Bosch Integra 500 Series Referenzhandbuch

Technical Service Bulletin:

Replacing Primary Fan & Main Burner

Models: C1210ESC, C1210ES, C1050ES, C950ES, 940ES, 940ESO, 830ES, 2400ES,

2700ES, 715ES, C800ES, C920ES/ESC, Integra 500, Evolution 500

Introduction

This procedure must be performed by a qualiﬁed technician.

Tools needed:

Phillips head screwdriver

30mm open end wrench or large adjustable wrench

8mm open end wrench

Preparation

1. Use the power button on the front of the water heater to turn

the appliance off and then unplug from the electrical outlet.

Isolate the gas supply to the water heater by closing the

installer supplied gas shut-off valve.

2. Shut the inlet and outlet water supply off to the water heater

3. Drain the water from the water heater.

4. Loosen two Phillips head screws located at bottom rear of

cover. (Fig. 1, step 1).

5. Lift front cover upward and remove. (Fig. 1, step 2).

Step 1 Step 2

20644956-11.1V

Step 3Step

Step

Figure 1

6. Remove combustion cover by unclipping two upper and two

lower clips securing cover. (Fig. 1, step 3)

7. Remove 3 Phillips screws on control unit (Fig. 2, step 1). Place

control unit into the service postion by engaging its tabs with

the holes in the horizontal sheet metal on bottom of the heater

chassis . (Fig. 2, step 2).

Step 2

Gas

Valve

Figure 2

Data subject to change without notice | Printed in the USA | BTC 740002329 A | 05.2014 Bosch Thermotechnology Corp.

Technical Service Bulletin Replacing Primary Fan & Main Burner | 2

Removing the Heat Exchanger

Models 2400ES, 2700ES, Evolution 500, and 715ES:

see bulletin TWH-G3-22 “Replacing Copper Heat Exchanger”

Models 830ES, 940ES, and 940ESO:

see Therm Bulletin “Replacing Copper Heat Exchanger”

Models C800ES, Integra 500, and C920ES/ESC:

see bulletin TWH-G3-21 “Replacing & Servicing the Condensing

Heat Exchanger”

see bulletin TWH-G3-22 “Replacing Copper Heat Exchanger”

Models C950ES, C1050ES, and C1210ES/ESC

see Therm Bulletin “Replacing & Servicing the Condensing Heat

Exchanger”

see Therm Bulletin “Replacing Copper Heat Exchanger”

Removing gas valve and gas/air mixer

1. Unplug wire connection from gas valve (Fig. 3, pos. 1).

2. Disconnect clear silicone pressure balance tube from right side

of gas valve. (Fig. 3, pos. 2)

3. Loosen and disconnect large 30mm hex nut on the left side of

gas valve (Fig. 3, pos. 3).

4. Remove 3 Phillips head screws on the black plastic air supply

duct and remove this component (Fig. 3, step 4).

Figure 3

5. Remove 4 Phillips head screws that attached the gas/air mixer

to the primary fan (Fig. 3, step 4).

6. Remove the gas valve and gas/air mixer as one piece

Removing secondary fan

1. Unplug wire connections into the secondary fan (Fig. 4, pos. 1).

2. Remove 2 Phillips head screws from the top of the secondary

fan (Fig. 4, pos. 2).

3. Secondary fan will drop down once second screw is removed.

The fan can now be removed.

Figure 4

Removing primary fan and burner

1. Unplug wire connection on the back left of the primary fan.

2. Disconnect the back ﬂow sensor on the front of the burner

(Fig. 3, pos. 6).

3. Remove 2 Phillips head screws from the burner retaining plate

left and right (Fig. 3, pos. 5).

4. Burner tray and primary fan can now be removed as one piece.

Extreme care must be taken with the Ceramat burner. This is

a ﬁberglass mat. Take care not to touch or poke the burner

mat material as any damage will require a complete new

burner tray to be installed.

5. Using an 8mm wrench, remove the 4 nuts that secure the

primary fan to the burner.

6. Separate the burner from the primary fan and replace fan or

burner.

Data subject to change without notice | Printed in the USA | BTC 740002329 A | 05.2014 Bosch Thermotechnology Corp.

Technical Service Bulletin

3 | Replacing Primary Fan & Main Burner

Bosch Thermotechnology Corp.

50 Wentworth Avenue

Londonderry, NH 03053

Tel: 1-800-283-3787

Fax: 1-603-965-7581

www.bosch-climate.us

Reinstalling primary fan and burner

1. Attach the burner to the primary fan and ensure gasket is in

place.

2. This gasket can be reused.

3. Using an 8mm wrench, secure the 4 nuts to secure the primary

fan to the burner.

4. Burner tray and primary fan can now be reinstalled as one

piece.

5. Insert the 2 Phillips head screws into the burner retaining plate

(Fig. 3, pos. 5).

6. Reconnect the back ﬂow sensor on the front of the burner

retaining plate.

7. Plug wire connection into the back left of the primary fan.

Reinstalling secondary fan

1. Insert tab on the back of secondary fan into bracket of burner

and then lift fan to align holes with the retaining bracket.

2. Insert the left Phillips head screw to secure fan and then insert

right Phillips head screw with secondary fan in place.

3. Plug wire connections into the secondary fan (Fig. 4, pos. 1).

Reinstalling gas valve and gas/air mixer

1. Install the gas valve and gas/air mixer as one piece.

2. Insert 4 Phillips head screws to secure the gas/air mixer to the

primary fan (Fig. 3, step 4).

3. Attach black plastic air supply duct and secure with 3 Phillips

head screws (Fig. 3, step 4).

4. Thread and tighten the large 30mm hex nut on the left side of

gas valve (Fig. 3, pos. 3).

5. Insert pressure balance tube on to brass nipple on right side of

the gas valve (Fig. 3, pos. 2).

6. Plug 4 wire connection into gas valve (Fig. 3, pos. 1).

7. Secure the control unit using the 3 Phillips head screws (Fig. 2,

step 1).

Reinstalling the Heat Exchanger

Reference appropriate bulletin(s) used for removal of copper

heat exchanger and/or secondary heat exchanger.

Placing the unit back into service

1. Slowly turn water on into the water to ensure all water

connections are secure. Search for any leaks on the pipe

connections.

2. Plug the water heater into the outlet and turn water heater on.

3. Turn the gas on to the water heater.

4. Install secondary combustion cover by uclipping two upper and

two lower clips to secure inner cover (Fig. 1, step 3).

5. Lift back corner of cover over tabs and lower into place (Fig. 1,

step 2).

6. Tighten two Phillips head screws located at bottom rear of

cover (Fig. 1, step 1).

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