Bosch Greentherm 9800 SE 160 Installation And Operating Instructions Manual

Bosch Greentherm 9800 SE 160 Installation And Operating Instructions Manual

Indoor residential and commercial tankless water heaters
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INDOOR RESIDENTIAL AND COMMERCIAL TANKLESS WATER HEATERS
Greentherm 9800 SE 160/199 | SEC 199
160 000/199 000 Btu- Natural Gas | 160 000/199 000 Btu - Liquefied Petroleum (LP) Gas
Installation and Operating Instructions
Temperature Modulated with Electronic Ignition Suitable for heating potable water and space heating
(Intended for variable flow applications, indoor use only)
Danger: 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 vapors and liquids in the vicinity of
this or any other appliance.
Installation and service must be performed by a trained and certified installer, service
agency or the gas supplier.
Improper installation, adjustment, alteration, service or maintenance can cause
injury or property damage. Refer to this manual. For assistance or additional informa-
tion 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
Turn off the gas shut-off valve. Open windows and doors.
Do not try to light any appliance.
Do not touch any electrical switch, telephone, and do not use outlets.
Extinguish all open flames. Do not smoke! Do not use lighters!
Warn all occupants of the building. Do not ring doorbells!
If you can hear gas leaking, leave the building immediately. Prevent others from
entering the building and notify the police and fire department from outside the
building.
From outside the building, call the gas utility company and a trained and certified
installer.

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Summary of Contents for Bosch Greentherm 9800 SE 160

  • Page 1 From outside the building, call the gas utility company and a trained and certified installer. INDOOR RESIDENTIAL AND COMMERCIAL TANKLESS WATER HEATERS Greentherm 9800 SE 160/199 | SEC 199 160 000/199 000 Btu- Natural Gas | 160 000/199 000 Btu - Liquefied Petroleum (LP) Gas Installation and Operating Instructions...
  • Page 2: Table Of Contents

    Gas type ......45 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 3: Key To Symbols And Safety Instructions

    If you smell flue gas ▶ Switch off the appliance. ▶ Open windows and doors. ▶ Inform the certified installer who installed the appliance. Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 4 ▶ Every appliance that has been submerged must be ▶ Before performing electrical work, disconnect the power replaced. and secure the unit against unintentional reconnection. ▶ Ensure the system has been disconnected from the power supply. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 5 Failure to do so could result in severe NOTICE: personal injury or death. ▶ Do not obstruct the flow of combustion and ventilation air. Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 6: Safety Information

    3 seconds 150 °F (65 °C) approx. 1.5 seconds 155 °F (68 °C) approx. 1 second Table 2 Approximate time-temperature relationship until there is a risk of scalding 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 7: Appliance Details

    Act. • Aquastat kit (7736504584) • Recirculation pump kit (7736504585) BOSCH water heater complies with the State of California Lead • Tank loading NTC (7736504583) Law (AB1953). BOSCH is constantly improving its products, therefore specifications are subject to Appliance details change without prior notice.
  • Page 8: Specifications (Technical Data)

    Polymer (PPS) (Polypropylene Polymer (PPS) (Polypropylene Combustion  250 (measured)  250 (measured) CO level level (set from factory) see table 25 see table 25 Dimensions Depth inches (mm) (250) (250) Table 3 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 9 Overheat prevention • Inlet water temperature sensor • Outlet water temperature sensor • Exhaust flue gas temperature sensor • Water flow sensor • Air flow sensing technology (Optiflow) Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 10: Unpacking The Heater

    140 °F (60 °C) for Residential appliances or 180 °F (82 °C) for Commercial appliances. In these applications a 3 way valve or thermostatic mixing valve must be installed. • Booster applications. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 11: General Rules To Follow For Safe Operation

    10. Failure to install the heater correctly may lead to unsafe operation. Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 12: Dimensions And Minimum Installation Clearances

    12 | Appliance details Dimensions and minimum installation clearances Fig. 5 Dimensions 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 13: Installation Instructions

    See chapter 7.2, page 47 “Winterizing” for draining instructions. Installation tools The following specialized tools may be required if converting from natural gas to LP: • Pressure manometer Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 14: Heater Placement And Clearances

    2" air gap or rigid insulation between the heater back and the wall. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 15: Venting

    194 °F. For flue damage. temperature above 145 °F the use of ▶ Appliance must be installed vertically. PVC flue material is not allowed. Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 16 ¼ inch per foot back to the appliance. This allows the condensate to drain properly. Maximum vent lengths and equivalent lengths per table 8 apply. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 17 Intake: 40 PVC / CPVC Concentric Termination Kit Exhaust: 2 IPEX 196021 / 197021 (4" by 36" long) Intake: 60 Table 6 Approved PVC/CPVC Vent Components & Terminations Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 18 (2" x 4") PP Horizontal Termination Kit - Concentric Exhaust: 20 M&G 810009710 (3" x 5") PP Horizontal Termination Kit - Concentric Intake: 40 Table 7 Approved PP Vent Components & Terminations 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 19 2" PP Vertical (Roof) Terminations Intake: 4 uring Ecco Exhaust: 8 Manufact 190395 3" PP Vertical (Roof) Terminations Intake: 8 uring Table 7 Approved PP Vent Components & Terminations Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 20 160 kBTU) maximum flue length must be reduced; contact Bosch support line for further assistance. Improper gas pressure or vent length may result in undesired symptoms or errors such as noisy burner, C1, C2. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 21 Clause 5.20, Draft hoods, or; b) a reference to the following footnote: “Clearance in accordance with local installation codes and the requirements of the gas supplier.” Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 22 Clause 5.20, Draft hoods, or; b) a reference to the following footnote: “Clearance in accordance with local installation codes and the requirements of the gas supplier.” 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 23 [C] 12 inches (305 mm) minimum above air intake opening Fig. 12 Horizontal venting system (concentric vent) [1] Exhaust [2] Air intake [3] Concentric Vent kit [4] Exhaust pipe [5] Air Intake pipe [LA] Minimum 1" Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 24 [2] Exhaust ▶ Avoid locating vent terminals near [X] At least 1foot (305mm) equipment, vegetation, plants or building features which can be subject to degradation from exhaust gases. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 25 Vertical venting system with flex PP (sealed Fig. 19 Appliance drain installation combustion) [1] Condensate drain connection [1] Intake [2] Exhaust Verify condensate disposal/neutralization is in accordance with federal, State, and local regulation. Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 26 ▶ Damage caused from back draft, ie. ▶ To allow accessibility, the damper must not be installed in freezing, are not covered by warranty. an enclosed section of vent pipe. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 27: Factory Regulation

    Louvers, grills and screens have a blocking effect, when used, increase the sizes of your openings by 300% for wood louvers (as wood type will reduce the free air by 75%) and 43% for Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 28: Gas Piping & Connections

    4.13, page 36 for the procedure to measure gas pressure. Proper gas pressure must be confirmed at time of installation. Fig. 23 Tighten gas pipe to the heater 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 29 Length of Corrugated Stainless Steel Tubing (CSST), Feet EHD* 1,530 1,090 Table 12 * EHD = Equivalent Hydraulic Diameter. The greater the value of EHD, the greater the gas capacity of the tubing. Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 30 (at 11 inches Water Column Inlet Pressure).(Based on a Pressure Drop of 0.5 Inch Water Column)* Source National Fuel Gas Code NFPA 54, ANSI Z223.1 - No Additional Allowance is necessary for an ordinary number of fittings. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 31: Water Quality

    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 NOTICE: recommends consulting a local water treatment professional ▶...
  • Page 32: Domestic Hot Water Recirculation With External Pump

    For this function, the external Fig. 27 Water filter pump must be electrically connected to the appliance - Bosch cable accessory (8738713226) is available. All the features of [1] Cap recirculation ( 6.5.3, A1 Recirculation) can be used.
  • Page 33: Space Heating Applications

    • Aquastat - 7 736 504 584 – The aquastat connector kit (7736504584) must be used to connect a field supplied aquastat to the appliance. Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 34 [8] Cold water supply [9] Check valve (field supplied) [10] Thermostatic mixing valve (field supplied) [11] Thermometer (optional) (field supplied) [12] DHW outlet [13] Thermostat (field supplied) [14] Air handler 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 35 Installation instructions | 35 Fig. 31 Pressure drop curve Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 36: Measuring Gas Pressure

    See Gas properly grounded. Connections, chapter 4.8, page 28. The water heater is wired as shown in the wiring diagram (chapter 10, Fig. 63). 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 37: Position Of The Fuses In Control Unit

    ▶ Press the four snaps inside the control unit and remove the PCB. NOTICE: ▶ Wipe down with a damp cloth. Do not use any aggressive or corrosive cleaning agents to clean the window. Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 38: For Your Safety Read Before Operating Your Water Heater

    Fig. 38 ▶ Touch and hold symbol for more than 3 sec. The LCD display shows the selected temperature. When the burner is on, the display shows symbol 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 39 Temp. inlet ≥ [Temp. set - 1 °F (0.5 °C)] Ex.: 111 °F (43.9 °C) ≥ [112 °F (44.4 °C) - 1 °F (0.5 °C)] Table 19 Fig. 39 Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 40: Information /Adjustments Menu

    Operation Cycles - number of times burner has been This menu allows you to purge the exhaust circuit. started. ▶ Access to information / adjustments menu. Display shows P4 Information. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 41 , to select Add New and repeat all Set the time: steps mentioned above. ▶ Touch the symbol Display shows Clock and Date menu. ▶ Touch the symbol to set the Clock. Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 42 Adjust “LCD display” position (Fig. 36, [7]); The burner will not activate while the appliance is in vacation mode. • Vertical • Horizontal ▶ Touch the symbol Display shows Vacation menu. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 43 This menu allows you to choose the units visible on the display. Fig. 47 Backlight control menu ▶ Touch the symbol ▶ Use the symbols to select DIM. ▶ Touch the symbol Fig. 45 A9 - Units Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 44: Service Menu - Au Technical Settings

    PF - Bypass Activation • PA - Actuator The water actuators calibration process takes several minutes. LM Temperature Limited ▶ Do not interfere with the appliance. Unlock the Temperature Limit 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 45: Gas Type

    49 and 50, to assure correct appliance performance. ▶ Access to menu P7 Gas Type. Display shows appliance gas type. ▶ Use the symbols to confirm gas type. Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 46: Maintenance And Service

    Immediately repair all faults to avoid damage to the system. Fig. 50 160kBTU appliance gas conversion kit ▶ Tighten the four screws. ▶ Open the gas supply valve. ▶ Turn On the appliance. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 47: Annual Maintenance

    7. Empty condensate trap. manufacturer's specifications. 8. Reconnect the water fittings and return the heater to service when danger of freezing has passed. Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 48: Mineral Scale Build-Up

    ▶ Close the cold water shutoff valve and reconnect hot water 60Hz properly grounded circuit required). Confirm power supply to the water heater. to the heater. ▶ Close the outlet drain connection. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 49: Water Is Too Hot

    See fig. 2, page 10 for location of rating If this slows the flow through the tankless water heater plate. below its deactivation point, it will shut off the burner. Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 50: Noisy Burner/Heater During Operation

    8.7.2 Low pitch noise 1. Verify if correct gas type is selected (see section 6.9). 1) Manifold gas pressure may differ from value on the rating plate for altitude installations. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 51: Adjusting Gas/Air Flow

    Manifold gas pressure refers to the relative pressure between gas manifold nozzles inlet and outlet [A]-[B]. Value Date Manifold gas pressure Table 22 Fig. 53 Combustion Auto Adjust ▶ Turn Off the appliance. Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 52 First step - Accessing the AU Technical Settings menu turning off backup appliances (i.e. ▶ Touch the symbol solar). Display shows P4 Information. ▶ Touch symbols to select AU Technical Settings menu. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 53 2) A2 Auto Adjust will calculate automatically the amount of 1) Increase L1 Gas Adjust parameter to increase output air in low fire (P2). This method uses P1 values to start power and vice-versa. calculation. Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 54 A2 Air Adjust - ION 1) Increase L2 Gas Adjust parameter to increase output 2) Increasing A2 values will cause a decrease in ION values power and vice-versa. and vice-versa. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 55: Co Emissions Check

    199 000 BTU Nat. Gas max. input 8.5 % - 8.9 % < 250 ppm min. input < 100 ppm LP Gas Table 25 CO & CO target numbers Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 56: Problem Solving

    Outlet hot water temperature sensor [17] ▶ Check connections or replace sensor. disconnected or damaged. ▶ Replace the sensor and/or wire connections, if the problem persists. Table 27 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 57 Water flow above 9.2gpm. ▶ Disconnect the appliance and purge hydraulic circuit to remove air. ▶ Install water flow restrictor. ▶ Check water pressure does not exceed 150psi.(section 3.2). Table 27 Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 58 ▶ Reset error (touch and hold on/off button for 3 seconds). If the problem persists: ▶ Check sensor resistance [18] (section 11) and replace the sensor if it is not according to 1) 2) specification. Table 27 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 59 ▶ Replace electronic control unit. Electronic control unit internal error. ▶ Reset error (touch and hold on/off button for 3 seconds). If the problem persists: ▶ Replace electronic control unit. Table 27 Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 60 Once the problem is solved, you may have to reset the error (touch and hold button for 3 seconds). Error reset will only take effect if error is visible on the display. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 61: Electrical Diagram

    Electrical diagram | 61 Electrical diagram Fig. 63 Electrical diagram Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 62 [19] Heat exchanger hot water temperature sensor [20] Inlet cold water temperature sensor [21] External water temperature sensor/Aquastat [22] Main water valve [23] Cascading in/Out [24] Touch control display connection 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 63: Sensor Resistance Charts

    6720816948-40.1V Fig. 64 Inlet, outlet and heat exchanger water temperature sensors characteristics 0.01 RESISTANCE (KOHM) 6720816948-41.1V Fig. 65 Flue gases and condensing unit flue gases temperature sensors characteristics Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 64: Interior Components Diagram

    [16] Condensate trap [7] Condensing unit [17] By-pass water valve [8] Main water valve [18] Ionization sensor [9] By-pass pipe [19] Ignition electrodes [10] HE drain [20] PRV connection 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 65: Btu Interior Components

    [18] Ionization sensor [7] Condensing unit [19] Ignition electrodes [8] Main water valve [20] PRV connection [9] By-pass pipe [10] HE drain [11] Power cord [12] Gas connection Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)
  • Page 66: Protecting The Environment

    2) See Chapter 4.13 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. Additional copies of the installation manual are available at www.boschheatingandcooling.com. 6 720 816 815 (2017/06) Greentherm 9800 SE 160/199 | SEC 199...
  • Page 67 | 67 Notes Greentherm 9800 SE 160/199 | SEC 199 6 720 816 815 (2017/06)

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