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. 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.
| Table of contents Table of contents 1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 3 1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2 FCC rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3 Appliance details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.
Key to symbols and safety instructions | 3 1 Key to symbols and safety instructions 1.1 Key to symbols Warnings Warnings in this document are identified by a warning triangle printed against a grey background. Keywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken.
| Key to symbols and safety instructions Risk of scalding at the hot water draw-off point ▶ When the water heater is in operation, temperatures in excess of 122 °F (50 °C) can occur. To limit the temperature at the tap, install a thermostatic DHW mixing valve. ▶ Water heated for washing the laundry, dishes and for other cleaning purposes can cause scalding and permanent injuries. ▶ Children, elderly, and handicapped persons are more likely to be permanently injured by hot water.
Key to symbols and safety instructions | 5 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. DANGER: Fatal accidents! Carbon monoxide poisoning. ▶ 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.
| FCC rules WARNING: Personal Injury from toxic chemicals. ▶ A water heater which will be used to supply potable water shall not be connected to any heating system or component(s) previously used with a nonpotable water heating appliance. WARNING: Installation in mobile homes. ▶ Installation in mobile homes shall conform to Title 24 CFR, part 3280 and/or CAN/CSA Z240 MH Series, Mobile Homes. 2 FCC rules FCC: This device complies with Part 15 of the FCC rules.
Appliance details | 7 3 Appliance details 3.1 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.
| Appliance details Technical characteristics Weight Units pounds (kg) 830 ES 67 (30.5) V AC 120 Hz 60 mA 40 Gas types Natural Gas LP Gas Voltage 3.3.1 The box includes • 830 ES • 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.boschclimate.
Appliance details | 9 ▶ Lift front cover panel upward and remove. • • • • • • Fig. 4 Remove the front cover 3.3.3 Remove combustion cover (service only) ▶ Open the four clips and remove the combustion cover. • • • In Canada: The Installation must conform with CSA B149.(1,2) INSTALLATION CODES and /or local installation codes. 2. Carefully plan where you install the heater. Correct combustion air supply and vent pipe installation are very important.
| Appliance details 3.5 Dimensions and minimum installation clearances Fig.
Installation instructions | 11 4 Installation instructions 4.1 Specialized tools The following specialized tools may be required for installation: • Manometer • Multi-meter • Combustion Gas Analyzer 4.2 Introduction Please follow these instructions. Failure to follow instructions may result in: ▶ Damage or injury. ▶ Improper operation. ▶ Loss of warranty. DANGER: ▶ The water heater must be installed by a qualified installer in accordance with these instructions.
| Installation instructions NOTICE: ▶ 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.
Installation instructions | 13 4.3.2 Vent specifications Install appliance as close to point of vent termination as possible. The exhaust piping must vent directly to the outside of the structure. Horizontal sections of vent must pitch upward towards termination ¼" for every foot of horizontal length, to prevent the pooling of condensate, and be supported at 4 foot intervals with overhead hangers. Exception: horizontal run between last elbow and termination must pitch down to termination 1/4" per foot.
| Installation instructions System used Number of 90° elbows needed: Number of 45° elbows needed: Concentric 1 2 Table 11 Calculation of example Max. length 90° elbow reduction sub-total = 45° elbow reduction Total = Calculation example for 4" venting: Exhaust System used Number of 90° elbows needed: Number of 45° elbows needed: Twin pipe 2 2 Table 15 28,5’ - 2,5’ 26’ - 2,5’ 23,5’ Table 12 For this example, the maximum allowable exhaust pipe length is 23,5 feet. Calculation of example Max.
Installation instructions | 15 Required direct vent terminal clearances (twin pipe / concentric penetration) Fig. 11 A Clearance above grade, veranda, porch, deck or balcony Canadian installations1) 12 in. B Clearance to window or door that may be opened 36 in. 12 in.
| Installation instructions Required other than direct vent terminal clearances (single pipe penetration) Fig. 12 A Clearance above grade, veranda, porch, deck or balcony Canadian installations1) 12 in. B Clearance to window or door that may be opened 36 in.
Installation instructions | 17 4.3.3 Vent configuration examples Below are approved examples of vertical and horizontal venting installations. Fig. 13 Horizontal side wall venting installation (single pipe penetration) [1] [2] [3] [4] [5] [6] [7] Termination Minimum above ground or normally expected snow accumulation level Appliance Drain tee Elbow (note: minimum 1ft of straight vent pipe required) Horizontal run ¼ " per foot down to termination Hanger strap Fig.
| Installation instructions Fig. 18 [LA] 3ft minimum Fig.
Installation instructions | 19 Fig. 20 Exhaust connection ▶ Attach the combustion air inlet accessory to the top of the unit fig. 21 (position 2) using the 3 screws and gasket provided, and install 3" air intake pipe over the accessory. Fig. 19 [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] 4.3.4 Fig.
| Installation instructions • 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. Listed below is an additional measure designed to further limit backdraft in extreme conditions assuming all other possible causes have been addressed.
Installation instructions | 21 4.3.7 Venting for manufactured (mobile) homes WARNING: ▶ In a manufactured (mobile) home installation, combustion air shall not be supplied from occupied spaces. When this appliance is installed in a mobile home, it is required that the venting be installed such that all combustion air is provided from outside the structure. As such, single pipe venting installations are forbidden in mobile home installations.
| Installation instructions 4.3.8 Fan speed adjustment necessary adjustments to fan speed values may result in improper operation of the appliance. NOTICE: 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.
Installation instructions | 23 Adjusting minimum power fan speed (P2) To select fan speed: ▶ Press ON/OFF button into ON. ▶ Press and hold simultaneously buttons + , seconds, until display reads P2. Adjusting maximum power fan speed (P1) To select fan speed: and P for 3 ▶ Press ON/OFF button into ON. ▶ Press and hold simultaneously buttons + , seconds, until display reads P2. and P for 3 Fig. 27 Fig. 28 ▶ Press P to enter P2 adjustment.
| Installation instructions 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.
Installation instructions | 25 NOTICE: Risk of appliance freezing! ▶ The water in this water heater is cold and always remains cold except for the times the burner is on. In the event of power outage in conjunction with freezing temperatures, it is recommended that the heater be drained. See chapter 7.2, page 37 “Winterizing” for draining instructions.
| Installation instructions 6720608158-05.1AL Fig. 31 Mounting the heater CAUTION: Personal injury and property damage. ▶ Appliance must be installed vertically. 4.8 Mounting installation for manufactured (mobile) homes Fig. 32 Mounting the heater in manufactured (mobile) homes When installing this appliance in a mobile home the unit must be additionally secured at the bottom of the water heater as shown in fig. 32.
Installation instructions | 27 4.9 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. In Canada: The Installation must conform to CGA B149 INSTALLATION CODES and/or local installation codes.
| Installation instructions 4.9.1 Gas Line Sizing Tables for NATURAL GAS For your convenience see below for an excerpt from gas line sizing tables for a single NG appliance. For details see the current NFPA 54. Specified pipe lengths are for one 830 ES which has a maximum input rating of 175,000 BTUs. The gas supply system must be sized for the combined total maximum BTU/hr load requirements of all gas appliances running simultaneously.
Installation instructions | 29 4.9.2 Gas Line Sizing Tables for LP GAS For your convenience see below for an excerpt from gas line sizing tables for a single LP appliance. Their intended use of is for pipe sizing between the the 2nd stage (low pressure) regulator and the appliance. For details see the current NFPA 54 or NFPA 58. Specified pipe lengths are for one 830 ES which has a maximum input rating of 175,000 BTUs.
| Installation instructions Description pH Fig. 35 Water filter [1] Water filter ▶ The use of unions when connecting both water pipes to the inlet and outlet connections is required. This will facilitate any necessary servicing. ▶ Plastic or PEX type plumbing line materials are not suitable for connecting directly to the water heater.
Installation instructions | 31 CAUTION: ▶ Propylene glycol may be used for freeze prevention ONLY on the space heating side of the heat exchanger. Do not use ethylene glycol (automotive antifreeze). CAUTION: ▶ The use of a flow switch is recommended to ensure DHW priority and to prevent “cold-blow” situations when the Bosch tankless water heater is used with an air-handling system. The flow switch should be used to disable the blower on the air-handling system when domestic water is used.
| Installation instructions Fig. 39 Space heating diagram [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [17] [18] [19] [20] [21] [22] 4.
Electrical connections | 33 Gas pressures lower than 3.5" W.C. for Natural Gas or 8" W.C. for LPG will result in insufficient degree rise to the hot water being used, reduced hot water volume, possible error code faults and must be corrected. See Gas Connections, chapter 4.9, page 27. P1 fan speed: Factory default: NG: 48, LP: 40 Lowering P1 fan speed reduces the maximum BTU input.
| Operation instructions 6 Operation instructions Fig. 45 [1] [2] [3] [4] [5] [6] [7] 6.1 On/Off button Reset button Program Key LCD display Up button Down button Power On or stand-by LED Description LCD Display WARNING: ▶ Do not use any cleaning aggressive or corrosive agents to clean the window. Fig. 49 Locked condition indicator (only with remote control) Fig. 50 Flame indicator Fig. 46 Power bar indicator (input) Fig. 51 Solar mode indicator (see chapter 6.4, page 35) Fig.
Operation instructions | 35 6.2 For your safety read before operating your water heater ▶ Press buttons + or in order to reach desired temperature. DANGER: Explosion hazard! ▶ If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance is equipped with electronic ignition for lighting the main burner. When turning the heater on, follow these instructions exactly.
| Operation instructions 6.6 Operation ▶ When a hot water tap is opened, main burner ignites and LCD displays indication . Fig. 57 ▶ LCD flashes until selected temperature is reached. ▶ Power bar indicates power percentage in use. 6.7 Reset button If the LCD shows the error symbol do not shut off power or unplug the heater. Follow instructions below to reset error first. Record the error code on LCD and consult “Problem solving” chapter 9.1, page 43. Fig. 55 6.
Maintenance and service | 37 ▶ Press “Program” key. LCD shows pre-memorized temperature, which is now the hot water selected temperature. 6.9 Locked condition This condition is only valid for appliances with one or more remote controls installed. operation. Flames should be steady and blue with no signs of yellowing. Yellow burner flames are an indication of improper combustion. Refer to Section 4.4, page 24, chapter 4.
| Maintenance and service ▶ Shut off the water supply to the water heater using (installer supplied) shutoff valve. ▶ Open hot water taps to drain and relieve pressure from the plumbing system. ▶ Drain water from the unit's heat exchanger by disconnecting inlet and outlet water connections from the heater. ▶ Connect a line (A) from the outlet of the circulating pump (installer supplied) to the inlet water fitting on the water heater (see fig. 62.
Maintenance and service | 39 Note: When making adjustments, make sure combustion cover is installed. Max. CO level CO2 range (%) (measured) Nat. Gas max. input P1 6.3 % - 6.9 % < 250 ppm min. input P2 2.3 % - 2.6 % < 60 ppm max. input P1 8.3 % - 8.9 % < 250 ppm min. input P2 2.6 % - 2.9 % < 60 ppm LP Gas * Values above are for climate controlled conditions. Inputs such as gas pressure, heating value of the gas, humidity and temperature of combustion air all impact CO and CO2 values.
| Maintenance and service Program P1 Description Maximum Power Factory Default NG: 48, LP: 40 MIN 21 MAX NG: 49, LP: 41 P2 Minimum Power 7 7 20 Comment see chapter 4.14, page 32 note: reducing P1 values below maximum will reduce maximum power of the appliance. see chapter 4.3.8, page 22 P3 _0 _0 6 see chapter 6.5, page 36 E 0d 10f see chapter 7.
Troubleshooting | 41 ▶ Select the sub-mode “H1”. Write the number that shows in the display. ▶ Select the sub-mode “H2”. Write the number that shows in the display.
| Troubleshooting 5. Avoid restrictive outlets. Clean all shower heads and faucet aerators. It may be necessary to upgrade to higher flow rate shower heads if allowable by local code. 6. In areas where the water has a high mineral content, periodic descaling may necessary. See chapter7.3, page 37 for directions. 8.4 Water is not hot enough 1. Selected temperature on the unit is too low. To raise output temperature, see chapter6.4, page 35. 2. Clean inlet filter screen. See chapter7.
Problem solving | 43 9 Problem solving 9.1 Error code diagnostics To remove error code from the display, press the reset button. Display (Flashing) Cause Fault in the flue gas limiter. Temperature above 230°F (110 °C) inside the cabinet. Solution 1. Check continuity of the flue gas limiter (see fig. 71, page 49). Go to steps two and three to determine flue gas limiter fault and repair it. 2.
| Problem solving Display Cause Solution No rotational speed sensor signal from 1. Disconnect power supply cord and check wire connections on back side of fan and primary fan. the two connectors on the control board, see fig. 78, page 56. 2. Check supply voltage. It must be 120VAC and properly grounded. 3. Possible defective component in fan or defective control unit call Bosch Water Heating for further instructions. (Flashing) Water flow signal over specified maximum value.
Problem solving | 45 Display Cause No flame ionization detected with water flow. Solution 1. Verify that all manual gas shut off valves are open. 2. Check gas type. See fig. 2, page 8. 3. Reset error code and open a water tap to cycle the heater in an effort to purge air. Cycling hot water tap on and off multiple times may be necessary. If heater still faults with EA error code, have a licensed gas technician properly purge air out of the gas line leading to the water heater. 4.
| Electrical diagram 10 Electrical diagram 16 20 15 13 M M 12 M E PS 11 10 19 T=104°C T=220°F 18 9 T=110°C T=230°F 8 FS 7 6 Casc. 5 input Casc. 4 output Back flow 3 2 1 17 16 21 14 ... 1 20 ... JP2 JP7 JP5 1 JP8 JP6 22 6720608158-92.1AL Fig.
Sensor resistance charts | 47 11 Sensor resistance charts Fig. 68 Outlet / Inlet immersion sensor characteristics Fig.
| Functional scheme 12 Functional scheme Fig.
Interior components diagram and parts list | 49 13 Interior components diagram and parts list 13.1 Interior components Fig.
| Interior components diagram and parts list Fig.
Interior components diagram and parts list | 51 13.2 Components diagram 13.2.1 Group 1 Fig.
| Interior components diagram and parts list 13.2.2 Group 2 Fig.
Interior components diagram and parts list | 53 13.2.3 Group 3 Fig.
| Interior components diagram and parts list 13.2.4 Group 4 Fig.
Interior components diagram and parts list | 55 13.2.5 Group 5 Fig.
| Interior components diagram and parts list 13.2.6 Group 6 6720644956-09.1V Fig. 78 Components Diagram Item 1 2 3 4 5 6 7 8 Description Control unit Fuse T2.5A Fuse T1.
Protecting the environment | 57 14 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. Saving water resources: ▶ Make sure you close all the taps after any use. Avoid leaving the taps dripping. Repair any leaking tap.
| Installer Checklist to be completed by installer upon installation 15 Installer Checklist to be completed by installer upon installation Serial Number (8 digit serial number is located on rating plate on right side panel) ___ ___ ___ ___ ___ ___ ___ ___ Gas Pressure Reading 1) Static Operating Water Pressure Building Water Pressure Range if on Well system Installing Company Installer name Address Phone Table 48 1) See Chapter 4.
| 59 Notes 830 ES 6 720 644 936 (2016/05)
