. Visit our web site at www.boschhot water.com for more detailed troubleshooting and servic e bulletins. For best resul ts, per[...]

6 720 608 782 36 Troubleshooting the heater. Wait 10 minutes and che ck all taps for water flow. There should be no water flowing. Any continuous flow of water, small or large, indicates a crossover and must be corrected. Consult a professiona l plumber for help i n correcting a crossover. Failing single lever faucets and mi xing valves are common [...]

6 720 608 782 Troubleshooting 37 out of adjustment. This will result in unstable burner flames and noise. Ensure gas pressure is in accordance with specifications in section 3.12, page 22 Measuring Gas Pressure. A gas pressure reading is needed to proceed furthe r. Contact you r original installer or a local certified gas techn ician to obtain this[...]

6 720 608 782 38 Problem solving 8 Problem solving 8.1 Error code diagnostics i To remove erro r code from the display, press the reset button. Display Cause Solution Fault in the flue gas limiter. 1. Check co ntinuity of the flue gas limiter (see Fig. 63 , page 46 ). Go to steps two and three to determ ine air box temperature sensor fault and repl[...]

6 720 608 782 Problem solving 39 (Flashing) Outlet temperature sensor not sensing expected output temperature. 1. Check that the sensor is firmly attached to the hot water pipe (see Fig. 69 , page 52 ). 2. Clean inlet filter screen and c lear any debris out of shower heads, faucet aerators and whole house filters. 3. Check venting specifications ar[...]

6 720 608 782 40 Problem solving Over-temperature detected by outlet temperature sensor on hot water pipe. Temperature > 185 °F 1. Check that the sensor is firmly attached to the vertical section of the hot water pipe (see Fig. 69 , page 52 ). 2. Check red wire connections at outlet temperature sensor. Clean terminals with an eraser. If badly c[...]

6 720 608 782 Problem solving 41 No flame ionization detected with water flow . 1. Verify that all manual gas shut off valves are open. 2. Check gas type, see Fig. 2 , page 5 . 3. Reset error code and open a water tap to cycle the heater in an effort to purge air o n new installations. Cycling hot water tap on and off multiple times may be necessar[...]

6 720 608 782 42 Electrical diagram 9 Electrical diagram Fig. 58 Electrical scheme 1 Intlet water tempera ture sensor 2 Outlet water temperature sensor 3 Exhaust temperature sensor 4 Cascading output connection 5 Cascading input connection 6 Ionization sensor 7 Water f low se nsor 8 Flue gas limiter 9 Heat Exchanger Overheat Sensor (ECO) 10 Gas val[...]

6 720 608 782 Sensor resistance charts 43 10 Sensor resistance charts Fig. 59 Fig. 60 O ut l et t em per at ur e sensor char act er i st i cs 32 37 42 47 52 57 62 67 72 77 82 87 92 97 10 2 10 7 112 117 12 2 12 7 13 2 13 7 14 2 14 7 15 2 15 7 16 2 16 7 17 2 17 7 18 2 18 7 19 2 19 7 202 207 21 2 21 7 222 0 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 [...]

6 720 608 782 44 Sensor resistance charts Fig. 61 Ba ck Fl ow ch aract er i st i cs 32 37 42 47 52 57 62 67 72 77 82 87 92 97 10 2 10 7 112 117 12 2 12 7 13 2 13 7 14 2 14 7 15 2 15 7 16 2 16 7 17 2 17 7 18 2 18 7 19 2 19 7 202 207 21 2 21 7 222 227 232 237 242 247 252 257 262 267 272 277 282 287 292 297 302 0 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 [...]

6 720 608 782 GWH 2400 ES Functional scheme 45 11 GWH 2400 ES Functional scheme Fig. 62 Functional scheme[...]

6 720 608 782 46 Interior components diagram and par ts list 12 Interior components diagram and parts list 12.1 Interior components Fig. 63 Components 1 Flue gas collector 2 Heat exchanger 3 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[...]

6 720 608 782 Interior components diagram and parts list 47 Fig. 64 Appliance overview[...]

6 720 608 782 48 Interior components diagram and par ts list 12.2 Components diagram 12.2.1 Group 1 Fig. 65 Components Diagram 9 9 8 5 1 2 3 6 7 9 10 12 9 14 16 17 11 13 15 15 4 67209029 73.AA JF Item Description Reference 1 Front cover 8 705 431 286 2 Cover shield 8 705 506 862 3 Trade mark badge 8 701 103 140 4 Cover screw 8 703 401 170 5 Combust[...]

6 720 608 782 Interior components diagram and parts list 49 12.2.2 Group 2 Fig. 66 Components Diagra m 1 3 2 4 5 6 7 8 9 6720902974.AA JF Item Description Reference 1 Heat exchanger 8 705 406 356 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 70[...]

6 720 608 782 50 Interior components diagram and par ts list 12.2.3 Group 3 Fig. 67 Components Diagram 15 14 1 3 4 6 7 8 2 12 9 10 11 13 16 17 5 6720902975.AA JF Item Description Reference 1 Main burner 8 708 120 642 2 Burner gasket 8 704 701 08 7 3 Primary fan 8 707 204 071 4 Backflow temperature sens or 8 707 206 459 5 Washer 8 704 701 097 6 Fan [...]

6 720 608 782 Interior components diagram and parts list 51 12.2.4 Group 4 Fig. 68 Components Diagra m 9 2 14 1 3 4 5 6 7 8 11 11 12 13 10 6720608158-73.1AL Item Description Reference 1 Gas valve 8 707 021 019 2 Pressure 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 sup[...]

6 720 608 782 52 Interior components diagram and par ts list 12.2.5 Group 5 Fig. 69 Components Diagram Item Description Reference 1 Water valve with eng ine 8 708 505 02 4 2 O-ring 8 700 205 14 7 3 Cold water pipe 8 700 715 394 4 Pipe connection cli p 8 701 201 028 5 Hot water pipe 8 700 715 392 6 Temperature se nsor 8 700 400 015 7 Outlet fitting [...]

6 720 608 782 Interior components diagram and parts list 53 12.2.6 Group 6 Fig. 70 Components Diagra m 14 1 2 3 7 6 9 5 12 15 13 10 11 4 6720608782-08.1AL Item Description Reference 1 Control unit 8 707 207 296 2 Fuse T2.5A 1 904 521 342 3 Fuse T1.6A 8 700 609 008 4 Power supply cabl es 8 704 401 371 5 Power supply cord 8 704 401 378 6 Fan cables 8[...]

6 720 608 782 54 Protecting the environment 13 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 th e end of the product life. Cont act your city auth orities for information about the disposal of recyclable products.[...]

6 720 608 782 Limited Warranty 55 14 Limited Warranty General Aquastar w ater heaters ar e warranted b y the Manufacturer (BOSCH) through Bosch thermotechnology corporation. Bosch thermotechnology corporati on will furnish a replacement heat exchanger and will furnish a replacement of any other part which fails in normal use and service within the [...]

Recycled paper © 200 8 Bosch Thermote chnology Corp ., W aitsfield, V T all rights rese rved Replacement Parts available from: Bosch T ermotecnologia, S.A . Estrada de C acia 380 1 - 8 56 Aveiro - P ORTU GAL BOSCH THERMOTECHNOLOGY CORPORATION Bosch Water Heating 340 Mad River Park Waitsfield, VT 05673 TEL. 800-642-3111 www.boschhotwater.com Instal[...]