1. Manuals
  2. Brands
  3. Bosch Manuals
  4. Water Heater
  5. Evolution 500
  6. Instruction manual

Bosch Evolution 500 Instruction Manual

Temperature modulated with electronic ignition suitable for heating potable water - not approved for space heating purposes
Hide thumbs Also See for Evolution 500:
Table of Contents

Quick Links

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
Warning: If the information in this manual is not
followed exactly, a fire or explosion may result
causing property damage, personal injury or death.
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other
appliance.
Improper
installation,
service or maintenance can cause injury or
property damage. Refer to this manual. For
assistance or additional information consult a
qualified installer, service agency or the gas
supplier.
In the Commonwealth of Massachusetts this
product must be installed by a licensed plumber or
gas fitter.
Upon completion of the installation, these
instructions should be handed to the user of the
appliance for future reference.
adjustment,
alteration,
What to do if you smell gas
• Close gas valve. Open windows.
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any
phone in your building.
• Immediately call your gas supplier from a neighbor's
phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire
department.
• Installation and service must be performed by a
qualified installer, service agency or the gas supplier.
Table of Contents
loading

Related Manuals for Bosch Evolution 500

Summary of Contents for Bosch Evolution 500

  • Page 1 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 Warning: If the information in this manual is not What to do if you smell gas followed exactly, a fire or explosion may result •...
  • Page 2 3.12 Measuring gas pressure Sensor resistance charts Electrical connections Electrical power supply Position of the fuses in control unit Evolution 500 Functional scheme Operation instructions Interior components diagram LCD Display functions and parts list For your safety read before operating 12.1 Interior components...
  • Page 3 Warning Warning Warning: The appliance should be located in an area where leakage of the For your safety heater or connections will not result in damage to the area adjacent to the Do not store or use gasoline or other flammable, appliance or to lower floors of the combustible or corrosive vapors and liquids in the structure.

  • Page 4: Appliance Details

    Water temperature over 125°F can (fits into a 3” PCV fitting - Intake vent) . cause severe burns instantly or death from scalds. BOSCH is constantly improving its Children, disabled and elderly are at highest risk of being scalded. products, therefore specifications are See instruction manual before subject to change without prior notice.

  • Page 5: Specifications (Technical Data)

    LP Gas. Maximum input Converting the gas type can only be done by a certified gas technician with a calibrated CO analyzer. 195,000 Btu/h (57.1 kW) Call Bosch Water Heating through Bosch Efficiency in % thermotechnology corp. for conversion instructions.

  • Page 6: Unpacking The Heater

    Rating plate Serial number Type 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) •...
  • Page 7 Appliance details General rules to follow for safe B 10. Failure to install heater correctly may lead to unsafe operation and void the warranty. operation B 1. You must follow these instructions when you install your heater. In the United States: The installation must conform with local codes or, in the absence of local codes, the National Fuel Gas Code ANSI Z223.1/ NFPA 54.

  • Page 8: Dimensions And Minimum Installation Clearances

    11 ¼" " 5 ¼" r e s e t 6720608158-04.2AL Fig. 6 Dimensions On/Off button Reset button Model Evolution 500 Program key TOP (A) 12” Power ON or stand-by LED LCD display FRONT (B) 1” Up button Down button BACK 0”...

  • Page 9: Installation Instructions

    • Adjustable pliers monoxide poisoning could result. • Pipe fitting tools Bosch Water Heating will not be responsible for improperly installed • Hacksaw appliances. • Hole saw. Warning: In areas where outside Introduction temperatures routinely come close to Please follow these instructions.
  • Page 10 Installation instructions Horizontal venting systems only: 3.3.2 Venting Specifications An optional stainless concentric vent/air intake Install appliance as close to point of vent termination as termination can be used to provide only one penetration possible. The exhaust piping must vent directly to the point through the exterior wall (see Fig.
  • Page 11 Installation instructions Company Contact info Air intake or # of 90° elbows Exhaust Z-flex www.z-flex.com system 800-654-5600 ProTech Industries www.protechinfo.com N/A* 800-766-3473 N/A* Heat-Fab www.heatfab.com 800-772-0739 Table 5 Vent manufacturers # of 45° N/A** elbows Condensate drain requirements N/A** An external condensate drain (not supplied with the heater) must be installed under the following N/A** N/A**...

  • Page 12: Required Direct Vent Terminal Clearances (Twin Pipe / Concentric Penetration)

    Installation instructions Required direct vent terminal clearances (twin pipe / concentric penetration) 6720608836-23.1Av Fig. 11 Canadian installations U.S. installations Clearance above grade, veranda, porch, deck or balcony 12 in. 12 in. Clearance to window or door that may be opened 36 in.

  • Page 13: Required Other Than Direct Vent Terminal Clearances (Single Pipe Penetration)

    Installation instructions Required other than direct vent terminal clearances (single pipe penetration) 6720608836-23.1Av Fig. 12 Canadian installations U.S. installations Clearance above grade, veranda, porch, deck or balcony 12 in. 12 in. Clearance to window or door that may be opened 36 in.
  • Page 14 Installation instructions 3.3.3 Venting configuration examples Below are approved examples of horizontal venting installations. 4" HORIZONTAL RUN 1/4" PER FOOT DOWN TO TERMINATOR. CONDENSATE DRAIN 6720608542-05.2AL Fig. 15 Horizontal twin pipe penetration 6720608542-02.2AL Below are approved examples of vertical venting Fig.
  • Page 15 Installation instructions 3.3.4 Vent connections B Attach the flue gas exhaust accessory (8 705 504 151) to the top of the unit (position 1) using the 4 screws and gasket provided. Fully insert stainless steel vent pipe 1.5” minimum into the accessory and tighten the clamp (position 2).
  • Page 16 Installation instructions 3.3.5 Condensate drain installation Note: Do not install condensate drain in areas where it may freeze. 1. Install condensate drain as close to heater as possi- ble. 2. Use 3/8" ID high temperature silicone tube to con- nect to condensate drain port. Do not use copper pip- ing for any portion of the condensate drain.
  • Page 17 Installation instructions 3.3.6 Fan speed adjustment Example Exhaust IMPORTANT! Installation adjustment: • 7 - 3' straight sections After installing the water heater, the fan speed values for minimum power (P2) and maximum power (P1) may • 1 - 1' straight section = Total straight pipe length 22’ need adjustment due to variations in altitude and vent •...
  • Page 18 Installation instructions Natural Gas Liquid propane Altitude Total Minimum Maximum Maximum (above sea equivalent power fan power fan speed power fan speed level) vent length speed (P2) (P1) (P1) 5.5 - 32 ft 0 - 2000 ft modification required modification required (0 - 610 m) 33 - 57 ft For operation at elevations...
  • Page 19 Installation instructions Attention residents of the Commonwealth of signage installed in accordance with the provisions of Massachusetts: 248 CMR 5.08(2)(a)1 through 4. In the Commonwealth of Massachusetts the following (b) EXEMPTIONS: The following equipment is exempt regulation went into effect on 12/30/2005: from 248 CMR 5.08(2)(a)1 through 4: (a) For all side wall horizontally vented gas fueled 1.

  • Page 20: Combustion Air Requirements

    Installation instructions Combustion air requirements below for providing adequate combustion air for the water heater as well as any other appliances that may consume air in the space. Always follow local codes if Warning: In areas where outside they are more stringent. temperatures routinely come close to freezing, sealed combustion operation When all requirements are followed, the unit will...

  • Page 21: Proper Location For Installing Your Heater

    Installation instructions Proper location for installing your Mounting installation heater Warning: before starting Carefully select the location of the water heater. For installation your safety and for proper heater operation, you must B Check that there are no loose or provide combustion air to the heater and a proper damaged parts...

  • Page 22: Gas Piping & Connections

    Installation instructions Gas piping & connections Before connecting the gas supply, check the rating plate on the right side of the heater to be sure that the heater is rated for the same gas to which it will be connected. In the United States: The installation must conform with local codes or, in the absence of local codes, the National Fuel Gas Code ANSI Z223.1/NFPA 54.
  • Page 23 Installation instructions Once connections are made, check for gas leaks at all joints. Apply some gas leak detection solution to all gas fittings. Bubbles are a sign of a leak. A combustible gas detector may also be used to detect for leaks. Danger: If you have a leak, shut off the gas.
  • Page 24 0.3” in Water Column (0.75mbar).(Based on a 0.60 Specific Gravity Gas) Btu numbers given in thousands. Follow boxed numbers for piping just one Evolution 500 (example: ¾” B.I. Natural Gas pipe for 10 ft (3.0m). will handle 278,000 btu’s (81.5 kWh). For multiple appliances combine the total maximum btu input load and then refer to applicable chart below.

  • Page 25: Water Connections

    Bosch recommends consulting a local tom left. Centrally locating the water heater is recom- water treatment professional for water softening/ mended to keep hot water distribution times even conditioning options.

  • Page 26: Domestic Hot Water Recirculation

    Although recirculation directly through the tankless only. Timed or thermostatically controlled operation of water heater is allowed, temperature stability is the pump is commonly done. Contact Bosch improved by recirculating through a mini-tank as shown Thermotechnology if further information is needed.
  • Page 27 Installation instructions B Press and hold "Program" (P) button and press ON/ OFF button to turn appliance ON. Fig. 33 Fig. 34 Gas pressure test port (left tapping) B As soon as '188' is displayed, release "Program" , button and the display should read P2. Static Gas Pressure Reading (see Chapter 3.12) B Press until P1 appears.

  • Page 28: Electrical Connections

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

  • Page 29: Lcd Display Functions

    Operation instructions Operation instructions Fig. 38 On/Off button Reset button Program Key LCD display Up button Down button LED - Power On indicator or Stand-by LCD Display functions Fig. 42 Lock indicator Warning: Do not use any cleaning or corrosive agent to clean the window. Fig.

  • Page 30: Temperature Selection

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

  • Page 31: Program Button

    Operation instructions Use of optional remote control accessory (part no. TSTAT2) Fig. 50 Reset button If the problem persists, contact your installer. Program button Program button can be used on the appliance and in the Fig. 47 Remote control remote control. The wireless remote control accessory (Fig.

  • Page 32: Maintenance And Service

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

  • Page 33: Mineral Scale Build-Up

    Maintenance and service such as anti-freeze is not permitted as they may cause 11.Make sure there are no leaks and the solution is damage to the water heater's internal components. flowing from the descaling reservoir through the heater and returning to the reservoir. 1.
  • Page 34 Maintenance and service adjusting CO until pressure is at or above these levels, P2 CO Reading: % CO but not to exceed 10.5” WC for Natural Gas and 13” WC for Propane. P1 CO Reading: % CO A. Once Gas Pressure is adequate C.
  • Page 35 Maintenance and service Max. CO range (%) level (measured) Nat. Gas max. input 7.5 % - 8.1 % < 250 ppm min. input 2.3 % - 2.6 % < 60 ppm LP Gas max. input 8.7 % - 9.3 % <...

  • Page 36: Program Values

    3.3.6, page 17 Remote Con- see chapter 5.5, page 31 trols installed Access to Diag- see chapter 6.6, page 37 nostic Mode Cascade Mode contact Bosch for details Temperature °F °F °C Unit Appliance Type Condensing / Non-condensing*...

  • Page 37: Control Board Diagnostics

    Maintenance and service Control board diagnostics Diagnostic menu 1. Turn on/off switch on water heater to off (O) position. Entry/Exit into sub-modes 2. Press and hold the program ( ) button while Set-point temperature (°F) turning the on/off switch to the on (I) position. The display will cycle through a startup procedure Inlet water temperature (°F) including the software version.

  • Page 38: Troubleshooting

    Troubleshooting Troubleshooting and mixing valves are common causes of plumbing Warning: If you are unable to perform crossovers. the tasks listed below, or need 8. With the ON/OFF switch turned to OFF (O) position additional assistance please contact and the power supply cord unplugged, remove the your original installer or licensed gas unit's front cover (See Page 6.

  • Page 39: Low Water Flow/Pressure

    Troubleshooting heater. Then open all of the hot water taps served by higher pressure cold water at the tap, the lower the heater. Wait 10 minutes and check all taps for pressure hot water can be overpowered. This will water flow. There should be no water flowing. Any shut down the burners because the hot water flow continuous flow of water, small or large, indicates a rate fell below the minimum flow rate required for...
  • Page 40 Troubleshooting 5. Lack of adequate gas pressure. Inadequate gas pressure will cause the fuel-to-air mixture (CO ) to be out of adjustment. This will result in unstable burner flames and noise. Ensure gas pressure is in accordance with specifications in section 3.12, page 26 Measuring Gas Pressure.

  • Page 41: Problem Solving

    Problem solving Problem solving Error code diagnostics To remove error code from the display, press the reset button. Display Cause Solution Fault in the flue gas limiter. 1. Check continuity of the flue gas limiter (see Fig. , page Temperature above 230°F (110°C) Go to steps two and three to determine air box temperature inside the cabinet.
  • Page 42 5. Check supply voltage. It must be 120VAC and properly grounded. 6. Possible defective control unit call Bosch Water Heating for further instructions. 7. Ensure that outlet temperature sensor is not placed on any bends in the hot water pipe or misreading may occur.
  • Page 43 Problem solving Display Cause Solution Over-temperature detected 1. Check that the sensor is firmly attached to the vertical section of outlet temperature sensor on hot the hot water pipe (see Fig. , page water pipe. 2. Check red wire connections at outlet temperature sensor. Temperature >...
  • Page 44 The voltage should measure 24VDC between the left pair of wires and 24VDC between the right pair of wires when the unit is operating. If voltage is not proper, contact Bosch Water Heating for further instruction. 3. Gas valve may be defective, contact Bosch Water Heating for further instruction.

  • Page 45: Electrical Diagram

    Electrical diagram Electrical diagram T=104°C T=220°F T=110°C T=230°F Casc. input Casc. output Back flow 6720608542-04.1AL Fig. 59 Electrical scheme Intlet water temperature sensor Outlet water temperature sensor Backflow temperature sensor Cascading output connection Cascading input connection Ionization sensor Water flow sensor Flue gas limiter Heat exchanger overheat sensor (ECO) Gas valve...

  • Page 46: Sensor Resistance Charts

    Sensor resistance charts Sensor resistance charts Outlet temperature sensor characteristics 2 2 2 2 17 10 5 2 12 10 0 2 0 7 2 0 2 19 7 19 2 18 7 18 2 16 7 16 2 14 7 14 2 13 7 13 2...
  • Page 47 Sensor resistance charts Back Flow characteristics 3 0 2 2 9 7 2 9 2 14 5 2 8 7 2 8 2 14 0 2 7 7 2 7 2 13 5 2 6 7 2 6 2 13 0 2 5 7 12 5 2 5 2...
  • Page 48 Evolution 500 Functional scheme Evolution 500 Functional scheme Fig. 63 Functional scheme 6 720 680 223...

  • Page 49: Interior Components Diagram And Parts List

    Interior components diagram and parts list Interior components diagram and parts list 12.1 Interior components Fig. 64 Components Flue gas collector Ignition electrodes Heat exchanger Observation window Flame sensor Backflow temperature sensor Primary fan (Mixer) Secondary air fan Outlet temperature sensor Gas valve LCD display Water valve with engine and temperature sensor...
  • Page 50 Interior components diagram and parts list Fig. 65 Appliance overview 6 720 680 223...

  • Page 51: Components Diagram

    Interior components diagram and parts list 12.2 Components diagram 12.2.1 Group 1 13 15 6720902973.AA JF Fig. 66 Components Diagram Item Description Reference Item Description Reference Combustion cover clip 8 701 201 032 Front cover 8 705 431 369 Grommet set 8 710 203 039 Cover shield 8 705 506 749...
  • Page 52 Interior components diagram and parts list 12.2.2 Group 2 6720902974.AA JF Fig. 67 Components Diagram Item Description Reference Item Description Reference Site window 8 701 000 401 Heat exchanger 8 705 406 422 Ignition group 8 701 302 249 Heat exchanger top gasket 8 704 701 052 Heat exchanger O-ring 8 700 205 147...
  • Page 53 Interior components diagram and parts list 12.2.3 Group 3 6720902975.AA JF Fig. 68 Components Diagram Item Description Reference Item Description Reference Air duct O-ring 8 700 205 149 Main burner 8 708 120 699 Venturi 8 700 306 226 Burner gasket 8 704 701 087 O-ring 8 700 205 224...
  • Page 54 Interior components diagram and parts list 12.2.4 Group 4 6720608158-73.1AL Fig. 69 Components Diagram Item Description Reference Item Description Reference Gas filter 8 700 507 002 Gas valve 8 707 021 019 Gasket 8 704 701 085 Pressure tapping 8 703 404 219 Gas / Fan connector 8 705 202 140 Washer...
  • Page 55 Interior components diagram and parts list 12.2.5 Group 5 Fig. 70 Components Diagram Item Description Reference Item Description Reference Inlet fitting with filter 8 703 305 356 Water valve with engine 8 708 505 024 O-ring 8 700 205 147 O-ring 8 700 205 157 Cold water pipe...
  • Page 56 Interior components diagram and parts list 12.2.6 Group 6 6720902978.AA JF Fig. 71 Components Diagram Item Description Reference Item Description Reference Electrode cables 8 704 401 346 Control unit 8 707 207 257 Flue gas limiter 8 700 400 032 Fuse T2.5A 1 904 521 342 Cascading kit (optional)

  • Page 57: Protecting The Environment

    Protecting the environment Protecting the environment Packing The packing box may be fully recycled as confirmed by the recycling symbol Components Many parts in the heater can be fully recycled in the end of the product life. Contact your city authorities for information about the disposal of recyclable products.

  • Page 58: Limited Warranty

    Bosch Thermotechnology Corp. shall be in lieu of any • 4. to failure of the heat exchanger resulting from the and all other warranties, express or implied, including...
  • Page 59 Limited Warranty 6 720 680 223...

  • Page 60: Installer Checklist To Be Completed By Installer Upon Installation

    Installation manual should be left with the owner after the installation is tested and completed Replacement Parts available from: BOSCH THERMOTECHNOLOGY CORP. Bosch Termotecnologia SA 50 Wentworth Avenue Estrada de Cacia Londonderry, NH 03053 USA Tel. 866-330-2730 3801 - 856 Aveiro - PORTUGAL www.boschpro.com © 2009 Bosch Thermotechnology Corp., Londonderry, NH...

Table of Contents