User manual BOSCH GWH 450 ESR

GWH 345/450 ESR Temperature Modulated with Electronic Ignition Suitable for heating and recirculating potable water GWH-345/450-ESR-N - Natural Gas GWH-345/450-ESR-L - 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 vapor 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 and doors, and evacuate the building. · Do not try to operate 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. 6 720 607 909 US (2007.04) JS Index Index 1 Warning 2 1 Warning 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 Appliance details Features GWH-345/450-ESR Specifications (Technical data) Unpacking the GWH-345/450-ESR heater General rules to follow for safe operation Dimensions and minimum installation clearances Applications Water quality 4 4 4 5 6 7 8 9 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 from lack of air, carbon monoxide poisoning or fire. Warning: Exhaust gas must be vented to outside using 3" single wall sealed stainless steel vent pipe suitable for category III vent systems and temperatures up to 480°F. 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. Warning: Place the recirculating water heater in a location where water leaks will do NOT DAMAGE 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 recirculating water heater, turn off the electrical power to the recirculating water heater at the main disconnect or circuit breaker. Failure to do so could result in severe personal injury or death. 3 3.1 3.2 3.3 3.4 3.5 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.6.6 3.6.7 3.7 3.8 3.9 3.10 3.11 Installation instructions Introduction Proper location for installing your heater Heater placement and clearances Mounting installation Combustion air requirements Venting Vent material and specifications Vent connections and air inlet restrictors Condensate drain requirements Room sealed installation (Twin pipe) Vertical terminations Horizontal terminations Exhaust vent configuration examples Gas piping & connections Measuring gas pressure 10 10 10 10 10 11 13 13 14 17 17 18 18 21 22 24 Checking restrictor plate size by measuring CO2 level value 24 Water connections 25 Electrical connections 25 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 Operating instructions Initial filling instructions For your safety read before operating your water heater Startup instructions Power Recirculating water temperature Temperature and hot water flow Freeze protection Electrical diagram 27 27 27 27 28 28 28 28 29 5 5.1 Maintenance and service Service mode 30 30 6 Troubleshooting 32 7 GWH-345/450-ESR Functional scheme 34 8 8.1 8.2 8.3 Interior components diagram and parts list Interior components Components diagram Parts list 35 35 36 37 9 Protecting the environment 38 10 Ten Year Limited Warranty 39 2 6 720 607 909 Warning Warning: The recirculating water 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 (14" W.C.). 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 operation. Caution: Any changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment. Fig. 1 6 720 607 909 3 Appliance details 2 2.1 Parts Appliance details Features Temperature Control Selection range: 115°F (45°C) - 190°F (90°C) Gas Requirement Gas connection (inches) - ¾" Inlet gas pressure under operation (with a high hot water flow rate)* · Propane: 11" - 14" water column · Natural Gas: 5.5" - 8" water column. * To measure gas pressure, see Measuring Gas Pressure, chapter 3.8. Venting 3" AL 29-4C single wall sealed stainless steel vent pipe. See chapter 3.6 for Venting. Water · Hot water connection - ¾" NPT · Cold water connection - ¾" NPT. Combustion · NOx 100 ppm · CO 250 ppm · CO2 level (see table 8 for correct restrictor dimension). Dimensions · Depth (in): 11 ¾" (300 mm) · Width (in): 15 ¾" (400 mm) · Height (in): 27 ½" (700 mm) · Weight: 47 pounds (21 kg). Gas types Natural Gas. Liquid Propane. The appliance is not field convertible. Voltage 120 V AC (50/60 Hz) Amperage Idle - 40 mA Operation - 1.5 A Noise 50 db (A) Safety devices · Flame failure device (Ionization flame control) · Overheat prevention (temperature limiter) · Pressure switch (blocked vent protection). · Sealed combustion burner. Safety · Ionization flame sensor · Over temperature protection. High quality materials for long working life · Copper heat exchanger · Compact space saver: mounts on a wall with supplied bracket. Features · LCD screen to display temperatures, burner operation and error codes · On/Off button and separate temperature controls for domestic water heating and recirculating water · Reset button · Failure codes for diagnostics and repair · Freeze prevention cycle. i 2.2 BOSCH is constantly improving its products, therefore specifications are subject to change without prior notice. GWH-345/450-ESR Specifications (Technical data) Approved in US/Canada Capacity GWH345 Maximum flow rate: 3.5 GPM (13 l/min) at a 45°F (25°C) rise. GWH450 Maximum flow rate: 4.5 GPM (17 l/min) at a 45°F (25°C) rise. Maximum output GWH345 - 77,900 Btu/h (22.8 kW) GWH450 - 98,400 Btu/h (28.8 kW) Maximum input GWH345 - 95,000 Btu/h (27.8 kW) GWH450 - 120,000 Btu/h (35.1 kW) Efficiency in % GWH345 Combustion efficiency: 82% GWH450 Combustion efficiency: 81% Min. Output GWH345 - 23,900 Btu/h (7 kW) GWH450 - 35,500 Btu/h (10.4 kW) 4 6 720 607 909 Appliance details Water resistant IP X4 (protection against water drops) To remove front cover 2.3 Unpacking the GWH-345/450-ESR heater i The front cover is secured with two screws to prevent unauthorized access. Always secure the control panel and front cover with these screws. This heater is packed securely. The box includes: · Wall-mounted gas fired recirculating water heater · Bracket and screws for wall hanging the heater · Exhaust vent adaptor (with 4 screws and gasket provided) · Combustion air inlet adaptor (with 4 screws and gasket provided) · Installation manual · Product registration card · Energy Guide label · Pressure relief valve · Inlet air restrictors ­ GWH 345 ESR N: Ø38/40/42 ­ GWH 345 ESR LP: Ø38/40/42 ­ GWH 450 ESR N: Ø44/47/50/55 ­ GWH 450 ESR LP: Ø47/50/55/60 Do not lose this manual. Please complete and return the enclosed product registration card. Before installing the unit, be certain you have the correct heater for your type of Gas - Propane or Natural Gas. Identification labels are found on the shipping box, and on the rating plate which is located on the right side panel of the cover. B Loosen the two Philips head screws located as shown in fig. 2. Fig. 2 Screws B Pull control panel outwards and then pull it downwards (Fig. 3). Front cover Low voltage access cover Control panel Fig. 3 Service position to access water and electric connections B Lift front cover upward and remove. The GWH-345/450-ESR is not approved or designed for: · Manufactured (mobile) homes, RV's or boats · Outdoor installation · Combination venting with other appliances · Closed loop heating applications. 6 720 607 909 5 Appliance details 2.4 General rules to follow for safe operation 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. In Canada: The Installation must conform with CGA B149.(1,2) INSTALLATION CODES and /or local installation codes. 2. Carefully plan where you install the heater. Correct combustion air supply and vent pipe installation are very important. If not installed correctly, fatal accidents can be caused by lack of air, carbon monoxide poisoning or fire. 3. When the unit is installed indoors with ROOM SEALED (twin pipe) combustion air and venting, it is permitted to be located in bathrooms, bedrooms and occupied rooms that are normally kept closed. See chapter 3.6. If the unit will be installed indoors and use indoor combustion air, the place where you install the heater must have enough ventilation. The National Fire Codes do not allow UNSEALED gas fired water heater installations in bathrooms, bedrooms or any occupied rooms normally kept closed. See chapter 3.2 and 3.5. 4. You must vent your heater. See chapter 3.6 Venting. 5. The appliance and its gas connection must be leak tested before placing the appliance in operation. The appliance must be isolated from the gas supply piping system by closing its individual manual gas shutoff valve (not supplied with heater) during any pressure testing at pressures in excess of ½ Psig (3.5 kPa). 6. Keep water heater area clear and free from combustibles and flammable liquids. Do not locate the heater over any material which might burn. 7. Correct gas pressure is critical for the optimum operation of this heater. Gas piping must be sized to provide the required pressure at the maximum output of the heater, while all the other gas appliances are in operation. Check with your local gas supplier, and see the section on connecting the gas supply. 8. Should overheating occur or the gas supply fails to shut off, turn off the gas supply at the manual gas shut off valve, on the gas line. Note: manual gas shutoff valve is not supplied with the heater. 9. Do not use this appliance if any part has been underwater. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been underwater. 10.Failure to install heater correctly may lead to unsafe operation and void the warranty. 11.The heater must not be installed in an unheated area where temperatures will reach 36°F or lower. If the heater is left in an area susceptible to such temperatures, drain the unit and disconnect from electrical supply. See Chapter 4.7 for additional freeze prevention information. 12.In areas where water supply has a high mineral content, a water softener is strongly recommended. A water softener is required if the water hardness exceeds 6 grains/gal (103 mg/l) calcium carbonate. Damage to the water heater resulting from hard water/scale deposits will not be covered under warranty. 6 6 720 607 909 Appliance details 2.5 Dimensions and minimum installation clearances Fig. 4 1 2 3 4 5 6 7 8 9 Dimensions Combustion air inlet adapter (right side only) Exhaust adapter with CO2 measuring point Front cover On/Off button Reset button Recirculating water temperature selector LED - (ON) warning light (blinks when in error lock out) Domestic hot water temperature selector Mounting plate Fig. 5 Minimum clearances Model GWH-345/450-ESR TOP FRONT (B) BACK SIDES BOTTOM 12" 4" 0" ½" 12" Table 1 Minimum clearances 6 720 607 909 7 Appliance details 2.6 Applications Caution: the water heater which will be used to supply potable water shall not be connected to any heating system or component(s) previously used with a nonpotable water heating appliance. Introduction The application designs provided in this manual are general guides to be used when installing this recirculating water heater. Pump Sizing Required PS pumps are Taco 007 Bronze or Grundfos 15-42B. PZ pumps should be sized by a professional plumbing contractor based on the specific application. Caution: Do not overpump the heater. Maximum 5 gpm water flow permitted through the heater. Instantaneous water heater (direct tank load design) Note: maximum amp draw: 1,5A. Do not connect additional pump to the appliance but use a relay panel if powering multiple pumps. Fig. 6 Front cover Low voltage access cover Control panel Fig. 7 Service position to access water and electric connections 6 720 607 909 8 Appliance details Pressure drop curves Note: Flow above 6 GPM is not permitted. 50 feet of head GWH 345 ESR Inlet pressure 40 feet of head 30 feet of head 20 feet of head 10 feet of head 0 feet of head 0 GPM 1 GPM 2 GPM 3 GPM 4 GPM 5 GPM 6 GPM water flow rate Fig. 8 GWH 345 ESR 50 feet of head GWH 450 ESR 40 feet of head Inlet pressure 30 feet of head 20 feet of head 10 feet of head 0 feet of head 0 GPM 1 GPM 2 GPM 3 GPM 4 GPM 5 GPM 6 GPM water flow rate Fig. 9 GWH 450 ESR 2.7 Water quality Water quality can have an impact on appliance performance and appliance longevity, and may not be covered by the manufacturer's warranty. For water analysis data call your local water department. If on a well system, have well water analyzed periodically. If water quality is exceeding one or more of the values specified below, Bosch recommends installing a water conditioner or softener. Description pH TDS (Total Dissolved Solids) mg/l or ppm 500 Total hardness Aluminum Chlorides Copper Iron Manganese Zinc Max. Levels pH range 6.5-8.5 mg/l or ppm 100 (6 grains) mg/l or ppm 0.2 mg/l or ppm 250 mg/l or ppm 1.0 mg/l or ppm 0.3 mg/l or ppm mg/l or ppm 5.0 0.05 Table 2 Venting Specifications 6 720 607 909 9 Installation instructions 3 3.1 Installation instructions Introduction 3.3 Heater placement and clearances Please follow these instructions. Failure to follow instructions may result in: · Property damage or personal injury · Improper operation · Heater damage · Loss of warranty. Please contact Bosch Water Heating with any questions. The GWH-345/450-ESR is design certified for installation on a combustible wall (see 3.4 Mounting installation) provided the floor covering below the heater is noncombustible. For installations in an alcove or closet, maintain the minimum clearances to combustible and non-combustible materials listed below. See also fig. 5. A. Top 12 inches (305 mm) B. Front 4 inches (100 mm) C. Back 0 inches D. Sides ½ inches (12 mm) E. Bottom 12 inches (305 mm) Clearances from any exhaust vent pipe are dependent upon the clearance requirements of the stainless steel vent pipe manufacturer. Single wall sealed stainless steel (AL29-4C) vent pipe (rated for Category III appliances) must be used when exhaust venting this appliance. See 3.6 Venting. 3.2 Proper location for installing your heater Carefully select the location of the water heater. For your safety and for proper heater operation, you must provide combustion air to the heater and a proper exhaust vent system. Follow the guidelines below: B 1. Locate the heater where venting, gas and plumbing connections are feasible and convenient. B 2. The hot water lines should be kept short to save energy. Centrally locating the water heater is best. It is always best to have hot water lines insulated. Warning: The water in this recirculating water heater is cold and always remains cold except for the times the burners are on. In the event of power outage in conjunction with freezing temperatures, it is recommended that the heater be drained to prevent heater from freezing. See chapter 9 for draining instructions. Warning: Flammable materials, gasoline, pressurized containers, or any other items or articles that are potential fire hazards must NOT be placed on or adjacent to the heater. The appliance area must be kept free of all combustible materials, gasoline and other flammable vapors and liquids. 3.4 Mounting installation Warning: before starting installation: B check that there are no loose parts inside the appliance B check that the gas type of the heater matches the gas supply you will be connecting to the heater. B ensure that gas pipe, gas valve, fan and burner have no damage and are properly fitted. Front cover should be removed (see instructions on page 5) in order to inspect components visually. i B Secure the wall mounting bracket provided with the heater to a wall surface. Warning: Do not install this appliance on a carpeted wall. The heater must be mounted on a wall using appropriate anchoring materials. If wall is a stud wall sheathed with plasterboard, it is recommended that support board(s), either 1x4's or 1/2" (minimum) plywood first be attached across a pair of studs. Then attach the heater's bracket to the upper support board. The heater should be kept level on the wall surface. See Fig. 10. 10 6 720 607 909 Installation instructions Single pipe Although it is permissible to draw combustion air from inside the structure, it is not the manufacturer's recommended installation method. Always install a 3 inch elbow on the combustion air inlet to prevent foreign objects from falling into the unit (see Fig. 11). Fig. 11 Fig. 10 Mounting the heater If a single pipe installation is performed. Use the following guidelines when providing adequate combustion air for the recirculating water heater as well as any other appliances that may consume air in the space. Always follow local codes if more stringent. · Appliances located in unconfined spaces: ­ a) An unconfined space is one whose volume is greater than 50 cubic feet (1.42 cubic meter) per 1000 Btu per hour (292.81 watts) of the combined rating of all appliances installed in the space. That would be 6200 cubic feet (175.6 cubic meter) of air required for the GWH-345/ 450-ESR alone. ­ b) In unconfined spaces in buildings of conventional frame, masonry, or metal construction, infiltration air is normally adequate to provide air for combustion. ­ c) Installations in structures that have been tightly constructed (air infiltration rate of 0.40 ACH or less) must provide combustion air per the National Fuel Gas Code. Consult an HVAC specialist if your air infiltration rate is questionable. For these types of installations, the twin pipe system must be used. 3.5 Combustion air requirements Warning: In areas where freezing temperatures are common the twin pipe system is recommended. In a single pipe installation, a negative air condition may result in cold air being drawn across the heat exchanger coil causing it to freeze and burst. This failure is not covered under the manufacturer's warranty. Warning: When installed in an environment where corrosive chemicals or dirty air are present the twin pipe system is required. Twin pipe The GWH-345/450-ESR is designed as a sealed combustion appliance. It is recommended that the combustion air be provided by a dedicated 3" pipe to the outside. If terminating combustion air piping horizontally, pitch vent down 1/4" per foot towards termination to prevent rain from entering the appliance. The combustion air pipe may be constructed of aluminum flex, PVC or any other rigid or semi rigid sealed pipe. The combustion air inlet must be located in such a manner as to provide a minimum 3 foot clearance from the exhaust vent terminator. The maximum length of the combustion air inlet is 39 feet with one elbow. Subtract 6 feet for each additional elbow. Maximum number of elbows permitted is 4. 6 720 607 909 11 Installation instructions · Appliances located in confined spaces: The confined space must be provided with two permanent openings, one commencing within 12 inches (304.8mm) of the top and one commencing within 12 inches (304.8mm) of the bottom of the enclosure. Each opening must have a minimum free area of one square inch per: ­ 1000 Btu/hr (292.81 watts) if all air is taken from inside the building ­ 2000 Btu/hr (585.62 watts) if all air is taken from the outside by horizontal ducts ­ 4000 Btu/hr (1171.24 watts)if all air is taken from the outside by direct openings. Or the confined space must be provided with one permanent opening or duct that is within 12 inches (304.8mm) of the ceiling of the enclosure. This opening must have a minimum free area of one square inch per: ­ 3000 Btu/hr (878.43 watts) if all air is taken from the outside by a direct opening. Louvers, grills and screens have a blocking effect, when used, increase the sizes of your openings by 400% for wood louvers (as wood type will reduce the free air by 75%) and 135% for metal louvers (as metal will reduce the free air by 30%). Refer to the National Fuel Gas Code for complete information. 12 6 720 607 909 Installation instructions 3.6 Venting Danger: Do not combination vent this appliance with any other appliance. tal length, to prevent the pooling of condensate, and be supported at 4 foot intervals with overhead hangers. See Table 3. The last horizontal run including the termination must be sloped to the outside 1/4" per foot to prevent rain from entering the venting system. Diam. Max length 39 feet with 1 elbow 39 feet with 1 elbow Material Warning: Do not reduce the vent (exhaust and combustion) pipe sizes. Exhaust Vent Intake Vent 3 inches Warning: Failure to vent the exhaust gases to the outside with sealed stainless steel vent pipe (AL29-4C) may result in dangerous flue gases filling the structure in which it is installed. Warning: Do not mix vent pipe or joining methods from different manufacturers. Caution: The vent system must be installed by a qualified individual or agency in accordance with these instructions. If improperly installed, a hazardous condition such as fire or carbon monoxide poisoning could result. Bosch Water Heating will not be responsible for improperly installed appliances. 3.6.1 Vent material and specifications Sealed stainless steel (AL29-4C) Aluminum flex, PVC or any other rigid or semi rigid sealed 3" pipe 3 inches Table 3 Venting Specifications The minimum exhaust vent length is 3 feet. The use of a 90 degree elbow is equivalent to 6 ft in vent length. The use of 45 degree elbow is equivalent to 3 ft in vent length. Fig. 12 Minimum exhaust vent length Establish vent clearances that comply with the vent manufacturer's specifications. In all cases follow local codes. Note: Listed thimbles or collars are necessary to pass through wall and ceiling partitions. If the vent system passes through combustible areas where the vent clearance requirements cannot be maintained, it is permissible to chase straight sections of sealed 3 inch single wall vent through 4 inch (or greater) Type-B vent. The distance to combustibles using this chase technique is 1 inch. Warning: Type-B vent should never be used as the actual exhaust vent system for the appliance, as it is not gas tight. Vent lengths The appliance should be located as close to the point of termination as possible. The maximum vent length is 39 feet (12 m) with one 90 degree elbow. Subtract 6 feet from the total vent length for each additional 90° elbow used (a maximum of four 90° elbows are permitted in the total vent length), or subtract 3 feet for every 45° elbow used. Horizontal section of vent must pitch upward from heater 1/4" for every foot of horizon- Vent pipe Reduce maximum length 6 ft for each 90 elbow after the first one and 3 ft for each 45 elbow. Combustion air intake Fig. 13 Maximum vent and combustion air lengths Vent material The GWH-345/450-ESR requires 3 inch sealed single wall stainless steel vent pipe (AL29-4C). Use of any other vent material will void the manufactures warranty and may result in a hazardous condition. For specific questions concerning vent material, specifications, 6 720 607 909 13 Installation instructions usage or installation, contact the vent manufacturer directly. Company Contact information 3.6.2 Vent connections and air inlet restrictors Exhaust vent connection B Attach the flue gas exhaust accessory (8 705 504 142) to the top of the unit (position 1) using the 4 screws and gasket provided B Insert 3" single wall stainless steel vent pipe into exhaust vent adapter 1.5" and tighten the clamp (position 2). Note: Failure to fully insert and tighten vent pipe may cause flue gas leakage or condensate damage that is not covered under the manufacturer's warranty. Z-flex www.z-flex.com 800-654-5600 www.protechinfo.com 800-766-3473 ProTech Industries Heat-Fab www.heatfab.com 800-772-0739 Table 4 Vent manufacturer contact information Z flex Protech Heat Fab 3" Horizontal terminator TEE only TEE only 9390 TEE 3" Vertical terminator 90° Condensate drain Tee Horizontal Condensate drain Vertical Condensate drain Condensate Drain Tube 2SVSRCF03 FSRC3 5300CI Fig. 14 Exhaust vent connection 2SVEVWCF03 FST3 & FSDF3 93PLSTEE 2SVEDWCF03 FSHD03 9321 2SVSEVDP03 N/A N/A 2SVEDTK N/A 7000TUBE Table 5 Approved vent termination and condensate drain part numbers (subject to change) Contact your Bosch supplier for stocked vent material. Vent Safety System The GWH-345/450-ESR will shut down if inadequate exhaust venting is detected or a lack of combustion air is provided to the unit; see troubleshooting section on page 32. Correct the problem and then reset the heater before operating. 14 6 720 607 909 Installation instructions Selecting inlet air restrictor Note: Before installing the combustion air inlet accessory, the appropriate inlet air restrictor must be determined using Tables 6, 7 and 8. Refer to Fig. 15 for mounting sequence. B Determine the total length of the straight sections of 3" stainless steel exhaust and enter that length in line 1. B Count the number of 90° elbows used and enter that value in line 2. B Count the number of 45° elbows used and enter that value in line 3. B For model GWH 345 ESR, enter a 1 in line 4 for model GWH 450 ESR enter a 1 in line 5. B Repeat steps 1 through 4 for the 3" intake pipe and enter those values in the intake section. B Add the totals from the Exhaust table and the Intake table to determine the equivalent vent length. Use this value in Table 6 to determine which restrictor size to use. Exhaust 1 2 3 4 5 6 Example Exhaust · 10 - 3' straight sections · 1 - 1' straight section Total length 31' · 1 - 90° elbow · 1 - GWH 450 ESR termination. Intake · 5 - 4' straight sections · 2 - 1' straight sections Total length 22' · 2 - 90° elbows · 1 - GWH 450 ESR termination. Example Exhaust Straight section length 90° elbows (qty) __ x 1 = __ x 6 = __ x 3 = __ x 15 = __ x 12 = Total: ____ ____ 31 x 1 = 1x6= 0x3= 0 x 15 = 1 x 12 = Total: 31 6 0 0 12 49 Straight section length 90° elbows (qty) 45° elbows (qty) GWH 345 ESR termination GWH 450 ESR termination 45° elbows (qty) GWH 345 ESR termination ____ GWH 450 ESR termination ____ ____ ____ Intake Straight section length 22 x .5 = 2x3= 0 x 1.5 = 0x6= 1x3= Total: Total equivalent vent length = Table 7 Determining equivalent length example Using table 8, the following restrictors would be required: · GWH 450 ESR NG - restrictor 55 · GWH 450 ESR LP - restrictor 55. 11 6 0 0 3 20 69 Intake 1 2 3 4 5 6 7 Straight section length 90° elbows (qty) 45° elbows (qty) GWH 345 ESR termination GWH 450 ESR termination __ x .5 = __ x 3 = __ x 1.5 __ x 6 = __ x 3 = Total: ____ ____ ____ 90° elbows (qty) 45° elbows (qty) GWH 345 ESR termination ____ GWH 450 ESR termination ____ ____ ____ Total equivalent vent length = Table 6 Determining equivalent vent length (see example in Table 7) 6 720 607 909 15 Installation instructions Use table below to define which restrictor to be used. Total equivalent length (ft) GWH345 NG 20 -38 38 -80 80 -100 18 - 28 28 -40 40 -65 65 -100 Total equivalent length (ft) GWH345 LPG 20 -38 38 -80 80 -100 18 -28 28 -50 50 -75 75 -100 Restrictor Ø 38 40 42 44 47 50 55 Restrictor Ø 38 40 42 47 50 55 60 Combustion air inlet connection The combustion air inlet accessory can only be connected to the top right of the appliance. The left side must remain sealed. Note: Before installing the combustion air inlet accessory, the appropriate inlet air restrictor must be determined using Tables 6, 7 and 8. Refer to Fig. 15 for mounting sequence. B Place gasket, deflector, gasket and inlet air restrictor on the air inlet opening lining up screw holes as seen in Fig. 15. GWH450 NG GWH450 LPG Fig. 15 Mounting sequence a b c d Gasket Deflector Restrictor Adaptor Table 8 Restrictors table After installation is complete, check CO2 levels per chapter 3.9. B Attach the combustion air inlet accessory (8 705 504 141) to the top of the unit (position 3) using the 4 screws provided. B Install 3" combustion air pipe over the air inlet accessory. If using flexible piping, secure with a clamp (position 4, not included). Fig. 16 Exhaust air inlet accessory 16 6 720 607 909 Installation instructions 3.6.3 Condensate drain requirements 3.6.4 Room sealed installation (Twin pipe) An external condensate drain must always be installed except when using one 90° elbow and less than 3 feet of horizontal pipe. Note: condensate must be disposed of according to local codes. 1. Install condensate drain as close to heater as possible. 2. Use 3/8" ID high temperature silicone tube to connect to condensate drain port. Do not use copper piping for any portion of the condensate drain. 3. Form a condensate trap by means of a 3" loop partially filled with water to form a gas trap. Add small amount of mineral oil if the trap is drying out. 4. To increase the tube length, connect to end of the high temperature silicone tubing with vinyl tubing, PVC or CPVC pipe. Do not reduce the internal diameter at any point. Although it is permitted to draw combustion air from inside, the recommended method is to provide combustion air through a 3" pipe from the outside. See Chapter 3.5 for more direction on combustion air. To reduce pressure differentials between the exhaust and combustion air intake, it is required that both terminators exit on the same wall or roof. See Fig. 18 for an example horizontal twin pipe termination and Fig. 19 for the vertical twin pipe termination example. Use only approved rain caps. For vertical air inlets use 2 90° elbows with opening facing down and covered with a screen. 6 ft 2 ft Fig. 18 Horizontal twin pipe termination Fig. 17 Required condensate drain installation Fig. 19 Vertical twin pipe termination 6 720 607 909 17 Installation instructions 3.6.5 Vertical terminations Caution: Failure to install a condensate drain may result in damage not covered by the manufacturer's warranty. See chapter 3.6.3. An approved vent terminator must be used. See Table 5 for known approved vertical vent terminations. Over 12/12 to 14/12 Over 14/12 to 16/12 Over 16/12 to 18/12 Over 18/12 to 20/12 Over 20/12 to 21/12 5.0 6.0 7.0 7.5 8.0 1.52 1.83 2.13 2.27 2.44 Table 9 Termination heights at various roof pitches Horizontal runs Any gas vent section that is greater than 45 degrees from the vertical is considered horizontal. Horizontal sections must slope upwards from heater at least ¼ inch for every foot of its horizontal length and be properly supported. Under no circumstances should the exhaust vent pipe pitch downward away from heater. Pitch the termination to the outside 1/4" per foot to prevent rain water from entering the pipe. Vent terminations The exhaust vent must terminate above the roof surface with an approved vent cap not less than 2 feet (0.6 m) above the highest point where it passes through the roof and at least 2 feet (0.6 m) higher than any vertical wall or similar obstruction within 10 feet (3.1m). See Fig. 18 and Table 9. Interior masonry chimneys The single wall stainless steel exhaust vent pipe must be permanently mounted inside the masonry chimney. The masonry chimney may have to be tile or metal lined before the insertion of the gas vent pipe; check local codes for clarification. You may not vent any other fuel burning appliances into any free space remaining in the chimney. The vent terminator must extend at least 3 feet (0.9 m) above where the chimney meets the roofline and at least 2 feet (0.6 m) higher than any vertical wall or similar obstruction within 10 feet (3.1 m). The top of the chimney must be sealed to prevent rain water or other elements from entering the chimney. Exterior Masonry Chimney Refer to the National Fuel Gas Code and consult a local venting HVAC contractor. Not recommended in cold climates. 3.6.6 Horizontal terminations Warning: Pitch the last horizontal pipe and the termination to the outside 1/4" per foot to prevent rain water from entering the pipe. An approved vent terminator must be used. See Table 5 for known approved horizontal vent terminations. Install a condensate drain if the total straight vent length is greater than 5 feet or if the exhaust vent pipe passes through an unconditioned space. The exhaust termination tee must project out a minimum of 10" and maximum of 16" on center from the wall thimble. Fig. 21 and table 10 show the required clearances for the vent termination. Follow local codes if more stringent. Fig. 20 Vertical vent termination clearances GAS VENT TERMINATIONS FOR LISTED VENT CAPS Roof pitch Flat to 6/12 6/12 to 7/12 Over 7/12 to 8/12 Over 8/12 to 9/12 Over 9/12 to 10/12 Over 10/12 to 11/12 Over 11/12 to 12/12 H (min.) feet 1.0 1.25 1.5 2.0 2.5 3.25 4.0 meters 0.30 0.38 0.46 0.61 0.76 0.99 1.22 Table 9 Termination heights at various roof pitches 18 6 720 607 909 Installation instructions 3.6.6.1Requirements for installation in Massachusetts Attention residents of the Commonwealth of Massachusetts: In the Commonwealth of Massachusetts the following regulation went into effect on 12/30/2005: (a)For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied: 1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors. a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level. b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed. 2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. 3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS". 4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4. (b)EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4: 1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and 2. Product approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes. (c)MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM REQUIRED. When the manufacturer of Product Approved side wall horizontally mounted gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for the installation of the equipment and the venting shall include: 1. Detailed instructions for the installation of the venting system or the venting system components: and 2. A complete parts list for the venting system design or venting system. (d)MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a product approved side wall horizontally vented gas fueled equipment does not provide the parts for the venting of flue gases, but identifies "special venting systems," the following requirements shall be satisfied by the manufacturer: 1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation instructions; and 2. The "special venting systems" shall be product approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions. (e) A copy of all installation instructions for all products approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation. 6 720 607 909 19 Installation instructions Recommended exhaust vent terminator position Fig. 21 Ref. A Description Directly below an opening; operable windows, doors and any nonmechanical fresh air openings Below a gutter, sanitary pipework or eaves Minimum distance 36 in (twin pipe installation) 48 in (single pipe installation) 24 in 12 in 12 in 12 in 7 ft 24 in 36 in 48 in 60 in B Below a gutter, sanitary pipework or eaves, protected by metal shielding From any internal corner Above ground or snow pack Above a paved sidewalk C D* E F G From an opposing wall or structure facing the termination From the relief valve of a Ip gas regulator From a terminator facing a terminator Vertically between two exhaust vent terminators on the same wall H Horizontally between two exhaust vent terminators on the same wall Horizontally and vertically from the combustion air inlet terminator 12 in 36 in 48 in 12 in 12 in I** From the gravity combustion air inlet any other equipment J K From any external corner Horizontally from an opening; operable windows, doors and any nonmechanical fresh air openings From wall on exhaust applications L 10 in Table 10 * Subject to local codes and anticipated snow level ** Other equipment that operates with a mechanical air inlet may require greater distances, reference manufacturer's instructions NOTICE: Exhaust and air intake must always be located on the same wall to cancel wind pressure effects. 20 6 720 607 909 Installation instructions 3.6.7 Exhaust vent configuration examples Fig. 22 Horizontal side wall venting installation Fig. 24 Vertical venting installation NOTE: If appliance uses room air, do not place any other combustion appliance in the same space, to avoid depressurizing of the building and winter freeze-up. Use room sealed operation instead. Fig. 23 Vertical venting Chimney installation - Masonry 6 720 607 909 21 Installation instructions 3.7 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. In Canada: The installation must conform to CGA B149 INSTALLATION CODES and/or local installation codes. Warning: DO NOT connect to an unregulated or high pressure propane line or to a high pressure commercial natural gas line. Warning: The heater must be isolated from the gas supply piping system during any pressure testing of that system at test pressures equal to or more than 0.5 psig. If overpressure has occurred, such as through improper testing of the gas lines or malfunction of the supply system, the gas valve must be checked for safe operation. GAS CONNECTIONS B Install a manual gas shut off valve (installer supplied) on the gas supply line. B Install a union when connecting gas supply. B The minimum diameter required for any appliance connector used is ¾". B National Fuel Gas Code requires that a sediment trap (drip leg) be installed on gas appliances not so equipped. The drip leg must be accessible and not subject to freezing conditions. Install in accordance with the recommendations of the serving gas supplier. When 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. Tighten appropriate fittings to stop leak. Turn the gas on and check again with a gas leak detection solution. Never test for gas leaks using a match or flame. GAS LINE SIZING The gas supply piping should be sized according to the applicable code for a maximum draw of 120,000 BTUH (GWH450ESR) or 96,000BTUH (GWH345ESR). Measure the length of gas supply line and use the tables in Fig. 26 or the gas line manufacturer's sizing tables to determine the pipe diameter necessary to accommodate the BTU demand of the unit. If there are more gas drawing appliances on the line, size the gas line according to the total maximum amount of BTU draw for all appliances. Note: Under sizing the gas line may result in diminished output and improper operation. See chapter 3.8 for the procedure to confirm gas pressure. Gas piping Fig. 25 Inlet gas particle screen 22 6 720 607 909 Installation instructions FOR NATURAL GAS Maximum Capacity of pipe in Cubic Feet of Gas per Hour for Gas Pressure of 0.5 Psig or less and a Pressure drop of 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 GWH-450-ESR (example: ¾" B.I. Natural Gas pipe for 20 ft (6.1m). will handle 190,000 btu's (55.7 kWh). For multiple appliances combine the total btu input load and then refer to applicable chart below. Follow the shaded numbers for just one GWH-345-ESR. Nominal Iron Pipe Size, Internal Diameter 10 32 72 132 278 520 1050 1600 3050 4800 8500 20 22 49 92 190 350 730 1100 2100 3300 5900 30 18 40 73 152 285 590 890 40 15 34 63 130 245 500 760 50 14 30 56 115 215 440 670 60 12 27 50 105 195 400 610 70 11 25 46 96 180 370 560 80 11 23 43 90 170 350 530 990 90 10 22 40 84 160 320 490 930 100 9 21 38 79 150 305 460 870 125 8 18 34 72 130 275 410 780 150 8 17 31 64 120 250 380 710 175 7 15 28 59 110 225 350 650 200 6 14 26 55 100 210 320 610 980 Length of Black Iron Pipe, Feet (inches) (inches) 1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4 0.364 0.493 0.622 0.824 1.049 1.380 1.610 2.067 2.469 3.068 4.026 1650 1450 2700 2300 4700 4100 1270 1150 1050 2000 1850 1700 1600 1500 1400 1250 3600 3250 3000 2800 2600 2500 2200 7,400 6,80 6,200 5,800 5,400 5,100 4,500 1130 1050 2000 1850 1700 4,100 3,800 3500 17,500 12,000 9,700 8,300 Length of Flexible Corrugated Stainless Steel Tubing (CSST), Feet Tube size, inches EHD* 10 20 58 116 231 456 30 47 96 188 374 40 41 83 162 325 50 37 75 144 292 60 34 68 131 267 1/2 3/4 1 1 1/4 18 EHD 82 23 EHD 161 30 EHD 330 37 EHD 639 * EHD = Equivalent Hydraulic Diameter. The greater the value of EHD, the greater the gas capacity of the tubing. FOR LP GAS Maximum Capacity of Pipe in Thousands of BTU per Hour of Undiluted Petroleum Gases (at 11 inches Water Column Inlet Pressure) (Based on a Pressure Drop of 0.5 Inch Water Column). * EHD = Equivalent Hydraulic Diameter. The greater the value of EHD, the greater the gas capacity of the tubing. Nominal iron pipe Inches Length of Flexible Corrugated Stainless Steel Tubing (CSST), Feet Black Iron Pipe Length of Pipe, Feet 10 1/2 3/4 1 291 608 20 30 40 50 60 80 100 84 175 330 125 74 155 292 150 67 140 265 200 58 120 227 Tube size inches EHD* 10 20 91 183 365 661 30 74 151 297 528 40 64 131 256 449 50 58 118 227 397 60 53 107 207 359 200 160 137 122 110 94 418 336 287 255 231 197 1/2 3/4 1 1 1/4 18 EHD 129 23 EHD 254 30 EHD 521 37 EHD 971 1145 787 632 541 480 434 372 Maximum Capacity of Semi-Rigid (flexible, non Outside diameter Inch 3/8 Copper Length of Tubing, Feet 10 39 92 20 26 62 30 21 50 107 40 19 41 90 50 _ 37 79 131 60 _ 35 72 70 _ 31 67 80 _ 29 62 90 100 _ 27 59 95 _ 26 55 90 corrugated) Tubing in Thousands of BTU per Hour of Undiluted Liquefied Petroleum Gases (at 11 inches Water Column Inlet Pressure). (Based on a Pressure Drop of 0.5 Inch Water Column) * Source National Fuel Gas Code NFPA 54, ANSI Z223.1 - No Additional Allowance is necessary for an ordinary number of fittings 1/2 5/8 3/4 199 131 329 216 181 145 121 112 104 Fig. 26 6 720 607 909 23 Installation instructions 3.8 Measuring gas pressure Static Gas Pressure Reading (see Chapter 3.8) enter here: ___________________ Operating Gas Pressure Reading (see Chapter 3.8) enter here: ___________________ Connecting manometer B Turn power off. B Shut off gas supply. B Remove front cover and locate the inlet gas measuring point (see Fig. 27). B Loosen screw inside test point fitting (do not remove) and connect manometer tube on test point. Table 11 3.9 Checking restrictor plate size by measuring CO2 level value. B Remove brass flat head screw on the exhaust collar. Fig. 27 Gas pressure measuring (lower tapping) Static pressure test B Turn gas supply on. B Operate all other gas appliances on same gas piping system at maximum output. B Keep unit off and record static pressure reading in Table 11. Operating pressure test B Press On/Off button to turn heater On. For this test the unit has to be put in Service Level B After 10 seconds, press and hold the reset button . B Rotate the recirculating water temperature selector (left knob) to the minimum and then to maximum. B Release the reset button and the display should show * (blinking). The unit has now entered Service Mode. B Place a demand for heat by turning external tank thermostat control to maximum for unit to fire at maximum input. B Record operating pressure reading in Table 11. B Press On/Off button to turn heater Off and exit Service Mode. Fig. 28 Measuring port B Insert CO2 analyzer probe into the measuring point. The tip of the probe should be in the center of the flue pipe. Avoid air gaps between probe and measuring port to avoid inaccurate readings. B Press On/Off button to turn heater On. For this test the unit has to be put in Service Level. B Open a hot water tap. B After 10 seconds, press and hold the reset button . B Rotate the recirculating water temperature selector (left knob) to the minimum and then to maximum. B Release the reset button and the display should show * (blinking). B Rotate the hot water temperature selector maximum. to the B The restrictor size is correct if the CO2 level is within the values as per table 13. CO2 value (%) enter here: ___________________ Table 12 i Note: after verification tighten the screw inside the test point. Operating gas pressures lower than 5.5" W.C. for natural gas or 11" W.C. for LP will result in improper operation and must be corrected. See Chapter 3.7 for gas line sizing requirements. 24 6 720 607 909 Installation instructions Appliance GWH-345-ESR-N GWH-345-ESR-L GWH-450-ESR-N GWH-450-ESR-L CO2 (%) 6.8 - 7.2 7.5 - 8.0 6.5 - 7.0 7.0 - 7.5 B Plastics or other PEX type plumbing line materials are not suitable for connecting directly to the water heater. B Keep water inlet and outlet pipes to no less than ¾" (19.05mm) diameter to allow the full flow capacity. B If the cold and hot connections to the heater are reversed, the heater will not function correctly. Be certain there are no loose particles or dirt in the piping. Blow out or flush the lines before connecting to the water heater. B Full port shut off valves should be installed on both the cold water supply and hot water outlet lines to facilitate servicing the heater (see Fig. 30). Connecting the pressure relief valve (PRV) The listed pressure relief valve supplied with the heater must be installed at the time of installation. No valve is to be placed between the PRV and the heater. No reducing coupling or other restriction may be installed in the discharge line. The discharge line must be a minimum of 4" above a drain and installed such that it allows complete drainage of both the PRV and the line. The location of the PRV must be readily accessible for servicing or replacement, and be mounted as close to the water heater as possible. See Fig. 30. To install the PRV, a suitable fitting connected to an extension on a "T" fitting can be sweated to the hot water line. Support all piping.