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Bosch Integra 500 Installation Manual

Temperature modulated with electronic ignition
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Integra 500
INDOOR MODEL
Temperature Modulated with Electronic Ignition
Suitable for heating potable water - Not approved for space heating purposes
(Intended for variable flow applications)
Integra 500 - Natural Gas
Integra 500 - 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
vapors 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.
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.
• 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.

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  Summary of Contents for Bosch Integra 500

  • Page 1 Suitable for heating potable water - Not approved for space heating purposes (Intended for variable flow applications) Integra 500 - Natural Gas Integra 500 - 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

    3.13 Measuring gas pressure Sensor resistance charts Electrical connections Electrical power supply Position of the fuses in control unit Integra 500 Functional scheme Operation instructions Interior components diagram Description LCD Display and parts list For your safety read before operating 12.1 Interior components...
  • Page 3: Warning

    Warning Warning For your safety Warning: The appliance should be Do not store or use gasoline or other flammable, located in an area where leakage of the combustible or corrosive vapors and liquids in the heater or connections will not result in vicinity of this or any other appliance.
  • Page 4: Appliance Details

    6720608643-16.1AL Fig. 1 • Condensate drain tee (196061) [included with Con- centric termination kit]. BOSCH is constantly improving its products, therefore specifications are subject to change without prior notice. 1) The freeze prevention kit is designed to provide protection for the water heater down to approximately 5°F for short term conditions only.
  • Page 5: Specifications (Technical Data)

    Appliance details Specifications (Technical data) Dimensions • Depth (in): 11¼” (286 mm) Approved in US/Canada • Width (in): 17 ” (452 mm) Capacity • Height (in): 30½” (775 mm) Maximum flow rate: 8.0 GPM (30 l/min) at a 45°F • Weight: 74 pounds (33.5 kg). (25°C) rise.
  • Page 6: Unpacking The Heater

    B Lift front cover panel upward and remove. Serial number Type of gas The box includes: • Integra 500 • Pressure relief valve (150 psi / 200,000 Btu rating) • Bracket for wall hanging the heater • Exhaust vent adaptor (with 4 screws and gasket provided) •...
  • Page 7: General Rules To Follow For Safe Operation

    Appliance details General rules to follow for safe B 10. Failure to install heater correctly may lead to unsafe operation and void the warranty. operation B 1. You must 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.
  • Page 8: Installation Clearances

    Appliance details Dimensions and minimum installation clearances 6720608000-03.2AL Fig. 6 Dimensions On/Off button Model Integra 500 Reset button Program key TOP (A) 12” Power ON or stand-by LED LCD display FRONT (B) 1” Up button BACK 0” Down button SIDES 1”...
  • Page 9: Installation Instructions

    Bosch Failure to do so may result in heat Thermotechnology Corp. exchanger freezing and bursting. This responsible improperly...
  • Page 10 Installation instructions 3.3.1 Vent material Kit part no. All combustion air and vent pipe materials and fittings Description Length and quantity must comply with the following: 196016 Item Material United States Canada 3- In. Rain Cap PVC schedule 40 ANSI/ASTM D1785 4- In.
  • Page 11 Installation instructions 3.3.2 Vent specifications Step 1: If using the twin pipe penetration system, refer to table 5. If using the concentric vent kit Establish vent clearances that comply with the vent system, refer to table 6. manufacturer's specifications applicable national/local codes.
  • Page 12 Installation instructions Required direct vent terminal clearances (twin pipe / concentric penetration) 6720608836-23.1Av Fig. 9 Canadian installations U.S. installations Clearance above grade, veranda, porch, deck or balcony 12 in. 12 in. Clearance to window or door that may be opened 36 in.
  • Page 13 Installation instructions Required other than direct vent terminal clearances (single pipe penetration) 6720608836-23.1Av Fig. 10 Canadian installations U.S. installations Clearance above grade, veranda, porch, deck or balcony 12 in. 12 in. Clearance to window or door that may be opened 36 in.
  • Page 14 Installation instructions 3.3.3 Vent configuration examples Below are approved examples of vertical and horizontal venting installations. MAINTAIN 12 IN. (18 IN. FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF. EXHAUST 6720608836-25.1Av Fig. 13 Horizontal parallel venting system (twin pipe INTAKE direct vent) DRAIN TEE...
  • Page 15 Installation instructions 3.3.4 Vent connections 3.3.5 Connecting the condensate water drain Warning: Attaching the exhaust and air inlet connection adaptors to the top of the heater B Failure to properly install condensate drain can damage the appliance and will B Attach the flue gas exhaust accessory to the top of void the warranty.
  • Page 16 Installation instructions External condensate drain installation 3.3.6 Fan speed adjustment If an external condensate drain (installer supplied) must ! IMPORTANT INFORMATION: be installed (Section 3.3.2), the following Natural gas heaters with installation altitudes recommended: below 2,000 ft above sea level disregard this section.
  • Page 17 Installation instructions Summary Exhaust Exhaust Straight section length __ = ____ Straight section length (feet) 11 x 1 = 90° elbows (qty) __ x 5 = ____ 90° elbows (qty) 0 x 5 = 45° elbows (qty) __ x 3 = ____ Total: ____...
  • Page 18 Installation instructions Natural Liquid propane Altitude Maximum Maximum Vent Total equivalent Minimum power (above sea power fan power fan terminal vent length fan speed (P2) level) speed (P1) speed (P1) 8 - 25 ft Concentric 26 - 46 ft 0 - 2000 ft modification modification (0 - 610 m)
  • Page 19 Installation instructions Attention residents of the Commonwealth of Massachusetts: In the Commonwealth of Massachusetts the following signage installed in accordance with the provisions of regulation went into effect on 12/30/2005: 248 CMR 5.08(2)(a)1 through 4. (a)For all side wall horizontally vented gas fueled (b)EXEMPTIONS: The following equipment is exempt equipment installed in every dwelling, building or from 248 CMR 5.08(2)(a)1 through 4:...
  • Page 20: Combustion Air Requirements

    Installation instructions Combustion air requirements below for providing adequate combustion air for the water heater as well as any other appliances that may consume air in the same space. Always follow local Warning: In areas where outside codes if they are more stringent and regulations. temperatures routinely come close to freezing, sealed combustion operation •...
  • Page 21: Proper Location For Installing Your Heater

    Installation instructions Proper location for installing your Front cover should be removed (see heater instructions on page 6) in order to inspect components visually. Carefully select the location of the water heater. For your safety and for proper heater operation, you must provide combustion air to the heater and a proper Warning: Do not install this appliance exhaust vent system.
  • Page 22 Installation instructions 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.
  • Page 23 Installation instructions Minimum Gas supply 3” Inlet gas particle screen (included) Fig. 24 Gas connection Gas piping Once connections are made, check for gas leaks at all joints. Apply some gas leak detection solution to all gas Fig. 25 fittings. Bubbles are a sign of a leak. A combustible gas detector may also be used to detect for leaks.
  • Page 24 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 Integra 500 (example: ¾” B.I. Natural Gas pipe for 10 ft (3.0m). will handle 278,000 btu’s (81.5 kWh). For multiple appliances combine the total maximum btu input load and then refer to applicable chart below.
  • Page 25: Water Connections

    Centrally locating the water heater is recom- specified below, Bosch recommends consulting a local mended to keep hot water distribution times even water treatment professional for water softening/ throughout the structure.
  • Page 26: Domestic Hot Water Recirculation

    Timed or thermostatically controlled operation of the pump is commonly done. Contact Bosch Thermotechnology if further information is needed. 6 720 680 226...
  • Page 27: Filling The Condensate Trap

    Installation instructions 3.12 Filling the condensate trap B Fill the condensate trap by pouring approx.14 oz. (400ml) of water into the top of the drain tube. To The condensate trap can be filled before or after avoid damage to the appliance use a funnel in this connecting the vent pipe.
  • Page 28: Measuring Gas Pressure

    Installation instructions 3.13 Measuring gas pressure Gas pressures lower than 3.5" W.C. for Natural Gas or 8" W.C. for LPG will result in insufficient degree rise to Confirm gas pressure upon installation. the hot water being used, reduced hot water volume, possible error code faults and must be corrected.
  • Page 29: Electrical Connections

    Electrical connections Electrical connections Electrical power supply Position of the fuses in control unit To check fuses, proceed as follows: safety reasons, Warning: B Remove the front cover, see Fig. 4, page 6. disconnect the power supply cord to the heater before any service or testing B Remove the three screws from the control unit.
  • Page 30: Operation Instructions

    Operation instructions Operation instructions Fig. 40 On/Off button Reset button Program Key LCD display Up button Down button Power On or stand-by LED Description LCD Display Fig. 44 Locked condition indicator (only with remote Warning: Do not use any cleaning control) agressive or corrosive agents to clean the window.
  • Page 31: Temperature Selection

    Operation instructions For your safety read before Temperature selection operating your water heater To select hot water temperature: B Press buttons in order to reach desired Warning: If you do not follow these temperature. instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 32: Operation

    Operation instructions Solar mode Operation The water heater will not ignite if inlet water temperature B When a hot water tap is opened, main burner ignites exceeds the set temperature on the appliance. In this and LCD displays indication condition, the solar mode indicator will show on the LCD display.
  • Page 33: Locked Condition

    Operation instructions 5.8.1 Memorizing selected temperature B Press buttons to select desired temperature. B 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 B Press “Program”...
  • Page 34: Maintenance And Service

    Maintenance and service Maintenance and service Inlet water filter Warning: Always shut off the electrical • Verify the inlet filter screen is clean and undamaged. power supply, shut off the manual gas The inlet water filter is located inside the cold water valve and shut off the water valves inlet fitting on the right side of the appliance (See whenever servicing.
  • Page 35: Mineral Scale Build-Up

    (see Fig. 58.) tified Bosch technician. 6. Using another line (B), connect the water outlet fitting on the water heater. Route the other end of this line into a descaling reservoir.
  • Page 36 Maintenance and service Adjusting CO (carbon dioxide) The CO can only be adjusted by a certified gas technician with a calibrated CO analyzer. adjustment is required in Natural Gas installations where energy content is less than 900 BTU/cuft, and in installations with repeated unresolved EA and EC errors (ref.
  • Page 37 Maintenance and service B After bringing the P1 CO readings in proper range, press the button to enter the P2 mode. Verify readings in P2 mode. 2. If P2 CO level is off: B Remove yellow painted #40 Torx cover from the front of the gas valve.
  • Page 38: Program Values

    3.3.6, page 16 Remote see chapter 5.5, page 32 Controls installed Access to see chapter 6.7, page 39 Diagnostic Mode Cascade Mode contact Bosch for details Temperature Unit °F °F °C Appliance Type Condensing / Non-condensing note: incorrect setting will cause errors.
  • Page 39: Control Board Diagnostics

    Maintenance and service Control board diagnostics Diagnostic menu 1. Press ON/OFF button to turn off the appliance. Entry/Exit into sub-modes 2. Press and hold "Program" button and press Set-point temperature ON/OFF button to turn appliance ON. Inlet water temperature (°F) 3.
  • Page 40: Troubleshooting

    Troubleshooting Troubleshooting single lever faucet mixing valves are common causes Warning: If you are unable to perform of plumbing crossovers. the tasks listed below, or need 8. With the power button pressed switch turned to OFF additional assistance please contact and the power supply cord unplugged, remove the your original installer or a licensed gas unit's front cover (See Page 6.
  • Page 41: Low Water Flow/Pressure

    Troubleshooting 7. Cold water is mixing into the hot water lines www.boschpro.com for a detailed service bulletin on (plumbing crossover). A plumbing crossover can overcoming temperature fluctuations. unintentionally mix cold water with the hot water 2. Unbalanced pressure in water lines. Any restriction in leaving the heater.
  • Page 42 Troubleshooting 4. Cross contamination. Ensure that intake and exhaust terminations maintain required clearances as stated in chapter 3.3, page 9. Cross contamination between intake and exhaust may cause unstable burner flames and noise. 5. Lack of gas pressure. Inadequate gas pressure will cause the fuel-to-air mixture (CO ) to be out of adjustment.
  • Page 43: Problem Solving

    3. Check gas pressure. Low gas pressure may prevent the heater from reaching desired output temperature. 4. Check supply voltage. It must be 120VAC and properly grounded. 5. Possible defective control unit call Bosch Water Heating for further instructions. Table 20 * By installer or service technician only.
  • Page 44 5. Check gas pressure. Low gas pressure may cause the fan to change its speed to meet desired temperature. 6. Possible defective control unit call Bosch Water Heating for further instructions. No rotational speed sensor signal 1.
  • Page 45 (non-volatile). venting with more than three elbows, blocked vent or combination chapter 3.3 page 9 venting may cause this failure. See 4. Call Bosch Water Heating for further instructions. Overheat sensor (ECO) open 1. Disconnect power supply cord and check wire connections on Fig.
  • Page 46 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. 3. Gas valve may be defective, contact Bosch Water Heating for further instrucation.
  • Page 47: Electrical Diagram

    Electrical diagram Electrical diagram T=90°C T=194°F T=104°C T=220°F T=110°C T=230°F Casc. input Casc. output Back flow 6720608158-01.1AL Fig. 65 Electrical scheme Intlet water temperature sensor Outlet water temperature sensor Backflow temperature sensor Cascading output connection Cascading input connection Ionization sensor Water flow sensor Flue gas limiter Heat exchanger overheat sensor (ECO)
  • Page 48: Sensor Resistance Charts

    Sensor resistance charts Sensor resistance charts Outlet NTC characteristics 2 2 2 2 17 10 5 2 12 10 0 2 0 7 2 0 2 19 7 19 2 18 7 18 2 16 7 16 2 14 7 14 2 13 7 13 2...
  • Page 49 Sensor resistance charts Back Flow and Exhaust NTC characteristics 3 0 2 2 9 7 2 9 2 14 5 2 8 7 2 8 2 14 0 2 7 7 2 7 2 13 5 2 6 7 2 6 2 13 0 2 5 7 12 5...
  • Page 50: Integra 500 Functional Scheme

    Integra 500 Functional scheme Integra 500 Functional scheme Fig. 69 Functional scheme 6 720 680 226...
  • Page 51: Interior Components Diagram And Parts List

    Interior components diagram and parts list Interior components diagram and parts list 12.1 Interior components Fig. 70 Components Exhaust temperature sensor Ignition electrodes Flue gas collector Observation window Heat exchanger Backflow temperature sensor Ionization sensor Secondary air fan Primary fan (Mixer) Gas valve Hot water temperature sensor Condensate trap...
  • Page 52 Interior components diagram and parts list 6720680226-01.1Av Fig. 71 Appliance overview 6 720 680 226...
  • Page 53: Components Diagram

    Interior components diagram and parts list 12.2 Components diagram 12.2.1 Group 1 13 15 6720902973.AB JF Fig. 72 Components Diagram Item Description Reference Item Description Reference Combustion cover clip 8 701 201 032 Front cover 8 705 431 369 Grommet set 8 710 203 039 Cover shield 8 705 506 749...
  • Page 54 Interior components diagram and parts list 12.2.2 Group 2 6720902980.AA JF Fig. 73 Components Diagram 6 720 680 226...
  • Page 55 Interior components diagram and parts list Item Description Reference Heat exchanger 8 705 406 421 Heat exchanger top gasket 8 704 701 052 Condensing exchanger inlet 8 705 700 159 Overheat sensor (ECO) 8 707 206 204 Heat exchanger bottom gasket 8 704 701 054 Site window 8 701 000 401...
  • Page 56 Interior components diagram and parts list 12.2.3 Group 3 6720902975.AA JF Fig. 74 Components Diagram Item Description Reference Item Description Reference Gas / Air Mixer 8 705 700 170 Main burner (Natural Gas) 8 708 120 642 Venturi 8 700 306 226 Main burner (LP Gas) 8 708 120 699 O-ring...
  • Page 57 Interior components diagram and parts list 12.2.4 Group 4 6720902976.AA JF Fig. 75 Components Diagram Item Description Reference Item Description Reference Gas filter 8 700 507 002 Gas valve 8 707 021 019 Gasket 8 704 701 085 Pressure tapping 8 703 404 219 Gas / Fan connector 8 705 202 140...
  • Page 58 Interior components diagram and parts list 12.2.5 Group 5 Fig. 76 Components Diagram Item Description Reference Item Description Reference Inlet fitting with filter 8 703 305 356 Water valve with engine and 8 708 505 024 temperature sensor O-ring 8 700 205 157 O-ring 8 700 205 147 Watervalve clip...
  • Page 59 Interior components diagram and parts list 12.2.6 Group 6 Fig. 77 Components Diagram Item Description Reference Item Description Reference Flue gas limiter 8 700 400 032 Control unit 8 707 207 257 Cascading kit (optional) TLINK Fuse T2.5A 1 904 521 342 Freeze prevention kit 7 709 003 665 Fuse T1.6A...
  • Page 60: 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 61: Limited Warranty

    Bosch Thermotechnology Corp. shall be in lieu of any • 4. to failure of the heat exchanger resulting from the and all other warranties, express or implied, including...
  • Page 62 Limited Warranty 6 720 680 226...
  • Page 63 Limited Warranty 6 720 680 226...
  • Page 64 Installation manual should be left with the owner after the installation is tested and completed Replacement Parts available from: BOSCH THERMOTECHNOLOGY CORP. Bosch Termotecnologia SA 50 Wentworth Avenue Estrada de Cacia Londonderry, NH 03053 USA Tel. 866-330-2730 3801 - 856 Aveiro - PORTUGAL www.boschpro.com © 2009 Bosch Thermotechnology Corp., Londonderry, NH...