For models: 660 EF/EFO

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1 Installaton Instructons Gas converson kts For models: 660 EF/EFO Part no. 660NGKIT/660LPKIT Warnng: Ths kt must be nstalled by a qualfed nstaller n accordance wth these nstructons and all applcable codes and requrements of the authortes havng jursdcton. (2010/04) US/CA

2 Gas Type Converson 1 Gas Type Converson For models: 660 EF/ 660 EFO only B 5. Remove the manfold plate by locatng and removng the 7 screws as ndcated n Fg. 1. Dscard the orgnal manfold plate. LP AND NG ARE EXTREMELY FLAMMABLE SO TAKE EXTRA PRECAUTIONS WHEN PERFORMING ANY WORK TO THE HEATER. PROCEDURE MUST BE PERFORMED BY A LICENSED GAS TECHNICIAN. Included Parts The followng parts are suppled n the converson kt. Check for any mssng tems before startng the converson. Manfold Plate (#1) O- Rng (#2) New Inlet and Manfold Pressure Ratng Stcker (#1) Date, Gas Type, Kt Number, Name of Company Stcker (#1). Fg. 1 B 6. Locate the 2 black O-Rngs on the gas valve as ndcated n Fg. 2. If torn or damaged, remove and replace these O-rngs wth the 2 new O-Rngs suppled n the converson kt. Dscard the old O- Rngs. A. Preparaton B 1. Tools needed: Bosch Remote Controller Manometer (capable of dsplayng dgts n tenths (.e. 2.4) and up to 20 W.C.) Phlps screwdrver (#2 recommended) Gas leak detector Do not attempt to perform a converson wthout access to a manometer and a Bosch remote controller. A dgtal manometer s recommended. B. Parts Replacement B 1. If the dsplay on the remote controller s on, turn off the unt by pressng the ON/OFF button on the remote controller. B 2. Dsconnect the electrcal power to heater by dsconnectng the electrcal plug from the outlet or shuttng off the breaker provdng power to the unt. B 3. Turn off the gas supply to the water heater by closng the gas shut-off valve. B 4. Remove the front cover of the unt by removng the 4 screws holdng t to the case. Fg. 2 2

3 Gas Type Converson B 7. Insert the new manfold plate suppled wth the converson kt. The orfce sze of the gas manfold plate should be marked as follows (Fg. 3) To fre Natural Gas (NG) 2.2 To fre Propane Gas (LPG) 1.5 Fg. 3 Manfold plate for 660 EF/EFO Natural Gas Warnng: DO NOT contnue wth converson f manfold plate s ncorrect. B 8. Make sure that O- Rngs are secured properly n place. Falure to do so wll cause gas leaks, possbly resultng n severe personal njury or death. B 9. Secure the new manfold plate to the unt usng the screws removed n step 5. The screws need only to be hand tghtened and should not be tghtened usng a drll. Frst, nsert screws 1-3 from Fgure 2, but do not fully tghten these screws. Insert and fully tghten screws 4-7. Then proceed to completely tghten screws 1-3. When tghtenng the screws, be certan to not apply excess force as the screws should turn easly. If extra force s requred, stop, remove the screw and tghten by hand frst. Excess force can strp out the orgnal holes. B 10. Before replacng the front cover, the unt must be adjusted and tested as descrbed n the next secton. 3

4 Adjustments and testng 2 Adjustments and testng A. Adjustments B 1.Before electrcal power s appled to the unt, nstall a remote controller to the unt f t s not already nstalled. B 2.Reconnect the electrcal power to the unt. B 3.Wthn the frst ten mnutes of connectng electrcal power to the unt, but before pressng the Power ON/OFF button (dsplay should be blank) hold the up button on the remote controller untl the dsplay blnks 99. Ths wll put the unt nto Mantenance Wrter mode. If pressng the up button does not put the unt nto Mantenance Wrter mode, make sure the remote dsplay s blank, unplug the unt for sxty seconds, and try agan. B 4.After accessng the Mantenance Wrter mode, use the up and down buttons to change the Mantenance Wrter tem number dsplay. Pressng the FLOW METER ALARM SET button for 0.5 seconds wll change the tem number settng from ON to OFF. If the Prorty lamp s flashng when an tem number s dsplayed, ths ndcates an ON settng for that tem number, and f the Prorty lamp s off, the tem number s OFF. B 5.Change FC and FE from OFF to ON. The prorty lght should be flashng on both tem numbers after pressng the FLOW METER ALARM SET. B 6.Choose the proper converson settng from the chart below and set the A1 Mantenance Wrter tem number accordng to the chart. Model Warnng: DO NOT change the other tem numbers. Ths wll cause a fault n the water heater. Desred Gas Type A1 If ths s not done, the unt wll not put the settng changes nto effect. B. Testng B 1.Before turnng on the gas supply to the unt, verfy that the gas supply pressure s wthn the followng operatng ranges: a. Natural Gas Supply: Mn. 4 Max nches W.C. b. Propane Supply: Mn. 8 Max. 14 nches W.C. The settng changes can be cancelled by pressng the Power ON/OFF button before confrmng the settngs, or f the unt s left alone for ten mnutes wthout confrmng the settngs. If the default settng needs to be changed agan, dsconnect the electrcal power to the unt, reconnect t and repeat ths procedure. If the supply pressure s hgher that the maxmum allowable pressure, adjust the pressure at the regulator or nstall a secondary regulator on the supply lne connected to the water heater. DO NOT attempt to operate heater f the gas supply pressure s not wthn the ranges specfed above. Hgh supply pressure can damage the unt and possbly cause a gas leak. B 2.Next, verfy the supply pressure at the unt. To check the gas supply pressure to the unt, a tap s provded on the gas nlet (Fg. 4). Make sure the gas supply s turned off to the unt. Remove the hex head Phlps screw from the tap. A 9/32 nut drver s recommended for the removal of ths screw. If a nut drver s not avalable, a Phlps screwdrver can be used. Gently remove the screw, so as not to strp out the screw. 660 EF/EFO Natural Gas ON 660 EF/EFO Propane OFF Table 1 ON: Prorty lght s flashng OFF: Prorty lght s off. B 7.After settng the A1 tem number for the desred gas type, press and hold the up and down buttons together for fve seconds to confrm the new settngs. The remote controller wll emt a tone and the dsplay wll go blank when the settngs are confrmed. Fg. 4 B 3.Connect a manometer to the tap by usng a slcone tube. Turn on the gas supply to unt and confrm the supply pressure. 4

5 Adjustments and testng B 4.After supply pressure to heater has been confrmed, turn off the gas supply, remove the manometer tube and replace the hex head screw. B 5.The manfold pressure wll also have to be checked usng a manometer (dgtal manometer s suggested). In order to check the gas manfold pressure, two taps are provded on the gas valve nsde the unt (Fg. 5). The pressure can checked ether by removng the hex head Phlps screw and connectng a manometer wth a slcon tube, or by removng the 1/8 NPT screw wth an Allen wrench and connectng the approprate pressure gauge. Be sure to zero out the manometer before attachng t to the tap. buttons on the rght sde of the crcut board (Fg. 6). Fg. 5 B 6.Turn on the gas supply to the unt. B 7.Before frng the unt, check for gas leaks at the gas nlet fttng and around the manfold plate usng a gas leak detector. B 8.If not already on, press the Power ON/ OFF button so that the unt s n standby mode. The prorty lght should be on. B 9.Open up several hot water fxtures (hgh flow rate s requred through the unt) and allow the unt to go through ts startup sequence. It may take several gnton attempts n order to purge ar from the gas chambers. If an 11 code appears on the remote controller, reset the unt by pressng the Power button on the remote controller off and then on agan. B 10.Once the heater has gnted and has begun to run contnuously, locate the manfold adjustment Fg. 6 B 11.Press and hold the maxmum pressure set button. Verfy from the table on the followng page that the approprate pressure s read from the manometer. Use values from Cover Off. If the pressure needs adjustments, use the manfold pressure ncrease and decrease buttons to adjust to the correct pressure, whle contnung to hold down the maxmum pressure set button. B 12.Press and hold the mnmum pressure set button. Verfy from the table on the followng page that the approprate pressure s read from the mano meter. Use values for Cover Off. If the pressure needs adjustment, use the manfold pressure ncrease and decrease buttons to adjust to the correct pressure, whle contnung to hold down the mnmum pressure set button. 5

6 Adjustments and testng Model Name Gas Type Supply Pressure (nch H2O) Manfold Pressure (nch H2O) Cover Off Max value Mn value 660 EF NGA LPG EFO NGA Table 2 LPG B 13.After the manfold pressures have been confrmed, verfy that the flame s a steady blue color usng the nspecton wndow (Fg. 7). Fg EF applances stckers Fg. 7 B 14.Turn off the water and the gas to the unt. Replace the screw from the manfold tap and turn on the gas supply to the unt. B 15.Perform a fnal gas leak check around the entre manfold plate, especally where the O-Rngs are seated aganst the plate usng a gas leak detector. B 16.If the remote controller needs to be removed, dsconnect electrcal power to heater and proceed to remove controller connectons. C. Apply converson labels B 1.Replace the front cover of the unt usng the 4 screws prevously removed. B 2.Locate the 2 converson stckers suppled n the converson kt. B 3.Place the stcker ndcatng the new nlet and manfold pressures drectly above the ratng stcker so as not to cover any exstng markngs as ndcated by A n Fg. 8. Fg EFO applances stckers B 4.Fll out the requred nformaton on the remanng stcker ndcatng the date, gas type, kt number, and name of the company performng the converson. Place ths stcker on the front cover as ndcated by B n Fg. 8 and 9 (unt dependng). Do not cover any exstng markngs. 6

7 Installaton Checklst 3 Installaton Checklst Parts Replacement Remove exstng manfold plate and O- Rngs. Dscard these parts. Replace wth new manfold plate and O-Rngs. Make sure that manfold plate and O-Rngs are securely n place. Adjustments Access Mantenance Wrter mode and set A1 and A2 tem numbers to desred gas type. Confrm gas type settngs. Testng Before openng gas valve to heater, verfy that gas supply pressure s wthn operatng range of heater. If gas supply pressure s not wthn specfcaton, adjust the pressure at the regulator or nstall a secondary regulator on the supply lne connected to the water heater. Remove hex Phlps screw from nlet of Bosch heater and confrm gas supply pressure at unt wth manometer. Replace screw after confrmaton of gas supply pressure. Remove hex Phlps screw or 1/8 NPT screw from gas valve and connect manometer to gas valve. Check for gas leaks around gas nlet fttng and manfold plate usng a gas leak detector. Check and confrm correct manfold pressures. Make adjustments f necessary. Replace screw after manfold pressures have been confrmed. Perform fnal gas leak check agan wth gas leak detector. Apply Converson Labels Place New Inlet and Manfold Pressure Ratng Stcker above ratng stcker on front cover. Fll out nformaton on Date, Gas Type, Kt Number, Name of Company Stcker and place on front cover. 7

8 BOSCH THERMOTECHNOLOGY CORPORATION 50 Wentworth Avenue Londonderry, NH Tel Bosch Termotecnologa, SA Estrada de Caca Avero - PORTUGAL Recycled paper 2010 Bosch Thermotechnology Corp., Londonderry, NH

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