Bosch Integra 500 Installation Manual

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

6 720 680 226 (2009/03) US

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, 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. 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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Index

1 Warning 3

2 Appliance details 4

2.1 Features 4

2.2 Specifications (Technical data) 5

2.3 Unpacking the heater 6

2.4 General rules to follow for safe operation 7

2.5 Dimensions and minimum installation clearances 8

3 Installation instructions 9

3.1 Specialized tools 9

3.2 Introduction 9

3.3 Venting 9

3.4 Combustion air requirements 20

3.5 Proper location for installing your heater 21

3.6 Heater placement and clearances 21

3.7 Mounting installation 21

3.8 Gas piping & connections 22

3.9 Water connections 25

3.10 Water quality 25

3.11 Domestic hot water recirculation 26

3.12 Filling the condensate trap 27

3.13 Measuring gas pressure 28

4 Electrical connections 29

4.1 Electrical power supply 29

4.2 Position of the fuses in control unit 29

5 Operation instructions 30

5.1 Description LCD Display 30

5.2 For your safety read before operating your water heater 31

5.3 Power 31

5.4 Temperature selection 31

5.5 Use of optional remote control accessory (part no. TSTAT2) 32

5.6 Operation 32

5.7 Reset button 32

5.8 Program button 32

5.9 Locked condition 33

6 Maintenance and service 34

6.1 Annual maintenance 34

6.2 Winterizing for seasonal use 34

6.3 Mineral scale build-up 35

6.4 Condensing heat exchanger unit 35

6.5 Adjusting CO2 (carbon dioxide) 36

6.6 Program values 38

6.7 Control board diagnostics 39

7 Troubleshooting 40

7.1 Introduction 40

7.2 Burner does not ignite when hot water is turned ON 40

7.3 Water is too hot 40

7.4 Water is not hot enough 40

7.5 Low water flow/pressure 41

7.6 Hot water temperature fluctuates at tap 41

7.7 Noisy burner/heater during operation 41

8 Problem solving 43

8.1 Error code diagnostics 43

9 Electrical diagram 47

10 Sensor resistance charts 48

11 Integra 500 Functional scheme 50

12 Interior components diagram

and parts list 51

12.1 Interior components 51

12.2 Components diagram 53

13 Protecting the environment 60

14 Limited Warranty 61

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Warning

1 Warning

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. Correct combustion air supply and flue pipe installation are very important. If a gas appliance is not installed correctly, fatal accidents can result such as, carbon monoxide poisoning or fire.

Warning: Exhaust gas must be vented to outside using approved vent material See table 2, page 10 (For Canada use only ULCS636 approved material). Vent and combustion air connector piping must be sealed gas-tight to prevent possibility of flue gas spillage, carbon monoxide emissions and risk of fire, resulting in severe personal injury or death. Approved vent terminators must be used when penetrating to the outside.

Warning: Place the heater in a location where water leaks will do NO DAMAGE to adjacent areas or lower 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, unplug power supply cord from outlet. Failure to do so could result in severe personal injury or death.

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.

Warning: The appliance should be located in an area where leakage of the heater or connections will not result in damage to the area adjacent to the appliance or to lower floors of the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow.

Warning: The maximum inlet gas pressure must not exceed the value specified by the manufacturer and that the minimum value listed is for the purposes of input adjustment.

Warning: If a water heater is installed in a closed water supply system, such as one having a backflow preventer in the cold water supply line, means shall be provided to control thermal expansion. Contact the water supplier or local plumbing inspector on how to control this situation.

Warning: Keeping appliance area clear and free from combustible materials, gasoline and other flammable vapors and liquids.

Warning: Do not obstruct the flow of combustion and ventilation air.

Warning: Precautions must be taken prior to manually operating the relief valve to avoid contact with hot water coming out of the relief valve and to prevent water damage.

Caution: Label all wires prior to disconnection when servicing controls. Wiring errors can use improper and dangerous operation. Verify proper operation after servicing.

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Appliance details

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.

Fig. 1

2 Appliance details

2.1 Features

Parts

• Key Pad interface control

• High power pre-mix compact burner with low NOx

emissions

• Modulating Gas Valve with constant gas:air ratio

control

• Modulating water valve for improved comfort and

temperature control.

High quality materials for long working life

• Copper heat exchanger

• High efficiency Ceramat Burner

• Compact space saver: mounts on a wall with a

supplied bracket.

Features

• Easily removable one-piece cover

• LCD Display with backlight

• On/Off and Temperature control switches

• Reset button

• Program button (Selectable temperature default)

• Failure codes for easy diagnostics and repair

• Real-time diagnostics for troubleshooting/informa-

tional purposes.

Accessories (Bosch part #)

• Optional wireless remote control to operate with the

appliance (TSTAT2)

• Cascading kit (TLINK)

• Outdoor kit (BSHTOK)

• External water filter (part # 8 703 305 356)

• Concentric termination kit (196016)

• Freeze prevention kit (7709003665)

• Exhaust/Intake bird screen (L2594)

• Condensate drain tee (196061) [included with Con-

centric termination kit].

Warning: If a relief valve discharges periodically, this may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct this situation. Do not plug the relief valve.

HOT

BURN

D A N G E R

Watertemperatureover125°Fcan causesevereburnsinstantlyor deathfromscalds.

Children,disabledandelderlyare athighestriskofbeingscalded.

Seeinstructionmanualbefore settingtemperatureatwater heater.

Feelwaterbeforebathingor showering.

6720608643-16.1AL

1) The freeze prevention kit is designed to provide protection for the water heater down to approximately 5°F for short term conditions only. It will not protect the appliance in areas where the temperature is routinely expected to be below freezing.

- The freeze prevention kit will not protect plumbing outside the appliance from freezing. Precautions should be taken.

BOSCH is constantly improving its products, therefore specifications are subject to change without prior notice.

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Appliance details

2.2 Specifications (Technical data)

Approved in US/Canada

Capacity

Maximum flow rate: 8.0 GPM (30 l/min) at a 45°F (25°C) rise.

Maximum output

179,300 Btu/h (52.5 kW)

Maximum input

195,000 Btu/h (57.1 kW)

Efficiency in %

Thermal efficiency > 92%

Minimum Input

19,900 Btu/h (5.8 kW)

Temperature Control

Selection range: 100°F (38°C) - 140°F (60°C) Default temperature: 122°F (50°C) Stability: +/- 2°F (+/- 1°C)

Gas Requirement

Gas connection (inches) - ¾”

Inlet gas pressure under operation (with a high hot water flow rate)*

• Propane: 8” - 13” water column

• Natural Gas: 3.5” - 10.5” water column. * To measure Gas Pressure, see Measuring Gas

Pressure, chapter 3.13, page 28.

Water

• Hot water connection (inches) - ¾”

• Cold water connection (inches) - ¾”

• Water valve material: Polymer (PPS) (Polypropylene Sulfid)

• Minimum water flow: 0.65 gallon/minute (2.5 l/m) Note: Activation varies with inlet water temperatures from 0.65 - 1.6 gallon/minute (2.5 - 6.1 l/m).

• Minimum recommended water pressure: 30 PSI (2.07 bar)

• Minimum well pressure 40 psi, see page 25.

• Connections: – Bottom of heater

Combustion

• NOx ≤ 14 Ng/J

(Nanograms of NOx (calculated as NO2) per

Joule of heat output).

• CO ≤ 290 ppm (measured)

• CO

level set from factory, see chapter 6.5, page 36.

Dimensions

• Depth (in): 11¼” (286 mm)

• Width (in): 17

” (452 mm)

• Height (in): 30½” (775 mm)

• Weight: 74 pounds (33.5 kg).

Gas types

Natural Gas. LP Gas.

Voltage

120 V AC (60 Hz) nominal

Amperage

Idle - 40 mA Operation - ≤ 2.5 A

Noise

45 - 65 db (A)

Safety devices

• Flame failure device (ionization flame rod sensor)

• Pressure relief valve (supplied with heater)

• Over heat prevention (temperature limiter)

• Inlet temperature sensor

• Outlet temperature sensor

• Back flow temperature sensor

• Exhaust gas temperature sensor.

Water protection

IP X4 (protection against water drops)

If appliance is installed at elevations above 2000ft, refer to Section 3.3.6 Fan speed adjustment.

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Appliance details

2.3 Unpacking the heater

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.

Fig. 2 Rating plate

A Serial number B 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)

• Combustion air inlet adaptor (with 3 screws and gasket provided)

• Installation manual (manual can be downloaded at www.boschpro.com)

• Product registration card

• Energy Guide label.

Please complete and return the enclosed product registration card.

The water heater is not approved or designed for:

• Manufactured (mobile) homes, boats or any mobile installation. (Modular homes are acceptable for installation).

• Use above 8000 ft A.S.L. altitude (see page 18).

• Outdoor installation without installation of

Outdoor kit (PTOK).

• Applications where inlet water temperature is higher than 140°F (60°C). A 3-way valve or mixing valve must be installed before the appliance if inlet water temperature exceeds this limit.

• Space heating purposes.

To remove front cover

B Loosen the two Philips head screws located on

bottom rear of cover (see Fig. 3).

Fig. 3 Loosen the two screws

B Lift front cover panel upward and remove.

Fig. 4 Remove the front cover

To remove combustion cover (service only)

B Open the four clips and remove the combustion

cover (see Fig. 5).

Fig. 5 Remove the combustion cover

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Appliance details

2.4 General rules to follow for safe 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. In Canada: The Installation must conform with CSA B149.(1,2) INSTALLATION CODES and /or local installation codes.

B 2. Carefully plan where you install the heater. Correct

combustion air supply and vent pipe installation are very important. If not installed correctly, fatal accidents can occur, such as carbon monoxide poisoning or fire.

B 3. When the unit is installed indoors and ROOM

SEALED (twin pipe) it is permitted to be located in bathrooms, bedrooms and occupied rooms that are normally kept closed. See chapter 3.3 (page 9). If the unit will be installed indoors and use indoor combustion air, the place where you install the heater must have enough ventilation. 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 3.4 (page 20).

B 4. You must correctly vent your heater. See

chapter 3.3 (page 9) on VENTING.

B 5. The appliance and its gas connection must be leak

tested before placing the appliance in operation. 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).

B 6. Keep water heater area clear and free from

combustibles and flammable liquids. Do not locate the heater over any material which might burn.

B 7. Correct gas pressure is critical for the proper

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. See chapter 3.8 (page 22).

B 8. 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 but must be field installed.

B 9. 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.

B 10. Failure to install heater correctly may lead to

unsafe operation and void the warranty.

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Appliance details

2.5 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

Fig. 7 Minimum clearances

Note: For servicing access, a 2ft clearance is recommended to the front cover.

6720608000-03.2AL

Model Integra 500

TOP (A) 12”

FRONT (B) 1”

BACK 0”

SIDES 1”

FLOOR (C) 12”

Table 1 Minimum clearances

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Installation instructions

3 Installation instructions

3.1 Specialized tools

The following specialized tools may be required for installation:

• Manometer

• Multi-meter

• Combustion Gas Analyzer.

3.2 Introduction

Please follow these instructions. Failure to follow instructions may result in:

B Damage or injury. B Improper operation. B Loss of warranty.

3.3 Venting

Warning: The water heater must be

installed by a qualified installer in accordance with these instructions. If improperly installed, a hazardous condition such as explosion or carbon monoxide poisoning could result. Bosch Thermotechnology Corp. is not responsible for improperly installed appliances.

Common installation practice is to first determine the venting/ combustion air point of termination, then design the piping layout back to the heater.

Warning:

B Do not reduce the exhaust or

combustion air vent pipe sizes.

B Do not common vent with any other

vented appliance or stove.

B Do not use Type-B vent as the actual

exhuast vent system for the appliance.

Warning: Failure to vent the exhaust gases to the outside (see Table 2 for proper material) may result in dangerous flue gases filling the structure in which it is installed.

Warning: In areas where outside temperatures routinely come close to freezing, sealed combustion operation is required. Concentric termination or separate terminations for combustion and vent, must be installed on the same wall or roof surface; however, never facing the direction of prevailing winds. Failure to do so may result in heat exchanger freezing and bursting. This failure is not covered under the manufacturer's warranty.

Warning: Protect the exhaust and inlet from leaves and debris by installing a screen on the end of the terminator. ¼" mesh minimum opening recommended on screen.

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Installation instructions

3.3.1 Vent material

All combustion air and vent pipe materials and fittings must comply with the following:

For specific questions concerning vent material, specifications, usage or installation, please contact the vent manufacturer directly.

All vent connections must be glued, except for the exhaust accessory (see section 3.3.4) which is screwed into place on the top of the appliance. Slide the vent pipe into the exhaust accessory. The exhaust pipe must be properly supported and must be pitched a minimum of a ¼ inch per foot back to the appliance. This allows the condensate to drain properly.

An optional concentric vent/air intake termination can be used for the installation of a vertical or horizontal venting system. (see Fig. 8). The concentric vent/air intake body can be ordered from your local wholesaler. (Part# 196016). The appliance can also be installed with separate air intake and exhaust piping (see Fig. 11, Fig. 17 and Fig. 18, page 16).

Fig. 8 Concentric vent kit example

Item Material United States Canada

Vent or air pipe

and

fitting

PVC schedule 40 ANSI/ASTM D1785

CSA or ULC certified only (ULC-S636)

PVC-DWV ANSI/ASTM D2665

CPVC schedule 40 ANSI/ASTM F441

ABS-DWV schedule 40 ANSI/ASTM D2661

Pipe

cement /

primer

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

ABS ANSI/ASTM D2235

Table 2 Approved vent material

Do not use cellular foam core pipe.

Description Length

Kit part no.

and quantity

196016

3- In. Rain Cap N/A 1

4- In. Diameter SDR-26 Pipe

24 In. long 1

3- In. Y Concentric Fitting

N/A 1

2- ½ In. Diameter SDR-26 Pipe

37-1/8 in. long 1

3- In. Termination Tee (part #

196061)

N/A 1

3x3x1.5- In Condensate drain bushing (part# 196278)

N/A 1

Table 3 Concentric vent part breakdown

6720608836-27.1Av

3 (76mm)"

INTAKE

EXHAUST

COMBUSTION AIR

MAINTAIN 12 IN. (18 IN. FOR CANADA) MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF.

EXHAUST

ROOF BOOT/ FLASHING (FIELD SUPPLIED

DRAIN TEE

(196278)

CONCENTRIC VENT KIT (196016)

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Installation instructions

3.3.2 Vent specifications

Establish vent clearances that comply with the vent manufacturer's specifications and all applicable national/local codes.

Venting specifications

Condensate drain requirements

An external condensate drain (not supplied with the heater) must be installed under the following conditions:

• All vertical terminating vent installations.

• Horizontal terminating vent installations where the

total linear vent length is greater than 6 feet (1.8 m).

• Vent installations where any section of the exhaust

vent pipe passes through an unconditioned space.

Minimum combustion air and exhaust pipe length

The minimum exhaust pipe length is 3 feet (1m) of straight vent pipe. The minimum combustion air pipe length is one 90° elbow.

Maximum combustion air and exhaust pipe length

The following tables (Tables 5 & 6) display the maximum allowable straight pipe lengths for combustion air and exhaust piping with consideration to the number of elbows used.

Step 1: If using the twin pipe penetration system, refer

to table 5. If using the concentric vent kit system, refer to table 6.

Step 2: Total the number of 90° elbows and 45°

elbows used on the exhaust piping.

Step 3: Use this value in the appropriate table to

determine the maximum straight exhaust pipe length allowed.

Step 4: Total the number of 90° elbows and 45°

elbows used on the combustion air piping.

Step 5: Use this value in the appropriate table to

determine the maximum straight combustion air pipe length allowed.

* Not allowed. At least one 90º elbow required. ** Not allowed. Minimum of 3 feet (1m) of straight pipe required.

* Not allowed. At least one 90º elbow required. ** Not allowed. Minimum of 3 feet (1m) of straight pipe required. Note: Include pipe length that is part of the concentric terminal.

Diam. Aproved terminals

x h a u

3 or 4 inches

“T” terminal

90° elbow

Concentric

(196016)

t a k e

3 or 4 inches

“T” terminal

90° elbow

Concentric

(196016)

Table 4 Venting specifications for intake and exhaust

Note: 90° elbows used for terminations should not be counted in the exhaust and combustion air piping.

Twin Pipe

System

# of 90° elbows

0 1 2 3 4

# of 45°

elbows

0 N/A* 26 21 16 11

1 N/A* 23 18 13 8

2 23 20 15 10 5

3 20 17 12 7 N/A**

4 17 14 9 4 N/A**

5 14 11 6 N/A** N/A**

6 11 8 3 N/A** N/A**

Maximum allowable straight pipe length (ft)

Table 5 Maximum allowable straight pipe length (twin

pipe)

Concentric

pipe System

# of 90° elbows

0 1 2 3 4

# of 45°

elbows

0 N/A* 18 13 8 3

1 N/A* 15 10 5 N/A**

2 15 12 7 N/A** N/A**

3 12 9 4 N/A** N/A**

4 9 6 N/A** N/A** N/A**

5 6 3 N/A** N/A** N/A**

6 3 N/A** N/A** N/A** N/A**

Maximum allowable straight pipe length (ft)

Table 6 Maximum straight pipe length (concentric ter-

minal)

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Installation instructions

Required direct vent terminal clearances (twin pipe / concentric penetration)

Fig. 9

* For clearances not specified in ANSI Z223.1 / NFPA 54 or CSA-B149.1, one of the following shall be indicated:

a) 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.”

6720608836-23.1Av

Canadian installations

U.S. installations

A Clearance above grade, veranda, porch, deck or balcony 12 in. 12 in.

B Clearance to window or door that may be opened 36 in. 12 in.

C Clearance to permanently closed window * *

D Vertical clearance to ventilated soffit located above the vent

terminator within a horizontal distance of 2 feet (61cm) from the center line of the terminator

* *

E Clearance to unventilated soffit * *

F Clearance to outside corner * *

G Clearance to inside corner * *

H Clearance to each side of center line extended above meter/

regulator assembly

36 in. within a height 15 feet above

meter/ regulator assembly

I Clearance to service regulator vent outlet 36 in. *

J Clearance to non-mechanical air supply inlet to building or the

combustion air inlet to any other application

36 in. 12 in.

K Clearance to mechanical air supply inlet 72 in. 36 in. above if within 10 feet

horizontally

L Clearance above paved sidewalk or paved driveway located on

public property

84 in.

M Clearance under veranda, porch deck or balcony 12 in.

Table 7

1) In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code

2) In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code

3) A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

4) Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.

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Installation instructions

Required other than direct vent terminal clearances (single pipe penetration)

Fig. 10

* For clearances not specified in ANSI Z223.1 / NFPA 54 or CSA-B149.1, one of the following shall be indicated:

6720608836-23.1Av

Canadian installations

U.S. installations

A Clearance above grade, veranda, porch, deck or balcony 12 in. 12 in.

B Clearance to window or door that may be opened 36 in. 4 feet below or to side of opening;

1 foot above opening

C Clearance to permanently closed window * *

D Vertical clearance to ventilated soffit located above the vent

terminator within a horizontal distance of 2 feet (61cm) from the center line of the terminator

* *

E Clearance to unventilated soffit * *

F Clearance to outside corner * *

G Clearance to inside corner * *

H Clearance to each side of center line extended above meter/

regulator assembly

36 in. within a height 15 feet above

meter/ regulator assembly

I Clearance to service regulator vent outlet 36 in. *

J Clearance to non-mechanical air supply inlet to building or the

combustion air inlet to any other application

36 in. 4 feet below or to side of opening;

1 foot above opening

K Clearance to mechanical air supply inlet 72 in. 36 in. above if within 10 feet

horizontally

L Clearance above paved sidewalk or paved driveway located on

public property

84 in.

M Clearance under veranda, porch deck or balcony 12 in.

Table 8

1) In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code

2) In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code

3) A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

4) Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor.

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Installation instructions

3.3.3 Vent configuration examples

Below are approved examples of vertical and horizontal venting installations.

Fig. 11 Vertical venting system (single pipe penetra-

tion*)

* Warning: For non-freezing climates only!

Fig. 12 Horizontal venting system (concentric vent)

Fig. 13 Horizontal parallel venting system (twin pipe

direct vent)

Fig. 14 Horizontal venting system (single pipe pene-

tration*)

*Warning: For non-freezing climates only!

6720608836-24.1Av

3" (80mm)

INTAKE

EXHAUST

MAINTAIN 12 IN. (18 IN. FOR CANADA)

MINIMUM CLEARANCE ABOVE

HIGHEST ANTICIPATED SNOW LEVEL.

MAXIMUM OF 24 IN. ABOVE ROOF.

DRAIN TEE

INTAKE

EXHAUST

MINIMUM

1”

EXHAUST

COMBUSTION

AIR

DRAIN TEE

6720608836-25.1Av

INTAKE

EXHAUST

4” Min.

DRAIN TEE

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Installation instructions

3.3.4 Vent connections

Attaching the exhaust and air inlet connection adaptors to the top of the heater

B Attach the flue gas exhaust accessory to the top of

the unit Fig. 13 (position 1) using the 4 screws and gasket provided, and fully insert vent pipe into the accessory.

Fig. 15 Exhaust connection

B Attach the combustion air inlet accessory to the top

of the unit Fig. 14 (position 2) using the 3 screws and gasket provided, and install 3" air intake pipe over the accessory.

Fig. 16 Inlet connection

3.3.5 Connecting the condensate water drain

Appliance condensate drain installation

The appliance comes equipped with an internal condensate drain and siphon. This drains condensation formed in the secondary heat exchanger. Piping must be installed under the condensate drain outlet on the water heater and piped for disposal in accordance with local codes.

Fig. 17 Appliance drain installation

NOTE: Vent pipe must be completely vertical when inserting or blue gasket inside exhaust accessory can become displaced. Exhaust accessory can be removed with vent pipe attached to check gasket position.

NOTE: The combustion air accessory can be installed on the top right or on the top left side of the heater. The combustion air inlet that is not used must be kept sealed.

6720608836-26.1Av

Warning:

B Failure to properly install condensate

drain can damage the appliance and will void the warranty.

Warning:

B Do not install condensate drain tubing in

areas where it may freeze.

The condensate must be disposed of in accordance with local codes. See chapter 3.12 “Filling the condensate trap”.

Use materials approved by the authority having jurisdiction. In the absence of other authority, PVC, and CPVC pipe must comply with ASTM D1785, F441 or D2665. Cement and primer must comply with ASTM D2564 or F493. For Canada, use CSA or ULC certied PVC or CPVC pipe, ttings and cement, see table 2.

Leave min. ¼" air gap

1 ½" x ½" PVC Reducer

Trap required

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Installation instructions

External condensate drain installation

If an external condensate drain (installer supplied) must be installed (Section 3.3.2), the following is recommended:

• 1. Install condensate drain on a horizontal section of the exhaust pipe as close to the heater as possible.

• 2. The condensate must be disposed of according to local codes.

• 3. To install condensate drain in vent system, use PVC 3" X 3" X 1.5" tee (part# 196278) and reduce for drain connection.

Fig. 18 External condensate drain installation

3.3.6 Fan speed adjustment ! IMPORTANT INFORMATION:

Natural gas heaters with installation altitudes below 2,000 ft above sea level disregard this section.

Installation adjustment:

After installing the tankless water heater, the fan speed values for minimum power (P2) and maximum power (P1) may need adjustment due to variations in altitude and vent pipe length. Failure to make necessary adjustments to fan speed values may result in improper operation of the appliance.

First calculate the total equivalent vent length. Use this value to determine the appropriate fan speed values found in table 12 and make any necessary adjustments. After changing fan speed values, proceed to section

6.5

to confirm CO2 values are within specifed ranges.

Total vent length calculation

Note: See table 5 for maximum vent lengths.

B Determine the total length of all straight sections of

vent pipe and enter in table 10, line 1.

B Count the number of 90° elbows used, multiply by 5,

and enter that value in line 2. (Do not count 90°

elbows used as terminations on intake and exhaust piping.)

B Count the number of 45° elbows used, multiply by 3,

and enter that value in line 3.

B Repeat steps 1 through 3 for air intake pipe and enter

those values in the intake section of table 10.

B Add line 4 from Exhaust to line 4 of Intake and enter

result in line 5. This is the total equivalent vent length.

6720608836-09.2AL

Dispose of condensate in accordance with local codes

4” Min.

Condensate drain

Fittings or Piping Equivalent

feet m

45 degree elbow 3 0.91

90 degree elbow 5 1.52

plastic pipe per foot 1 0.30

Table 9 Friction Loss Equivalent in piping and fittings

Note: If using concentric terminal include pipe length that is part of the concentric terminal.

6 720 680 226

Installation instructions

Concentric Pipe Example

Exhaust

• 3 - 3’ straight sections

• 1 - 2’ straight section – Total length 11'

• 1 - 90° elbow.

Intake

• 2 - 3’ straight sections

• 1 - 2’ straight sections – Total length 8'

• 3 - 45° elbow.

Summary

Exhaust

Straight section length __ =

____

90° elbows (qty) __ x 5 =

____

45° elbows (qty) __ x 3 =

____

4 Total:

____

Intake

Straight section length __ x 1 =

____

90° elbows (qty) __ x 5 =

____

45° elbows (qty) __ x 3 =

____

Total:

____

Total equivalent vent length =

____

Table 10Determining vent length combination (see

example in Table 11)

Exhaust

Straight section length (feet) 11 x 1 = 11

90° elbows (qty) 0 x 5 = 0

45° elbows (qty) 0 x 3 = 0

Total: 11

Intake

Straight section length (feet) 8 x 1 = 8

90° elbows (qty) 0 x 5 = 0

45° elbows (qty) 1 x 3 = 3

Total: 11

Total equivalent vent length = 22

Table 11 Determining vent length combination

example for concentric terminal

Total equivalent length must not exceed 62 ft for separate pipes.

Total equivalent length must not exceed 46 ft for concentric terminal.

6 720 680 226

Installation instructions

Adjusting minimum power fan speed (P2)

To select fan speed:

B Press ON/OFF button into OFF. B Press and hold "Program" button and press

ON/OFF button to turn appliance ON.

Fig. 19

B As soon as '188' is displayed, release "Program"

button , and the display reads P2.

B Press to enter P2 adjustment. The current set-

ting will appear on the

display (factory default: 12).

B Press or to choose the fan speed suitable

with your installation, see table 12.

B Press and hold (± 5 sec.) “Program” button until

the display flashes, then the selected value is memorized.

Adjusting maximum power fan speed (P1)

To select fan speed:

B Press ON/OFF button into OFF. B Press and hold "Program" button and press

ON/OFF button to turn appliance ON.

Fig. 20

B As soon as '188' is displayed, release "Program" but-

ton , and the display reads P2.

B Press the minus button to display P1. B Press “Program” button to enter P1 adjustment.

The current setting will appear on the display.

B Press or to choose the fan speed suitable

with your installation, see Table 12.

B Press and hold (± 5 sec.) “Program” button until

the display flashes, then the selected value is memorized.

Natural

Gas

Liquid

propane

Altitude

(above sea

level)

Vent

terminal

Total equivalent

vent length

Minimum power

fan speed (P2)

Maximum

power fan

speed (P1)

Maximum

power fan

speed (P1)

0 - 2000 ft

(0 - 610 m)

Concentric

8 - 25 ft 12

modification

required

modification

required

For operation at eleva-

tions above 2,000 ft

(610 m) the equip-

ment ratings shall be

reduced at the rate of

4% for each 1,000 ft

(305 m) above sea

level

26 - 46 ft 13

Twin

system

8 - 37 ft 12

38 - 62 ft 13

2000 - 4500 ft

(610 - 1372 m)

Concentric

8 - 25 ft 14* 52* 52*

26 - 46 ft 14* 53* 53*

Twin

system

8 - 37 ft 13* 52* 52*

38 - 62 ft 14* 53* 53*

4500 - 8000 ft

(1372 - 2439 m)

Concentric

8 - 25 ft 14* 53* 53*

26 - 46 ft 16* 53* 53*

Twin

system

8 - 37 ft 14* 53* 53*

38 - 62 ft 15* 53* 53*

* Above 2000 ft, CO2 levels must be checked with a combustion gas analyzer, see section

6.5

for instructions.

Table 12 Fan speed adjustment

1) Full equivalent length (inlet + outlet piping + fittings)

Do set P2 to greather then 16.

Proceed directly to Section 6.5 to confirm CO2 values are within range.

6 720 680 226

Installation instructions

Attention residents of the Commonwealth of Massachusetts:

In the Commonwealth of Massachusetts the following regulation went into effect on 12/30/2005:

(a)For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE

DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.

a.In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an at tic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2.APPROVED CARBON MONOXIDE DETECTORS.

Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall

be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".

4. INSPECTION. The state or local gas inspector of the

side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and

signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

(b)EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and

2. Product approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

(c) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM REQUIRED. When the manufacturer of Product Approved side wall horizontally mounted gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for the installation of the equipment and the venting shall include:

1. Detailed instructions for the installation of the venting 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 identifies "special venting systems," the following requirements shall be satisfied by the manufacturer:

1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation instructions; and

2. The "special venting systems" shall be product approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all products approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

6 720 680 226

Installation instructions

3.4 Combustion air requirements

Twin pipe and Concentric pipe

The water heater is designed as a sealed combustion appliance. It is recommended that the combustion air be provided by a dedicated 3” or 4” pipe from the outside (twin pipe) or by connecting to the Concentric vent kit (see Fig. 8). The combustion air pipe may be PVC or any other rigid sealed 3" or 4" pipe. The combustion air piping must pitch down 1/4 inch per foot towards termination to prevent rain water from entering the appliance. In twin pipe penetrations, combustion air inlet, whether terminating vertically or horizontally, must be located in such a manner as

to provide a minimum 3 foot clearance from the exhaust vent terminator. See Fig. 9 and 10 Letter I,

page 12.

For the maximum length of the combustion air pipe, see Tables 5 & 6.

Single pipe Note: This appliance requires 9950 cubic feet of

available combustion air, or a minimum of 1243 square feet of space with an 8 foot ceiling to operate. If the large amount of air space, which equates to about half of most average sized homes, is not available, the appliance must pull air from the outside (see twin pipe above).

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 90° elbow on the top of the combustion air inlet adaptor to prevent foreign objects from falling into the unit. If a single pipe installation is utilized, follow guidelines

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 codes if they are more stringent and regulations.

• Appliances located in unconfined spaces: – a) An unconfined space is one whose volume is

greater than 50 cubic feet (1.42 cubic meter) per 1000 Btu per hour (292.81 Watts) of the combined rating of all appliances installed in the space. That would be 9950 cubic feet (281.8 cubic meters) for the water heater alone.

– b) In unconfined spaces in buildings of

conventional frame, masonry, or metal construction, infiltration air is normally adequate to provide air for combustion.

• Appliances located in confined spaces: The confined space must be provided with two permanent openings, one commencing within 12 inches (304.8mm) of the top and one commencing within 12 inches (304.8mm) of the bottom of the enclosure. Each opening must have a minimum free area of one square inch per:

– 1000 Btu/hr (292.81 Watts) if all air is taken from

inside the building

– 2000 Btu/hr (585.62 Watts) if all air is taken from

the outside by horizontal ducts

– 4000 Btu/hr (1171.24 Watts)if all air is taken from

the outside by direct openings or vertical ducts

Or the confined space must be provided with one permanent opening or duct that is within 12 inches (304.8mm) of the ceiling of the enclosure. This opening must have a minimum free area of one square inch per:

– 3000 Btu/hr (878.43 Watts) if all air is taken from

the outside by a direct opening or vertical duct.

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 metal louvers (as metal will reduce the free air by 30%). Refer to the National Fuel Gas Code for complete information. In buildings of tight construction all air should be taken from outside.

Warning: In areas where outside temperatures routinely come close to freezing, sealed combustion operation is required. Use a concentric termination or separate terminations for combustion and vent, which must be installed on the same wall or roof surface, however never facing the direction of prevailing winds. Failure to do so may result in heat exchanger freezing up and bursting. This failure is not covered under the manufacturer's warranty.

Warning: When installed in an environment where corrosive chemicals or dirty air (e.g. hair salons, car washes) are present the twin pipe system is required.

Warning: Terminations must prevent rain and debris from entering the combustion air and exhaust vent piping.

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Bosch Integra 500 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual