Bosch Evolution 500 User manual

Evolution 500

INDOOR MODEL

Temperature Modulated with Electronic Ignition

Suitable for heating potable water - Not approved for space heating purposes

(Intended for variable flow applications)

Evolution 500 - Natural Gas

Evolution 500 - Liquefied Petroleum (LP) Gas

6 720 680 223 (2009/04) 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.

6 720 680 223

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 Tools required for installation 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 Measuring gas pressure 26

4 Electrical connections 28

4.1 Electrical power supply 28

4.2 Position of the fuses in control unit 28

5 Operation instructions 29

5.1 LCD Display functions 29

5.2 For your safety read before operating

your water heater 30

5.3 Power 30

5.4 Temperature selection 30

5.5 Use of optional remote control accessory

(part no. TSTAT2) 31

5.6 Operation 31

5.7 Reset button 31

5.8 Program button 31

5.9 Locked condition 31

6 Maintenance and service 32

6.1 Annual maintenance 32

6.2 Winterizing for seasonal use 32

6.3 Mineral scale build-up 33

6.4 Adjusting CO2 (carbon dioxide) 33

6.5 Program values 36

6.6 Control board diagnostics 37

7 Troubleshooting 38

7.1 Introduction 38

7.2 Burner do not ignite when hot water

is turned ON 38

7.3 Water is too hot 38

7.4 Water is not hot enough 38

7.5 Low water flow/pressure 39

7.6 Hot water temperature fluctuates at tap 39

7.7 Noisy burner/heater during operation 39

8 Problem solving 41

8.1 Error code diagnostics 41

9 Electrical diagram 45

10 Sensor resistance charts 46

11 Evolution 500 Functional scheme 48

12 Interior components diagram

and parts list 49

12.1 Interior components 49

12.2 Components diagram 51

13 Protecting the environment 57

14 Limited Warranty 58

6 720 680 223

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 stainless steel vent

material suitable for category III vent

systems and temperatures up to 480°F.

Vent 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.

Warning: In order for the freeze

prevention kit to provide adequate

protection,120V AC must always be

supplied to the water heater.

6 720 680 223

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

• Real-time diagnostics for troubleshooting/informational

purposes

• LCD Display with backlight

• On/Off and Temperature control switches

• Reset button

• Program button (Selectable temperature default)

• Failure codes for easy diagnostics and repair

• Easily removable one-piece cover

• Built in freeze prevention.

Note: The freeze prevention 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 will not protect plumbing outside

the appliance from freezing. Precautions should be taken.

Accessories (Bosch part #)

• Optional wireless remote control accessory to operate

with the appliance (TSTAT2)

• Cascading kit (TLINK)

• Outdoor kit (BSHTOK)

• Gas conversion kit (8719002176)

• Vertical vent kit (ESVVT)

• Concentric vent /air intake kit (ESHCK)

• Horizontal vent kit (AQ3ES

)

•

Stainless steel bird screen (L2594)

(fits into a 3” PCV fitting - Intake vent)

Warning: The anti freeze 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.

BThe anti freeze kit will not protect

plumbing outside the appliance from

freezing. Precautions should be taken.

BAlways drain the water heater if it will be

exposed to long term freezing

conditions. See Section 6.2 Winterizing

for seasonal use.

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) AQ3 vent kit is compatible with this appliance but

requires the purchase of an additional 12" piece of

straight pipe to meet minimum vent length requirements.

The aluminum flex piping included with this kit is not per-

missible for use with this appliance.

BOSCH is constantly improving its

products, therefore specifications are

subject to change without prior notice.

6 720 680 223

Appliance details

2.2 Specifications (Technical data)

Approved in US/Canada

Capacity

Maximum flow rate: 7.15 GPM (27 l/min) at a 45°F

(25°C) rise.

Maximum output

160,500 Btu/h (47.0 kW)

Maximum input

195,000 Btu/h (57.1 kW)

Efficiency in %

Thermal efficiency > 82%

Min. 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 3.12.

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.

• Minimum recommended water pressure: 30 PSI

(2.07 bar)

• Minimum recommended well pressure: 40 PSI (2.75

bar), see chapter 3.9.

• Connections:

– Bottom of heater

Combustion

• NOx ≤40 Ng/J

(Nanograms of NOx (calculated as NO2) per

Joule of heat output).

• CO ≤250 ppm (measured)

• CO

level set from factory, see chapter 6.4.

Dimensions

• Depth (in): 11¼” (286 mm)

• Width (in): 17

” (452 mm)

• Height (in): 30½” (775 mm)

• Weight: 67 pounds (30,5 kg).

Gas types

Natural Gas.

LP Gas.

Converting the gas type can only be done by a certified

gas technician with a calibrated CO

analyzer.

Call Bosch Water Heating through

Bosch

thermotechnology corp.

for conversion instructions.

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

• Backflow 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.

6 720 680 223

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

ASerial number

BType of gas

The box includes:

• Evolution 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 gas-

ket provided)

• Installation manual (manual can be downloaded at

www.boschhotwater.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 (AQOK)

• Space heating purposes

• Preheated inlet water supply.

To remove front cover

BLoosen the two Philips head screws located on

bottom rear of cover (see Fig. 3).

Fig. 3 Loosen the two screws

BLift front cover panel upward and remove.

Fig. 4 Removing the front cover

To remove combustion cover (service only)

BOpen the four clips and remove the combustion

cover see Fig. 5.

Fig. 5 Remove the combustion cover

6 720 680 223

Appliance details

2.4 General rules to follow for safe

operation

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 CGA

B149.(1,2) INSTALLATION CODES and /or local

installation codes.

B2. 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.

B3. 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 Code does not allow UNSEALED gas fired

water heater installations in bathrooms,

bedrooms or any occupied rooms normally

kept closed. See chapter

3.5

(

page 21

) and

3.4

(

page 20

B4. You must vent your heater. See

chapter 3.3

VENTING.

B5. 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).

B6. Keep water heater area clear and free from

combustibles and flammable liquids. Do not locate

the heater over any material which might burn.

B7. 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

Section 3.8, page 17.

B8. 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.

B9. 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.

10. Failure to install heater correctly may lead to

unsafe operation and void the warranty.

6 720 680 223

Appliance details

2.5 Dimensions and Minimum installation clearances

Fig. 6 Dimensions

1On/Off button

2Reset button

3Program key

4Power ON or stand-by LED

5LCD display

6Up button

7Down button

Fig. 7 Minimum clearances

Note: For servicing access, a 2ft clearance to front

cover is recommended.

6720608158-04.2AL

re s e t

5 ¼" 30 ½"

17 "

785 ¼"

11 ¼"

2 ¾"

6 ½"

2 "

5 ¼"

2 "

4 "

116

6 "

516

116

516

Model Evolution 500

TOP (A) 12”

FRONT (B) 1”

BACK 0”

SIDES 1”

FLOOR (C) 12”

Table 1 Minimum clearances

6 720 680 223

Installation instructions

3 Installation instructions

3.1 Tools required for installation

• Philips head screwdriver

• Flat head screwdriver

• Adjustable wrench

• Level

• Thermometer

• Standard plumbing tools

• Manometer

• Drill

• Pipe wrench

• Adjustable pliers

• Pipe fitting tools

• Hacksaw

• Hole saw.

3.2 Introduction

Please follow these instructions. Failure to follow

instructions may result in:

BDamage or injury.

BImproper operation.

BLoss of warranty.

If you are unable to perform the tasks required to install

this heater properly, please contact a locally licensed

plumber or gas technician.

3.3 Venting

3.3.1 Vent material

Establish vent clearances that comply with the vent

manufacturer's specifications. In all cases, follow local

codes. See Table 2.

Common installation practice is to deter-

mine the venting/intake system layout and

penetration and then work back to the

heater.

Warning: Do not reduce the vent

(exhaust and combustion) pipe sizes

and do not common vent with any other

vented appliance or stove.

Warning: Failure to vent the exhaust

gases to the outside with sealed

stainless steel vent pipe (AL29-4C)

may result in dangerous flue gases

filling the structure in which it is

installed.

Warning: Do not mix vent pipe or

joining methods from different

manufacturers.

Warning: Approved terminators must

be used for inlet and exhaust vent sys-

tems to prevent rain from entering the

appliance. Failure to do so may result in

damage to the appliance. This failure is

not covered under the manufacturer’s

warranty.

Caution: The vent system 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 Water Heating will not be

responsible for improperly installed

appliances.

Warning: In areas where outside

temperatures routinely come close to

freezing, sealed combustion operation

is required. Use 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.

Diam. Material

Exhaust

Vent

3 or 4 inches Sealed single wall stainless steel

(AL29-4C)

Intake

Vent

3 or 4 inches Sealed PVC or any other rigid pipe

Table 2 Venting Specifications

6 720 680 223

Installation instructions

Horizontal venting systems only:

An optional stainless concentric vent/air intake

termination can be used to provide only one penetration

point through the exterior wall (see Fig. 8, 9 & 10). The

concentric vent/air intake kit can be ordered from your

local wholesaler. (Part# ESHCK). Note: Only tee

terminals are approved for use with the

concentric vent/air intake kit (see Table 3). Vent

piping and tee terminal used with kit must be

from the same vent pipe manufacturer. The

appliance can also be installed with separate air

intake and exhaust piping (see Fig. 15 ).

Fig. 8 Concentric kit part # ESHCK

Fig. 9 Concentric kit vent assembly

Fig. 10 Concentric kit installation

3.3.2 Venting 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. Note: For horizontal terminations, venting must

terminate once it penetrates to the outside of the

structure. There must be no sections of vent pipe

exposed to the outdoors other than the termination.

Note: Listed thimbles or collars are necessary where

venting passes through wall and ceiling partitions. If the

vent system passes through combustible areas where

the vent clearance requirements cannot be maintained,

it is permissible to chase straight sections of sea led 3

inch single wall vent through 4 inch (or greater) T ype-B

vent. The distance to combustibles using this chase

technique is 1 inch 1). Note: Type-B vent must never be

used as the actual exhaust vent system for the

appliance, as it is not gas tight and illegal for use with

this appliance. This will create a serious health hazard

and void the warranty.

For specific questions concerning vent material, speci-

fications, usage or installation, please contact the vent

manufacturer directly.

6720608782-09.1Av

6720608782-10.1Av

12"

6720608782-11.1Av

Min. 3 Feet

3” stainless steel pipe

3”

VENTING

Z flex Protech Heat Fab

3 or 4"

90° elbow 2SVEEWCF0390 FSELB9003 9314

3" Tee

Terminal 2SVSTTF03 FSTT3 9390TEE

3”

Horizontal

Terminal

2SVSTB03 FSTB3 N/A

3” Vertical

Terminal 2SVSRCF03 FSRC3 5300CI

Table 3 Terminator Part Numbers

Fittings or Piping Equivalent

feet m

45 degree elbow 1.25 0.38

90 degree elbow 2.5 0.76

pipe per foot 1 0.30

Table 4 Friction Loss Equivalent in piping and fittings

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