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Bosch AQUA STAR 2400E LP Installation And Operating Instructions Manual

Temperature modulated with electronic ignition suitable for heating potable water only
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MODEL 2400E NG and 2400E LP - INDOOR MODEL
Temperature Modulated with Electronic Ignition
Not approved for space heating purposes
2400 E NG - Natural Gas
2400 E LP - Liquefied Petroleum (LP) Gas
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,
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.
Suitable for heating potable water only
(Intended for variable flow applications)
adjustment,
alteration,
What to do if you smell gas
• Close gas valve. Open windows.
• 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.

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  Summary of Contents for Bosch AQUA STAR 2400E LP

  • Page 1 MODEL 2400E NG and 2400E LP - INDOOR MODEL Temperature Modulated with Electronic Ignition Suitable for heating potable water only Not approved for space heating purposes (Intended for variable flow applications) 2400 E NG - Natural Gas 2400 E LP - Liquefied Petroleum (LP) Gas Warning: If the information in this manual is not What to do if you smell gas followed exactly, a fire or explosion may result...
  • Page 2: Table Of Contents

    Index Index Warning Warning For your safety Appliance details Features Do not store or use gasoline or other flammable, 2400 E Specifications (Technical data) combustible or corrosive vapors and liquids in the Unpacking the 2400 E heater General rules to follow for safe operation vicinity of this or any other appliance.
  • Page 3 Warning 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 opera- tion.
  • Page 4: E Specifications (Technical Data)

    Sulfid) • Horizontal vent termination kit (Part # 4TWHVK3S) . • Minimum water flow for activation: 0.8 gallon/minute (3 l/m) BOSCH is constantly improving its • Minimum recommended water pressure: 30 PSI products, therefore specifications are (2.07 bar) subject to change without prior notice.
  • Page 5 The 2400 E must be plumbed in line Unpacking the 2400 E heater before the mini-tank water heater and supplied with cold water only. Contact Bosch Water Heating if further Before installing the unit, be certain you have the instruction is needed.
  • Page 6 Appliance details B 11. The heater must not be installed in an unheated General rules to follow for safe area where temperatures will reach 36°F or lower. If operation the heater is left in an area susceptible to such B 1. You must follow these instructions when you temperatures, refer to Section 5.4 on Winterizing.
  • Page 7 Appliance details Dimensions and Minimum installation clearances Fig. 4 Dimensions Cover On/Off switch Reset button LCD display Program button Temperature buttons Fig. 5 Minimum clearances Model 2400 E TOP (A) 12” FRONT (B) 1” BACK 0” SIDES 1” FLOOR (C) 12”...
  • Page 8: Installation Instructions

    B. Front 1 inches (25 mm) plumber or gas technician. C. Back 0 inches Please contact Bosch Water Heating with any D. Sides 1 inches (25 mm) questions. E. Bottom 12 inches (306 mm)
  • Page 9: Combustion Air Requirements

    Installation instructions pitch down towards termination ¼ inch for every foot of horizontal length. Single pipe method: Although it is permissible to draw combustion air from the inside, it is not the manufacturer’s recommended installation method. Always install a 3 inch elbow on the top of the combustion air inlet adaptor to prevent foreign objects from falling into the unit.
  • Page 10 Installation instructions Fuel Gas Code. Consult a HVAC specialist if your air infiltration rate is questionable. The space must have two permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure.
  • Page 11: Venting

    Bosch Water Heating will not be responsible for improperly installed Fig. 8 Minimum exhaust vent length appliances. 3.6.1 Vent material and specifications Establish vent clearances that comply with the vent manufacturer's specifications.
  • Page 12: Vent Connections

    Installation instructions may result in a hazardous condition. For specific page 33. Correct the problem and then reset the heater questions concerning vent material, specifications, before operating. usage or installation, contact the vent manufacturer 3.6.2 Vent connections directly. Exhaust vent connection Vent manufacturer Contact information B Attach the flue gas exhaust accessory (8 705 504...
  • Page 13: Condensate Drain Tube Requirements

    Installation instructions 3.6.3 Condensate drain tube requirements Note: Condensate must be disposed of according to local codes. Exhaust collar condensate drain installation Note: Do not install condensate drain in areas where it (supplied with heater) may freeze. B The condensate drain tube kit must be used for all 1.
  • Page 14: Vertical Terminations

    Installation instructions B Use of two 90° elbows (candy-cane) is an accepta- a 3" or 4" pipe from the outside. See Chapter 3.5 for more direction on combustion air. ble termination for combustion air intake from the roof. See Fig. 15 for an example. B To reduce pressure differentials between the exhaust B Screening (no smaller than 1/4"...
  • Page 15: Horizontal Terminations

    Installation instructions The masonry chimney may have to be tile or metal lined alarm is installed on each additional level of the dwell- before the insertion of the gas vent pipe; check local ing, building or structure served by the side wall hor- izontal vented gas fueled equipment.
  • Page 16 Installation instructions 1. Detailed instructions for the installation of the vent- ing system or the venting system components: and 2. A complete parts list for the venting system design or venting system. (d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a product approved side wall horizontally vented gas fueled equipment does not provide the parts for the venting of flue gases, but...
  • Page 17 Installation instructions Recommended exhaust vent terminator clearances Fig. 17 Ref. Description Minimum distance Directly below an opening; operable windows, doors and any non- 36 in (twin pipe installation) mechanical fresh air openings 48 in (single pipe installation) Below a gutter, sanitary pipework or eaves 24 in Below a gutter, sanitary pipework or eaves, protected by metal 12 in...
  • Page 18: Exhaust Vent Configuration Examples

    Installation instructions 3.6.7 Exhaust vent configuration examples Supporting the exhaust vent system Fig. 18 Horizontal side wall venting installation (combustion air piping not shown) Note: Pitch venting up 1/4" per foot to termination and add additional condensate drain for vent runs longer than 5 linear feet.
  • Page 19: Gas Piping & Connections

    Installation instructions Gas piping & connections manufacturer’s sizing tables to determine the pipe diameter necessary to accommodate the 175,000 BTU Before connecting the gas supply, check the rating demand of the heater. If there are more gas drawing plate on the right side of the heater to be sure that the appliances on the line, size the gas line according to the heater is rated for the same gas to which it will be total maximum amount of BTU draw for all appliances.
  • Page 20 Installation instructions 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 E (example: ¾”...
  • Page 21: Measuring Gas Pressure

    Installation instructions Measuring gas pressure Confirm proper gas pressure upon installation. Connecting Manometer B Shut off gas supply at installer supplied shutoff valve. B Remove front cover and locate inlet gas pressure measuring point (see Fig. 24). B Loosen screw inside left test point fitting (do not remove) and connect manometer tube to test point.
  • Page 22: Water Connections

    Installation instructions Water connections or flush the lines before connecting to the water heater. B Full port shutoff valves should be installed on both Warning: This heater must be supplied with cold potable water. It is not the cold water supply and hot water outlet lines to approved preheated water...
  • Page 23: Electrical Connections

    The 2400 E must be supplied with cold water only and plumbed in line 3.11 Cascading function before the mini-tank water heater. Contact Bosch Water Heating if further information is needed. Cascading enables the appliance to be connected in parallel with up to 4 appliances.
  • Page 24: Operation Instructions

    For your safety, read before oper- control switch is jammed, close the gas supply and call ating your water heater Bosch Technical Support. Attempted forceful repair may result in a fire or explosion. Warning: The front cover of this D. Do not use this appliance if any part has been under...
  • Page 25: Temperature Selection

    Operation instructions B To shut down the appliance move the on/off switch to the “off” position (0). Temperature selection To select output water temperature: B Press buttons in order to reach desired temperature. Fig. 30 If the outlet water temperature is set too high, the heater can produce temperatures that are too hot.
  • Page 26 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 E 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.
  • Page 27: Use Of Optional Remote Control Accessory

    Operation instructions B press reset button in order to return heater to normal Use of optional remote control operation. accessory Fig. 35 Reset button If the problem persists or error code will not reset, contact your installer. Fig. 32 Remote control Program button The wireless remote control accessory and the temperature selector buttons on the front of the water...
  • Page 28: Maintenance And Service

    Maintenance and service Maintenance and service Descaling Warning: Always turn off the electrical • In areas where the water supply has a high mineral power supply, turn off the manual gas content, the heat exchanger may need to be flushed valve and turn off the manual water with a descaling solution.
  • Page 29: Mineral Scale Build-Up

    Maintenance and service Mineral scale build-up 16.Reconnect electrical supply to unit, open water isolation valves, and return the unit to service. Periodic descaling may be necessary in areas with high mineral content in the water. Scale buildup in the heat exchanger may result in lower flow rates, error codes of A7 and E9 and boiling sounds in the heat exchanger.
  • Page 30 Maintenance and service pipe (approx 1.5" inserted). Avoid air gaps between Max CO probe and measuring port as it can alter readings. level level Nat. Gas 9.7 ± 0.3 % max. input 300 ppm 9.5 ± 0.5 % min. input LP Gas 10.7 ±...
  • Page 31 Maintenance and service Fig. 43 Adjusting P2 CO level 3. Verify both P1 and P2 CO readings are within the ranges specified in table 10. Repeat steps 1 and 2 as necesssary until CO values are within the specified ranges. 4.
  • Page 32: Control Board Diagnostics

    Maintenance and service Control board diagnostics Diagnostic menu 1. Turn on/off switch on water heater to off (O) position. Entry/Exit into sub-modes 2. Press and hold the program ( ) button while Set-point temperature turning the on/off switch to the on (I) position. The display will cycle through a startup procedure Inlet water temperature (F) including the software version.
  • Page 33: Troubleshooting

    Troubleshooting Troubleshooting unit's front cover (See Page 5. Fig 3). Check wire Warning: If you are unable to perform connections between the water valve, control unit the tasks listed below, or need and electrode set. See chapter 9.2 for location of additional assistance please contact these parts.
  • Page 34: Low Water Flow/Pressure

    Troubleshooting 7. Cold water is mixing into the hot water lines each step below before proceeding to the next. After (plumbing crossover). A plumbing crossover can each step, test the hot water flow to see if it remains unintentionally mix cold water with the hot water constant without turning cold.
  • Page 35 Troubleshooting 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 correct accordance with specifications in chapter 3.6. 3. Lack adequate combustion air.
  • Page 36: Error Code Diagnostics

    5. Check supply voltage is 120VAC and is properly grounded. 6. Possible defective control unit. Call Bosch Water Heating for further instructions. Table 12 * By installer or service technician only.
  • Page 37 5. Check gas pressure. See chapter *. Low gas pressure may cause the fan to change its speed to meet desired temperature. 6. Possible defective control unit. Call Bosch Water No rotational speed sensor from fan. 1. Disconnect power supply cord. Check wire (part# 8707204039) connections on back side of fan and the two large wire connectors on the control unit.
  • Page 38 Troubleshooting Display Cause Solution Over-temperature detected by temperature 1. This water heater must be supplied with cold sensor on hot water pipe. water for domestic hot water only. Do not (part# 8700400015) recirculate water through this heater or supply with preheated water.
  • Page 39 7. Observe inside the viewing window of the heat exchanger when a hot water tap is opened. Sparking should be followed by a steady blue flame. If not, Call Bosch Water Heating with observations. Readings from above gas pressure test will be required.
  • Page 40 If voltage is not correct, contact Bosch Water Heating for further instruction. 3. Gas valve may be defective, contact Bosch Water Heating for further instruction. Electronic noise on control unit. 1. Improper resetting of other error codes. Using the...
  • Page 41: Electrical Diagram

    Electrical diagram Electrical diagram Fig. 44 Electrical scheme Intlet water temperature sensor Ionization sensor Water flow sensor Flue gas limiter Temperature limiter / ECO Gas valve 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...
  • Page 42: E Functional Scheme

    2400 E Functional scheme 2400 E Functional scheme Fig. 45 Functional scheme 6 720 608 263...
  • Page 43: Interior Components Diagram And Parts List

    Interior components diagram and parts list Interior components diagram and parts list Interior components Fig. 46 Components Cover On/Off switch Reset button LCD display Program button Temperature switches Flue gas collector Mixer Heat exchanger Observation window Inlet air duct Control unit Exhaust fan Water valve Gas valve...
  • Page 44: Components Diagram

    Interior components diagram and parts list Components diagram Fig. 48 Components Diagram 6 720 608 263...
  • Page 45: Parts List

    8 700 103 710 Gasket Set Combustion Chamber 8 704 701 046 O-ring air duct 8 700 205 149 “BOSCH” decal 8 701 103 124 Cold water connection bushing 8 703 305 295 Hot water connection bushing 8 703 305 297...
  • Page 46: Protecting The Environment

    Protecting the environment 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.
  • Page 47: Twelve Year Limited Warranty

    Service Labor Costs Aquastar water heaters are warranted by the This warranty does not cover any labor costs Manufacturer (BOSCH) through BBT North America. associated with service, removal or re-installation of BBT North America (BBTNA) will furnish a replacement part(s). All such costs must be borne by the Purchaser.
  • Page 48 Replacement Parts available from: BBT NORTH AMERICA Bosch Group Bosch Water Heating BBT Termotecnologia Portugal S.A. 340 Mad River Park Estrada de Cacia Waitsfield, VT 05673 3801 - 856 Aveiro - PORTUGAL Phone 800-642-3111 Fax (802) 496-6924 www.boschhotwater.com techsupport@boschhotwater.com Recycled paper ©...

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Aqua star 2400e ngAquastar 2400e lpAquastar 2400e ng