Bosch GWH 635 ES, Pro Tankless GWH-635-ES-L, Pro Tankless GWH-635-ES-N User Manual

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Bosch GWH 635 ES, Pro Tankless GWH-635-ES-L, Pro Tankless GWH-635-ES-N User Manual | Manualzz

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.

Index

Index

1 Warning 2

2

2.1

2.2

2.3

Appliance details

Features

GWH-635-ES Specifications (Technical data)

Dimensions and Minimum installation clearances

2.4

2.5

2.6

2.7

General rules to follow for safe operation

Proper location for installing your heater

Clearances

Mounting installation

2.8

2.9

Combustion air requirements

Venting

2.9.1

Venting options

2.10

Gas piping & connections

2.11

Gas line sizing

2.12

Measuring gas pressure

2.12.1 Connecting Manometer

2.12.2 Static Pressure Test

2.12.3 Operating Pressure Test

2.13

Water connections

2.14

Electrical connections

18

19

2.15

Operating instructions 19

2.16

For your safety read before operating your water heater 19

2.17

Lighting and operating instructions 19

17

17

17

17

12

15

8

9

17

8

8

7

7

4

6

4

4

3.4

3.5

3.6

3.7

3

3.1

3.2

3.3

Operation instructions

Power

Temperature selection

Use of remote control accessory

Operation

Reset button

Program button

Locked condition

23

23

23

23

21

21

21

23

6

7

4

5

Maintenance and service

Troubleshooting

Electrical diagram

GWH-635-ES Functional scheme

8

8.1

8.2

8.3

Interior components diagram and parts list

Interior components

Components diagram

Parts list

9

10

Special adjustment for measuring and adjusting CO

2 levels 32

Protecting the environment 34

29

29

30

31

27

28

24

24

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.

11 Fifteen Year Limited Warranty 35

2

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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

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3

4

Appliance details

2 Appliance details

2.1

Features

Parts

• 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.

i BOSCH is constantly improving its products, therefore specifications are subject to change without prior notice.

2.2

GWH-635-ES Specifications

(Technical data)

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

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Appliance details

Combustion

• NOx ≤ 55 ppm

• CO ≤ 250 ppm

• CO

2

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 CO

2

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 GWH-

635-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.

5

Appliance details

2.3

Dimensions and Minimum installation clearances

Fig. 4 Dimensions

3

4

1

2

5

6

Cover

On/Off switch

Reset button

LCD display

Program button

Temperature buttons

6

Fig. 5 Minimum clearances

TOP (A)

FRONT (B)

BACK

SIDES

FLOOR (C)

VENT DIAMETER

Model GWH-635-ES

12”

1”

0”

1”

12”

3”

Table 1 Minimum clearances

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Appliance details

2.4

General rules to follow for safe operation

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 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 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.

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

2.5

Proper location for installing your heater

Carefully select the location of the water heater. For your safety and for proper heater operation, you must provide combustion air to the heater and a proper exhaust vent system.

Follow the guidelines below:

B 1. Locate the heater where venting, gas and plumbing connections are feasible and convenient.

B 2. It is strongly recommended that the heater be installed as a ROOM SEALED heater (twin pipe). If the heater will be installed as an UNSEALED heater

(single pipe) than National building codes require that you do not install this appliance in bathrooms, bedrooms or any occupied rooms normally kept closed. Heaters that are UNSEALED require a considerable amount of combustion air, see chapter 2.8. If installing the heater UNSEALED within a laundry room, be certain that the dryer is properly vented. Failure to properly vent a dryer could result in a gradual accumulation of lint build up inside the combustion chamber of the heater.

B 3. 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.

Warning: The water in this water heater is cold and always remains cold except for the times that hot water is being used DO NOT INSTALL IN AN

AREA WHERE IT COULD FREEZE .

Drain the heater entirely if freezing temperatures are anticipated in area where heater is installed by disconnecting both the inlet and outlet connections at the bottom of heater.

To prevent any freeze damage, introduce short bursts of compressed air (20-40psi) through these connections to remove the residual water in the horizontal pipes and water valve.

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.

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7

Appliance details

8

2.6

Clearances

The GWH-635-ES is design certified for installation on a combustible wall (see 2.7 Mounting installation) provided the floor covering below the heater is noncombustible. For installations in an alcove or closet, maintain the minimum clearances to combustible and non-combustible materials listed below. See also Fig. 5.

A. Top 12 inches (306 mm)

B. Front 1 inches (25 mm)

C. Back 0 inches

D. Sides 1 inches (25 mm)

E. Bottom 12 inches (306 mm)

Clearances from any exhaust vent pipe are dependent upon the clearance requirements of the stainless steel vent pipe manufacturer. Single wall stainless steel

(AL29-4C) vent pipe (vent type rated for Category III appliances) must be used when exhaust venting this appliance. See 2.9 Venting.

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.

i Front cover should be removed (see instructions on page 4) in order to inspect components visually.

The GWH-635-ES is design certified for mounting on a wall. Secure the wall mounting bracket provided with the heater to a wall surface. See Fig. 6.

Do not install this appliance on a carpeted wall or over floor covering which is combustible, such as carpet.

The heater must be mounted on a wall using appropriate anchoring materials.

If the mounting bracket is unable to line up on two wall studs it is recommended that support board(s), either

1x4's or ½" (minimum) plywood first be attached across a pair of studs and then the heater should be attached to the support boards. The heater should be kept level on the wall surface. See Fig. 6.

Expansion and contraction of piping due to changing water temperature in the pipes imparts movement to the heater which, if mounted directly to a brittle, friable board, such as plasterboard, can cause failure of mounting.

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. 6 Mounting the heater

2.8

Combustion air requirements

The GWH-635-ES is a sealed water heater and it’s recommended that outdoor combustion air be supplied to the unit (TWIN PIPE SYSTEM). The combustion air pipe system may be constructed of either 3" aluminum or aluminum flex, PVC or galvanized pipe. See Fig.

10, 12 and 13. Select a point for building penetration being sure that a 3 foot minimum distance is maintained between the combustion air terminator and the exhaust vent terminator, see Fig. 16 Letter I. NOTE: Observe all local building codes when penetrating a building wall.

NOTE: The combustion air inlet location on the side of a building must never be less than 3 feet away from the units exhaust vent terminator, see

Fig. 16 Table 4.

The heater has the ability to operate without combustion air being piped to it from the outside, provided there is an adequate amount of combustion air available in the room area. Observe the following instructions concerning combustion air when following the SINGLE PIPE (exhaust venting only) SYSTEM only and follow Fig. 14 and 15 for proper setup.

• Appliances located in unconfined spaces:

– a) An unconfined space is one whose volume is greater than 50 cubic feet (1.42 cubic meter) per

1000 Btu per hour (292.81 Watts) of the combined rating of all appliances installed in the space. That would be 8750 cubic feet (247.8

cubic meter) for the GWH-635-ES alone.

– b) In unconfined spaces in buildings of conventional frame, masonry, or metal

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Appliance details construction, infiltration air is normally adequate to provide air for combustion.

• Appliances located in confined spaces:

The confined space must be provided with two permanent openings, one commencing within 12 inches (304.8mm) of the top and one commencing within 12 inches (304.8mm) of the bottom of the enclosure. Each opening must have a minimum free area of one square inch per:

– 1000 Btu/hr (292.81 Watts) if all air is taken from inside the building

– 2000 Btu/hr (585.62 Watts) if all air is taken from the outside by horizontal ducts

– 4000 Btu/hr (1171.24 Watts)if all air is taken from the outside by direct openings or vertical ducts

Or the confined space must be provided with one permanent opening or duct that is within 12 inches

(304.8mm) of the ceiling of the enclosure. This opening must have a minimum free area of one square inch per:

– 3000 Btu/hr (878.43 Watts) if all air is taken from the outside by a direct opening or vertical duct.

Louvers, grills and screens have a blocking effect, when used, increase the sizes of your openings by 300% for wood louvers (as wood type will reduce the free air by

75%) and 40% for metal louvers (as metal will reduce the free air by 30%). Refer to the National Fuel Gas

Code for complete information. In buildings of tight construction all air should be taken from outside.

NOTE: It is not recommended to use interior room air (SINGLE PIPE vent system) in areas that commonly experience below freezing temperatures. Clothes dryers, furnaces, woodstoves, bathroom or kitchen fans or other gas appliances can create negative air pressure when operating by removing air from the building. Cold air will be drawn back into the building, and if drawn through the water heater a freezing situation may occur. TWIN PIPE (room sealed) method of venting is recommended, see page 12.

NOTE: When installed in beauty shops, barber shops, or other facilities where chemicals that generate corrosive or flammable products such as aerosol sprays are routinely used, shall be installed as sealed unit following the TWIN PIPE

SYSTEM method of venting.

2.9

Venting

Warning: Do not reduce the vent

(exhaust and combustion) pipe sizes and do not common vent with any other vented appliance or stove.

NOTE: This appliance's exhaust must be vented to the outside1 with sealed stainless steel vent pipe (AL29-4C), the minimum vent length is 3 feet

(a 90 degree vent elbow is equivalent to 2 ½ feet).

The appliance's flue gasses are under positive pressure and must travel through a stainless steel 3" or 4" pipe that is sealed gas tight.

NOTE: The exhaust collar on the water heater is

3" diameter and its collar must always be used, a

3" to 4" increaser will be required to be first connected to the exhaust collar when 4" venting is used. Different stainless steel vent manufacturer's have different joint systems, do not mix vent pipe or joining methods from different manufacturer's.

Stainless steel vent pipe is equipped with sealing gaskets for ease of installation, proper safety and durability. The heater shall not be vented in combination with any other appliance; the appliance must only be vented with a dedicated sealed vent system.

Z flex Protech Heat Fab BBTNA

3” VENTING

3” Horizontal

Terminal

3” Vertical terminal

4” VENTING

Requires a 3” to 4” Increaser

2SVSTB03

2SVSRCF03

2SVI0304

4” Horizontal terminal

2SVSRTF04

FSTB3

FSRC3

FS0304TI

FSTB4

9390 TEE

5300CI

2SVSTB03

2SVSRCF03

9374

9490TEE

2SVI0304

FXHOOD

4” Vertical terminal

2SVSRCF04 FSRC4 5400CI ----------

Table 2 Terminals/Adapters Part Numbers

Caution: The vent system must be installed by a qualified agency in accordance with these instructions. If improperly installed a hazardous condition such as explosion or Carbon

Monoxide poisoning could result.

BBTNA will not be responsible for improperly installed appliances.

Establish vent clearances that comply with the vent manufacturer's specifications. In all cases follow local codes. See table 3.

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9

Appliance details

The maximum flue gas exhaust temperature on the GWH-635-ES is 437°F (225°C)

Venting

Options

Exhaust vent diameter and material

* Exhaust vent maximum length

* Exhaust vent minimum length

Combustion air pipe diameter and material

Combustion air pipe maximum length

Vent pipe clearances within an unenclosed space

Vent pipe clearances within an enclosed space

Room sealed

(twin pipe)

Open combustion

(single pipe)

3 or 4

+ inch stainless steel

(AL29-4C) sealed vent pipe

3 or 4

+ inch stainless steel

(AL29-4C) sealed vent pipe

26 feet (8 m) with one elbow. Less

2½ feet for each additional

90° elbow

26 feet (8 m) with one elbow. Less

2½ feet for each additional

90° elbow

3 feet

3 feet

3 inch PVC, aluminum or galvanized pipe

See chapter 2.8

26 feet (8 m) with one elbow. Less

2½ feet for each additional

90° elbow

See chapter 2.8

** See vent manufacturer's specifications

** See vent manufacturer's specifications

** See vent manufacturer's specifications

** See vent manufacturer's specifications

Exhaust vent is always fan assisted. Installation of exhaust vent and combustion air piping may be run vertically or horizontally and in separate directions if required.

+

The exhaust collar on the water heater is 3" diameter and its collar must always be used, a 3" to 4" increaser will be required to be first connected to the exhaust collar when 4" venting is used.

* A maximum of three 90 degree elbows are permitted in both the exhaust and combustion air vent lengths. The total vent length must be reduced by 1 ¼ feet for every 45° elbow used in the vent system.

** Stainless steel (AL29-4C) vent pipe is manufacturerd by Z-Flex, Protech and Heat Fab. NOTE: clearance distances are variable depending if the vent pipe is installed in an enclosed or unenclosed space, the exhaust flue gas temperature and the orientation of the vent pipe.

Table 3

Minimum exhaust vent size and length

The appliance should be located as close to the point of termination as possible. The maximum vent length is

26 feet (8 m) with one 90 degree elbow. Subtract 2½ feet from the total vent length for each additional 90° elbow used (a maximum of three 90° elbows are permitted in the total vent length), or subtract 1 ¼ feet for every 45° elbow used. Horizontal sections of vent must pitch ¼" for every foot of horizontal length, to prevent the pooling of condensate, and be supported at

4 foot intervals with overhead hangers.

Note: Listed thimbles or collars are necessary to pass through wall and ceiling partitions. If the vent system passes through combustible areas where the vent clearance requirements cannot be maintained, it is permissible to chase straight sections of sealed 3 inch single wall vent through 4 inch (or greater) Type-B vent.

The distance to combustibles using this chase technique is 1 inch. Note: Type-B vent should never be used as the actual exhaust vent system for the appliance, as it is not gas tight.

Fig. 7

Maximum exhaust vent and combustion air inlet lengths

The minimum exhaust vent length is

3 feet.

The use of a 90 degree elbow is equivalent to 2 ½ ft in vent length.

The use of 45 degree elbow is equivalent to 1 ¼ ft in vent length.

Fig. 8

10

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Appliance details

Note: reduce 2½ ft for each 90° elbow used after the first one, reduce 1 ¼ ft for each 45° elbow.

Vent Safety System

The GWH-635-ES will shut down if inadequate exhaust venting is detected or a lack of combustion air is provided to the unit; see troubleshooting section on page 24. See error code to confirm error, correct the problem and then reset the heater before operating.

Attaching the exhaust and air inlet connection adaptors to the top of the heater

Use of the external condensate drain tube kit

(supplied with the heater) on the exhaust collar

B The condensate drain tube kit must be used for all installation types. Failure to install condensate drain will void the warranty .

B When installing the condensate drain tube kit at the exhaust collar (see diagram below), be sure to form a trap by means of a 3" (76.2 mm) loop filled with water. The supplied tube is 3/8" ID high temperature silicone and must be attached to the condensate tapping on the exhaust collar with its supplied gear clamp (first remove screw at tapping point).

B To increase tube length, connect vinyl type tubing after the supplied tube.

B The condensate must be disposed of according to local regulations.

Condensate port on exhaust collar

1. Remove tapping screw

Fig. 9

Fig. 10

B Attach the flue gas exhaust accessory (8 705 504

114) to the top of the unit (position 1) using the 4 screws and gasket provided, and fully insert 3" stainless steel vent pipe into the accessory and tighten the clamp (position 2).

B Attach the combustion air inlet accessory (8 705

504 115) to the top of the unit (position 3) using the

3 screws and gasket provided, and fully insert 3" combustion air pipe into the accessory and tighten the clamp (position 4). NOTE: The appliance has the possibility to mount the combustion air inlet accessory on the top right or on the top left side of the heater. The combustion air inlet that is not used must be kept sealed.

2. Fit tube with gear clamp

3. Coil tube into 3” circle with nylon tie (don't crimp tubing) and fill circle with water

Fig. 11

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Appliance details

2.9.1

Venting options

Installing this water heater as a room sealed (TWIN

PIPE SYSTEM) is the recommended method. Contact

BBTNA or dealer for available vent termination kits and vent materials for this water heater.

i Exhaust venting shall be done with 3" or

4" stainless steel (AL29-4C) vent pipe.

Room sealed installation (TWIN PIPE SYSTEM)

Open combustion installation (SINGLE PIPE

SYSTEM)

Not recommended in cold climate areas, see

Chapter 2.8.

Fig. 14

Exhaust vent pipe: ≤ 26 ft (8 m)

Fig. 12

Combustion air pipe: ≤ 26 ft (8 m)

Exhaust vent pipe: ≤ 26 ft (8 m)

Fig. 13

Combustion air pipe: ≤ 26 ft (8 m)

Exhaust vent pipe: A+B+C ≤ 23½ ft (7.2 m)

Note: reduce 2½ ft for each 90° elbow used after the first one, reduce 1 ¼ ft for each 45° elbow.

A maximum of three 90-degree elbows are permitted in both the exhaust and combustion air vent lengths.

i The exhaust vent pipe and combustion air pipe can be run vertically or horizontally.

Maximum length for each individual pipe is

26 feet (8 m) with one elbow, for each additional 90° elbow after the first elbow you must reduce 2½ feet from the total vent length, or 1 ¼ feet for each 45° elbow.

Fig. 15

Exhaust vent pipe: A+B+C ≤ 23½ ft (7.2 m)

The exhaust vent system must vent directly to the outside of the building and an adequate amount of indoor combustion air must be provided for this installation. See chapter 2.8.

Connecting a one piece 90 degree elbow pipe to the combustion air inlet adaptor is necessary, this will prevent debris or objects from ever falling into the inlet opening.

Note: reduce 2½ ft for each elbow used after the first one, reduce 1 ¼ ft for each 45° elbow.

A maximum of three 90-degree elbows are permitted.

12

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Recommended exhaust vent terminator position

Appliance details

Fig. 16

F

G

Ref.

Description

A

B

C

D*

Directly below an opening; operable windows, doors and any nonmechanical fresh air openings

Below a gutter, sanitary pipework or eaves

Below a gutter, sanitary pipework or eaves, protected by metal shielding

From any internal corner

Above ground

Above a paved sidewalk

From an opposing wall or structure facing the termination

E

From any other building opening, gas utility meter, service regulator or the like

From a terminator facing a terminator

Vertically between two exhaust vent terminators on the same wall

Minimum distance

36 in

24 in

12 in

12 in

12 in

7 ft

24 in

36 in

48 in

60 in

H Horizontally between two exhaust vent terminators on the same wall 12 in

I**

J

K

Horizontally from combustion air inlet of GWH-635-ES

Vertically above or below combustion air inlet of GWH-635-ES

From the combustion air inlet of any other equipment

From any external corner

Horizontally from an opening; operable windows, doors and any non-mechanical fresh air openings

36 in

6 ft

12 in

12 in

L

Vertically from a wall, roof slope, or obstruction (venting through a flat or pitched roof) see ABOVE THE ROOF requirements on following page

Table 4

* Subject to local codes and anticipated snow level

** Other equipment that operates with a mechanical air inlet may require greater distances, reference manufacturer's instructions

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Appliance details

Supporting the exhaust vent system i The venting materials and accessories required to properly install the water heater are available from BBTNA and their distributors.

Fig. 17 Horizontal side wall venting installation

(combustion air piping not being shown)

Fig. 18 Above the roof clearance requirements from rain cap (combustion air piping not being shown)

B A condensate drain tube must be attached to the exhaust collar of the heater for all vent type applications, see page 11.

Fig. 19 Vertical venting installation (combustion air piping not being shown)

A condensate drain tube must be attached to the exhaust collar of the heater for all vent type applications, see page 11.

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2.10 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

National Fuel Gas Code for a maximum draw of

175,000 BTUH. First determine the effective length of the gas supply line by measuring the actual length of piping, and then adding 5 ft. (1.52m) for every elbow or

“T” to the actual length. Use the charts in Fig. 22 to determine the pipe diameter necessary to accommodate the BTU (Wh) demand of the unit. If there are more gas drawing appliances on the line, size according to the maximum amount of BTU (Wh) demand.

Note: It is important that if any flexible gas line is used, above or below ground between the gas supply meter/ regulator and the water heater, that it be sized properly.

Consult the gas sizing specification tables provided by the flexible gas line manufacturer and sample CSST flexible gas line tables in Figure 22.

Fig. 20 Vertical venting installation - Masonry

Chimney (combustion air piping not being shown)

A condensate drain tube must be attached to the exhaust collar of the heater for all vent type applications, see page, see page 11.

Inlet gas particle screen

Gas piping

Fig. 21

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 critical, this will facilitate any necessary servicing and cleaning of the inlet gas particle screen.

B Flexible gas line connectors are not recommended because they are commonly undersized and restrict gas flow. Oversize the diameter of any flexible gas appliance connector if one must be used.

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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 635-ES (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 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

Length of Black Iron Pipe, Feet

10 20 30 40 50 60 70 80

32

72

132

278

520

1050

1600

3050

22

49

92

190

350

18

40

73

152

285

730 590

1100 890

500

760

2100 1650 1450

15

34

63

130

245

14

30

56

12

27

50

115 105 96

215 195 180

11

25

46

440 400 370

670 610 560

350

530

1270 1150 1050 990

11

23

43

90

170

90 100

10

22

40

84

160

320

490

930

9

21

38

79

150

305

460

870

125

8

18

34

72

130

275

410

780

150 175 200

8

17

31

64

120

250

380

710

7

15

28

59 55

110 100

6

14

26

225 210

350 320

650 610

Length of Flexible Corrugated Stainless Steel Tubing (CSST), Feet

Tube size, inches EHD*

10 20 30 40 50 60

1/2 18 EHD 82 58 47 41 37 34

3/4

1

23 EHD 161

30 EHD 330

1 1/4 37 EHD 639

116

231

456

96

188

374

83

162

325

75

144

292

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 10 20 30 40

Black Iron Pipe

Length of Pipe, Feet

50 60 70 80 90

275 189 152 129 114 103 96 89 83

100

78

125

69

150

63 1/2

3/4

1

567 693 315 267 237 217 196 185 173 162 146 132

107 732 590 504 448 409 378 346 322 307 275 252

1 1/4 220 149 121 103 913 834 771 724 677 630 567 511

1 1/2 330 229 185 155 141 127 118 108 102 976 866 787

Tube size inches

Length of Flexible Corrugated Stainless Steel Tubing (CSST), Feet

EHD*

10 20 30 40 50

1/2 18 EHD 129 91 74 64 58

60

53

3/4 23 EHD 254 183 151

1 30 EHD 521 365 297

1 1/4 37 EHD 971 661 528

131

256

449

118

227

397

107

207

359

Maximum Capacity of Semi-Rigid (flexible, non corrugated) Tubing in Thousands of BTU per Hour of

Undiluted Liquefied Petroleum Gases (at 11 inches

Water Column Inlet Pressure).

Outside diameter

Inch

(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

Fig. 22

Copper

Length of Tubing, Feet

10 20

3/8 39 26

1/2 92 62

30 40

21 19

50 41

50

_

37

60 70 80 90 100

_ _ _ _ _

35 31 29 27 26

5/8 199 131 107 90 79 72 67 62 59 55

3/4 329 216 181 145 131 121 112 104 95 90

16

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Appliance details

2.11

Gas line sizing

B It is strongly recommended that the Natural Gas pipe be Black Iron pipe the entire distance from the outside meter to the inlet of the gas connection. ¾”

Black Iron pipe up to 20 feet (6.1m) and 1” Black Iron pipe up to 70 feet (21.34m) distances. Flex line is

NOT recommended, but if used, then oversize the diameter of the flex pipe, keep the length to a minimum and try to keep the flex line as straight as possible.

B It is strongly recommended that the LP Gas pipe be semi-rigid copper or Black Iron pipe from the outside regulator to the inlet of the gas connection. For semirigid copper piping: 5/8” up to 10 feet (3.05m) and

¾” up to 30 feet (9.14m) distances. For Black Iron piping: ½” up to 20 feet (6.1m) and ¾” up to 80 feet

(24.38m) distances. Flex line is NOT recommended, but if used, then oversize the diameter of the flex pipe, keep the length to a minimum and try to keep the flex line as straight as possible.

i THESE FIGURES ARE FOR GWH-635-

ES SUPPLY ONLY, ALL OTHER

APPLIANCES IN THE BUILDING MUST

BE INCLUDED IN THE PIPE SIZING.

National Fuel Gas Code requires that a sediment trap

(drip leg) be installed on gas appliances not so equipped. Also, a manual gas shut off valve must be installed on the gas supply line within close proximity of the water heater and be visible from the water heater.

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.

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 soapy water to all gas fittings. Soap bubbles are a sign of a leak.

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 soapy solution. Never test for gas leaks using a match or flame.

2.12 Measuring gas pressure

2.12.1 Connecting Manometer

B Shut off gas.

B Remove front cover and locate inlet gas pressure measuring point (see Fig. 24).

B Loosen screw inside test point fitting (do not remove) and connect manometer tube on test point.

2.12.2 Static Pressure Test

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 5.

2.12.3 Operating Pressure Test

B ON/OFF switch in position OFF (0).

B Press and hold "Program" (M) button and turn ON/

OFF switch to ON position.

Fig. 23

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.

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 5.

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 2.10.

Fig. 24 Gas pressure measuring (left tapping)

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Appliance details

Static Gas Pressure Reading (see Chapter 2.12

)

enter here: ___________________

Operating Gas Pressure Reading (see Chapter 2.12

)

enter here: ___________________

Table 5

HIGH ALTITUDE OPERATION

Altitude Natural

Gas:

Liquid

Propane:

0 - 4,000 ft

(0 - 1,219 m)

4,000 ft - 7,000 ft

(1,219 m - 2,134 m) no modification no modification

CO

2

adjustment with flue gas analyzer required See chapter

9

for instructions.

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

Above 7,000 ft

(above 2,134 m)

Table 6

Not approved

2.13 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 centrally in the building if possible and make hot water piping runs as short as possible.

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.

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. 26). 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 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. 26. 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. 25

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 the building may be other than copper, we recommend that copper, galvanized or suitably rated stainless steel flex line piping be used for the water heater connections (follow

Fig. 26 Plumbing Connections and Pressure Relief

Valve

18

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Appliance details

2.14 Electrical connections

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-ES 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. 37).

2.15 Operating instructions

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.

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 NOTE: A default temperature setting of

122 F will appear on the display screen.

2.16 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, set the On/Off switch to the On ( I ) 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.

2.17

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 position ( 0 ). 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 ( I ) 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.

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Appliance details i

NOTE: on a first time initial installation or after gas line work has been done, existence of air in the gas line will cause ignition delay when the hot water is turned on.

This will result in an error (EA) on the units display screen. This is normal. When this occurs, leave the hot water running and wait 3-5 seconds, then reset the unit (Fig.

26, pos. 2). Wait for (EA) to disappear. The heater will begin to attempt ignition again, if the (EA) 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 on the supply line to the heater and set the ON/OFF switch to the OFF ( 0 ) position. Note: a manual gas shut off valve is not supplied with the heater.

20

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Operation instructions

3 Operation instructions

Fig. 27

3

4

1

2

5

6

On/Off switch

Reset button

Program Key

Increasing temperature selector

Decreasing temperature selector

LCD display

3.1

Power

On

B To start the appliance switch the button to position

( I ).

LCD display the default temperature - temperature factory setting 122°F (50°C).

B Press buttons and requested temperature.

in order to reach

Fig. 28

Off

B To shut down the appliance switch the button to position ( 0 ).

3.2

Temperature selection

To select water temperature outlet:

Fig. 29

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.

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21

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-ES 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

5.00

4.00

3.00

2.00

1.00

0.00

90 130 140 150 100

Inlet (ºF) 40

110 120

Hot water temperature (ºF)

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

Inlet (ºC) 4

45 50

Hot water temperature (ºC)

Inlet (ºC) 10 Inlet (ºC) 16

55

Inlet (ºC) 21

60

Programming the heater to display temperature readings in Celsius is possible, contact BBTNA for instruction.

65

Fig. 30 Flow/temperature charts

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Operation instructions

3.3

Use of remote control accessory

Fig. 31 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. 29, component 12) is required when programming the remote control with this heater.

i NOTE: up to 6 remote controls can be programmed for one single water heater, each with a range distance of 98 ft (30 m).

3.4

Operation

B When a hot water tap is opened, main burner ignites and LCD displays indication .

Fig. 34 Reset button

If the problem persists, contact your installer.

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).

Fig. 32

B LCD blinks until selected temperature is reached.

3.5

Reset button

If the LCD shows the error symbol .

See the error code on LCD and consult

“Troubleshooting” section.

Fig. 35 “Program” key

B Press buttons and to select temperature to be memorized.

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.

3.7

Locked condition

This condition is only valid for appliances with more then 1 controller (appliances with remote control).

Fig. 33

After following instructions indicated in

“Troubleshooting” section

B press reset button in order to make the appliance ready-to-work.

Fig. 36 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.

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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.

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 Remove plastic decals on front panel (Page 5, Fig.

3).

B Loosen the two Philips head screws located behind decals.

B Lift front cover panel upward and remove.

Systems and parts that should be checked at least once a year

Reference diagrams on pages 29 and 30.

• Venting system

• Burners -see page 29 for observation window

• Manual operation of the pressure relief valve to insure correct operation

• Periodic cleaning of the water filter screen, see Fig.

25, chapter 2.13.

• 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-ES 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 water flow valve causing it to malfunction; 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 26. A Functional Scheme of the

GWH-635-ES is detailed on page 28. If there is a problem with the installation, venting or operation of the unit, the heater will communicate the source by these error codes.

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 2.10 - 2.12. The

GWH-635-ES requires adequate gas pressure to reach desired temperatures, to compensate for inadequate gas supply or lack of gas pressure the

GWH-635-ES will effectively reach the selected output temperature by reducing the hot water flow rate. Its motorized water valve makes this adjustment

24

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Troubleshooting

• Cold water is mixing with the hot water outlet

(crossover)

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-ES will effectively support two 2.0-

2.5 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 22.

• Btu input is too low due to inadequate gas line sizing

See specifications in chapter 2.10 - 2.12. The

GWH-635-ES 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-ES 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 22.

• 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 25AUB-

¾” or N35B-¾” pressure relief valves or equivalent are suggested.

NOISY BURNER / HEATER DURING OPERATION

• CO

2

range is out of adjustment. The cover must be in place to confirm CO

2

readings. Operating with the cover removed may cause a noisy or unstable burner.

See Chapter 9, CO by a certified gas technician with a calibrated CO

2 analyzer.

2

adjustments can only be done

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25

Troubleshooting

F7

E0

A7

Display Cause

E9

EA

EC

FA

A9

C1

C6

C7

CA

E2

Temperature limiter opened circuit

(overheat). Trips at 220F (104C).

No ionization during safety time (safety time out).

Note: appliance makes 3 ignition attempts before entering error mode “EA”.

The ionization signal momentarily disappeared more then 5 times in less then

30 seconds.

Leakage error (gas valves do not close gas circuit).

Solution

Check connections.*

Check heat exchanger condition.*

Check gas pressure.*

Check that gas is not diluted with air, as a result from recent gas pipeline rework.*.

Check if vent terminal is blocked (especially when the appliance starts up for some seconds and then looses ionization signal).*

Check ionization electrode.*

Check for a proper ground.*

Check gas valve and control unit.*

Ionization error (flame sensing at stand-by).

Check control unit.*

Internal software/hardware failure.

Check control unit.*

Hot water temperature sensor/receiver defect (from control unit).

Hot water temperature sensor/receiver misassembled (from control unit).

Note: if display shows “A9” flashing, the appliance can be operated normally, but performance may be affected.

Check water temperature sensor/receiver and connections.*

Check room area temperature where heater is located, it must be above 36°F (2°C)

Close water tap and allow 30 seconds for purging time.

Open water tap and wait for 2 minutes to see if A9 message is deleted from the display.

Check that the water temperature sensor/receiver is properly assembled in the water pipe.*

Check that the water temperature sensor/receiver is in proper condition.*

FAN rotation too low at start-up (from control unit).

Check supply voltage.*

Check fan and connections.*

Check control unit.*

Check if vent terminal is blocked or if vent terminal is according with

Check CO chapter 2.9

. *

2

levels (see chapter 9 ).*

FAN rotation too low at operation (from control unit).

Check supply voltage.*

Check fan and connections.*

Check control unit.*

Check if vent terminal is according with chapter 2.9

.*

No rotational speed sensor signal from FAN Check fan and connections.*

Check control unit.*

Check CO

2

levels (see chapter 9 ).*

Water flow signal over specified maximum value

Check water valve and flow sensor.*

Inlet temperature sensor fault Check water temperature sensor/receiver and connections.*

Check room area temperature where heater is located, it must be above 36°F (2°C)

A2 Overheat protection fault Check connections to the overheat protection.*

Check sensor continuity.*

Check heat exchanger sealings and walls.*

Table 7

* By installer or service technician only.

26

6 720 607 072

6 Electrical diagram

Electrical diagram

Fig. 37 Electrical scheme

12

13

14

15

16

8

9

10

11

5

6

7

3

4

1

2

17

Intlet water temperature sensor

Ionization sensor

Water flow sensor

Over heat protection

Temperature limiter

Gas valve

Fan

Water valve

AC Plug

Ignition electrode

Display PCB

ON/OFF switch

Fuse T 2,5A

Fuse T 3,15A

Terminal block

Ground post

Outlet water temperature sensor

6 720 607 072

27

GWH-635-ES Functional scheme

7 GWH-635-ES Functional scheme

Fig. 38 Functional scheme

28

6 720 607 072

Interior components diagram and parts list

8 Interior components diagram and parts list

8.1

Interior components

12

13

14

15

8

9

10

11

5

6

7

3

4

1

2

Fig. 39 Components

Cover

On/Off switch

Reset button

LCD display

Program button

Temperature switches

Flue gas collector

Mixer

Heat exchanger

Observation window

Inlet air duct

Control unit

Exhaust fan

Water valve

Gas valve

6 720 607 072

Fig. 40 Appliance overview

29

Interior components diagram and parts list

8.2

Components diagram

41

34

31

42

32

30 3

4

33

43

2

40

7

8

36

39

7

8

38

35

5 7

9

5

10

6

15

13

14

10

12

25

1

44

19

24

37

11

Fig. 41 Components Diagram

30

23

21

22

16

20 18

17

26

27

29

6720607072-34.3 JF

28

6 720 607 072

Interior components diagram and parts list

8.3

Parts list

Item

40

41

42

37

38

39

32

33

34

35

36

27

28

29

30

31

22

23

24

25

26

17

18

19

20

21

12

13

14

15

16

7

8

9

5

6

10

11

1

2

3

4

43

44

Table 8

Description

Front cover

Shield

Heat exchanger

Heat exchanger top gasket

Clip

Heat exchanger bottom gasket

O-ring

Temperature sensor

Washer 1/2"

Wireform spring

Air inlet duct

Water filter

O-ring

Water valve with engine

Main burner

Fan / Burner gasket

Set of electrodes

Exhaust Fan

Gas / Air Mixer

Mixer / Fan gasket

Gas valve washer

Gas valve

Gas valve washer

Remote control

Control unit

Ignition cable

Cables / 24V

Cables

Power supply cord

Overheat cutoff fuse

Flue gas exhaust accessory

Combustion air inlet accessory

Flue gas collector

Flue gas collector collar

Cold water pipe

Hot water pipe

Air inlet screen

Crossover tube

Overheat sensor (ECO)

Clip - Heat exchanger

Clip - Over heat fuse

Gasket Exhaust

Gasket Set Combustion Chamber

O-ring air duct

Reference

8 707 021 019

8 700 103 014

8 707 207 153

8 707 207 133

8 704 401 220

8 704 401 214

8 704 401 239

8 704 401 221

8 700 400 019

8 705 504 137

8 705 504 115

8 705 700 100

8 705 700 114

8 700 715 156

8 700 715 155

8 700 507 069

8 700 715 247

8 707 206 204

8 701 201 028

8 701 201 024

8 700 103 710

8 704 701 046

8 700 205 149

8 705 421 837

8 705 506 661

8 705 406 285

8 704 701 052

8 716 102 607

8 704 701 054

8 700 205 147

8 700 400 015

8 710 103 045

8 714 606 002

8 705 700 097

8 700 507 001

8 700 205 134

8 708 505 016

8 708 120 515

8 704 701 050

8 708 107 020

8 707 204 039

8 705 700 115

8 704 701 059

8 704 701 062

6 720 607 072

31

Special adjustment for measuring and adjusting CO2 levels

9 Special adjustment for measuring and adjusting CO

2

levels

The CO

2

can only be adjusted by a certified gas technician with a calibrated CO

2

analyzer.

Caution: One factor that may affect

CO

2

levels is improper gas pressure.

Please see Chapter 2.12 for the procedure to measure gas pressure and record your findings below:

Static Gas Pressure:

P1 Operating Pressure:

“ WC

“ WC

B. Measuring CO

2

(Cover Installed):

B Open hot water taps to achieve a flow rate of at least

4 gallons per minute. (1 tub and 2 sinks should be sufficient).

B Record the CO

2

reading in P2 below. (Analyzer reading may take several minutes to stabilize).

B Press the ‘+’ button until P1 appears. Unit will ramp up to high fire and the flow should increase.

B Record the CO

2

reading in P1 below.

P2 CO

2

Reading: % CO

2

P1 CO

2

Reading: % CO

2 The P1 minimum operating pressure is 5" WC for

Natural Gas and 11"WC for Propane. Do not proceed in adjusting CO

2

until pressure has been verified to be at or above these levels, but not to exceed 14” WC.

A. Once Pressure is good

B Turn ON/OFF switch to the OFF (O) position.

B Remove brass flat head screw on the exhaust collar as seen in Fig. 42.

B Insert CO

2

analyzer probe into the measuring port.

The tip of the probe should be in the center of the flue pipe (approx 1.5" inserted).

Compare your readings to those found in table 9 under the “With Front Cover” column. If CO make adjustments as outlined below.

2

readings are off

Note : The “Without Front Cover” column give approximate values with the cover off to ease the adjustment process. Final readings should be taken with the cover on.

Fig. 42

B While holding the Program (M) button, move the ON/

OFF switch to ON (I) position (see Fig. 43). As soon as ‘188’ flashes on the display, release the Program button. The display should now read P2.

C. Adjusting CO

2

:

Note : P1 adjustment will change the P2 reading.

Confirm the P1 value BEFORE adjusting the P2 level.

1. P1 CO

2

level off:

B Loosen yellow painted Philips screw (1) and cover should rotate down (2) revealing a brass slotted screw. Fig. 44.

B Adjusting the slotted screw counter clockwise will raise P1 CO

2

levels and clockwise will lower P1

CO

2

levels. Adjustments to the slotted screw will also change P2 CO

2

levels.

2. P2 CO

2

level off:

B Remove yellow painted #40 Torx cover from the front of the gas valve. (Fig. 45) A plastic #40 Torx screw will be revealed.

B Adjusting the plastic #40 Torx screw counter clockwise will lower P2 CO will raise P2 CO

2

levels.

2

levels and clockwise

Note : These screw adjustment are very sensitive and may take several minutes to stabilize.

3. Verify both P1 and P2 are within the ranges specified in table 1 under the “With Front Cover” column. Repeat steps 1 and 2 as necesssary until CO

2 the specified ranges.

values are within

Fig. 43

32

6 720 607 072

Special adjustment for measuring and adjusting CO2 levels

D. Returning to Service:

1. Return slotted cover to original position.

2. Reinstall Torx cover.

3. Remove CO

2

analyzer probe and reinstall flathead screw in exhaust collar.

4. Turn ON/OFF switch to the OFF (O) position and then back to the ON (I) position.

5. Heater is ready for normal operation.

Without Front

Cover

% CO

2

With Front

Cover max. input min. input max. input min. input

P1

P2

P1

P2

Nat. Gas

9.1 ± 0.1 %

9.4 ± 0.1 %

LP Gas

Nat. Gas

9.7 ± 0.1 %

9.7 ± 0.1 %

LP Gas

10.1 ± 0.1 % 10.7 ± 0.1 %

10.4 ± 0.1 % 10.7 ± 0.1 %

* Final reading must be confirmed with the front cover on, CO

2

levels increase when the cover is installed.

Table 9

Final Readings

P2 CO

2

Reading:

P1 CO

2

Reading: % CO

2

Fig. 45

Fig. 44

6 720 607 072

33

Protecting the environment

10 Protecting the environment

Packing

The packing box may be fully recycled as confirmed by the recycling symbol .

Components

Many parts in the heater can be fully recycled in the end of the product life. Contact your city authorities for information about the disposal of recyclable products.

Saving water resources:

B Make sure you close all the taps after any use. Avoid leaving the taps dripping. Repair any leaking tap.

B Whenever possible use taps with built-in water flow limiters. They will give you the same comfort level while saving water.

B Define the temperature you want, in the appliance or with the remote control. This way you have the precise water flow needed (mixing cold water to regulate temperature will increase the water flow with consequent waste of water).

For increased safety shut off the appliance from the main water supply if your are staying away from home for a considerable time.

At below freezing temperatures, disconnect the plumbing connections to the heater and allow the heater to drain.

To prevent any freeze damage, introduce short bursts of compressed air (20-40 psi) through these connections to remove the residual water in the horizontal pipes and water valve.

34

6 720 607 072

Fifteen Year Limited Warranty

11 Fifteen Year Limited Warranty

General

BOSCH PRO water heaters are warranted by the

Manufacturer (BOSCH) through BBT North America.

BBT North America (BBTNA) will furnish a replacement heat exchanger and will furnish a replacement of any other part which fails in normal use and service within the applicable periods specified below, in accordance with the terms of this warranty. The BBTNA replacement will be warranted for the unexpired portion of the original warranty. This warranty will be valid only for water heaters in possession of the original purchaser as recorded on the warranty card.

The Heat Exchanger

If the heat exchanger fails within fifteen (15) years after the original installation and operation, BBTNA will furnish a replacement heat exchanger. However, if the water heater is installed in other than a single family dwelling, this heat exchanger warranty is limited to two

(2) years from date of original installation and operation.

Exceptions

This warranty will not apply:

• 1.

to defects or malfunctions resulting from failure to properly install, operate or maintain the unit in accordance with the printed instructions provided;

• 2.

to damage or abuse, accident, neglect or freezing and other acts of nature;

• 3.

to damage resulting from operation with either the flame sensor rod or overheat sensor removed;

• 4.

to failure of the heat exchanger resulting from the operation of the water heater in a corrosive atmosphere or at water temperatures exceeding the maximum rating, or if the water heater is not supplied with potable water;

• 5.

to defects or damage cause by any attachment or modification, including any energy-saving device.

All Other Parts

If any other part fails within three (3) years after original installation and operation, BBTNA will furnish a replacement part free of charge.

Shipping costs

In addition to supplying the replacement part(s),

BBTNA will provide ground service delivery for these parts. Expedited or upgraded shipping will be charged to the customer.

Service Labor Costs

This warranty does not cover any labor costs associated with service, removal or re-installation of part(s). All such costs must be borne by the Purchaser.

Additionally, this warranty does not cover any labor costs associated with service, removal or re-installation of the original water heater or a replaced water heater.

Certain service labor allowances are available to PHCC member contractors, dependent on prior authorization by BBTNA.

i NOTE: the water heater must be free of damaging scale deposits and not subject to gas pressures greater than those shown on the rating plate, which must not be altered, defaced or removed .

How to Make a Claim

Any claim for warranty parts should be made to your local dealer, distributor or to BBTNA. If BBTNA, please contact the Technical Support Department:

BBT NORTH AMERICA

Bosch Group

340 Mad River Park

Waitsfield, VT 05673

Phone 866-330-2730 www.boschpro.com

In most cases, the dealer or distributor will be able to promptly honor your claim and subsequently notify

BBTNA. However, all replacements are made subject to validation by BBTNA of in-warranty coverage. The damaged or defective item must be made available in exchange for the replacement.

Miscellaneous

No one is authorized to make any other warranties on behalf of BBTNA. It is expressly understood that the replacement warranty of BBTNA shall be in lieu of any and all other warranties, express or implied, including warranties of merchantability or fitness for a particular use or purpose, and further that BBTNA shall not be liable for any loss or damage directly or indirectly arising from the use of the hot water heater, or for any consequential damages arising from such use

(including damages from water leakage). BBTNA sole liability with respect to any defect shall be for the replacement of the defective part(s). Some states do not allow such limitations and exclusions, so the above may not apply to you.

This warranty gives specific legal rights. You may also have other rights which vary from state to state.

35

6 720 607 072

Installer Checklist, to be performed by installer upon installation

Serial Number ___ ___ ___ ___ ___ ___ ___ ___

(8 digit serial number is located on rating plate on right side panel)

Gas Pressure Reading*

Building Water Pressure

Installing Company

Installer name

Static__________ Operating__________

__________ Range if on Well system __________

_____________________________________________

_____________________________________________

Address

Phone

_____________________________________________

_____________________________________________

* See Chapter 2.12 and gas pressure table (to be filled out by installer)

Installation manual should be left with the owner after the installation is tested and completed

Replacement Parts available from:

BBT NORTH AMERICA

Bosch Group

Bosch Water Heating

340 Mad River Park

Waitsfield, VT 05673

Phone 866-330-2730

Fax (802) 426-6924 www.boschpro.com

[email protected]

Recycled paper

VULCANO Termodomésticos S.A.

Estrada de Cacia

3801 - 856 Aveiro - PORTUGAL

© 2005 BBT NORTH AMERICA,

Waitsfield, VT all rights reserved

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