GWH-635-ES INDOOR MODEL Temperature Modulated with Electronic Ignition Suitable for heating potable water only - Not approved for space heating purposes (Intended for variable flow applications) GWH-635-ES-N - Natural Gas GWH-635-ES-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. · Do not try to light any appliance. · Do not touch any electrical switch; do not use any phone in your building. · If you cannot reach your gas supplier, call the fire department. · Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. · Installation and service must be performed by a qualified installer, service agency or the gas supplier. 6 720 607 072 US (05.12) AL Index Index 1 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.9.1 2.10 2.11 2.12 2.12.1 2.12.2 2.12.3 2.13 2.14 2.15 2.16 2.17 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4 5 6 7 8 8.1 8.2 8.3 9 Warning Appliance details Features GWH-635-ES Specifications (Technical data) Dimensions and Minimum installation clearances General rules to follow for safe operation Proper location for installing your heater Clearances Mounting installation Combustion air requirements Venting Venting options Gas piping & connections Gas line sizing Measuring gas pressure Connecting Manometer Static Pressure Test Operating Pressure Test Water connections Electrical connections Operating instructions For your safety read before operating your water heater Lighting and operating instructions Operation instructions Power Temperature selection Use of remote control accessory Operation Reset button Program button Locked condition Maintenance and service Troubleshooting Electrical diagram GWH-635-ES Functional scheme Interior components diagram and parts list Interior components Components diagram Parts list 2 4 4 4 6 7 7 8 8 8 9 12 15 17 17 17 17 17 18 19 19 19 19 21 21 21 23 23 23 23 23 24 24 27 28 29 29 30 31 1 Warning Warning: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. Warning: 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. Upon completion of the installation, these instructions should be handed to the user of the appliance for future reference. Featuring Electronic Ignition and Power Venting 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 proper vent material 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 heater in a location where water leaks will do NO DAMAGE to adjacent areas or lower floors. Special adjustment for measuring and adjusting CO2 levels 32 Protecting the environment 34 10 11 Fifteen Year Limited Warranty 35 2 6 720 607 072 Warning 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, turn off the electrical power to the water heater at the main disconnect or circuit breaker. Failure to do so could result in severe personal injury or death. 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. 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. 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 Fig. 2 6 720 607 072 3 Appliance details 2 2.1 Parts Appliance details Features 2.2 GWH-635-ES Specifications (Technical data) · Touch 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. Safety · Flame sensor (ionization) rod · Overheat sensor · Temperature limiter · Fan speed monitoring. 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. · Easily removable one-piece cover. Features · LCD Display · On/Off and Temperature control switches · Reset button · Program Key (Selectable temperature default) · Failure codes for easy diagnostic and repair. Accessories · Optional wireless remote control accessory to operate with the appliance · Vent termination kit. Approved in US/Canada Capacity Maximum flow rate: 6.35 GPM (24 l/min) at a 45°F (25°C) rise. Maximum output 142,968 Btu/h (41.8 kW) Maximum input 175,000 Btu/h (51.2 kW) Efficiency in % Recovery efficiency 86.5% Min. Output 31,131 Btu/h (9.1 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: 11" - 14" water column · Natural Gas: 5" - 14" water column. * To measure Gas Pressure, see Measuring Gas Pressure, chapter 2.12. Venting A condensate trap is integrated into the exhaust flue gas collar of the heater, the supplied condensate drain tube must be installed to it for proper removal of condensate from the trap. See chapter 2.9 for Venting. Water · Hot water connection (inches) - ¾" · Cold water connection (inches) - ¾" · Water valve material: Polymer (PPS) (Polypropylene Sulfid) · Minimum water flow: 0.8 gallon/minute (3 l/m) · Minimum recommended water pressure: 30 PSI (2.07 bar) · Connections: ­ Bottom of heater i BOSCH is constantly improving its products, therefore specifications are subject to change without prior notice. 4 6 720 607 072 Appliance details Combustion · NOx 55 ppm · CO 250 ppm · CO2 level set from factory, see chapter 9. Dimensions · Depth (in): 8 ½" (220 mm) · Width (in): 15 ¾" (400 mm) · Height (in): 23 ½" (600 mm) · Weight: 47 pounds (21 kg). Gas types Natural Gas. LP Gas. Converting the gas type can only be done by a certified gas technician with a calibrated CO2 analyzer. Call BBTNA for conversion instructions. Voltage 120 V AC (50/60 Hz) Amperage IDLE - 40 mA Operation - 2,5 A Noise 50 db (A) Safety devices · Flame failure device (ionization flame rod sensor) · Pressure relief valve (supplied with heater) · Over heat prevention (temperature limiter). Water resistant IP X4 (protection against water drops) UNPACKING THE GWH-635-ES HEATER This heater is packed securely. The box includes: · Pressure relief valve (150 psi / 200,000 Btu rating) · Bracket for wall hanging the heater · Exhaust vent adaptor (with 4 screws and gasket provided) · Condensate drain tube kit · Combustion air inlet adaptor (with 3 screws and gasket provided) · Plastic decal shields for covering front cover screws and control panel, installer should affix these decals to the front of the unit after installation is complete. See Fig. 3 · Installation manual · Product registration card · Energy Guide label. 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. To remove front cover · Loosen the two Philips head screws located on front panel (beneath plastic decal shields if they are already attached, see Fig. 3) · Lift front cover panel upward and remove. Plastic decals Fig. 3 Remove front cover The GWH-635-ES is not approved or designed for: · Manufactured (mobile) homes, RV's or boats · Heating or other recirculating/pumping applications* · Outdoor installation (use only Outdoor Model GWH635-ESO) · Solar/preheat backup or high temperature booster use. * This includes domestic hot water circulator pump loop systems that may previously exist in a home hot water system. The use of a small electric mini-tank (4-6 gallon size) should be used for this application; when designed so the pump will circulate the hot water in the mini-tank only and through the building's hot water return loop (timed or thermostatic controlled operation of the pump is commonly done). The GWH-635-ES should be plumbed in line before the mini-tank water heater, contact BBTNA if further instruction is needed. 6 720 607 072 5 Appliance details 2.3 Dimensions and Minimum installation clearances Fig. 4 1 2 3 4 5 6 Dimensions Cover On/Off switch Reset button LCD display Program button Temperature buttons Fig. 5 Minimum clearances Model GWH-635-ES TOP (A) FRONT (B) BACK SIDES FLOOR (C) VENT DIAMETER 12" 1" 0" 1" 12" 3" Table 1 Minimum clearances 6 6 720 607 072 Appliance details 2.4 General rules to follow for safe operation 2.5 Proper location for installing your heater B 1. You should 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 should conform with CGA 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 be caused by lack of air, 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 2.9. 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 2.5 and 2.8. B 4. You must vent your heater. See section 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). 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 optimum ope ...