AquaStar 2400 ES User manual

Outdoor Kit Installation Instructions
Aquastar Tankless Water Heater
For Aquastar models: 2400 ES, 2700 ES
Part no. AQOK
Warning: This kit must be installed by a qualified
installer in accordance with these instructions and
all applicable codes and requirements of the
authorities having jurisdiction.
6 720 608 835 (2009/02) US

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2
Warning
1 Warning
This outdoor kit includes:
• Supports (2) with screws
• Sealing gasket
• Control panel shield
• Outdoor vent cap.
Danger: The top of the outdoor kit will
get very hot during operation. Keep
away from children. Install heater in a
location where the top of the kit cannot
be reached by small children.
Danger: Flue gas will be released
through the outdoor kit. Flue gas is very
hot and contains carbon monoxide. The
outdoor kit cannot be installed on a
water heater mounted indoors. To
prevent risk of fire and carbon monoxide
poisoning, maintain all clearances
indicated in these instructions.
Danger: Do not place or store any
combustible material within 5 feet of the
appliance. Maintain specified clearance
to combustibles on the wall where the
appliance is installed and any adjacent
walls or overhang. Observe all
clearances required in this manual.
Danger: Surface temperature of the kit
is less than 140°F, except highest top
surface which may reach 300°F.
Warning: Do not mount water heater
directly onto vinyl siding, see Fig. 9.
Danger: the freeze prevention kit on
the appliance is designed to provide
protection from temperatures 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 must be taken:
BAlways drain the water heater if it will
be exposed to long term freezing
conditions.
Danger: the water in this appliance is
cold and always remains cold except for
the times when the burner is on. In the
event of power outage in conjunction
with freezing temperatures, it is
recommended that the heater be
drained.
Warning: Damage to the appliance
from freezing is not covered under the
manufacturer's warranty.

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Selecting heater location
3
2 Selecting heater location
Before proceeding, read the water heater installation
manual. If the information in that manual is not followed
exactly, a fire, explosion or poisoning by carbon monox-
ide may result causing property damage, personal injury
or death.
BChoose an outside wall for the installation.
Installation on a wall protected by an overhang above
is recommended.
BSize the water and gas connections according to the
instructions in the water heater installation manual.
Use unions when connecting both water lines and
gas supply line to the heater.
Minimum clearances
If the appliance is installed under an overhang, there
must be a 36” clearance from the top of the appliance
and the mounting area must be open in front and on the
sides of the appliance.
Fig. 1
Ref. Description Min.
distances
ADirectly below or adjacent to
an opening; operable
windows, doors and any fresh
air openings
≥1 ft
B
C
D From any adjacent wall ≥4 ft
EBelow a gutter, sanitary
pipework, eaves or overhang ≥3 ft
F Above ground ≥1 ft
GFrom a gas meter or gas
regulator
≥5 ft
Table 1 Clearances
i
Best practice note: The clearances in
Fig. 1 and table 1 are the minimum
allowed by the standard.
When possible consider maximizing the
clearances A, B and C to allow for the
effects of wind and frequently used door
and window openings.

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Installing outdoor kit
3 Installing outdoor kit
Replace the control panel shield
BLoosen the two Philips head screws located on
bottom rear of cover (see Fig. 2).
Fig. 2 Loosen the two screws
BRemove the front cover panel and replace the
original control panel shield with shield provided in
the kit, see Fig. 3.
Fig. 3 Replace the control panel shield
BAfter replacing the control panel re-position the front
cover.
B1. Remove the cover plate (A) installed on the top of
the appliance, as shown in Fig. 4.
B2. Attach the supports (B) to the appliance by
fastening with the four provided screws, as shown in
Fig. 4.
Fig. 4
Before mounting the outdoor kit in the appliance:
B3. Attach the gasket provided with the kit as shown
in Fig. 5.
Fig. 5
BPosition the outdoor vent cap on the top of the
appliance, as shown in Fig. 6.
Warning: The control panel shield
must always remain closed, except
when making adjustments, to prevent
damage to heater from weather.
6720608547-14.1AL
1.
1.
3.
2.

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Installing outdoor kit
5
Fig. 6
BAttach the outdoor vent cap to the appliance by fas-
tening the two provided screws and washers, see
Fig. 7.
Fig. 7
i
NOTE: Once this kit is installed, the
outdoor vent cap will need to be removed
before removing the front cover.

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Mounting instructions
4 Mounting instructions
BThe water heater is approved for installation directly
on an outside wall. Secure the wall mounting bracket
provided with the water heater to a wall surface. See
Fig. 8.
BThe installation method of the mounting bracket will
depend on the type of mounting surface. Due to the
varieties of building siding or surfacing, the installer
must decide on how best to support and level the
heater on an outside wall. It is recommended that
horizontal or vertical support boards or plywood
sheathing (1/2” minimum) first be attached to the
wall surface. The heater must also be kept level on
the wall surface.
Fig. 8 Installation on wood siding
Fig. 9 Installation on vinyl siding
Warning: Do not mount heater directly
to vinyl siding. With vinyl siding, a 6' x 4'
area of the siding must first be removed
and then replaced with wood or other
non-plastic material. See Fig. 9.
Plywood (½" minimum)
or other solid wood
material(s) to anchor the
wall support bracket and
keep the heater level
against wall surface
Wood
siding
6720608835-08.1JS

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Electrical connections
7
5 Electrical connections
5.1 Electrical power supply
The water heater requires an electrical power supply
from a 120VAC / 60Hz circuit (with a dedicated outlet)
and must be properly grounded.
The heater is wired as shown in the wiring diagram of
the water heater installation manual.
Fig. 10 Connecting power supply cord
1Power cord length: 3ft.
Note: Outlet appliance is plugged in to should be
clear from possible water damage.
BRefer to water installation manual to complete
installation of gas and water piping connections.
BStart and operate the water heater according to the
water heater installation manual. NOTE: Open the
control panel shield to access the controls of the
heater, see Fig. 3.
Warning: For safety reasons,
disconnect the power supply cord 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. Do not rely
on the gas or water piping to ground the
metal parts of the heater.
Warning: Confirm that the water
heater is appropriately grounded and
that the installation meets all applicable
electrical codes for outdoor
installations.

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Measuring carbon dioxide (CO2)
6 Measuring carbon dioxide (CO
2
)
BSee the water heater installation manual for details
on measuring carbon dioxide (CO
2
).
BTo measure CO
2
on this appliance, a measuring port
is available under the louvered grill on the front of the
outdoor vent cap.
BTo access measuring port, remove two screws on
either side of the louvered grill.
BPull louvered grill free from vent cap.
BWhen measuring is complete, replace louvered grill
with screws.
Fig. 11
1Measuring port
Warning: Outdoor vent cap will get
very hot during operation.
BEnsure the vent cap is cool before
performing the procedure below.

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Notes
9
7 Notes

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Notes

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Notes
11

Replacement Parts available from:
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Estrada de Cacia
3801 - 856 Aveiro - PORTUGAL
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Londonderry, NH
BOSCH THERMOTECHNOLOGY
CORPORATION
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Waitsfield, VT 05673
Tel. [phone]
www.boschhotwater.com