GWH-635-ESO Outdoor Model For exterior use only Electronic Ignition and built in Freeze protection Suitable for heating potable water only - Not approved for space heating purposes GWH-635-ESO-N - Natural Gas GWH-635-ESO-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. · 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. 6 720 607 437 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 2.9.2 2.9.3 2.10 2.11 2.12 2.13 2.14 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-ESO Specifications (Technical data) Dimensions and Minimum installation clearances General rules to follow for safe operation Proper location for installing your heater Heater Placement and Clearances Mounting installation Gas piping & connections 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-ESO Functional scheme Interior components diagram and parts list Interior components Components diagram Parts list 2 4 4 4 6 7 7 8 8 10 12 12 12 12 13 14 14 15 15 16 16 16 18 18 18 18 18 19 19 22 23 24 24 25 26 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. If a gas appliance is not installed correctly, fatal accidents can result from lack of air, carbon monoxide poisoning or fire. Warning: Place the heater in a location where water leaks will do NO DAMAGE to adjacent areas. 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. Special adjustment for measuring and adjusting CO2 levels 27 Protecting the environment Fifteen Year Limited Warranty 29 30 10 11 2 6 720 607 437 Warning What to do if you smell gas · Close gas valve. · 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 6 720 607 437 3 Appliance details 2 2.1 Parts Appliance details Features 2.2 GWH-635-ESO 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 · Freeze protection. 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 two-piece cover. Features · Electronic Ignition · 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. 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 maximum operation* · Propane: 11" - 14" water column · Natural Gas: 5" - 14" water column. * To measure Gas Pressure, see Measuring Gas Pressure, chapter 2.9. 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 6 720 607 437 Appliance details Combustion · NOx 55 ppm · CO 250 ppm. Dimensions · Depth (in): 8 ½" (220 mm) · Width (in): 15 ¾" (400 mm) · Height (in): 26" (650 mm) · Weight: 47 pounds (21 kg). Gas types Natural Gas. LP Gas. CO2 analyzer is required to convert from one gas type to another. Please contact BBTNA for specific 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 X5 (protection against water drops). UNPACKING THE GWH-635-ESO HEATER This heater is packed securely. The box includes: · Control panel shield · Pressure relief valve · Bracket for wall hanging the heater · 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. 6. · Installation manual · Product registration card. 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. The GWH-635-ESO is not approved or designed for: · Manufactured (mobile) homes, RV's or boats · Heating or other recirculating/pumping applications* · 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-ESO should be plumbed in line before the mini-tank water heater, contact BBTNA if further instruction is needed. 6 720 607 437 5 Appliance details 2.3 Dimensions and Minimum installation clearances Fig. 3 1 2 3 4 5 6 Dimensions Cover On/Off switch Reset button LCD display Program button Temperature buttons Fig. 4 Minimum clearances Model GWH-635-ESO TOP (A) FRONT (B) BACK SIDES BOTTOM (C) 3 ft. 4 ft. 0" 4 ft. 1 ft. Table 1 Minimum clearances 6 6 720 607 437 Appliance details 2.4 General rules to follow for safe operation Electrical power must be maintained to the heater to allow this to function. WARNING: Proper insulation of the water lines below the heater is required if below freezing temperatures, below 32°F, are ever anticipated! Danger: If the temperature drops below 5°F, freeze damage to the water heater itself must be prevented by turning off the power to the heater, then disconnecting the plumbing connections and introducing short bursts of compressed air (20-40 psi) through the heater's connections. This will remove the residual water in the horizontal pipes and water valve.. Danger: Keep children away as the top of the water heater vent cap will get very hot during operation. Install in a place that prevents the top of the heater being reached by small children. Danger: Flue gases will be released through the vent cap. Flue gas is very hot and contains carbon monoxide. The heater cannot be installed indoors. To prevent risk of fire and poisoning by carbon monoxide, assure all clearances indicated in manual. Danger: Surface temperature around vent cap is less than 140°F, except highest top surface of vent cap may reach 400°F. Danger: Do not place or store any combustible material within 5 feet of the appliance. Risk of fire could be caused by hot flue gas. Note: Exception is made for the wall where the appliance is installed and any adjacent walls or overhang. In this case observe clearances required in chapter 2.6. 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. 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. Proper clearances must be followed. B 3. 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). The appliance and its gas connection must be leak tested before placing the appliance in operation. B 4. Keep water heater area clear and free from combustibles and flammable liquids. Do not locate the heater over any material which might burn. B 5. 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. B 6. Should overheating occur or the gas supply fail to shut off, turn off the gas supply at the manual gas shut off valve, on t ...