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Bosch 940 ES Installation And Operating Instructions Manual

Indoor model natural gas/ liquefied petroleum (lp) gas
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Installation and Operating Instructions
INDOOR MODEL
940 ES
940 ES - Natural Gas / 940 ES - Liquefied Petroleum (LP) Gas
WARNING!
Improper installation, adjustment, alteration, service or maintenance can cause
injury or property damage. Refer to this manual. For assistance or additional infor-
mation consult a qualified installer, service agency or the gas supplier.
NOTICE
Upon completion of the installation, these instructions should be handed to the
user of the appliance for future reference.

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  Summary of Contents for Bosch 940 ES

  • Page 1 Installation and Operating Instructions INDOOR MODEL 940 ES 940 ES - Natural Gas / 940 ES - Liquefied Petroleum (LP) Gas WARNING! Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional infor- mation consult a qualified installer, service agency or the gas supplier.
  • Page 2: Table Of Contents

    6.3 Power ........48 6.4 Temperature selection ..... . 48 940 ES – 6 720 644 930 (2019/09)
  • Page 3: Key To Symbols And Safety Instructions

    Massachusetts, the water heater  a reference to a related part in the document must be installed by a licensed • a list entry plumber. – a list entry (second level) Table 1 940 ES – 6 720 644 930 (2019/09)
  • Page 4 H DANGER: building. ▶ From outside the building, call the gas Danger of explosion of flammable utility company and a trained and gases. certified installer. 940 ES – 6 720 644 930 (2019/09)
  • Page 5 H CAUTION: circumstances. Children must not be Instruct the customer. allowed to operate hot water faucets ▶ Explain to the customer how the themselves. appliance works and how to operate 940 ES – 6 720 644 930 (2019/09)
  • Page 6 To protect against corrosion and ensure compliance with the rules for electrical safety, observe the following points: ▶ Use metal fittings for potable water heating systems with plastic piping. ▶ Use only original accessories from the manufacturer. 940 ES – 6 720 644 930 (2019/09)
  • Page 7 Damage to the appliance from over pressure. ▶ The heater must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures equal to or more than 0.5 psi. 940 ES – 6 720 644 930 (2019/09)
  • Page 8: Fcc Rules

    It can be heating appliance. used as the basis for determining the safest water temperature for your application. 940 ES – 6 720 644 930 (2019/09)
  • Page 9: Appliance Details

    • Recess box kit (7736500043) • Pressure relief valve (7 738 001 152) BOSCH water heater complies with the State of California Lead • Isolation Valve Kit (7738003449) Law (AB1953). Appliance details BOSCH is constantly improving its products, therefore specifications are subject to change without prior notice.
  • Page 10: Specifications (Technical Data)

    (set from factory) see table 37 Dimensions Depth inches (mm) 11 ¼ (286) Width inches (mm) (452) Height inches (mm) 30½ (775) Weight pounds (kg) 67 (30.5) Gas types Natural Gas LP Gas Voltage 940 ES – 6 720 644 930 (2019/09)
  • Page 11 4.3.8 Fan speed adjustment. Safety devices • Flame failure device (ionization flame rod sensor) • Overheat prevention (temperature limiter) • Inlet temperature sensor • Outlet temperature sensor • Back flow temperature sensor 940 ES – 6 720 644 930 (2019/09)
  • Page 12: Unpacking The Heater

    • Energy Guide label (in the front cover) Please complete and return the enclosed product registration card. The 940 ES is not approved or designed for: • Manufactured (mobile) homes, boats or any mobile installation. (Modular homes are acceptable for installation).
  • Page 13: General Rules To Follow For Safe Operation

    The National Fuel Gas Codes do not allow UNSEALED gas fired water heater installations in bathrooms, bedrooms or any occupied rooms normally kept closed. See chapter 4.4 (page 33). 940 ES – 6 720 644 930 (2019/09)
  • Page 14: Dimensions And Minimum Installation

    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 940 ES – 6 720 644 930 (2019/09)
  • Page 15: Installation Instructions

    WARNING: Specialized tools ▶ Do not mix vent pipe or joining methods from different The following specialized tools may be required for installation: manufacturers. • Manometer • Multi-meter • Combustion Gas Analyzer 940 ES – 6 720 644 930 (2019/09)
  • Page 16 In all cases, follow local codes. See table 5: Item Diam. Material Exhaust Vent 3 or 4 inches Sealed single wall stainless steel (AL29-4C) Intake Vent Sealed PVC or any other rigid pipe Table 5 Venting Specifications 940 ES – 6 720 644 930 (2019/09)
  • Page 17 Heat-Fab www.heatfab.com appliance. This will create a serious health hazard and void the 800-772-0739 warranty. Table 8 Vent manufacturers 940 ES – 6 720 644 930 (2019/09)
  • Page 18 = 23,5’ 45° elbow reduction - 1,25’ Max. number of 90° elbows 3" venting 4" venting Total = 22,25’ Table 14 Max number of elbows Table 10 940 ES – 6 720 644 930 (2019/09)
  • Page 19 61,25’ 90° elbow reduction - 1,25’ sub-total = 60’ 45° elbow reduction - 1,5’ Total = 58,5’ Table 18 For this example, the maximum allowable combustion air pipe length is 58,5 feet. 940 ES – 6 720 644 930 (2019/09)
  • Page 20 Clearance to non-mechanical air supply inlet to building or the 36 in. 12 in. combustion air inlet to any other application Clearance to mechanical air supply inlet 72 in. 36 in. above if within 10 feet horizontally 940 ES – 6 720 644 930 (2019/09)
  • Page 21 A minimum clearance value determined by testing in accordance with section 2.20, or; b) A reference to the following footnote: “Clearance in accordance with local installation codes and the requirements of the gas supplier.” 940 ES – 6 720 644 930 (2019/09)
  • Page 22 Clearance to inside corner Clearance to each side of center line extended above meter/ 36 in. within a height 15 regulator assembly feet above meter/ regulator assembly Clearance to service regulator vent outlet 36 in. 940 ES – 6 720 644 930 (2019/09)
  • Page 23 A minimum clearance value determined by testing in accordance with section 2.20, or; b) A reference to the following footnote: “Clearance in accordance with local installation codes and the requirements of the gas supplier.” 940 ES – 6 720 644 930 (2019/09)
  • Page 24 [5] Elbow (note: minimum 1ft of straight vent pipe required) [6] Horizontal run ¼" per foot down to termination WARNING: [7] Hanger strap ▶ Single pipe penetration should be used in non-freezing climates only! 940 ES – 6 720 644 930 (2019/09)
  • Page 25 WARNING: Below are approved examples of vertical venting installations. ▶ Single pipe penetration should be used in non-freezing Important: climates only! Note: Pitch horizontal runs down toward the heater, ¼" per foot. 940 ES – 6 720 644 930 (2019/09)
  • Page 26 [3] Elbow [4] Hose clamp [5] Hanger strap [6] Horizontal run ¼" rise/ft [7] May be insulated if necessary [8] Chimney [9] Rain cap [10] Storm collar [11] Flashing [12] Silicone seal 940 ES – 6 720 644 930 (2019/09)
  • Page 27 ASTM D1785, F441 orD2665. Cement and primer must comply with ASTM D2564 or F493. For Canada, use CSA or ULC certified PVC or CPVC pipe, fittings and cement, see fig. 5. 940 ES – 6 720 644 930 (2019/09)
  • Page 28 [7] Flashing Solution Two [8] 4" minimum air space If the required clearances of the Zflex termination hood cannot [9] Condensate drain Tee be met, the Zflex damper is the preferred alternative (see 940 ES – 6 720 644 930 (2019/09)
  • Page 29 • Do not install damper in unconditioned spaces (e.g. attics) Condensation can build up while the heater is running which can later freeze and potentially block the flapper 940 ES – 6 720 644 930 (2019/09)
  • Page 30 31 on how to adjust the fan speeds if an adjustment is table 22: necessary. After changing fan speed values, proceed to chapter 7.4 to confirm CO values are within specified ranges. 940 ES – 6 720 644 930 (2019/09)
  • Page 31 1) Full equivalent length (inlet + outlet piping + fittings) Table 24 Fan speed adjustment for 4" piping Adjusting minimum power fan speed (P2) To select fan speed: ▶ Push power button to shut the water heater off. 940 ES – 6 720 644 930 (2019/09)
  • Page 32 248 CMR 5.08(2)(a)1 through 4.(b) 940 ES – 6 720 644 930 (2019/09)
  • Page 33: Combustion Air Requirements

    This failure is not falling into the unit. covered under the manufacturer's warranty. If a single pipe installation is utilized, follow guidelines below for providing adequate combustion air for the water heater as well 940 ES – 6 720 644 930 (2019/09)
  • Page 34: Proper Location For Installing Your Heater

    See fig. 6, page 14. – 3000 BTU/hr (878.43 Watts) if all air is taken from the outside by a direct opening or vertical duct. 940 ES – 6 720 644 930 (2019/09)
  • Page 35: Hanging Appliance On The Wall

    The heater must be kept level on the wall surface, see fig. 28, page 36. ▶ Hang the appliance on the bracket, see fig. 29, page 37. 6720608158-64.1AL Fig. 28 Leveling wall mounting bracket 940 ES – 6 720 644 930 (2019/09)
  • Page 36: Mounting Installation For Manufactured

    Explosion hazard! bottom of the unit as shown in fig. 27. ▶ DO NOT connect to an unregulated or high pressure propane line or to a high pressure commercial natural gas line. 940 ES – 6 720 644 930 (2019/09)
  • Page 37 Once 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. 940 ES – 6 720 644 930 (2019/09)
  • Page 38: 4.9.1 Gas Line Sizing Tables For Natural Gas

    For your convenience see below for an excerpt from gas line sizing tables for a single NG appliance. For details see the current NFPA Specified pipe lengths are for one 940 ES, which has a maximum input rating of 199,000 BTUs. The gas supply system must be sized for the combined total maximum BTU/hr load requirements of all gas appliances running simultaneously.
  • Page 39: 4.9.2 Gas Line Sizing Tables For Lp Gas

    2nd stage (low pressure) regulator and the appliance. For details see the current NFPA 54 or NFPA 58. Specified pipe lengths are for one 940 ES which has a maximum input of 199,000. The gas supply system must be sized for the combined total maximum BTU/hr load requirements of all gas appliances running simultaneously.
  • Page 40: 4.10 Water Connections

    For water analysis data call your local water department, or if on a well, have well water analyzed periodically. If water quality exceeds one or more of the values specified below, Bosch 940 ES – 6 720 644 930 (2019/09)
  • Page 41: 4.12 Domestic Hot Water Recirculation

    Copper mg/l or ppm recirculation design using the water heater in conjunction with a Bosch electric mini tank water heater. This schematic is for Iron mg/l or ppm illustration only and must not be used for actual Installation...
  • Page 42: 4.13 Space Heating Applications

    (closed-loop setup). Bosch supports applications of combination DHW and space heating in an open loop configuration if plumbed similar to FIG. 37. Use of a Bosch tankless water heater in a combination DHW and space heating 940 ES – 6 720 644 930 (2019/09)
  • Page 43 Installation instructions 940ES 6720644930-01.1V Flow (GPM) Fig. 36 Pressure drop curve 940 ES – 6 720 644 930 (2019/09)
  • Page 44 [9] Check valve [10] Pump [11] Thermostatic mixing valve [12] Thermometer (optional) [13] DHW outlet [14] Water to water heat exchanger [15] Thermostat [16] Space heating zone [17] Zone controller [18] Space heating pump 940 ES – 6 720 644 930 (2019/09)
  • Page 45: 4.14 Measuring Gas Pressure

    LPG will result in insufficient degree rise to the hot water being used, reduced hot water volume, possible error code faults and must be corrected. See Gas Connections, chapter 4.9, page 36. 940 ES – 6 720 644 930 (2019/09)
  • Page 46: Electrical Connections

    Note: The outlet the appliance is plugged into should be clear from possible water damage. Position of the fuses in control unit To check fuses, proceed as follows: ▶ Remove the front cover, see fig. 4, page 12. 940 ES – 6 720 644 930 (2019/09)
  • Page 47: Operation Instructions

    Fig. 47 Flame indicator Fig. 48 Solar mode indicator (see chapter 6.4, page 48) Fig. 43 Power bar indicator (input) Fig. 49 Remote control indicator Fig. 44 Temperature indicator 940 ES – 6 720 644 930 (2019/09)
  • Page 48: For Your Safety Read Before Operating Your Water Heater

    Low flowing fixtures are the leading cause of this type of temperature overshoot. To combat this symptom, clean fixtures or replace with higher flowing ones if necessary. 940 ES – 6 720 644 930 (2019/09)
  • Page 49: Use Of Optional Remote Control Accessory

    Follow instructions below to reset error first. Fig. 52 Record the error code on LCD and consult “Problem solving” chapter 9.1, page 60. 940 ES – 6 720 644 930 (2019/09)
  • Page 50: Program Button

    ▶ Hold “Program” button for 3 seconds to save temperature. When LCD stops blinking, temperature is saved in memory. Using “Program” function In order to select memorized temperature ▶ Press “Program” key. 940 ES – 6 720 644 930 (2019/09)
  • Page 51: Maintenance And Service

    Observe burner flames minutes, a crossover of the hot and cold water pipes is during heater operation. Flames should be steady and blue present and must be corrected before proceeding. 940 ES – 6 720 644 930 (2019/09)
  • Page 52: Mineral Scale Build-Up

    ▶ Run solution through the heater until the solution returning to the descaling reservoir comes out clear. (Changing to a fresh solution may be necessary during this process). 940 ES – 6 720 644 930 (2019/09)
  • Page 53 ▶ Press the ‘+’ button until P2 appears. Unit will ramp down to made in small increments. It may take several minutes for low fire and the water flow should decrease. readings to stabilize. ▶ Record the CO reading in P2 below. 940 ES – 6 720 644 930 (2019/09)
  • Page 54 4. Press ON/OFF button to turn OFF the heater and then turn ON the heater. 5. Heater is ready for normal operation. Fig. 61 Adjusting P1 CO level 6720608158-38.1AL Fig. 62 Adjusting P2 CO level 940 ES – 6 720 644 930 (2019/09)
  • Page 55: Program Values

    “P” - button Cascading type This menu is only available when cascade mode is selected CC. Contact Bosch Water Heating for details. Primary/Secondary mode Table 37 Program values, factory default settings and ranges. 940 ES – 6 720 644 930 (2019/09)
  • Page 56: Control Board Diagnostics

    500 + 2nd most recent error Number in H2 0 (X 10 000) = 3rd most recent error (H0 + H1 + H2) = Total of hours 4th most recent error Table 40 940 ES – 6 720 644 930 (2019/09)
  • Page 57: Troubleshooting

    Visit our web site at www.bosch- See chapter 13.2, page 69 for location of these parts. climate.us for more detailed troubleshooting. For best results, 9.
  • Page 58: Low Water Flow/Pressure

    2. Improper venting. Venting that is unsealed, the wrong material, too big in diameter or too long in run will result in unstable burner flames and noise. Ensure venting is in accordance with specifications in chapter 4.3, page 15. 940 ES – 6 720 644 930 (2019/09)
  • Page 59 6. Verify proper CO readings per chapter 7.4, page 52. CO adjustments must be done by a certified gas technician with a calibrated combustion gas analyzer. 940 ES – 6 720 644 930 (2019/09)
  • Page 60: Problem Solving

    2. Check supply voltage. It must be 120VAC and properly grounded. (Status message, not an error). 3. Possible defective control unit call Bosch Water Heating for further instructions. Primary fan rotation too low in 1. Disconnect power supply cord and check wire connection on back side of fan operation.
  • Page 61 74, page 74. 2. Check supply voltage. It must be 120VAC and properly grounded. 3. Possible defective component in fan or defective control unit call Bosch Water Heating for further instructions.
  • Page 62 GPM. Measure voltage at the gas valve wire plug connection. The voltage should measure 24VDC between the left pair of wires and 24VDC between the right pair of wires when the unit is operating. If voltage is not proper, contact Bosch Water Heating for further instruction.
  • Page 63: Electrical Diagram

    [7] Water flow sensor [21] Fuse [8] Flue gas limiter [22] Fuse [9] Heat exchanger overheat sensor (ECO) [10] Gas valve [11] Jumper resistance [12] Water valve [13] Primary fan [14] ON/OFF switch 940 ES – 6 720 644 930 (2019/09)
  • Page 64: Sensor Resistance Charts

    Sensor resistance charts Sensor resistance charts Fig. 64 Outlet / Inlet immersion sensor characteristics 940 ES – 6 720 644 930 (2019/09)
  • Page 65 Sensor resistance charts Fig. 65 940 ES – 6 720 644 930 (2019/09)
  • Page 66 Functional scheme Functional scheme Fig. 66 Functional scheme 940 ES – 6 720 644 930 (2019/09)
  • Page 67: Interior Components Diagram And Parts List

    [17] Water valve with engine and temperature sensor [7] On/Off button [18] Control unit [8] Reset button [19] Up button [9] Program key [20] Down button [10] Flue gas limiter [21] LED [11] Heat exchanger overheat sensor 940 ES – 6 720 644 930 (2019/09)
  • Page 68 Interior components diagram and parts list Fig. 68 Appliance overview 940 ES – 6 720 644 930 (2019/09)
  • Page 69 8 705 504 116 0 Observation window 8 705 600 003 0 Mounting bracket 8 701 309 164 0 Holding bracket 8 708 104 103 0 Table 42 Screw 8 703 403 012 0 940 ES – 6 720 644 930 (2019/09)
  • Page 70 Flue gas collector 8 705 700 153 0 Rubber grommet 8 710 303 027 0 Overheat sensor (ECO) 8 707 206 204 0 Table 43 Heat exchanger bottom gasket 8 704 701 054 0 940 ES – 6 720 644 930 (2019/09)
  • Page 71 Secondary fan - LPG 8 707 204 072 0 Screw 8 703 403 012 0 Gas / Air Mixer 8 705 700 170 0 Air duct O-ring 8 700 205 149 0 940 ES – 6 720 644 930 (2019/09)
  • Page 72 8 700 715 389 0 Gas valve washer 8 700 103 014 0 Gas filter 8 700 507 002 0 Gasket 8 704 701 085 0 Gas / Fan connector 8 705 202 140 0 940 ES – 6 720 644 930 (2019/09)
  • Page 73 8 700 400 033 0 O-ring bypass 8 700 205 129 0 Table 46 Hydraulic block 8 738 704 672 0 Filter 8 700 507 059 0 Filter cover 8 738 702 550 0 940 ES – 6 720 644 930 (2019/09)
  • Page 74 8 704 401 347 0 Screw (optional) 8 703 401 109 0 Wire harness 8 738 701 757 0 Printed circuit transceiver 8 708 300 123 0 Cable 8 704 401 244 0 Table 47 940 ES – 6 720 644 930 (2019/09)
  • Page 75: Protecting The Environment

    1) See Chapter 4.14, page 45 and gas pressure table (to be filled out by installer) Table 48 Installation manual should be left with the owner after the installation is tested and completed. 940 ES – 6 720 644 930 (2019/09)
  • Page 76 50 Wentworth Avenue Londonderry, NH 03053 Tel. 603-552-1100 Fax 603-965-7581 www.boschheatingandcooling.com U.S.A. Products manufactured by Bosch Thermotechnik GmbH Junkersstrasse 20-24 D-73249 Wernau www.bosch-thermotechnology.com Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances.