Bosch Integra 500 User manual

Integra 500
INDOOR MODEL
Temperature Modulated with Electronic Ignition
Suitable for heating potable water - Not approved for space heating purposes
(Intended for variable flow applications)
Integra 500 - Natural Gas
Integra 500 - Liquefied Petroleum (LP) Gas
6 720 680 226 (2009/03) 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.

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2
Index
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 Specialized tools 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 Filling the condensate trap 27
3.13 Measuring gas pressure 28
4 Electrical connections 29
4.1 Electrical power supply 29
4.2 Position of the fuses in control unit 29
5 Operation instructions 30
5.1 Description LCD Display 30
5.2 For your safety read before operating
your water heater 31
5.3 Power 31
5.4 Temperature selection 31
5.5 Use of optional remote control accessory
(part no. TSTAT2) 32
5.6 Operation 32
5.7 Reset button 32
5.8 Program button 32
5.9 Locked condition 33
6 Maintenance and service 34
6.1 Annual maintenance 34
6.2 Winterizing for seasonal use 34
6.3 Mineral scale build-up 35
6.4 Condensing heat exchanger unit 35
6.5 Adjusting CO2 (carbon dioxide) 36
6.6 Program values 38
6.7 Control board diagnostics 39
7 Troubleshooting 40
7.1 Introduction 40
7.2 Burner does not ignite when
hot water is turned ON 40
7.3 Water is too hot 40
7.4 Water is not hot enough 40
7.5 Low water flow/pressure 41
7.6 Hot water temperature fluctuates at tap 41
7.7 Noisy burner/heater during operation 41
8 Problem solving 43
8.1 Error code diagnostics 43
9 Electrical diagram 47
10 Sensor resistance charts 48
11 Integra 500 Functional scheme 50
12 Interior components diagram
and parts list 51
12.1 Interior components 51
12.2 Components diagram 53
13 Protecting the environment 60
14 Limited Warranty 61

6 720 680 226
Warning
3
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 approved vent material
See table 2, page 10 (For Canada use
only ULCS636 approved material).
Vent and combustion air connector
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.

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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 opera-
tion.
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
• Easily removable one-piece cover
• LCD Display with backlight
• On/Off and Temperature control switches
• Reset button
• Program button (Selectable temperature default)
• Failure codes for easy diagnostics and repair
• Real-time diagnostics for troubleshooting/informa-
tional purposes.
Accessories (Bosch part #)
• Optional wireless remote control to operate with the
appliance (TSTAT2)
• Cascading kit (TLINK)
• Outdoor kit (BSHTOK)
• External water filter (part # 8 703 305 356)
• Concentric termination kit (196016)
• Freeze prevention kit (7709003665)
1)
• Exhaust/Intake bird screen (L2594)
• Condensate drain tee (196061) [included with Con-
centric termination kit].
Warning: If a relief valve discharges pe-
riodically, this may be due to thermal ex-
pansion in a closed water supply
system. Contact the water supplier or
local plumbing inspector on how to cor-
rect 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) The freeze prevention 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.
- The freeze prevention kit will not protect plumbing
outside the appliance from freezing. Precautions should
be taken.
i
BOSCH is constantly improving its
products, therefore specifications are
subject to change without prior notice.

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Appliance details
5
2.2 Specifications (Technical data)
Approved in US/Canada
Capacity
Maximum flow rate: 8.0 GPM (30 l/min) at a 45°F
(25°C) rise.
Maximum output
179,300 Btu/h (52.5 kW)
Maximum input
195,000 Btu/h (57.1 kW)
Efficiency in %
Thermal efficiency > 92%
Minimum 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 3.13, page 28.
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 (2.5 - 6.1 l/m).
• Minimum recommended water pressure: 30 PSI
(2.07 bar)
• Minimum well pressure 40 psi, see page 25.
• Connections:
– Bottom of heater
Combustion
• NOx ≤14 Ng/J (Nanograms of NOx (calculated as NO2) per
Joule of heat output).
• CO ≤290 ppm (measured)
• CO
2
level set from factory, see chapter 6.5, page 36.
Dimensions
• Depth (in): 11¼” (286 mm)
• Width (in): 17
7
/
8
” (452 mm)
• Height (in): 30½” (775 mm)
• Weight: 74 pounds (33.5 kg).
Gas types
Natural Gas.
LP Gas.
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
• Back flow temperature sensor
• Exhaust gas temperature sensor.
Water protection
IP X4 (protection against water drops)
i
If appliance is installed at elevations above
2000ft, refer to Section 3.3.6 Fan speed
adjustment.