Bosch Appliances ESVVT manual

M OD E L G W H 2 7 0 0 E S N G an d G WH 2 7 0 0 E S LP - I N D OO R M O D E L T emper atu re Modu lat ed wit h E lec t ronic Ignit ion Suit able for heat ing pot able wa ter only Not app roved for spac e he at ing pur poses (Intended for variable flow applications) GWH 2700 ES NG - Natur al Gas GWH 2700 ES LP - Liqu efied Pet roleum (LP ) Gas 6 72[...]

6 720 608 542 2 Index Index 1 Warning 3 2 Appliance de tails 4 2.1 Features 4 2.2 Specification s (Technical data) 5 2.3 Unpacking th e heater 6 2.4 General rule s to follow for safe operation 7 2.5 Dimensions and Minimum installation cl earances 8 3 Installation instructions 9 3.1 Tools require d for installation 9 3.2 Introductio n 9 3.3 Venting [...]

6 720 608 542 Warning 3 1 Warning For your sa fety Do not store or use gas oline or other flammable, combustib le or c orrosive vapors and liquids in the vicinity of th is or any other appl iance. Warning: Carefully pla n w here you install the heater. Correct combus tion air supply and flue pipe installation are very impor tant. If a gas ap plianc[...]

6 720 608 542 4 Appliance de tails FCC: This device c omplies w ith Pa rt 15 of th e FCC rules. Operation is subject t o the following two conditions: (1) This device may not cause harmful inter ference, and (2 ) this device must acc ept any int erference receiv ed, including interference t hat may cause undesired operation. Fig. 1 2 Applianc e det[...]

6 720 608 542 Appliance detai ls 5 2.2 Specifications (Technical data) Approved in US/Canada Capacity Maximum flow r ate: 7.1 5 G PM (27 l/min) at a 45°F (25°C) rise . Maximum out put 160,500 B tu/h (47.0 kW) Maximum in put 199,000 B tu/h (58.3 kW) Efficiency in % Thermal eff iciency > 82% Min. Inpu t 19,900 Btu /h (5.8 kW) Temperatu re Contro[...]

6 720 608 542 6 Appliance de tails 2.3 Unpacking the heater Before inst alling the unit, be c ertain you h ave the correct heate r for your type of Gas: Propane or Natural Gas. Identification labels are found on the shipping box, and on the rating plate whic h is located on the right side panel of the cover. Fig. 2 Rating plate A Serial n umber B T[...]

6 720 608 542 Appliance detai ls 7 2.4 General rules to follow for safe operation B 1. You m ust fo llow these instructions when you ins tall your heater. In the United State s: The installation must conform with local co des or, in the ab sence of local codes, the Na tional Fuel Gas Co de A NSI Z 223.1/ NFPA 54. In Canada: The Ins tallation must c[...]

6 720 608 542 8 Appliance de tails 2.5 Dimensions and Minimum installation clearances Fig. 6 Dimensions 1 On/Off b utton 2 Reset button 3 Program key 4 Power O N or stan d-by LED 5 LCD d isplay 6 Up bu tton 7 Down button Fig. 7 Minimum clea rances Note: For serv icing access, a 2ft cl earance to front cover is reco mmended. 6720608158-04.2AL 2 3 1 [...]

6 720 608 542 Installation instructions 9 3 Inst allation ins truction s 3.1 Tools required for installation • Philips head sc rewdriver • Flat head screwd river • Adjustable wren ch • Level • Thermometer • Standard plumbin g tools • Manometer • Drill • Pipe wrench • Adjustable pliers • Pipe fitting tools • Hacksaw • Hole [...]

6 720 608 542 10 Installation instructions Horizontal ve nting systems onl y: An optional stainless c once ntric v ent /air intake termina- tion can be used to provide only one penetration poi nt through the exterior wall (see Fig. 8, 9 & 10). The con- centric ve nt/air intake kit can be ordered f rom your local wholesaler. (Pa rt# ESHCK). Note[...]

6 720 608 542 Installation instructions 11 Condensate drain requireme nts An exter nal condensate drain (not supplied wi th the heater) must be i nstalled un der the following conditions: • All vertical termi nating vent installati ons. • Horizontal terminati ng vent installa tions w here t he total linear vent length is greater t han 10 feet ([...]

6 720 608 542 12 Installation instructions Required di rect vent terminal clearances (twin p ipe / concentric penetration) Fig. 11 * For clearance s not specified in ANSI Z223. 1 / NFPA 54 or CSA -B149.1, one of the follo wing shall be indicated: a) A minimum cl earance value determine d by testing in accordanc e with section 2.20, or; b) A referen[...]

6 720 608 542 Installation instructions 13 Required ot her than direct v ent terminal clea rances (single pipe penetration) Fig. 12 * For clearanc es not specified in ANSI Z223.1 / NFPA 54 or CSA -B149.1, one of the f ollowing shall be indicate d: a) A minimu m clearance value determin ed by testing in accor dance with section 2.20, or; b) A refere[...]

6 720 608 542 14 Installation instructions 3.3.3 Venting configur ation examples Below are appr oved e xamples of horizontal venting insta llations. Fig. 13 H orizontal side wall venting installa tion (single pipe penetra tion)* * Warning: for non-freezing cli mates only! Important: Note: Pitch ho rizontal runs down tow ard the heater, except horiz[...]

6 720 608 542 Installation instructions 15 Fig. 17 Vert ical ven ting inst allation (twin pipe penetra- tion) Fig. 18 Vert ical venting installa tion - Masonry Chi m- ney (combust ion air piping not shown) 3.3.4 Vent connecti ons B Attach the flue gas exhaust a ccessory (8 705 50 4 162) to the top of the unit (po sition 1) using the 4 screws and ga[...]

6 720 608 542 16 Installation instructions 3.3.5 Condensate drain installation Note: Do not in stall condensate drain in areas where it may freeze. 1. Install condensate drain as close to he ater as possi- ble. 2. Use 3/8" ID high te mperature silicone tube to con- nect to conden sate drain port. Do not use copper p ip- ing for any port ion of[...]

6 720 608 542 Installation instructions 17 3.3.6 Fan speed ad justment IMPORTA NT! Installation ad justment: After installin g the water heater, the fan speed v alues for minimum power (P2 ) and maximu m po wer (P 1) may need adj ustment due t o variations in a ltitude and ve nt pipe length. Failure to make ne cessary adjus tments to fan speed valu[...]

6 720 608 542 18 Installation instructions Adjusting min imum power fa n speed (P2) To select fan speed: B Press ON/ OFF button into O FF. B Press and hold "P rogram" b utton and press ON/OFF but ton to turn applia nce ON. Fig. 22 B As soon as '188' i s d isplayed, release "Program" button , and the displ ay should rea[...]

6 720 608 542 Installation instructions 19 Attention re sidents of the Com monwealth of Massachu setts: In th e Commonwe alth of M assachusetts t he following regulation went into effect on 1 2/30/2005: (a) For all s ide wall horizontally vented g as fueled equipment in stalled in every dwelling , buildin g or structure used i n who le or in par t [...]

6 720 608 542 20 Installation instructions 3.4 Combustion air requirements Twin pipe a nd Concentric pipe The water hea ter is designed as a se aled combustion appliance. It is recomme nded that t he c ombustion air be provided from the outside by a dedicated pipe (twin pipe) or by connecting to the concentric vent kit (se e Fig. 8, 9 & 1 0). T[...]

6 720 608 542 Installation instructions 21 3.5 Proper location for installing your heater Carefully selec t the location of the wa ter heater. For your safety and for proper heate r opera tion, you must provide combustion ai r to the heater a nd a proper exhaust ve nt system. Follow the gui delines below: B 1. Locate the heater where venti ng, gas [...]

6 720 608 542 22 Installation instructions Fig. 25 Le veling the mountin g bracket on the stud s Fig. 26 Mo unting the heater 3.8 Gas pi ping & c onnecti ons Before connecting the gas supply , check the rating plate on the right side of the heate r to be sure tha t th e heater is rated for th e sa me gas to which it will be connected. In the Un[...]

6 720 608 542 Installation instructions 23 Once connecti ons a re ma de, check for gas leaks at all joints. Apply some gas leak detection solution to all gas fittings. Bubbles are a sign of a leak. A combustible gas detector may also be used to d etect for leaks. GAS LI N E S IZ I N G The gas supply pipin g for a singl e heater shou ld be sized for[...]

6 720 608 542 24 Installation instructions FOR NA TU R AL GAS Maximum Cap acity 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 W ater Column (0.75mba r).(Based on a 0.60 Specific Gravity Gas ) Btu numbers giv en in thousands. Fig. 29 Follow boxed numbers for pip ing just one GWH 27 00 ES[...]

6 720 608 542 Installation instructions 25 3.9 Water connections B When facing th e hea ter, th e ¾” cold connection is o n the bottom right and the hot connection i s on the bot- tom left. Cen trally l ocating the water he ater is recom- mended to keep hot water distributio n times even throughout the st ructure. Fig. 30 B The use of u nions wh[...]

6 720 608 542 26 Installation instructions Connecting the pressure relie f valve (PRV) A listed pressure relief v alve suppli ed with t he heat er must be installed at the time of i nsta llation. No valve is to be placed between the PRV and the heater. No reducing coupling or other restriction m ay be inst alled in the discharge line. The discha rg[...]

6 720 608 542 Installation instructions 27 3.12 Measuring gas pressure Confirm gas pressure upon inst allation. Connectin g manometer B Shut off gas sup ply at installe r suppli ed shutoff valve for this water h eater. B Remove front cover and loc ate inl et gas pressure measuring point (see Fig. 34). B Loosen screw inside left test point fitt ing [...]

6 720 608 542 28 Electrical conn ections 4 Electr ical con nections 4.1 Electrical power supply The w ater heat er requires an electrical pow er sup ply from a 120VAC / 60Hz prop erly rated receptacle and must be properl y grounded. The heater is wired as shown in the wiring diagram (chapter 9, Fig. 59). Fig. 35 Con necting power su pply cord 1 Pow[...]

6 720 608 542 Operation inst ructions 29 5 Oper ation ins tructions Fig. 38 1 On/O ff button 2 Reset button 3 Prog ram Key 4 LCD d isplay 5 Up bu tton 6 Down button 7 LED - Power On indicator o r Stand-b y 5.1 LCD Display functions Fig. 39 Pow er bar indicator Fig. 40 Te mperature indicat or Fig. 41 Err or indicator Fig. 42 L ock indicator Fig. 43 [...]

6 720 608 542 30 Operation i nstructions 5.2 For your safety read before operating your water heater A. This appliance i s equipped with elec tronic ignition for lighting the main burne r. Wh en turning the heater on, follow these inst ructions exactly. B. Before op erating the unit, press the On/Off button . WH A T T O D O I F Y OU S M E LL GAS B [...]

6 720 608 542 Operation inst ructions 31 5.5 Use of optional remote control accessory (part no. TSTAT2) Fig. 47 Rem ote control The wirel ess remote control a ccessory (Fig. 7 1, component 13) a nd the temperatur e selector buttons on the front of the water heater operate identically. Contact your distributor to o rder the remote control accessory.[...]

6 720 608 542 32 Maintenance and service 6 Main tenance and service The unit should be checked once a year by a gas technician. If repairs are neede d, t he re pairs sho uld be done by a ga s technician. 6.1 Annual maintenance (To remove front cover, see page 6.) Venting Sys tem • V enting system - inspe ct inside of flue pipe for any blockage or[...]

6 720 608 542 Maintenance and service 33 space w hich is likely t o e xperience fre ezing temperatures, all wate r must be dr ained from the heater. If precauti ons are not taken, re sulting damag e will not be covere d under the w arranty. NOTE: U se of agents such as a nti-freeze is not permitted as they may cause damage to t he water heater&apos[...]

6 720 608 542 34 Maintenance and service Static Gas Press ure: “ WC P1 Operating Pressure: “ WC The P1 minimum operating gas pressu re is 3.5" WC for Natural Gas a nd 8" WC for Prop ane. Do not proce ed in adjusting C O 2 until pres sure is at or above these levels, but not to exce ed 10.5” WC for Na tural Gas and 13 ” WC for Prop[...]

6 720 608 542 Maintenance and service 35 Final Read ings P2 CO 2 Reading: % CO 2 P1 CO 2 Reading: % CO 2 Fig. 57 Ad justing P1 CO 2 level Fig. 58 Ad justing P2 CO 2 level CO 2 range (%) Max. CO level (measured) Nat. Gas max. input P1 7.5 % - 8.1 % < 250 ppm min. input P2 2.3 % - 2.6 % < 60 ppm LP Gas max. input P1 8.7 % - 9.3 % < 250 ppm m[...]

6 720 608 542 36 Maintenance and service 6.5 Program values This section describes detail s on programming the appliance. For most applications the factory de fault values will robust and s table ope ration. Only adjust the factory settings if the insta llation requires changes as indicated in t he appropriate sect ion of this manual. Refer to cha [...]

6 720 608 542 Maintenance and service 37 6.6 Control board diagnostics 1. Turn on/of f switch on w ater heater to of f (O) position. 2. Press and hold t he program ( ) button whi le turning the on/off swi tch to t he on (I ) pos ition. T he display w ill cyc le thr ough a startup procedu re including the sof tware version. 3. Release the ' &ap[...]

6 720 608 542 38 Troubleshoot ing 7 Troub leshootin g 7.1 Introduction Many of the quest ions customers ask rega rding operation o f this uni t can be a nswered by following th e troubleshooti ng steps as ou tlined below. Visit our web site at www.b oschhotwater.com for more detailed troubleshooti ng and servic e bul letins. For be st results, perf[...]

6 720 608 542 Troubleshooti ng 39 heater. Then open all of the hot water taps served by the heater. Wa it 10 minut es and check all taps for water flow. Th ere should be no wa ter flowing. A ny continuous flow of wate r, small or large, indicates a crossover and must be correc ted. Consul t a professional p lumber for help in c orrecting a crossove[...]

6 720 608 542 40 Troubleshoot ing 5. L ack of adeq uate ga s pre ssure. In adequate gas pressure wil l cause the fuel-to-air mixtu re (CO 2 ) to be out of adjustment. This will re sult in u nstable burn er flames and noise. Ensure gas pres sure is i n accordance with specifications i n section 3.12, page 27 Meas uring G as Pressure. A gas pressu re[...]

6 720 608 542 Problem sol ving 41 8 Pro blem solvi ng 8.1 Error code diagnostics i To remove error code from the display, press the reset button. Display Caus e Solution Fault in the flue gas limiter. 1. Check continuity of the flue gas limiter (see Fig. 64 , page 49 ). Go to steps two and three to determine air box temperature sensor fault and rep[...]

6 720 608 542 42 Problem solvin g (Flashing) Out let temperature sensor not sensing expected output temperature. 1. Check that t he sensor is firmly attached to the hot water pipe (see Fig. 70 , page 55 ). 2. Clean inlet f ilter screen and clear any debris out of shower heads, faucet aerators and whole house filters. 3. C heck venting specification[...]

6 720 608 542 Problem sol ving 43 Over-temperature detected by outlet temperature sensor o n hot water pipe. Temperature > 185 °F 1. Check that the senso r is firmly a ttached to the vert ical section of the hot water pipe (see Fig. 70 , page 55 ). 2. Check red wire connection s at outlet temperature sensor. Clean terminals with an eraser. If b[...]

6 720 608 542 44 Problem solvin g 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 6 . 3. Reset error code and open a water tap to cycle the heater in an effort to purge air on new installations. Cycling hot water tap on and off m ultiple times may be necessar[...]

6 720 608 542 Electrical dia gram 45 9 Elect rical dia gram Fig. 59 Ele ctrical scheme 1 Intlet w ater temp erature s ensor 2 Outl et water temp erature se nsor 3 Backf low temper ature sen sor 4 Casca ding outp ut connec tion 5 Casca ding inpu t connect ion 6 Ionizat ion sensor 7 Water flow sens or 8 Flue ga s limiter 9 Heat exchanger o verheat s [...]

6 720 608 542 46 Sensor res istance charts 10 Sensor r esistance charts Fig. 60 Fig. 61 O utl et t emperature sen sor characteri sti c s 3 2 3 7 4 2 4 7 5 2 57 6 2 6 7 7 2 77 8 2 8 7 9 2 9 7 1 0 2 1 0 7 1 12 1 17 1 2 2 1 2 7 1 3 2 1 3 7 1 4 2 1 4 7 1 5 2 1 5 7 1 6 2 1 6 7 1 7 2 1 7 7 1 8 2 1 8 7 1 9 2 1 9 7 2 0 2 2 0 7 2 1 2 2 1 7 2 2 2 0 1 2 3 4 5[...]

6 720 608 542 Sensor re sistance charts 47 Fig. 62 Bac k Fl ow characteri sti cs 3 2 3 7 4 2 4 7 5 2 5 7 6 2 6 7 7 2 7 7 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 15 2 15 7 16 2 16 7 17 2 17 7 18 2 18 7 19 2 19 7 202 207 2 12 2 17 222 227 232 237 242 247 252 257 262 267 272 277 282 287 292 297 302 0 1 2 3 4 5 6 7 8 9 1 0 1 1 1[...]

6 720 608 542 48 GWH 2700 E S Functional schem e 11 GWH 270 0 ES Fun ctional s cheme Fig. 63 Func tional scheme[...]

6 720 608 542 Interior compon ents diagram and parts list 49 12 Interio r componen ts diagr am and p arts list 12.1 Interior components Fig. 64 C omponents 1 Flue ga s collec tor 2 Heat exchanger 3 Flame sensor 4 Primary fan (Mix er) 5 Outl et tempera ture senso r 6 LCD d isplay 7 On/O ff button 8 Reset button 9 Prog ram key 10 F lue gas lim iter 1[...]

6 720 608 542 50 Interior co mponents diagram and parts list Fig. 65 Ap pliance overview[...]

6 720 608 542 Interior compon ents diagram and parts list 51 12.2 Components diagram 12.2.1 Group 1 Fig. 66 C omponents Diagra m 9 9 8 5 1 2 3 6 7 9 10 12 9 14 16 17 11 13 15 15 4 6720902973. AA JF Item Description Reference 1 Front cover 8 705 431 286 2 Cover s hield 8 70 5 506 862 3 Trade mark badg e 8 70 1 103 140 4 Cover s crew 8 703 401 17 0 5[...]

6 720 608 542 52 Interior co mponents diagram and parts list 12.2.2 Group 2 Fig. 67 Comp onents Diagram 1 3 2 4 5 6 7 8 9 672 0902974 .AA JF Item Description Reference 1 Heat exc hanger 8 705 406 422 2 Heat exc hanger top gasket 8 704 7 01 052 3 Flue gas collecto r 8 705 700 1 53 4 Overh eat senso r (ECO) 8 707 2 06 204 5 Heat exc hanger bo ttom ga[...]

6 720 608 542 Interior compon ents diagram and parts list 53 12.2.3 Group 3 Fig. 68 C omponents Diagra m 15 14 1 3 4 6 7 8 2 12 9 11 13 16 17 5 67 209 029 75 .AA JF Item Description R eference 1 Mai n burner 8 70 8 120 69 9 2 Burn er gasket 8 7 04 701 087 3 Prima ry fan 8 707 204 071 4 Bac kflow temp erature se nsor 8 707 206 459 5 Was her 8 704 70[...]

6 720 608 542 54 Interior co mponents diagram and parts list 12.2.4 Group 4 Fig. 69 Comp onents Diagram 9 2 14 1 3 4 5 6 7 8 11 11 12 13 10 6720608158-73.1AL Item Description Reference 1 Gas v alve 8 707 02 1 019 2 Pressu re tapping 8 703 40 4 219 3 Washe r 8 7 00 203 04 1 4 Pressu re balance tube 8 700 7 03 136 5 Pressu re balance nut 8 703 30 0 0[...]

6 720 608 542 Interior compon ents diagram and parts list 55 12.2.5 Group 5 Fig. 70 C omponents Diagra m Item Description R eference 1 Wate r valve w ith engine 8 708 505 024 2 O-ri ng 8 70 0 205 147 3 Co ld water p ipe 8 700 7 15 394 4 Pip e connect ion clip 8 701 201 028 5 Hot water pip e 8 700 7 15 469 6 Te mperature s ensor 8 700 400 015 7 Ou t[...]

6 720 608 542 56 Interior co mponents diagram and parts list 12.2.6 Group 6 Fig. 71 Comp onents Diagram 15 1 2 3 7 6 9 5 11 13 16 14 10 12 8 4 67 2090 297 8.AA JF Item Descrip tion Reference 1 Co ntrol unit 8 707 207 2 57 2 Fuse T2.5A 1 904 52 1 342 3 Fuse T1.6A 8 700 60 9 008 4 Pow er supply c ables 8 704 401 3 71 5 Pow er supply c ord 8 704 401 3[...]

6 720 608 542 Protecting t he environment 57 13 Protectin g the en vironmen t Packing The packing box may be fully re cycled as confirmed by the recyclin g symbol . Componen ts Many parts in the heater can be fully re cycled in the en d of the product life. Contact your city authorities for information a bout the disposal of recyclable produ cts.[...]

6 720 608 542 58 Limited War ranty 14 Limited Warranty General Aquastar w ater heaters are wa rranted by th e Manufacturer (BOSC H) through Bosch Thermotech nology Corp. . Bosch thermote chnology corporation wil l furn ish a replacement heat exchang er an d wil l fu rnish a replacement of any oth er part which fails in norma l use and service withi[...]

6 720 608 542 Limited Wa rranty 59[...]

6720608542 © 200 9 Bosch Thermotechnology Corp ., Londonderr y, N H a ll rights reser ved Replac ement Pa rts availabl e from : Bos c h T ermotecnologia SA Estrada de Cacia 38 0 1 - 856 Aveiro - P ORTU GAL BOSCH THERMOT ECHNOLOGY C ORP. 50 Wentworth Avenue Londonderry, NH 03053 Tel. 866-330-2730 www.boschhotwater.com Installe r Chec klist to be co[...]