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 ...