User manual PROTANKLESS 635ESO

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 the gas line. Note: manual gas shutoff valve is not supplied with the heater. B 7. 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 2.5 Proper location for installing your heater Carefully select the location of the water heater. Follow the guidelines below: B 1. Locate the heater where an adequate gas line size 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 to prevent the possibility of any freeze damage. B 3. The water in this heater is cold and always remains cold except for the times that hot water is being used. The heater is equipped with freeze prevention equipment that will operate and prevent freezing of the water in the heater to 5°F with no wind chill. 6 720 607 437 7 Appliance details 2.6 Heater Placement and Clearances 2.7 Mounting installation Warning: before starting installation: B check that there are no loose parts inside the appliance B ensure that gas pipe, gas valve, mixer, fan and burner have no damage and are properly fitted. The GWH-635-ESO is design certified for installation directly on a combustible wall. (see 2.7 Mounting installation) For installation on vinyl siding see Fig. 10. Keep the area below the heater free of combustible material. Minimum clearances If the appliance is installed under an overhang, there must be a 36" clearance from the top of the appliance and the mounting area must be open in front and on the sides of the appliance. i Front cover should be removed in order to inspect components visually (see instructions below). To remove front cover. B Loosen the two Philips head screws located on front panel (beneath plastic decal shields if they are already attached, see Fig. 6). Plastic decals Fig. 5 Danger: The top of the kit will get hot due to the flue gases. Install away from children. Ref. A B C D E F G Description Directly below or from an opening; operable windows, doors and any fresh air openings From any adjacent wall or tall shruberry Below a gutter, sanitary pipework, eaves or overhang Above ground From a gas meter, gas regulator, electrical box or another 635-ESO heater. Min. distances 4 ft Fig. 6 Remove front cover 4 ft 3 ft 1 ft 3 ft B Remove the two top screws securing the vent cap to the top of the heater, being careful the washers on the screws are not lost, see Fig. 7. Table 2 Clearances Fig. 7 B Lift the top vent cap completely upward from the heater. B From the bottom of the heater, holding the sides, lift the front cover panel of the heater upward and slightly toward you to remove. 8 6 720 607 437 Appliance details B After inspection, replace front cover and tighten screws, then replace plastic decal shields B Fix the top vent cap on the top of the heater, as shown in Fig. 8). Make sure the vent cap is well fitted by taking special care that the front cover stays inside the extended corners of the vent cap, as shown in Fig. 8). The sides of the cover must be pressed with your hands to ensure it fits inside those corners. Secure it in place with its two screws. attached to the wall surface. The heater must also be kept level on the wall surface. Fig. 9 Warning: Do not mount heater directly to vinyl siding. With vinyl siding surfacing, a 6' x 4' area of the siding must first be removed and then replaced with wood or other non-plastic made material. See Fig. 10. Fig. 8 B The water heater is design certified for mounting on a wall. Secure the wall mounting bracket provided with the water heater to a wall surface. See Fig. 9. B The installation method of the mounting bracket will depend on what type of surface it's being mounted to. Due to the varying types of building surfaces, the installer must decide on how best to support and level the heater on an outside wall. It is always recommended that horizontal or vertical support boards or plywood sheathing (1/2" minimum) first be Fig. 10 Vent Safety System The GWH-635-ESO will shut down if the intake or exhaust louvers on the vent cap are blocked for any reason; see troubleshooting section on page 19. See error code table to confirm error, correct the problem and then reset the heater before operating. 6 720 607 437 9 Appliance details 2.8 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 should conform with CGA B149 INSTALLATION CODES and/or local installation codes. GAS LINE SIZING The gas supply piping should be sized according to the applicable plumbing code for a maximum draw of 175,000 BTUH. Measure the length of gas supply line and use the tables in Fig. 12 or the gas line manufactures 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 2.9 for the procedure to confirm gas pressure. 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. The water heater must not be piped with gas supply pressures in excess of 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. 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. Inlet gas particle screen Gas piping Fig. 11 B Install a manual gas shut off valve, on the gas supply line. B The use of a union when connecting gas pipe to the gas inlet connection is important, this will facilitate any necessary servicing and cleaning of the inlet gas particle screen. 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. 10 6 720 607 437 Appliance details 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-635-ESO (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. Nominal Iron Pipe Size, Internal Diameter 10 32 72 132 278 520 1050 1600 3050 20 22 49 92 190 350 730 1100 2100 30 18 40 73 152 285 590 890 1650 40 15 34 63 130 245 500 760 1450 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 Length of Black Iron Pipe, Feet inches inches 1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2 0.364 0.493 0.622 0.824 1.049 1.380 1.610 2.067 1270 1150 1050 Length of Flexible Corrugated Stainless Steel Tubing (CSST), Feet Tube size, inches 1/2 3/4 1 1 1/4 EHD* 10 18 EHD 82 23 EHD 161 30 EHD 330 37 EHD 639 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 * 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 Size, Inches Length of Flexible Corrugated Stainless Steel Tubing (CSST), Feet Black Iron Pipe Length of Pipe, Feet 10 20 30 40 50 60 70 80 89 90 83 100 78 125 69 146 275 567 866 150 63 132 252 511 787 Tube size inches 1/2 3/4 1 1 1/4 EHD* 10 18 EHD 129 23 EHD 254 30 EHD 521 37 EHD 971 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 1/2 3/4 1 275 189 152 567 693 315 107 732 590 129 114 103 96 267 237 217 196 185 173 162 504 448 409 378 346 322 307 103 913 834 771 724 677 630 155 141 127 118 108 102 976 1 1/4 220 149 121 1 1/2 330 229 185 Maximum Capacity of Semi-Rigid copper 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 Outside diameter Inch 3/8 1/2 5/8 3/4 10 39 92 20 26 62 30 21 50 Copper Length of Tubing, Feet 40 19 41 90 50 _ 37 79 131 60 _ 35 72 70 _ 31 67 80 _ 29 62 90 100 _ 27 59 95 _ 26 55 90 199 131 329 216 107 181 145 121 112 104 Fig. 12 6 720 607 437 11 Appliance details 2.9 2.9.1 Measuring gas pressure Connecting Manometer Static Gas Pressure Reading (see Chapter 2.9) enter here: ___________________ Operating Gas Pressure Reading (see Chapter 2.9) enter here: ___________________ B Shut off gas. B Remove front cover and locate inlet gas pressure measuring point (see Fig. 14). B Loosen screw inside test point fitting (do not remove) and connect manometer tube on test point. 2.9.2 Static Pressure Test Table 3 HIGH ALTITUDE OPERATION Altitude Natural Gas: Liquid Propane: For operation at elevations above 2,000 ft (610 m) the equipment ratings shall be reduced at the rate of 4% for each 1,000 ft (305 m) above sea level B Turn gas supply back on. B Operate all other gas appliances on same gas piping system at maximum output. B Record static gas pressure reading in table 3. 2.9.3 Operating Pressure Test 4,000 ft - 7,000 ft (1,219 m - 2,134 m) CO2 adjustment with flue gas analyzer required See chapter 9 for instructions. 0 - 4,000 ft (0 - 1,219 m) no modification no modification B ON/OFF switch in position OFF (0). B Press and hold "Program" (M) button and turn ON/ OFF switch to ON position. Above 7,000 ft (above 2,134 m) Not approved Table 4 Fig. 13 B As soon as '188' is displayed, release "Program" button and the display should read P2. B Press , until P1 appears. Note: While in this mode the appliance will run constantly at maximum power and allow maximum water flow. These program modes are for test purposes only and not intended for normal operation. B Turn on high volume of hot water flow (at least 6 gpm) and heater will ignite. B Record operating gas pressure reading in table 3. Gas pressures lower than 5" W.C. for Natural Gas or 11" W.C. for LPG will result in insufficient degree rise to the hot water being used, and must be corrected. See Gas Connections, chapter 2.8. Fig. 14 Gas pressure measuring (left tapping) 12 6 720 607 437 Appliance details 2.10 Water connections When facing the heater, the ¾" cold water inlet is on the bottom right and the hot water outlet is on the bottom left. Install the heater where it's centrally close to hot water use of points if possible, and make hot water piping runs as short as possible. lowest pressure range setting recommended is 30-50 psi (2.07 and 3.45bar). Connecting the pressure relief valve (PRV) A 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. 16. 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. INLET FILTER SCREEN HOT COLD Fig. 15 B THE USE OF A UNION WHEN CONNECTING BOTH WATER PIPES TO THE INLET AND OUTLET CONNECTIONS IS RECOMMENDED, THIS WILL FACILITATE ANY NECESSARY SERVICING AND REQUIRED CLEANING OF THE INLET WATER PARTICLE SCREEN. Although water piping throughout your structure may be other than copper, we recommend that copper piping or suitably rated stainless steel flex line piping be used for at least three feet before and after the heater (follow local codes if more stringent). Never sweat any rigid piping directly to or beneath the water connections, damage can occur to the internal water valve from heating of the pipe. Plastics or other PEX type plumbing line materials are not suitable for connecting directly to the water heater. Keep water inlet and outlet pipes to no less than ¾" (19.05mm) diameter to allow the full flow capacity. It is recommended that all water piping below the heater be properly insulated to avoid heat loss. If below freezing temperatures are ever anticipated where the heater is located, insulation material is required and must be capable of protecting the piping from freezing. The freeze protection that is equipped within the heater will not prevent any freeze damage to the exterior water piping. If the cold and hot connections to the heater are reversed, the heater will not function. Be certain there are no loose particles or dirt in the piping. Blow out or flush the lines before connecting to the water heater. Full port valves should be installed on both the cold water supply and hot water outlet lines to facilitate servicing the heater (see Fig. 16). For installation on a private well system with the use of a pressure tank, the Fig. 16 Plumbing Connections and Pressure Relief Valve 6 720 607 437 13 Appliance details 2.11 Electrical connections Warning: Confirm that the water heater is appropriately grounded and that the installation meets all electrical codes. Outdoor electrical outlets have special requirements. Warning: For safety reasons, disconnect the power supply to the heater before any service or testing is performed. Warning: This heater must be electrically grounded in accordance with the most recent edition of the National Electrical Code. NFPA 70. In Canada, all electrical wiring to the heater should be in accordance with local codes and the Canadian Electrical Code, CSA C22.1 Part 1. Do not rely on the gas or water piping to ground the metal parts of the heater. The GWH-635-ESO requires an electrical power supply from a 120VAC 60Hz circuit and must be properly grounded. A means for switching off the 120VAC power supply must be provided. The heater is wired as shown in the wiring diagram (chapter 6, Fig. 29). Warning: The heater is equipped with freeze prevention equipment that will operate and prevent freezing of the water in the heater to 5°F with no wind chill. 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. 2.12 Operating instructions B Remove the control cover shield to access the controls of the water heater. Fig. 18 Warning: The control cover must be replaced after the initial operation begins, and must be in place at all times. B Before proceeding with the operation of the heater make sure that the system is filled with water. B Turn off power supply to heater. B Open the cold water inlet supply to the heater fully. B Open a hot water faucet to permit the water to fill the heater and the piping and to eliminate the air trapped in the system. Appliance electrical power supply Fig. 17 B Close the hot water faucet after the water flows freely and all the air has escaped from the system. Turn on power supply to heater. The water heater is now ready to operate. i 14 NOTE: A default temperature setting of 122 F will appear on the display screen. 6 720 607 437 Appliance details 2.13 For your safety read before operating your water heater Warning: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance is equipped with electronic ignition for lighting the main burners. When turning the heater on, follow these instructions exactly. B. Before operating the unit, turn the On/Off switch to the right position. WHAT TO DO IF YOU SMELL GAS B Do not try to light any appliance. B Do not touch any electric switch; do not use any phone in your building. B Immediately call your gas supplier from a neighbors phone. Follow the gas supplier's instructions. B If you cannot reach your gas supplier, call the fire department. C. Use only your hand to turn the on/off control switch. Never use tools. Follow these instructions exactly. If control switch is jammed, close the gas supply and call a qualified service technician. Attempted forceful repair may result in a fire or explosion. D. Do not use this appliance if any part has been under water. 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 under water. i NOTE: on a first time initial installation or after gas line work has been done, air in the gas line will cause ignition delay when the hot water is turned on. This will result in an error (EA or EC) on the units display screen. This is normal. When this occurs, leave the hot water running and wait 3-5 seconds, then press reset button to reset the unit (Fig. 19, pos. 2). Wait for (EA or EC) to disappear. The heater will begin to attempt ignition again, if the (EA or EC) reappears then repeat this same process until all air has been bled from the gas line. When the heater is in operation you will hear its power vent fan and burner operating. Upon turning off the hot water flow the power vent fan will continue to operate for up to 60 seconds to exhaust all flue gases. The power vents fan speed is variable depending on the rate of hot water used and the burner output. TO TURN OFF GAS TO APPLIANCE B Turn off the manual gas shut off valve on the supply line to the heater and set the ON/OFF switch to the OFF position (turn to the left position). Note: a manual gas shut off valve is not supplied with the heater. 2.14 Lighting and operating instructions B 1. STOP! Read the previous safety information. B 2. The gas valve must be shut off by putting the ON/ OFF switch to the OFF position (turn to the left position). Wait five (5) minutes to clear out any gas. If you smell gas, STOP! Follow "B" in the safety information above. If you do not smell gas, go to the next step. B 3. This appliance is equipped with electronic ignition for lighting the main burners. When turning the heater on, follow these instructions exactly. B 4. Set the ON/OFF switch to the ON position (turn to the right position). In this position, the water heater is ready to use. B 5. Open a hot water tap. B 6. The burners will remain on until the hot water tap is turned off. 6 720 607 437 15 Operation instructions 3 Operation instructions Fig. 19 1 2 3 4 5 6 On/Off switch Reset button Program button Increasing temperature button Decreasing temperature button LCD display B Press buttons and requested temperature. in order to reach 3.1 On Power B To start the appliance switch the button to the ON position (turn to the right position). LCD display the default temperature - temperature factory setting 122°F (50°C). Fig. 21 If the outlet water temperature is set too high, the heater can produce temperatures that are too hot. A temperature balance shower valve can automatically mix in cold water to reduce such hot water temperature. In the event of any temperature instability with the use of a temperature balance shower valve, refer to shower valve manufacturer's instructions for internal adjustment setting. Adjustments should be made to the hottest setting in the shower valve. Additionally the temperature control of the heater can be lowered to produce a more comfortable hot water temperature. Fig. 20 Off B To shut down the appliance, switch the button to the OFF position (turn to the left position). 3.2 Temperature selection To select water temperature outlet: 16 6 720 607 437 Operation instructions Setting the water temperature The desired temperature of the hot water can be adjusted on the front control panel of the heater. The GWH-635-ESO has an electronically controlled gas valve that modulates the burner input in response to both varying hot water flow rates and/or changes in any incoming and outgoing water temperatures. Hot Water Flow and Temperature with Various Inlet Temperature (gpm/Fahrenheit) 7.00 6.00 Hot Water Flow (GPM) 5.00 4.00 3.00 2.00 1.00 0.00 90 100 110 120 130 140 150 Hot water temperature (ºF) Inlet (ºF) 40 Inlet (ºF) 50 Inlet (ºF) 60 Inlet (ºF) 70 Hot Water Flow and Temperature with Various Inlet Temperature (lpm/Celsius) 24.00 20.00 16.00 12.00 8.00 4.00 0.00 35 40 45 50 55 60 65 Hot Water Flow (l/min) Hot water temperature (ºC) Inlet (ºC) 4 Inlet (ºC) 10 Inlet (ºC) 16 Inlet (ºC) 21 Fig. 22 Flow/temperature charts 6 720 607 437 17 Operation instructions 3.3 Use of remote control accessory Fig. 26 Reset button If the problem persists, contact your installer. Fig. 23 Remote control The wireless remote control accessory and the temperature selector buttons on the front of the water heater operate identically. Contact your distributor or BBTNA to order if the remote control accessory is preferred. Modification of the water heaters interior control unit (Fig. 24, component 12) is required when programming the remote control with this heater. 3.6 Program button Program button can be used/programmed in the appliance and in the remote control. Programming "Program" function Programming actions are similar for both controls (appliance control pad and wireless remote control). i 3.4 NOTE: up to 6 remote controls can be programmed for one single water heater, each with a range distance of 98 ft (30 m). Operation Fig. 27 "Program" key B Press buttons be memorized. and to select temperature to B When a hot water tap is opened, main burner ignites and LCD displays indication . B Hold "Program" button for 3 seconds to save temperature. When LCD stops blinking. Temperature is saved on "Program". Using "Program" function In order to select memorized temperature B Press "Program" key. LCD shows pre-memorized temperature, which is now the hot water selected temperature. Fig. 24 B LCD blinks until selected temperature is reached. 3.5 Reset button If the LCD shows the error symbol . Note: do not use the ON/OFF switch when error is present. See the error code on LCD and consult "Troubleshooting" section. 3.7 Locked condition This condition is only valid for appliances with more than 1 controller (an appliance with one or more remote controls). Fig. 25 After following instructions "Troubleshooting" section indicated in Fig. 28 Locked condition Whenever LCD shows the temperature setting cannot be adjusted because the appliance is in use by a user which already selected a different temperature. Appliance will be automatically unlocked after closing hot water tap. B press reset button in order to make the appliance ready-to-work. 18 6 720 607 437 Maintenance and service 4 Maintenance and service Warning: Always turn off the electrical power supply, turn off the manual gas valve and turn off the manual water control valves whenever servicing. BURNERS DO NOT IGNITE WHEN HOT WATER IS TURNED ON · Cold incoming water connection made to wrong side of heater Make sure cold water inlet connection is plumbed to the right side of heater when facing unit · Water flow rate at hot water tap is too low A minimum of 0.8 gallon/minute (3 l/m) is required to activate the heater · Cold water inlet filter screen is dirty Remove water inlet filter screen and clean. The screen is located at the inlet connection to the water heater, disconnecting the main cold supply line at the heater is required. Check and clean faucet aerator screens too. · Crossover in plumbing The heater activates when there is sufficient water flow through its water valve, a minimum of 0.8 gallon/ minute (3 l/m) is required. If there is a crossover in the plumbing, the necessary hot water flow rate through the unit may not be reached, even though the flow at the hot water tap is sufficient. A plumbing crossover can be caused by a failed washer at a single lever faucet, incorrect plumbing or a faulty mixing valve in the piping. The crossover will create a back pressure on the water heater and prevent an adequate flow of water through it. To confirm there is no crossover in the plumbing, shut off the cold water supply feed to the water heater. Individually open each of the hot water taps. There should be no water flowing under a constant pressure. If there is a constant flow of water then the plumbing crossover must be corrected before the heater can operate properly. WATER IS TOO HOT · Temperature selection too high Lower temperature adjustment on heater or wireless remote control accessory, see chapter 3.2. WATER IS NOT HOT ENOUGH · Temperature selection too low Increase temperature adjustment on heater or wireless remote control accessory, see chapter 3.2 · Btu input is too low due to inadequate gas line sizing See specifications in chapter 2.8 - 2.9. The GWH635-ESO requires adequate gas pressure to reach desired temperatures, to compensate for inadequate gas supply or lack of gas pressure the GWH-635ESO will effectively reach the selected output temperature by reducing the hot water flow rate. Its motorized water valve makes this adjustment · Cold water is mixing with the hot water outlet (crossover) The unit should be checked once a year by a gas technician. If repairs are needed, the repairs should be done by a gas technician To remove front cover B See instructions to remove front cover on page 8. Systems and parts that should be checked at least once a year Reference diagrams on pages 24 and 25. · Venting system · Burners -see page 24 for observation window · See relief valve manufacture's instruction for pressure relief valve maintenance · Periodic cleaning of the water filter screen, see Fig. 15, chapter 2.10. · Flushing the heat exchanger with a descaling solution if mineral build up is evident. Scale build up will shorten the life of the water heater, descale heat exchanger thoroughly and repeat annually depending on mineral content of ground water. 5 Troubleshooting Introduction The GWH-635-ESO burner is activated by a water flow valve. Numerous water related problems can cause this water valve to malfunction such as: Insufficient water flow volume to activate the burners at its minimum flow requirement; Dirt in the inlet filter screen; Sediment build-up in faucet aerators, or shower heads; Uneven pressures between cold and hot (with single lever mix valves); and Plumbing crossovers. These water flow related problems can cause the heater to deliver less than its full output, or to fail to ignite or to shut down completely. Problems stated below in upper case and in bold face should be investigated when there is a problem with the performance of the water heater but there is NO error code on the heater's LCD display or wireless remote control. Any failures that result in a displayed error code are referenced on page 21. A Functional Scheme of the GWH-635-ESO is detailed on page 23. If there is a problem with the installation, venting or operation of the unit, the heater will communicate the source by these error codes. 6 720 607 437 19 Troubleshooting Test by following 4th bullet under BURNERS DO NOT IGNITE WHEN HOT WATER IS TURNED ON. LOW WATER FLOW/PRESSURE · Too many hot water applications are being used simultaneously or too much flow is being demanded The GWH-635-ESO will effectively support two 2.02.5 gpm shower heads simultaneously or multiple sink applications. Greater draws will result in increased pressure drop and reduced flow at taps. See flow/temperature chart on page 17. · Btu input is too low due to inadequate gas line sizing See specifications in chapter 2.8 - 2.9. The GWH635-ESO requires adequate gas pressure to reach expected temperatures and flow rates, to compensate for inadequate gas supply or lack of gas pressure the GWH-635-ESO will effectively reach the selected output temperature, but only by reducing the hot water flow rate. Its motorized water valve makes this adjustment. Proper gas pressure will need to be delivered before the motorized water valve will allow greater flow rates through it. Lowering the set temperature will also allow increased water flow rate through the motorized water valve. See flow/temperature chart on page 17. · Cold water inlet filter screen is dirty Remove water inlet filter screen and clean. The screen is located at the inlet connection to the water heater, disconnecting the main cold supply line at the heater is required. Check and clean faucet aerator screens too. HOT WATER TEMPERATURE FLUCTUATES / UNIT DEACTIVATED · Unbalanced pressure in water lines Any restriction caused by the water heater in the hot water system can result in uneven pressures between the cold and the hot. In such cases when mixing cold water at the tap (manually or automatically through a mix-type shower valve) the lower hot water pressure may be overpowered by the higher cold water pressure in the building and cause the hot water flow rate to fall below the minimum rate required. A pressure balance valve will help to resolve this symptom. · Temperature balance valves If the outlet water temperature is set too high, the heater can produce temperatures that are too hot. A temperature balance shower valve can automatically mix in cold water to reduce such hot water temperature. In the event of any temperature instability with the use of a temperature balance shower valve, refer to shower valve manufacturer's instructions for internal adjustment setting. Adjustments should be made to the hottest setting in the shower valve. Additionally the temperature control of the heater can be lowered to produce a more comfortable hot water temperature. · Inlet water pressure is erratic due to fluctuating supply water pressure For installation on a private well system with the use of a pressure tank, the lowest pressure range setting recommended is 30-50 psi (2.07-3.45 bar). The use of a pressure reducing valve after the pressure tank is also an effective way to maintain a constant water pressure to the water heater. Watts brand 25AUB¾" or N35B-¾" pressure relief valves or equivalent are suggested. 20 6 720 607 437