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MODEL 2400 EO - OUTDOOR MODEL
For exterior use only
Electronic Ignition and built in Freeze protection
Suitable for heating potable water only
Not approved for space heating purposes
2400 EO NG - Natural Gas
2400 EO LP - Liquefied Petroleum (LP) Gas
6 720 608 257 US (06.11) JS
Warning: If the information in this manual is not
followed exactly, a fire or explosion may result
causing property damage, personal injury or death.
Do not store or use gasoline or other flammable
vapor and liquids in the vicinity of this or any other
appliance.
Improper installation, adjustment, alteration,
service or maintenance can 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 you smell gas
• Close gas valve.
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any
phone in your building.
• If you cannot reach your gas supplier, call the fire
department.
• Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions
• Installation and service must be performed by a
qualified installer, service agency or the gas supplier.
Index
Index
1
Warning
2
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.9.1
2.9.2
2.9.3
2.10
2.11
2.12
2.13
2.14
Appliance details
Features
2400 EO Specifications (Technical data)
Dimensions and Minimum installation clearances
General rules to follow for safe operation
Proper location for installing your heater
Heater Placement and Clearances
Mounting installation
Gas piping & connections
Measuring gas pressure
Connecting Manometer
Static Pressure Test
Operating Pressure Test
Water connections
Electrical connections
Operating instructions
For your safety read before operating your water
heater
Lighting and operating instructions
15
15
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
Operation instructions
Power
Temperature selection
Use of remote control accessory
Operation
Reset button
Program button
Locked condition
16
16
16
18
18
18
18
18
4
Maintenance and service
19
5
Troubleshooting
19
6
Electrical diagram
22
7
2400 EO Functional scheme
23
8
8.1
8.2
8.3
Interior components diagram and parts list
Interior components
Components diagram
Parts list
24
24
25
26
9
Special adjustment for measuring and adjusting
CO2 levels
27
10
Protecting the environment
29
11
Twelve Year Limited Warranty
30
4
4
4
6
7
7
8
8
10
12
12
12
12
13
14
14
1
Warning
Warning: If the information in this
manual is not followed exactly, a fire or
explosion may result causing property
damage, personal injury or death.
Warning:
Improper
installation,
adjustment, alteration, service or
maintenance can cause injury or
property damage. Refer to this manual.
For assistance or additional information
consult a qualified installer, service
agency or the gas supplier.
Upon completion of the installation,
these instructions should be handed to
the user of the appliance for future
reference.
Featuring
Electronic Ignition and Power Venting.
2
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.
Warning: Carefully plan where you
install the heater. If a gas appliance is
not installed correctly, fatal accidents
can result from lack of air, carbon
monoxide poisoning or fire.
Warning: Place the heater in a location
where water leaks will do NO DAMAGE
to adjacent areas or floors.
Warning: Field wiring connections and
electrical grounding must comply with
local codes, or in the absence of local
codes, with the latest edition of the
National Electric Code, ANSI/NFPA 70,
or in Canada, all electrical wiring must
comply with the local codes and the
Canadian Electrical Code, CSA C22.1
Part 1.
Warning: Shock hazard line voltage is
present. Before servicing the water
heater, turn off the electrical power to
the water heater at the main disconnect
or circuit breaker. Failure to do so could
result in severe personal injury or death.
6 720 608 257
Warning
What to do if you smell gas
• Close gas valve.
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any
phone in your building.
• Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire
department.
• Installation and service must be performed by a
qualified installer, service agency or the gas supplier.
Warning: The heater 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.
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 harmful interference, and (2)
this device must accept any interference received,
including interference that may cause undesired
operation.
Caution:
Any
changes
or
modifications not expressly approved
by the party responsible for compliance
could void the user’s authority to
operate the equipment.
Fig. 1
Fig. 2
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3
Appliance details
2
Appliance details
2.1
Features
2.2
Parts
2400 EO Specifications (Technical
data)
• Touch Pad interface control
Approved in US/Canada
• High power pre-mix compact burner with low NOx
emissions
Capacity
• Modulating Gas Valve with constant gas: air ratio
control
• Modulating water valve for improved comfort and
temperature control
Maximum flow rate: 6.35 GPM (24 l/min) at a 45°F
(25°C) rise.
Maximum output
142,968 Btu/h (41.8 kW)
• Freeze protection.
Maximum input
Safety
175,000 Btu/h (51.2 kW)
• Flame sensor (ionization) rod
Efficiency in %
• Overheat sensor
Recovery efficiency 86.5%
• Temperature limiter
Min. Output
• Fan speed monitoring.
31,131 Btu/h (9,1 kW)
High Quality Materials for Long Working Life
Temperature Control
• Copper heat exchanger
Selection range: 100°F (38°C) - 140°F (60°C)
• High efficiency Ceramat Burner
Default temperature: 122°F (50°C)
• Compact space saver: mounts on a wall with a
supplied bracket.
Stability: +/- 2°F (+/- 1°C)
• Easily removable two-piece cover.
Features
• Electronic Ignition
• LCD Display
• On/Off and Temperature control switches
• Reset button
• Program Key (Selectable temperature default)
• Failure codes for easy diagnostic and repair.
Accessories
• Optional wireless remote control accessory to
operate with the appliance.
i
BOSCH is constantly improving its
products, therefore specifications are
subject to change without prior notice.
Gas Requirement
Gas connection (inches) - ¾”
Inlet gas pressure under maximum operation*
• Propane: 11” - 14” water column
• Natural Gas: 5” - 14” water column.
* To measure Gas Pressure, see Measuring Gas
Pressure, chapter 2.9.
Water
• Hot water connection (inches) - ¾”
• Cold water connection (inches) - ¾”
• Water valve material: Polymer (PPS) (Polypropylene
Sulfid)
• Minimum water flow: 0.8 gallon/minute (3 l/m)
• Minimum recommended water pressure: 30 PSI
(2.07 bar)
• Connections:
– Bottom of heater
4
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Appliance details
Combustion
UNPACKING THE 2400 EO HEATER
• NOx ≤ 55 ppm
This heater is packed securely.
• CO ≤ 250 ppm.
The box includes:
Dimensions
• Control panel shield
• Depth (in): 8 ½” (220 mm)
• Width (in): 15 ¾” (400 mm)
• Height (in): 26” (650 mm)
• Weight: 47 pounds (21 kg).
Gas types
Natural Gas.
LP Gas.
CO2 analyzer is required to convert from one gas type
to another. Please contact BBTNA for specific
instructions.
Voltage
120 V AC (50/60 Hz)
Amperage
• Pressure relief valve
• Bracket for wall hanging the heater
• Plastic decal shields for covering front cover screws
and control panel, installer should affix these decals
to the front of the unit after installation is complete.
See Fig. 6
• Installation manual
• Product registration card.
Do not lose this manual. Please complete and return
the enclosed product registration card.
Before installing the unit, be certain you have the
correct heater for your type of Gas - Propane or
Natural Gas. Identification labels are found on the
shipping box, and on the rating plate which is located on
the right side panel of the cover.
IDLE - 40 mA
Operation - ≤ 2,5 A
Noise
≤ 50 db (A)
The 2400EO is not approved or designed for:
Safety devices
• Manufactured (mobile) homes, RV's or boats
• Flame failure device (ionization flame rod sensor)
• Heating or other recirculating/pumping applications*
• Pressure relief valve (supplied with heater)
• Solar/preheat backup or high temperature booster
use
* This includes domestic hot water circulator pump loop
systems that may previously exist in a home hot water
system. The use of a small electric mini-tank (4-6 gallon
size) should be used for this application; when
designed so the pump will circulate the hot water in the
mini-tank only and through the building's hot water
return loop (timed or thermostatic controlled operation
of the pump is commonly done). The 2400EO should
be plumbed in line before the mini-tank water heater,
contact BBTNA if further instruction is needed.
• Over heat prevention (temperature limiter).
Water resistant
IP X5 (protection against water drops).
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5
Appliance details
2.3
Fig. 3
1
2
3
4
5
6
Dimensions and Minimum installation clearances
Dimensions
Cover
On/Off switch
Reset button
LCD display
Program button
Temperature buttons
Fig. 4
Minimum clearances
Model 2400 EO
TOP (A)
3 ft.
FRONT (B)
4 ft.
BACK
0”
SIDES
4 ft.
BOTTOM (C)
1 ft.
Table 1 Minimum clearances
6
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Appliance details
2.4
General rules to follow for safe
operation
B 1. You should follow these instructions when you
install your heater. In the United States: The
installation must conform with local codes or, in the
absence of local codes, the National Fuel Gas Code
ANSI Z223.1/NFPA 54.
In Canada: The Installation should conform with
CGA B149.(1,2) INSTALLATION CODES and /or
local installation codes.
B 2. Carefully plan where you install the heater. Proper
clearances must be followed.
B 3. 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 ½ Psig
(3.5 kPa).
The appliance and its gas connection must be leak
tested before placing the appliance in operation.
B 4. Keep water heater area clear and free from
combustibles and flammable liquids. Do not locate
the heater over any material which might burn.
B 5. Correct gas pressure is critical for the optimum
operation of this heater. Gas piping must be sized to
provide the required pressure at the maximum output
of the heater, while all the other gas appliances are in
operation. Check with your local gas supplier, and
see the section on connecting the gas supply.
B 6. Should overheating occur or the gas supply fail to
shut off, turn off the gas supply at the manual gas
shut off valve, on the gas line. Note: manual gas
shutoff valve is not supplied with the heater.
B 7. Do not use this appliance if any part has been
underwater. Immediately call a qualified service
technician to inspect the appliance and to replace
any part of the control system and any gas control
which has been underwater.
2.5
Proper location for installing your
heater
Carefully select the location of the water heater.
Follow the guidelines below:
B 1. Locate the heater where venting, gas and
plumbing connections are feasible and convenient.
B 2. The hot water lines should be kept short to save
energy. Centrally locating the water heater is best. It
is always best to have the water lines insulated to
prevent the possibility of any freeze damage.
B 3. The water in this heater is cold and always remains
cold except for the times that hot water is being used.
The heater is equipped with freeze prevention
equipment that will operate and prevent freezing of
the water in the heater to 5°F with no wind chill.
Electrical power must be maintained to the heater to
allow this to function.
6 720 608 257
WARNING: Proper insulation of the
water lines below the heater is required
if below freezing temperatures, below
32°F, are ever anticipated!
Danger: If the temperature drops
below 5°F, freeze damage to the water
heater itself must be prevented by
turning off the power to the heater, then
disconnecting the plumbing connections and introducing short bursts of
compressed air (20-40 psi) through the
heater's connections. This will remove
the residual water in the horizontal
pipes and water valve..
Danger: Keep children away as the top
of the water heater vent cap will get very
hot during operation. Install in a place
that prevents the top of the heater being
reached by small children.
Danger: Flue gases will be released
through the vent cap. Flue gas is very
hot and contains carbon monoxide. The
heater cannot be installed indoors. To
prevent risk of fire and poisoning by
carbon monoxide, assure all clearances
indicated in manual.
Danger: Surface temperature around
vent cap is less than 140°F, except
highest top surface of vent cap may
reach 400°F.
Danger: Do not place or store any
combustible material within 5 feet of the
appliance. Risk of fire could be caused
by hot flue gas. Note: Exception is
made for the wall where the appliance
is installed and any adjacent walls or
overhang. In this case observe
clearances required in chapter 2.6.
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 appliance
area must be kept free of all
combustible materials, gasoline and
other flammable vapors and liquids.
7
Appliance details
2.6
Heater Placement and Clearances
2.7
The 2400 EO is design certified for installation directly
on a combustible wall. (see 2.7 Mounting installation)
For installation on vinyl siding see Fig. 10. Keep the area
below the heater free of combustible material.
Mounting installation
Warning: before starting installation:
B check that there are no loose parts
inside the appliance
B ensure that gas pipe, gas valve, mixer,
fan and burner have no damage and are
properly fitted.
Minimum clearances
If the appliance is installed under an overhang, there
must be a 36” clearance from the top of the appliance
and the mounting area must be open in front and on the
sides of the appliance.
i
Front cover should be removed in order to
inspect components visually (see
instructions below).
To remove front cover.
B Loosen the two Philips head screws located on front
panel (beneath plastic decal shields if they are
already attached, see Fig. 6).
Plastic decals
Fig. 5
Danger: The top of the kit will get hot
due to the flue gases. Install away from
children.
Ref.
Description
Min.
distances
A
Directly below or from an
opening; operable windows,
doors and any fresh air
openings
≥ 4 ft
Fig. 6
D
From any adjacent wall or tall
shruberry
≥ 4 ft
B Remove the two top screws securing the vent cap to
the top of the heater, being careful the washers on
the screws are not lost, see Fig. 7.
E
Below a gutter, sanitary
pipework, eaves or overhang
≥ 3 ft
F
Above ground
≥ 1 ft
G
From a gas meter, gas
regulator, electrical box or
another 2400EO heater
≥ 3 ft
B
C
Remove front cover
Table 2 Clearances
Fig. 7
B Lift the top vent cap completely upward from the
heater.
B From the bottom of the heater, holding the sides, lift
the front cover panel of the heater upward and
slightly toward you to remove.
8
6 720 608 257
Appliance details
B After inspection, replace front cover and tighten
screws, then replace plastic decal shields.
B Fix the top vent cap on the top of the heater, as
shown in Fig. 8). Make sure the vent cap is well fitted
by taking special care that the front cover stays inside
the extended corners of the vent cap, as shown in
Fig. 8). The sides of the cover must be pressed with
your hands to ensure it fits inside those corners.
Secure it in place with its two screws.
Fig. 9
Warning: Do not mount heater directly
to vinyl siding. With vinyl siding
surfacing, a 6' x 4' area of the siding
must first be removed and then
replaced with wood or other non-plastic
made material. See Fig. 10.
Fig. 8
B The water heater is design certified for mounting on
a wall. Secure the wall mounting bracket provided
with the water heater to a wall surface. See Fig. 9.
B The installation method of the mounting bracket will
depend on what type of surface it’s being mounted
to. Due to the varying types of building surfaces, the
installer must decide on how best to support and
level the heater on an outside wall. It is always
recommended that horizontal or vertical support
boards or plywood sheathing (1/2” minimum) first be
attached to the wall surface. The heater must also be
kept level on the wall surface.
Fig. 10
Vent Safety System
The 2400 EO will shut down if the intake or exhaust
louvers on the vent cap are blocked for any reason; see
troubleshooting section on page 19. See error code
table to confirm error, correct the problem and then
reset the heater before operating.
6 720 608 257
9
Appliance details
2.8
Gas piping & connections
Before connecting the gas supply, check the rating
plate on the right side of the heater to be sure that the
heater is rated for the same gas to which it will be
connected.
In the United States: The installation must conform with
local codes or, in the absence of local codes, the
National Fuel Gas Code ANSI Z223.1/NFPA 54.
In Canada: The Installation should conform with CGA
B149 INSTALLATION CODES and/or local installation
codes.
GAS LINE SIZING
The gas supply piping should be sized according to the
applicable plumbing code for a maximum draw of
175,000 BTUH. Measure the length of gas supply line
and use the tables in Fig. 12 or the gas line
manufactures sizing tables to determine the pipe
diameter necessary to accommodate the BTU demand
of the unit. If there are more gas drawing appliances on
the line, size the gas line according to the total maximum
amount of BTU draw for all appliances.
Warning: The heater must be isolated
from the gas supply piping system
during any pressure testing of that
system at test pressures equal to or
more than 0.5 psig.
The water heater must not be piped with gas supply
pressures in excess of 0.5 psig. If overpressure has
occurred, such as through improper testing of the gas
lines or malfunction of the supply system, the gas valve
must be checked for safe operation.
When connections are made, 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 detect for leaks.
Danger: If you have a leak, shut off the
gas. Tighten appropriate fittings to stop
leak. Turn the gas on and check again
with a gas leak detection solution.
Never test for gas leaks using a match
or flame.
Note: Under sizing the gas line may result in diminished
output and improper operation. See chapter 2.9 for the
procedure to confirm gas pressure.
Inlet gas particle screen
Gas piping
Fig. 11
B Install a manual gas shut off valve, on the gas supply
line.
B The use of a union when connecting gas pipe to the
gas inlet connection is important, this will facilitate
any necessary servicing and cleaning of the inlet gas
particle screen.
B The minimum diameter required for any appliance
connector used is ¾”.
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
supplier.
10
6 720 608 257
Appliance details
FOR NATURAL 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.
Follow boxed numbers for piping just one 2400 EO (example: ¾” B.I. Natural Gas pipe for 20 ft (6.1m). will
handle 190,000 btu’s (55.7 kWh). For multiple appliances combine the total btu input load and then refer to
applicable chart below.
Nominal
Iron
Length of Black 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
730
590
500
440
400
370
350
320
305
275
250
225
210
1 1/2
1.610
1600
1100
890
760
670
610
560
530
490
460
410
380
350
320
2
2.067
3050
2100
1650
1450
1270 1150 1050
990
930
870
780
710
650
610
Length of Flexible Corrugated Stainless Steel Tubing (CSST), Feet
Tube
size,
inches
EHD*
10
20
30
40
50
60
1/2
18 EHD 82
58
47
41
37
34
3/4
23 EHD 161
116
96
83
75
68
1
30 EHD 330
231
188
162
144
131
1 1/4
37 EHD 639
456
374
325
292
267
* EHD = Equivalent Hydraulic Diameter. The greater the
value of EHD, the greater the gas capacity of the tubing .
FOR LP GAS
Maximum Capacity of Pipe in Thousands of BTU per Hour of Undiluted Petroleum Gases (at 11 inches Water Column Inlet
Pressure) (Based on a Pressure Drop of 0.5 Inch Water Column).
* EHD = Equivalent Hydraulic Diameter. The greater the
value of EHD, the greater the gas capacity of the tubing.
Length of Flexible Corrugated Stainless Steel Tubing (CSST), Feet
Nominal
Tube
size
inches
Black Iron Pipe
Iron Pipe
Length of Pipe, Feet
Size,
10
Inches
20
30
40
50
60
70
80
90
100
125
150
89
83
1/2
275 189 152
129 114 103 96
78
69
63
3/4
567 693 315
267 237 217 196 185 173 162
146
132
1
107 732 590
504 448 409 378 346 322 307
275
252
10
20
30
40
50
60
18 EHD 129
91
74
64
58
53
3/4
23 EHD 254
183
151
131
118
107
1
30 EHD 521
365
297
256
227
207
1 1/4
37 EHD 971
661
528
449
397
359
1/2
1 1/4 220 149 121
103 913 834 771 724 677 630
567
511
1 1/2 330 229 185
155 141 127 118 108 102 976
866
787
EHD*
Maximum Capacity of Semi-Rigid copper Tubing in
Thousands of BTU per Hour of Undiluted Liquefied
Petroleum Gases (at 11 inches Water Column Inlet
Copper
Length of Tubing, Feet
Outside
diameter
Inch
10
20
30
40
50
60
70
80
3/8
39
26
21
19
_
_
_
_
_
_
(Based on a Pressure Drop of 0.5 Inch Water Column)
1/2
92
62
50
41
37
35
31
29
27
26
* Source National Fuel Gas Code NFPA 54, ANSI
Z223.1 - No Additional Allowance is necessary for an
ordinary number of fittings
5/8
199 131
107
90
79
72
67
62
59
55
3/4
329 216
181 145
131
121 112 104
95
90
Pressure).
90 100
Fig. 12
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11
Appliance details
2.9
Measuring gas pressure
2.9.1
Connecting Manometer
B Shut off gas.
B Remove front cover and locate inlet gas pressure
measuring point (see Fig. 14).
B Loosen screw inside test point fitting (do not remove)
and connect manometer tube on test point.
2.9.2
Static Pressure Test
Static Gas Pressure Reading (see Chapter 2.9)
enter here: ___________________
Operating Gas Pressure Reading (see Chapter 2.9)
enter here: ___________________
Table 3
HIGH ALTITUDE OPERATION
Altitude
Natural
Gas:
Liquid
Propane:
no
modification
no
modification
B Turn gas supply back on.
B Operate all other gas appliances on same gas piping
system at maximum output.
0 - 4,000 ft
(0 - 1,219 m)
B Record static gas pressure reading in table 3.
2.9.3
Operating Pressure Test
B ON/OFF switch in position OFF (0).
B Press and hold "Program" (M) button and turn ON/
OFF switch to ON position.
4,000 ft - 7,000 ft
(1,219 m - 2,134 m)
Above 7,000 ft
(above 2,134 m)
CO2 adjustment with flue
gas analyzer required See
chapter 9 for instructions.
For operation at
elevations
above 2,000 ft
(610 m) the
equipment
ratings shall be
reduced at the
rate of 4% for
each 1,000 ft
(305 m) above
sea level
Not approved
Table 4
Fig. 13
B As soon as '188' is displayed, release "Program"
button and the display should read P2.
B Press
, until P1 appears.
Note: While in this mode the appliance will run
constantly at maximum power and allow maximum water
flow. These program modes are for test purposes only
and not intended for normal operation.
B Turn on high volume of hot water flow (at least 6
gpm) and heater will ignite.
B Record operating gas pressure reading in table 3.
Gas pressures lower than 5" W.C. for Natural Gas or
11" W.C. for LPG will result in insufficient degree rise
to the hot water being used, and must be corrected.
See Gas Connections, chapter 2.8.
Fig. 14 Gas pressure measuring (left tapping)
12
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Appliance details
2.10 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 where it’s centrally close to hot
water use points if possible, and make hot water piping
runs as short as possible.
INLET FILTER
SCREEN
lowest pressure range setting recommended is 30-50
psi (2.07 and 3.45bar).
Connecting the pressure relief valve (PRV)
A listed pressure relief valve supplied with the heater
must be installed at the time of installation. 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 line must be a
minimum of 4” above a drain and installed such that it
allows complete drainage of both the PRV and the line.
The location of the PRV must be readily accessible for
servicing or replacement, and be mounted as close to
the water heater as possible. See Fig. 16. To install the
PRV, a suitable fitting connected to an extension on a
“T” fitting can be sweated to the hot water line.
Support all piping.
COLD
HOT
Fig. 15
B THE USE OF A UNION WHEN CONNECTING
BOTH WATER PIPES TO THE INLET AND
OUTLET CONNECTIONS IS RECOMMENDED,
THIS WILL FACILITATE ANY NECESSARY
SERVICING AND REQUIRED CLEANING OF
THE INLET WATER PARTICLE SCREEN.
Although water piping throughout your structure may be
other than copper, we recommend that copper piping
or suitably rated stainless steel flex line piping be used
for at least three feet before and after the heater (follow
local codes if more stringent). Never sweat any rigid
piping directly to or beneath the water connections,
damage can occur to the internal water valve from
heating of the pipe. Plastics or other PEX type plumbing
line materials are not suitable for connecting directly to
the water heater. Keep water inlet and outlet pipes to no
less than ¾" (19.05mm) diameter to allow the full flow
capacity.
It is recommended that all water piping below the
heater be properly insulated to avoid heat loss. If
below freezing temperatures are ever anticipated
where the heater is located, insulation material
is required and must be capable of protecting the
piping from freezing. The freeze protection that is
equipped within the heater will not prevent any
freeze damage to the exterior water piping.
If the cold and hot connections to the heater are
reversed, the heater will not function. Be certain there
are no loose particles or dirt in the piping. Blow out or
flush the lines before connecting to the water heater.
Full port valves should be installed on both the cold
water supply and hot water outlet lines to facilitate
servicing the heater (see Fig. 16). For installation on a
private well system with the use of a pressure tank, the
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Fig. 16 Plumbing Connections and Pressure Relief
Valve
13
Appliance details
2.11 Electrical connections
Warning: The heater is equipped with
freeze prevention equipment that will
operate and prevent freezing of the
water in the heater to 5°F with no wind
chill. Electrical power must be
maintained to the heater to allow this to
function.
WARNING:
Proper
insulation of the water lines below
the heater is required if below
freezing temperatures, below 32°F,
are ever anticipated.
Warning: Confirm that the water
heater is appropriately grounded and
that the installation meets all electrical
codes. Outdoor electrical outlets have
special requirements.
Warning:
For
safety
reasons,
disconnect the power supply to the
heater before any service or testing is
performed.
2.12 Operating instructions
Warning: This heater must be
electrically grounded in accordance
with the most recent edition of the
National Electrical Code. NFPA 70. In
Canada, all electrical wiring to the
heater should be in accordance with
local codes and the Canadian Electrical
Code, CSA C22.1 Part 1. Do not rely
on the gas or water piping to ground the
metal parts of the heater.
B Remove the control cover shield to access the
controls of the water heater.
The 2400 EO requires an electrical power supply from
a 120VAC 60Hz circuit and must be properly
grounded.
A means for switching off the 120VAC power supply
must be provided.
The heater is wired as shown in the wiring diagram
(chapter 6, Fig. 29).
Fig. 18
Warning: The control cover must be
replaced after the initial operation
begins, and must be in place at all
times.
B Before proceeding with the operation of the heater
make sure that the system is filled with water.
B Turn off power supply to heater.
B Open the cold water inlet supply to the heater fully.
B Open a hot water faucet to permit the water to fill the
heater and the piping and to eliminate the air trapped
in the system.
Appliance electrical
power supply
Fig. 17
B Close the hot water faucet after the water flows freely
and all the air has escaped from the system. Turn on
power supply to heater. The water heater is now
ready to operate.
i
14
NOTE: A default temperature setting of
122 F will appear on the display screen.
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Appliance details
2.13 For your safety read before
operating your water heater
Warning: If you do not follow these
instructions exactly, a fire or explosion
may result causing property damage,
personal injury or loss of life.
A. This appliance is equipped with electronic ignition for
lighting the main burners. When turning the heater on,
follow these instructions exactly.
B. Before operating the unit, turn the On/Off switch to
the right position.
WHAT TO DO IF YOU SMELL GAS
B Do not try to light any appliance.
B Do not touch any electric switch; do not use any
phone in your building.
B Immediately call your gas supplier from a neighbors
phone. Follow the gas supplier’s instructions.
B If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to turn the on/off control switch.
Never use tools. Follow these instructions exactly. If
control switch is jammed, close the gas supply and call
a qualified service technician. Attempted forceful repair
may result in a fire or explosion.
D. Do not use this appliance if any part has been under
water. Immediately call a qualified service technician to
inspect the appliance and to replace any part of the
control system and any gas control which has been
under water.
i
NOTE: on a first time initial
installation or after gas line work
has been done, air in the gas line
will cause ignition delay when the
hot water is turned on. This will
result in an error (EA or EC) on the
units display screen. This is
normal. When this occurs, leave
the hot water running and wait 3-5
seconds, then press reset button
to reset the unit (Fig. 19, pos. 2).
Wait for (EA or EC) to disappear.
The heater will begin to attempt
ignition again, if the (EA or EC)
reappears then repeat this same
process until all air has been bled
from the gas line.
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 flue gases. The
power vents fan speed is variable depending on the rate
of hot water used and the burner output.
TO TURN OFF GAS TO APPLIANCE
B Turn off the manual gas shut off valve on the supply
line to the heater and set the ON/OFF switch to the
OFF position (turn to the left position). Note: a
manual gas shut off valve is not supplied with the
heater.
2.14 Lighting and operating instructions
B 1. STOP! Read the previous safety information.
B 2. The gas valve must be shut off by putting the ON/
OFF switch to the OFF position (turn to the left
position). Wait five (5) minutes to clear out any gas.
If you smell gas, STOP! Follow “B” in the safety
information above. If you do not smell gas, go to the
next step.
B 3. This appliance is equipped with electronic ignition
for lighting the main burners. When turning the
heater on, follow these instructions exactly.
B 4. Set the ON/OFF switch to the ON position (turn to
the right position).
B 5. Open a hot water tap.
B 6. The burners will remain on until the hot water tap
is turned off.
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15
Operation instructions
3
Operation instructions
Fig. 19
1
2
3
4
5
6
On/Off switch
Reset button
Program button
Increasing temperature button
Decreasing temperature button
LCD display
3.1
B Press buttons
and
requested temperature.
in order to reach
Power
On
B To start the appliance switch the button to the ON
position (turn to the right position).
LCD display the default temperature - temperature
factory setting 122°F (50°C).
Fig. 21
If the outlet water temperature is set too high, the heater
can produce temperatures that are too hot. A
temperature balance shower valve can automatically
mix in cold water to reduce such hot water temperature.
In the event of any temperature instability with the use
of a temperature balance shower valve, refer to shower
valve manufacturer's instructions for internal adjustment
setting. Adjustments should be made to the hottest
setting in the shower valve. Additionally the temperature
control of the heater can be lowered to produce a more
comfortable hot water temperature.
Fig. 20
Off
B To shut down the appliance, switch the button to the
OFF position (turn to the left position).
3.2
Temperature selection
To select water temperature outlet:
16
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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 EO has an electronically controlled gas valve that modulates the burner input in response to both varying
hot water flow rates and/or changes in any incoming and outgoing water temperatures.
Hot Water Flow and Temperature with Various Inlet Temperature (gpm/Fahrenheit)
7.00
Hot Water Flow (GPM)
6.00
5.00
4.00
3.00
2.00
1.00
0.00
90
100
110
120
130
140
150
Hot water temperature (ºF)
Inlet (ºF) 40
Inlet (ºF) 50
Inlet (ºF) 60
Inlet (ºF) 70
Hot Water Flow and Temperature with Various Inlet Temperature (lpm/Celsius)
Hot Water Flow (l/min)
24.00
20.00
16.00
12.00
8.00
4.00
0.00
35
40
45
50
55
60
65
Hot water temperature (ºC)
Inlet (ºC) 4
Inlet (ºC) 10
Inlet (ºC) 16
Inlet (ºC) 21
Fig. 22 Flow/temperature charts
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17
Operation instructions
3.3
Use of remote control accessory
Fig. 26 Reset button
If the problem persists, contact your installer.
3.6
Fig. 23 Remote control
The wireless remote control accessory and the
temperature selector buttons on the front of the water
heater operate identically. Contact your distributor or
BBTNA to order if the remote control accessory is
preferred. Modification of the water heaters interior
control unit (Fig. 32, component 12) is required when
programming the remote control with this heater.
i
3.4
Program button
Program button can be used/programmed in the
appliance and in the remote control.
Programming “Program” function
Programming actions are similar for both controls
(appliance control pad and wireless remote control).
NOTE: up to 6 remote controls can be
programmed for one single water heater,
each with a range distance of 98 ft (30 m).
Operation
B When a hot water tap is opened, main burner ignites
and LCD displays indication
.
Fig. 27 “Program” key
B Press buttons
be memorized.
and
to select temperature to
B Hold “Program” button for 3 seconds to save
temperature.
When LCD stops blinking. Temperature is saved on
“Program”.
Fig. 24
B LCD blinks until selected temperature is reached.
Using “Program” function
In order to select memorized temperature
3.5
B Press “Program” key.
Reset button
If the LCD shows the error symbol
.
Note: do not use the ON/OFF switch when error is
present.
See the error code on LCD and consult
“Troubleshooting” section.
LCD shows pre-memorized temperature, which is now
the hot water selected temperature.
3.7
Locked condition
This condition is only valid for appliances with more than
1 controller (an appliance with one or more remote
controls).
Fig. 25
After
following
instructions
“Troubleshooting” section
indicated
in
B press reset button in order to make the appliance
ready-to-work.
18
Fig. 28 Locked condition
Whenever LCD shows
the temperature setting
cannot be adjusted because the appliance is in use by
a user which already selected a different temperature.
Appliance will be automatically unlocked after closing
hot water tap.
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Maintenance and service
4
Maintenance and service
Warning: Always turn off the electrical
power supply, turn off the manual gas
valve and turn off the manual water
control valves whenever servicing.
The unit should be checked once a year by a gas
technician. If repairs are needed, the repairs should be
done by a gas technician
To remove front cover
B See instructions to remove front cover on page 8.
Systems and parts that should be checked at
least once a year
Reference diagrams on pages 24 and 25.
• Venting system
• Burners -see page 24 for observation window
• See relief valve manufacture's instruction for
pressure relief valve maintenance
• Periodic cleaning of the water filter screen, see Fig.
15, chapter 2.10.
• Flushing the heat exchanger with a descaling
solution if mineral build up is evident. Scale build up
will shorten the life of the water heater, descale heat
exchanger thoroughly and repeat annually depending
on mineral content of ground water.
5
Troubleshooting
Introduction
The 2400 EO burner is activated by a water flow valve.
Numerous water related problems can cause this water
valve to malfunction such as: Insufficient water flow
volume to activate the burners at its minimum flow
requirement; Dirt in the inlet filter screen; Sediment
build-up in faucet aerators, or shower heads; Uneven
pressures between cold and hot (with single lever mix
valves); and Plumbing crossovers. These water flow
related problems can cause the heater to deliver less
than its full output, or to fail to ignite or to shut down
completely.
Problems stated below in upper case and in bold face
should be investigated when there is a problem with the
performance of the water heater but there is NO error
code on the heater's LCD display or wireless remote
control.
Any failures that result in a displayed error code are
referenced on page 21. A Functional Scheme of the
2400 EO is detailed on page 23. If there is a problem
with the installation, venting or operation of the unit, the
heater will communicate the source by these error
codes.
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BURNERS DO NOT IGNITE WHEN HOT WATER IS
TURNED ON
• Cold incoming water connection made to
wrong side of heater
Make sure cold water inlet connection is plumbed to
the right side of heater when facing unit
• Water flow rate at hot water tap is too low
A minimum of 0.8 gallon/minute (3 l/m) is required to
activate the heater
• Cold water inlet filter screen is dirty
Remove water inlet filter screen and clean. The
screen is located at the inlet connection to the water
heater, disconnecting the main cold supply line at the
heater is required. Check and clean faucet aerator
screens too.
• Crossover in plumbing
The heater activates when there is sufficient water
flow through its water valve, a minimum of 0.8 gallon/
minute (3 l/m) is required. If there is a crossover in the
plumbing, the necessary hot water flow rate through
the unit may not be reached, even though the flow at
the hot water tap is sufficient. A plumbing crossover
can be caused by a failed washer at a single lever
faucet, incorrect plumbing or a faulty mixing valve in
the piping. The crossover will create a back pressure
on the water heater and prevent an adequate flow of
water through it. To confirm there is no crossover in
the plumbing, shut off the cold water supply feed to
the water heater. Individually open each of the hot
water taps. There should be no water flowing under
a constant pressure. If there is a constant flow of
water then the plumbing crossover must be
corrected before the heater can operate properly.
WATER IS TOO HOT
• Temperature selection too high
Lower temperature adjustment on heater or wireless
remote control accessory, see chapter 3.2.
WATER IS NOT HOT ENOUGH
• Temperature selection too low
Increase temperature adjustment on heater or
wireless remote control accessory, see chapter 3.2
• Btu input is too low due to inadequate gas line
sizing
See specifications in chapter 2.8 - 2.9. The 2400
EO requires adequate gas pressure to reach desired
temperatures, to compensate for inadequate gas
supply or lack of gas pressure the 2400 EO will
effectively reach the selected output temperature by
reducing the hot water flow rate. Its motorized water
valve makes this adjustment
• Cold water is mixing with the hot water outlet
(crossover)
19
Troubleshooting
Test by following 4th bullet under BURNERS DO
NOT IGNITE WHEN HOT WATER IS TURNED ON.
LOW WATER FLOW/PRESSURE
• Too many hot water applications are being
used simultaneously or too much flow is being
demanded
The 2400 EO will effectively support two 2.0-2.5
gpm shower heads simultaneously or multiple sink
applications. Greater draws will result in increased
pressure drop and reduced flow at taps. See flow/
temperature chart on page 17.
control of the heater can be lowered to produce a
more comfortable hot water temperature.
• Inlet water pressure is erratic due to
fluctuating supply water pressure
For installation on a private well system with the use
of a pressure tank, the lowest pressure range setting
recommended is 30-50 psi (2.07-3.45 bar). The use
of a pressure reducing valve after the pressure tank
is also an effective way to maintain a constant water
pressure to the water heater. Watts brand 25AUB¾” or N35B-¾” pressure relief valves or equivalent
are suggested.
• Btu input is too low due to inadequate gas line
sizing
See specifications in chapter 2.8 - 2.9. The 2400 EO
requires adequate gas pressure to reach expected
temperatures and flow rates, to compensate for
inadequate gas supply or lack of gas pressure the
2400 EO will effectively reach the selected output
temperature, but only by reducing the hot water flow
rate. Its motorized water valve makes this adjustment.
Proper gas pressure will need to be delivered before
the motorized water valve will allow greater flow rates
through it. Lowering the set temperature will also
allow increased water flow rate through the
motorized water valve. See flow/temperature chart
on page 17.
• Cold water inlet filter screen is dirty
Remove water inlet filter screen and clean. The
screen is located at the inlet connection to the water
heater, disconnecting the main cold supply line at the
heater is required. Check and clean faucet aerator
screens too.
HOT WATER TEMPERATURE FLUCTUATES /
UNIT DEACTIVATED
• Unbalanced pressure in water lines
Any restriction caused by the water heater in the hot
water system can result in uneven pressures
between the cold and the hot. In such cases when
mixing cold water at the tap (manually or
automatically through a mix-type shower valve) the
lower hot water pressure may be overpowered by the
higher cold water pressure in the building and cause
the hot water flow rate to fall below the minimum rate
required. A pressure balance valve will help to
resolve this symptom.
• Temperature balance valves
If the outlet water temperature is set too high, the
heater can produce temperatures that are too hot. A
temperature balance shower valve can automatically
mix in cold water to reduce such hot water
temperature. In the event of any temperature
instability with the use of a temperature balance
shower valve, refer to shower valve manufacturer's
instructions for internal adjustment setting.
Adjustments should be made to the hottest setting in
the shower valve. Additionally the temperature
20
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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 ignition attempts
before entering error mode “EA”.
EC
The ionization signal momentarily disappeared
more then 5 times in less then 30 seconds. CO2
may be out of adjustment
Check gas pressure. (see chapter 2.9) *
Check that gas is not diluted with air, as a
result from recent gas pipeline rework.*.
Check if vent terminal is blocked (especially
when the appliance starts up for some seconds and then looses ionization signal).*
Check ionization electrode.*
Check for a proper ground.*
Check CO2 levels.* (see chapter 9)
FA
Leakage error (gas valves do not close gas
circuit).
Check gas valve and control unit.*
F7
Ionization error (flame sensing at stand-by).
Check control unit.*
E0
Internal software/hardware failure.
Check control unit.*
A7
Hot water temperature sensor/receiver defect
(from control unit).
Check water temperature sensor/receiver and
connections.*
Check incoming water temperature to heater, it
must be above 32°F (0°C)
A9
(flashing)
Hot water temperature sensor/receiver misassembled (from control unit).
Note: if display shows “A9” flashing, the
appliance can be operated normally, but
performance may be affected.
Check that the water temperature sensor/receiver is
properly assembled on the horizontal of the hot
water pipe.*
Check that the water temperature sensor/receiver is
free from corrosion or moisture.*
C1
FAN rotation too low at start-up (from control
unit).
Check supply voltage.*
Check fan and connections.*
Check control unit.*
Check if vent terminal is blocked.*
C6
FAN rotation too low at operation (from control
unit).
Check supply voltage.*
Check fan and connections.*
Check control unit.*
C7
No rotational speed sensor signal from FAN
Check fan and connections.*
Check control unit.*
CA
Water flow signal over specified maximum value
Check water valve and flow sensor.*
E2
Inlet temperature sensor fault
Check water temperature sensor/receiver and
connections.*
Check incoming water temperature to heater, it
must be above 32°F (0°C)
A2
Overheat protection fault
Check connections to the overheat protection.*
Check sensor continuity.*
Check heat exchanger sealings and walls.*
Table 5
* By installer or service technician only.
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21
Electrical diagram
6
Electrical diagram
Fig. 29 Electrical scheme
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Intlet water temperature sensor
Ionization sensor
Water flow sensor
Over heat protection
Temperature limiter
Gas valve
Fan
Water valve
AC Plug
Ignition electrode
Display PCB
ON/OFF switch
Fuse T 2,5A
Fuse T 3,15A
Terminal block
Ground post
Outlet water temperature sensor
Connector for Anti-freeze
Anti-freeze device (Heating resistors)
Temperature sensor
Fig. 30 Anti-freeze electrical scheme
22
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2400 EO Functional scheme
7
2400 EO Functional scheme
Fig. 31 Functional scheme
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23
Interior components diagram and parts list
8
Interior components diagram and parts list
8.1
Interior components
Fig. 32 Components
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Cover
On/Off switch
Reset button
LCD display
Program button
Temperature buttons
Flue gas collector
Mixer
Heat exchanger
Observation window
Inlet air duct
Control unit
Exhaust fan
Water valve
Gas valve
Fig. 33 Appliance overview
24
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Interior components diagram and parts list
8.2
Components diagram
31
42
34
30
33
4
43
3
32
39
40
7
38
7
6
5 7
8
8
35
14
36
2
13
5
10
9
5
25
12
10
15
16
1
26
19
17
44
20
37
18
27
24
11
23
21
28
29
22
6720607440-08.4 JF
Fig. 34 Components Diagram
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25
Interior components diagram and parts list
8.3
Item
Parts list
Description
Reference
1
Front cover
8 705 421 915
2
Shield
8 705 506 753
3
Heat exchanger
8 705 406 285
4
Heat exchanger top gasket
8 704 701 052
5
Clip
8 716 102 607
6
Heat exchanger bottom gasket
8 704 701 054
7
O-ring
8 700 205 147
8
Temperature sensor
8 700 400 015
9
Washer 1/2"
8 710 103 045
10
Wireform spring
8 714 606 002
11
Air inlet duct
8 705 700 097
12
Water filter
8 700 507 001
13
O-ring
8 700 205 134
14
Water valve with engine
8 708 505 016
15
Main burner
8 708 120 515
16
Fan / Burner gasket
8 704 701 050
17
Set of electrodes
8 708 107 020
18
Exhaust Fan
8 707 204 039
19
Gas / Air Mixer
8 705 700 115
20
Mixer / Fan gasket
8 704 701 059
21
Gas valve washer
8 704 701 062
22
Gas valve
8 707 021 019
23
Gas valve washer
8 700 103 014
24
Remote control
8 707 207 153
25
Control unit
8 707 207 133
26
Ignition cable
8 704 401 220
27
Cables / 24V
8 704 401 214
28
Cables
8 704 401 239
29
Power supply cord
8 704 401 287
30
Overheat cutoff fuse
8 700 400 032
31
Top vent cap
7 709 003 243
32
Freeze protection device
8 700 400 022
33
Flue gas collector
8 705 700 100
34
Flue gas collector collar
8 705 700 114
35
Cold water pipe
8 700 715 156
36
Hot water pipe
8 700 715 155
37
Air inlet screen
8 700 507 069
38
Crossover tube
8 700 715 247
39
Overheat sensor (ECO)
8 707 206 204
40
Clip - Heat exchanger
8 701 201 028
42
Gasket Exhaust
8 700 103 710
43
Gasket Set Combustion Chamber
8 704 701 046
44
O-ring air duct
8 700 205 149
Table 6
26
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Special adjustment for measuring and adjusting CO2 levels
9
Special adjustment for measuring and adjusting CO2 levels
The CO2 can only be adjusted by a certified gas
technician with a calibrated CO2 analyzer.
Caution: One factor that may affect
CO2 levels is improper gas pressure.
Please see Chapter 2.9 for the
procedure to measure gas pressure
and record your findings below:
B. Measuring CO2 (Cover Installed):
B Open hot water taps to achieve a flow rate of at least
4 gallons per minute. (1 tub and 2 sinks should be
sufficient).
B Record the CO2 reading in P2 below. (Analyzer
reading may take several minutes to stabilize).
B Press the
button until P1 appears. Unit will ramp
up to high fire and the flow should increase.
Static Gas Pressure:
“ WC
B Record the CO2 reading in P1 on the next page.
P1 Operating Pressure:
“ WC
P2 CO2 Reading:
% CO2
P1 CO2 Reading:
% CO2
The P1 minimum operating pressure is 5" WC for
Natural Gas and 11"WC for Propane. Do not proceed
in adjusting CO2 until pressure has been verified to be
at or above these levels, but not to exceed 14” WC.
A. Once Pressure is good
B Turn ON/OFF switch to the OFF (O) position.
B Remove plug by prying with a small flathead
screwdriver. Fig. 35
B Insert CO2 analyzer probe into the measuring port on
the front right of the vent cap at an angle. The tip of
the probe should be inserted to the middle of the vent
cap (approx 5" inserted).
Note: Vent cap must be in place in order to measure
CO2.
Compare your readings to those found in table 1 under
the “With Front Cover” column. If CO2 readings are off
make adjustments as outlined below.
Note: The “Without Front Cover” column gives
approximate values with the cover off to ease the
adjustment process. Final readings should be taken
with the cover on.
C. Adjusting CO2:
Note: P1 adjustment will change the P2 reading.
Confirm the P1 value BEFORE adjusting the P2 level.
1. P1 CO2 level off:
B Loosen yellow painted Philips screw (1) and cover
should rotate down (2) revealing a brass slotted
screw. Fig. 37.
B Adjusting 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.
2. P2 CO2 level off:
B Remove yellow painted #40 Torx cover from the front
of the gas valve. (Fig. 38) A plastic #40 Torx screw
will be revealed.
Fig. 35
B While holding the Program (M) button, move the ON/
OFF switch to ON (I) position (see Fig. 36). As soon
as ‘188’ flashes on the display, release the Program
button. The display should now read P2.
B Adjusting the plastic #40 Torx screw counter
clockwise will lower P2 CO2 levels and clockwise
will raise P2 CO2 levels.
Note: These screw adjustment are very sensitive and
may take several minutes to stabilize.
3. Verify both P1 and P2 are within the ranges specified
in table 1 under the “With Front Cover” column. Repeat
steps 1 and 2 as necesssary until CO2 values are within
the specified ranges.
Fig. 36
6 720 608 257
27
Special adjustment for measuring and adjusting CO2 levels
D. Returning to Service:
1. Return slotted cover to original position.
2. Reinstall Torx cover.
3. Remove CO2 analyzer probe and reinstall plug in
exhaust collar.
4. Turn ON/OFF switch to the OFF (O) position and
then back to the ON (I) position.
5. Heater is ready for normal operation.
Without Front
Cover
With Front
Cover
Nat. Gas
Nat. Gas
max. input
P1
9.1 ± 0.1 %
9.7 ± 0.1 %
min. input
P2
9.4 ± 0.1 %
9.7 ± 0.1 %
LP Gas
LP Gas
max. input
P1
10.1 ± 0.1 %
10.7 ± 0.1 %
min. input
P2
10.4 ± 0.1 %
10.7 ± 0.1 %
Fig. 38
* Final reading must be confirmed with the front cover
on, CO2 levels increase when the cover is installed.
Table 7
Final Readings
P2 CO2 Reading:
% CO2
P1 CO2 Reading:
% CO2
Fig. 37
28
6 720 608 257
Protecting the environment
10
Protecting the environment
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.
Saving water resources:
B Make sure you close all the taps after any use. Avoid
leaving the taps dripping. Repair any leaking tap.
B Whenever possible use taps with built-in water flow
limiters. They will give you the same comfort level
while saving water.
B Define the temperature you want, in the appliance or
with the remote control. This way you have the
precise water flow needed (mixing cold water to
regulate temperature will increase the water flow with
consequent waste of water).
For increased safety shut off the appliance from
the main water supply if your are staying away
from home for a considerable time.
At below freezing temperatures, disconnect the
plumbing connections to the heater and allow
the heater to drain.
To prevent any freeze damage, introduce short
bursts of compressed air (20-40 psi) through
these connections to remove the residual water
in the horizontal pipes and water valve.
6 720 608 257
29
Twelve Year Limited Warranty
11
Twelve Year Limited Warranty
General
Service Labor Costs
Aquastar water 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 use and service within
the applicable periods specified below, in accordance
with the terms of this warranty. The BBTNA
replacement will be warranted for the unexpired portion
of the original warranty. This warranty will be valid only
for water heaters in possession of the original purchaser
as recorded on the warranty card.
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 warranty does not cover any labor
costs associated with service, removal or re-installation
of the original water heater or a replaced water heater.
i
NOTE: the water heater must be free of
damaging scale deposits and not subject
to gas pressures greater than those
shown on the rating plate, which must not
be altered, defaced or removed.
The Heat Exchanger
If the heat exchanger fails within twelve (12) years after
the original installation and operation, BBTNA will
furnish a replacement heat exchanger. However, if the
water heater is installed in other than a single family
dwelling, this heat exchanger warranty is limited to two
(2) years from date of original installation and operation.
How to Make a Claim
Any claim for warranty parts should be made by the
original installer or service person to the local dealer,
distributor or to BBTNA. If BBTNA, please contact the
Technical Support Department:
Exceptions
BBT NORTH AMERICA
Bosch Group
This warranty will not apply:
340 Mad River Park
• 1. to defects or malfunctions resulting from failure to
properly install, operate or maintain the unit in
accordance with the printed instructions provided;
Waitsfield, VT 05673
• 2. to damage or abuse, accident, neglect or freezing
and other acts of nature;
• 3. to damage resulting from operation with either the
flame sensor rod or overheat sensor removed;
• 4. to failure of the heat exchanger resulting from the
operation of the water heater in a corrosive
atmosphere or at water temperatures exceeding the
maximum rating, or if the water heater is not supplied
with potable water;
• 5. to defects or damage cause by any attachment
or modification, including any energy-saving device.
All Other Parts
If any other part fails within two (2) years after original
installation and operation, BBTNA will furnish a
replacement part free of charge.
Shipping costs
In addition to supplying the replacement part(s),
BBTNA will provide ground service delivery for these
parts. Expedited or upgraded shipping will be charged
to the customer.
30
Phone: 800-642-3111
www.boschhotwater.com
In most cases, the dealer or distributor will be able to
promptly honor your claim and subsequently notify
BBTNA. However, all replacements are made subject to
validation by BBTNA of in-warranty coverage. The
damaged or defective item must be made available in
exchange for the replacement.
Miscellaneous
No one is authorized to make any other warranties on
behalf of BBTNA. It is expressly understood that the
replacement warranty of BBTNA shall be in lieu of any
and all other warranties, express or implied, including
warranties of merchantability or fitness for a particular
use or purpose, and further that BBTNA shall not be
liable for any loss or damage directly or indirectly arising
from the use of the hot water heater, or for any
consequential damages arising from such use
(including damages from water leakage). BBTNA sole
liability with respect to any defect shall be for the
replacement of the defective part(s). Some states do
not allow such limitations and exclusions, so the above
may not apply to you.
This warranty gives specific legal rights. You may also
have other rights which vary from state to state.
6 720 608 257
Twelve Year Limited Warranty
6 720 608 257
31
Installer Checklist, to be performed by installer upon installation
Serial Number
___ ___ ___ ___ ___ ___ ___ ___
(8 digit serial number is located on rating plate on right side panel)
Gas Pressure Reading*
Static__________
Operating__________
Building Water Pressure
__________ Range if on Well system __________
Average Winter Temperature
__________
Average Summer Temperature
__________
Installing Company
_____________________________________________
Installer name
_____________________________________________
Address
_____________________________________________
Phone
_____________________________________________
* See Chapter 2.9 and gas pressure table (to be filled out by installer)
Installation manual should be left with the owner after the installation is tested and completed
Replacement Parts available from:
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.com
techsupport@boschhotwater.com
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Estrada de Cacia
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© 2006 BBT NORTH AMERICA,
Waitsfield, VT all rights reserved