GWH C 800 ES (GWH C 800 CTDR EFS) Temperature Modulated with Electronic Ignition Suitable for heating potable water - Not approved for space heating purposes (Intended for variable flow applications) GWH C 800 ES - Natural Gas GWH C 800 ES - 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 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. 6 720 608 643 US (2007.03) AL Index Index 1 2 2.1 2.2 2.3 2.4 2.5 Warning Appliance details Features GWH C 800 ES Specifications (Technical data) Unpacking the GWH C 800 ES heater General rules to follow for safe operation Dimensions and minimum installation clearances Installation instructions Tools required for installation Introduction Proper location for installing your heater Heater placement and clearances Mounting installation Gas piping & connections Water connections Water quality Recirculation application Filling the condensate trap Combustion air requirements Venting Measuring gas pressure Electrical connections Electrical power supply Position of the fuses in control unit Operation instructions Description LCD Display For your safety read before operating your water heater Power Temperature selection Use of optional remote control accessory (part no. TSTAT2) Operation Reset button Program button Locked condition 3 4 4 4 5 6 7 8 8 8 8 8 8 10 12 12 13 14 15 16 26 27 27 27 28 28 29 29 29 30 30 30 30 30 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 8 8.1 9 10 4 4.1 4.2 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 11 12 Maintenance and service Annual maintenance Winterizing for seasonal use Mineral scale build-up Condensing heat exchanger unit Adjusting CO2 Program values Control board diagnostics Troubleshooting Introduction Burner does not ignite when hot water is turned ON Water is too hot Water is not hot enough Low water flow/pressure Hot water temperature fluctuates at tap Noisy burner/heater during operation Problem solving Error code diagnostics Electrical diagram Sensor resistance charts GWH C 800 ES Functional scheme 31 31 31 32 33 33 35 36 37 37 37 37 37 38 38 38 40 40 45 46 48 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 Interior components diagram and parts list 12.1 Interior components 12.2 Components diagram 13 14 Protecting the environment Limited Warranty 49 49 51 58 59 2 6 720 608 643 Warning 1 Warning 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. 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 3, page 17 (For Canada use only PVC ULCS636). 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. Fig. 1 6 720 608 643 3 Appliance details 2 2.1 Parts Appliance details Features 2.2 GWH C 800 ES 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 199,000 Btu/h (58.3 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: 9" - 14" water column · Natural Gas: 4" - 14" water column. * To measure Gas Pressure, see Measuring Gas Pressure, chapter 3.13, page 26. 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 12. · Connections: ­ Bottom of heater Combustion · NOx 55 ppm · CO 250 ppm (air free) · CO2 level set from factory, see chapter 6.5, page 33. · 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/informational purposes. Accessories (Bosch part #) · Optional wireless remote control to operate with the appliance (TSTAT2) · Cascading kit (TLINK) · Outdoor kit (PTOK) · External water filter (part # 8 703 305 356) · Concentric termination kit (KGAVT0601CVT). i BOSCH is constantly improving its products, therefore specifications are subject to change without prior notice. 4 6 720 608 643 Appliance details 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) 2.3 Unpacking the GWH C 800 ES heater 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. Fig. 2 A B Rating plate Serial number Type of gas The box includes: · GWH C 800 ES · Pressure relief valve (150 psi / 200,000 Btu rating) · Bracket for wall hanging the heater · Exhaust vent adaptor (with 4 screws and gasket provided) · Combustion air inlet adaptor (with 3 screws and gasket provided) · Installation manual (manual can be downloaded at www.boschpro.com) · Product registration card · Energy Guide label. Please complete and return the enclosed product registration card. The GWH C 800 ES is not approved or designed for: · Manufactured (mobile) homes, boats or any mobile installation. · Use above 4500ft A.S.L. altitude. · Outdoor installation without installation of Outdoor kit (PTOK). · Applications where inlet water temperature is higher than 140°F (60°C). A 3-way valve or mixing valve must be installed before the appliance if inlet water temperature exceeds this limit. · Space heating purposes. i If appliance is installed at elevations between 2000ft and 4500ft, a combustion gas analyzer is required for proper calibration of appliance. (see page 26). 6 720 608 643 5 Appliance details To remove front cover B Loosen the two Philips head screws located on bottom rear of cover (see Fig. 3). 2.4 General rules to follow for safe operation B 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 CSA B149.(1,2) INSTALLATION CODES and /or local installation codes. B 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 occur, such as carbon monoxide poisoning or fire. B 3. When the unit is installed indoors and ROOM SEALED (twin pipe) it is permitted to be located in bathrooms, bedrooms and occupied rooms that are normally kept closed. See chapter 3.12 (page 16). 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 Fuel Gas Codes do not allow UNSEALED gas fired water heater installations in bathrooms, bedrooms or any occupied rooms normally kept closed. See chapter 3.11 (page 15). B 4. You must correctly vent your heater. See chapter 3.12 (page 16) on VENTING. B 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). Fig. 3 Loosen the two screws B Lift front cover panel upward and remove. Fig. 4 Remove the front cover To remove combustion cover (service only) B Open the four clips and remove the combustion cover (see Fig. 5). B 6. Keep water heater area clear and free from combustibles and flammable liquids. Do not locate the heater over any material which might burn. B 7. Correct gas pressure is critical for the proper 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. See chapter 3.6 (page 10). B 8. Should overheating occur or the gas supply fail 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 but must be field installed. B 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. Fig. 5 Remove the combustion cover B 10. Failure to install heater correctly may lead to unsafe operation and void the warranty. 6 6 720 608 643 Appliance details 2.5 Dimensions and minimum installation clearances Fig. 6 1 2 3 4 5 6 7 Dimensions On/Off button Reset button Program key Power ON or stand-by LED LCD display Up button Down button Model GWH C 800 ES TOP (A) FRONT (B) BACK SIDES FLOOR (C ...