MODEL 2400E NG and 2400E LP - INDOOR MODEL Temperature Modulated with Electronic Ignition Suitable for heating potable water only Not approved for space heating purposes (Intended for variable flow applications) 2400 E NG - Natural Gas 2400 E LP - Liquefied Petroleum (LP) Gas 6 720 608 263 US (06.11) JS Warning: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
Index Index 1 Warning 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.9.1 2.10 2.11 2.12 2.12.1 2.12.2 2.12.3 2.13 2.14 2.15 2.16 2.
Warning 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, turn off the electrical power to the water heater at the main disconnect or circuit breaker.
Appliance details 2 Appliance details 2.1 Features 2.2 Parts 2400 E Specifications (Technical data) • Touch Pad interface control Approved in US/Canada • High power pre-mix compact burner with low Nox emissions Capacity • Modulating Gas Valve with constant gas:air ratio control • Modulating water valve for improved comfort and temperature control. Maximum flow rate: 6.35 GPM (24 l/min) at a 45°F (25°C) rise. Maximum output 142,968 Btu/h (41.
Appliance details Combustion • NOx ≤ 55 ppm • CO ≤ 250 ppm • CO2 level set from factory, see chapter 9. Dimensions • Depth (in): 8 ½” (220 mm) • Width (in): 15 ¾” (400 mm) Do not lose this manual. Please complete and return the enclosed product registration card. 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.
Appliance details 2.3 Dimensions and Minimum installation clearances Fig. 4 Dimensions 1 2 3 4 5 6 Cover On/Off switch Reset button LCD display Program button Temperature buttons Fig.
Appliance details 2.4 General rules to follow for safe operation B 1. You should 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 should conform with CGA B149.(1,2) INSTALLATION CODES and /or local installation codes. B 2. Carefully plan where you install the heater.
Appliance details 2.6 Clearances The 2400 E is design certified for installation on a combustible wall (see 2.7 Mounting installation) provided the floor covering below the heater is noncombustible. For installations in an alcove or closet, maintain the minimum clearances to combustible and non-combustible materials listed below. See also Fig. 5. A. Top 12 inches (306 mm) B. Front 1 inches (25 mm) C. Back 0 inches D. Sides 1 inches (25 mm) E.
Appliance details 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.
Appliance details The maximum flue gas exhaust temperature on the 2400 E is 437°F (225°C) Venting Options Exhaust vent diameter and material * Exhaust vent maximum length * Exhaust vent minimum length Combustion air pipe diameter and material Combustion air pipe maximum length Vent pipe clearances within an unenclosed space Vent pipe clearances within an enclosed space Room sealed (twin pipe) 3 or 4+ inch stainless steel (AL29-4C) sealed vent pipe 26 feet (8 m) with one elbow.
Appliance details Note: reduce 2½ ft for each 90° elbow used after the first one, reduce 1 ¼ ft for each 45° elbow. Use of the external condensate drain tube kit (supplied with the heater) on the exhaust collar Vent Safety System B The condensate drain tube kit must be used for all installation types. Failure to install condensate drain will void the warranty.
Appliance details 2.9.1 Venting options Installing this water heater as a room sealed (TWIN PIPE SYSTEM) is the recommended method. Contact BBTNA or dealer for available vent termination kits and vent materials for this water heater. i Open combustion installation (SINGLE PIPE SYSTEM) Not recommended in cold climate areas, see Chapter 2.8. Exhaust venting shall be done with 3" or 4" stainless steel (AL29-4C) vent pipe. Room sealed installation (TWIN PIPE SYSTEM) Fig.
Appliance details Recommended exhaust vent terminator position Fig. 16 Ref.
Appliance details Supporting the exhaust vent system i The venting materials and accessories required to properly install the water heater are available from BBTNA and their distributors. Fig. 17 Horizontal side wall venting installation (combustion air piping not being shown) Fig. 19 Vertical venting installation (combustion air piping not being shown) Fig.
Appliance details 2.10 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 should conform with CGA B149 INSTALLATION CODES and/or local installation codes.
Appliance details FOR NATURAL GAS Maximum Capacity of pipe in Cubic Feet of Gas per Hour for Gas Pressure of 0.5 Psig or less and a Pressure drop of 0.3 in Water Column (0.75mbar).(Based on a 0.60 Specific Gravity Gas) Btu numbers given in thousands. Follow boxed numbers for piping just one 2400 E (example: ¾” B.I. Natural Gas pipe for 20 ft (6.1m). will handle 190,000 btu’s (55.7 kWh). For multiple appliances combine the total btu input load and then refer to applicable chart below.
Appliance details 2.11 Gas line sizing B It is strongly recommended that the Natural Gas pipe be Black Iron pipe the entire distance from the outside meter to the inlet of the gas connection. ¾” Black Iron pipe up to 20 feet (6.1m) and 1” Black Iron pipe up to 70 feet (21.34m) distances. Flex line is NOT recommended, but if used, then oversize the diameter of the flex pipe, keep the length to a minimum and try to keep the flex line as straight as possible.
Appliance details Static Gas Pressure Reading (see Chapter 2.12) enter here: ___________________ Operating Gas Pressure Reading (see Chapter 2.12) enter here: ___________________ Table 5 HIGH ALTITUDE OPERATION Altitude 0 - 4,000 ft (0 - 1,219 m) 4,000 ft - 7,000 ft (1,219 m - 2,134 m) Above 7,000 ft (above 2,134 m) Natural Gas: Liquid Propane: no modification no modification CO2 adjustment with flue gas analyzer required See chapter 9 for instructions.
Appliance details 2.14 Electrical connections Warning: For safety reasons, disconnect the power supply to the heater before any service or testing is performed. Warning: This heater must be electrically grounded in accordance with the most recent edition of the National Electrical Code. NFPA 70. In Canada, all electrical wiring to the heater should be in accordance with local codes and the Canadian Electrical Code, CSA C22.1 Part 1.
Appliance details i NOTE: on a first time initial installation or after gas line work has been done, existence of air in the gas line will cause ignition delay when the hot water is turned on. This will result in an error (EA) on the units display screen. This is normal. When this occurs, leave the hot water running and wait 3-5 seconds, then reset the unit (Fig. 26, pos. 2). Wait for (EA) to disappear.
Operation instructions 3 Operation instructions Fig. 27 1 2 3 4 5 6 On/Off switch Reset button Program Key Increasing temperature selector Decreasing temperature selector LCD display 3.1 B Press buttons and requested temperature. in order to reach Power On B To start the appliance switch the button to position (I). LCD display the default temperature - temperature factory setting 122°F (50°C). Fig.
Operation instructions Setting the water temperature The desired temperature of the hot water can be adjusted on the front control panel of the heater. The 2400 E has an electronically controlled gas valve that modulates the burner input in response to both varying hot water flow rates and/or changes in any incoming and outgoing water temperatures. Hot Water Flow and Temperature with Various Inlet Temperature (gpm/Fahrenheit) 7.00 Hot Water Flow (GPM) 6.00 5.00 4.00 3.00 2.00 1.00 0.
Operation instructions 3.3 Use of remote control accessory Fig. 34 Reset button If the problem persists, contact your installer. Fig. 31 Remote control 3.6 The wireless remote control accessory and the temperature selector buttons on the front of the water heater operate identically. Contact your distributor or BBTNA to order if the remote control accessory is preferred. Modification of the water heaters interior control unit (Fig.
Maintenance and service 4 Maintenance and service Warning: Always turn off the electrical power supply, turn off the manual gas valve and turn off the manual water control valves whenever servicing. The unit should be checked once a year by a gas technician. If repairs are needed, the repairs should be done by a gas technician To remove front cover B Remove plastic decals on front panel (Page 5, Fig. 3). B Loosen the two Philips head screws located behind decals.
Troubleshooting Test by following 4th bullet under BURNERS DO NOT IGNITE WHEN HOT WATER IS TURNED ON. LOW WATER FLOW/PRESSURE • Too many hot water applications are being used simultaneously or too much flow is being demanded The 2400 E will effectively support two 2.0-2.5 gpm shower heads simultaneously or multiple sink applications. Greater draws will result in increased pressure drop and reduced flow at taps. See flow/ temperature chart on page 22.
Troubleshooting Display Cause Solution E9 Temperature limiter opened circuit (overheat). Trips at 220F (104C). Check connections.* Check heat exchanger condition.* EA No ionization during safety time (safety time out). Note: appliance makes 3 ignition attempts before entering error mode “EA”. EC The ionization signal momentarily disappeared more then 5 times in less then 30 seconds. Check gas pressure.* Check that gas is not diluted with air, as a result from recent gas pipeline rework.*.
Electrical diagram 6 Electrical diagram Fig.
2400 E Functional scheme 7 2400 E Functional scheme Fig.
Interior components diagram and parts list 8 Interior components diagram and parts list 8.1 Interior components Fig. 39 Components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Cover On/Off switch Reset button LCD display Program button Temperature switches Flue gas collector Mixer Heat exchanger Observation window Inlet air duct Control unit Exhaust fan Water valve Gas valve Fig.
Interior components diagram and parts list 8.2 Components diagram Fig.
Interior components diagram and parts list 8.
Special adjustment for measuring and adjusting CO2 levels 9 Special adjustment for measuring and adjusting CO2 levels The CO2 can only be adjusted by a certified gas technician with a calibrated CO2 analyzer. Static Gas Pressure: “ WC P1 Operating Pressure: “ WC The P1 minimum operating pressure is 5" WC for Natural Gas and 11"WC for Propane. Do not proceed in adjusting CO2 until pressure has been verified to be at or above these levels, but not to exceed 14” WC. A.
Special adjustment for measuring and adjusting CO2 levels D. Returning to Service: 1. Return slotted cover to original position. 2. Reinstall Torx cover. 3. Remove CO2 analyzer probe and reinstall flathead screw in exhaust collar. 4. Turn ON/OFF switch to the OFF (O) position and then back to the ON (I) position. 5. Heater is ready for normal operation. Without Front Cover With Front Cover Nat. Gas Nat. Gas max. input P1 9.1 ± 0.1 % 9.7 ± 0.1 % min. input P2 9.4 ± 0.1 % 9.7 ± 0.
Protecting the environment 10 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: B Make sure you close all the taps after any use. Avoid leaving the taps dripping. Repair any leaking tap.
Twelve Year Limited Warranty 11 Twelve Year Limited Warranty General Service Labor Costs Aquastar water heaters are warranted by the Manufacturer (BOSCH) through BBT North America. BBT North America (BBTNA) will furnish a replacement heat exchanger and will furnish a replacement of any other part which fails in normal use and service within the applicable periods specified below, in accordance with the terms of this warranty.
Installer Checklist, to be performed by installer upon installation Serial Number ___ ___ ___ ___ ___ ___ ___ ___ (8 digit serial number is located on rating plate on right side panel) Gas Pressure Reading* Static__________ Operating__________ Building Water Pressure __________ Range if on Well system __________ Installing Company _____________________________________________ Installer name _____________________________________________ Address _____________________________________________ Phone
