Bosch Appliances GWH-635-ES manual

Water heat ers for u se with Natural an d L.P.G. GWH-635-ES T emperat ur e Modulat ed wit h Elec t ronic Ignit ion Suit able for heat ing pot able w ater only - Not a pproved fo r spac e heat ing purpose s (Intend ed for vari able fl ow applicatio ns with multiple t apping poi nts) GWH- 635-ES -N GWH- 635-ES -L 6 720 607 072 (04.03) JS Warn ing: I [...]

6 720 607 072 2 Index Index 1 Warning 2 2 Applianc e details 4 2.1 Features 4 2.2 GWH-635-ES Speci fications (Technical d ata) 4 2.3 Dimensions an d Minimum installation clearances 6 2.4 Genera l rules to follow for safe operation 7 2.5 Proper location for installing your heater 7 2.6 Cle arances 8 2.7 Mounting installation 8 2.8 Combustion air req[...]

6 720 607 072 Warning 3 What t o do if you s mell gas • Clos e gas v alve. O pen w indows. • Do not t ry to li ght any ap pliance. • Do n ot t ouch a ny e lectrical switch; do not use a ny phone in your buildi ng. • I m me di at el y c a ll yo ur ga s su pp li er f ro m a n ei g hb or ’s phone. F ollow the ga s sup plier’s in structio n[...]

6 720 607 072 4 Applia nce de tails 2 Applianc e details 2.1 Featur es Parts • Tou ch Pa d interfa ce contro l • High power pre-mix compact burner with low Nox emissions • Modulating Gas Valve with constant gas:a i r ratio contr ol • Modulating water valve for improved c omfort and tempe rature co ntrol. Safet y • Flame sensor (i onizatio[...]

6 720 607 072 App lia nce details 5 • Minim um recommended water pressure: 30 PSI (2.07 bar) • Connecti ons: – Bottom of heate r Comb ustion •N O x ≤ 55 ppm •C O ≤ 250 ppm •C O 2 level set from fact ory, see cha pter 9.1. Dimens ions • Dep th (i n): 8 ½ ” (2 20 mm ) • Width (in): 1 5 ¾” (400 mm) • Heigh t (in): 23 ½” [...]

6 720 607 072 6 Applia nce de tails 2.3 Dimension s and Minimum ins tallation clear ances Fig. 5 Dimension s 1 Cover 2 On/Off switch 3 Rese t butt on 4 LCD di splay 5 Program bu tton 6 Temperature buttons Fig. 6 M inimum clearances Model GWH-635- ES TOP (A) 12” FRONT (B) 4” BACK 0” SIDES 4” FLOOR (C ) 12” VENT DIAMETER 3” Table 1 M inim[...]

6 720 607 072 App lia nce details 7 2 . 4 G e n e r a l r u l e s t o f o l l o w f o r s a f e operatio n B 1. Y ou shoul d fol low thes e instruc tions when y ou instal l your h eater. In the Un ited S tates: T he i n s t a l l a t i o n m u s t c o n f o r m w i t h l o c a l co d e s o r , i n t h e absence of local codes, the National Fuel Gas[...]

6 720 607 072 8 Applia nce de tails 2.6 Cleara nces The GWH- 635-ES is design cert ified for installat i on o n a comb ustible wall (see 2. 7 Mo unting installatio n) provid ed the floor cover ing bel ow the heate r is noncom bustibl e. For installation s in an alcove or closet, mainta in the min imum cleara nces to comb ustible and non-c ombustibl[...]

6 720 607 072 App lia nce details 9 – b) In un confined s paces in buildi ngs of convent ional frame, ma sonry, or metal const ruction , in filtrati on air is normal ly adequat e t o provide air for combustion. • App liance s lo cated in confi ned spaces : The confined spa ce m ust be pro vided w ith tw o perm anent open ings, one commenc ing w[...]

6 720 607 072 10 Applia nce de tails The maximum flue gas exhaust t emperature on the GWH -635-ES is 437°F ( 225°C) Venting Optio ns Exhaust vent diameter and material * Exhaust ven t maximum length * Exhaust vent minimum length Comb ustio n air pipe diameter and ma terial Combustion air pipe maxi mum length Vent pipe clearances with in an unencl[...]

6 720 607 072 App lia nce details 11 The ap pliance should be located a s c lose to the point of termina tion as poss ible. The maximum ven t length is 26 feet ( 8 m) with one 90 degre e elbow. Subtra ct 2½ feet from the total ve nt len gth for each additional 90° elbow used (a maximum o f three 90 ° elb ows a re p e rm i tt ed in t h e to ta l [...]

6 720 607 072 12 Applia nce de tails Room sea led ins tallation (TWIN PIPE SYSTEM) Fig. 12 Combus tion air pipe: ≤ 26 ft (8 m) Exha ust vent pipe: ≤ 26 ft ( 8 m) A con densate t rap (drai n t ee) must be used in any side w a l l in s t al l a t io n i f t he t o t a l e x h a u s t v e nt l en g t h i s g r e at e r than or equ al to 5 feet ( 1[...]

6 720 607 072 App lia nce details 13 Recomm ended e xhaust vent te rminator position Fig. 16 * Subject to local c odes and anticipat ed snow level ** Other equip m ent that op erates with a mechanic al air inlet may require great er distances, reference m anufact urer's instructio ns Ref. Description Minimum distan ce A Directly below an openi[...]

6 720 607 072 14 Applia nce de tails Supportin g the exhaust vent sys tem and the use of an externa l conden sate t rap Extern al c ondens ate tr aps B A conden sate trap must be used in any sidewa l l exha ust vent instal lations w hen the tota l v ent l ength is ≥ 5 ft (1. 5 m) OR the vent p ipe pa sses t hrough an unheat ed space (below 6 0F).[...]

6 720 607 072 App lia nce details 15 Fig. 20 Vert ical venting installation - Masonry Chimney (combusti on air piping not being shown) A cond ensate tr ap (drain t ee) must b e us ed for a ny vertica l e xhaust vent installati on. T he condensa te t rap should be positioned as nea r to the t op of the heat er as possible. 2.10 Gas piping & conn[...]

6 720 607 072 16 Applia nce de tails FOR NA TU RAL GAS Maxi mum Capac ity o f pip e in Cubic Fee t of Ga s pe r Hour fo r Gas Press ure of 0 .5 Ps ig or less and a Pres sure drop of 0. 3 in Water Col umn (0 . 75mba r).(Based on a 0.60 Specifi c Grav ity G as) Btu n u mber s given in thou sands. Fig. 22 Follow bo xed numbers f or p iping jus t on e [...]

6 720 607 072 App lia nce details 17 2.11 Gas line sizing B It i s stro ngly recom mended that the Natur al Gas pipe be Bla ck Iron p ipe the entire distanc e from t he outside meter to th e inlet of the g as co nnection. ¾” B l a c k I r o n p i p e u p t o 2 0 f e e t ( 6 . 1 m ) a n d 1 ” B l a c k I r o n pipe up to 70 feet (21.34m) distan[...]

6 720 607 072 18 Applia nce de tails 2.13 Water con nections W h e n f a c i n g t h e h e a t e r , t h e ¾ ” c o l d w a t e r i n l e t i s o n t h e b o t t o m r i g h t a n d t h e h o t w a t e r o u t l e t i s o n t h e b o t t o m left . Install the hea ter centrall y in the build ing if possi ble and ma ke hot water pip ing runs as sh[...]

6 720 607 072 App lia nce details 19 2.14 Ele ctrical conne ctions The GW H-635 -ES requi res an elec trical po wer sup ply f r o m a 1 2 0 V A C 6 0 H z c i r c u i t a n d m u s t b e p r o p e r l y ground ed. A means f or switching off th e 120VAC power supply must be provided. The heater is wired as shown in the wiring diagr am (chapter 6, Fig[...]

6 720 607 072 20 Applia nce de tails When the hea ter is i n op eration you wi ll hear its power vent fan and burner opera ting. Upon turning off the hot water flow the p ower vent fan will cont inue to operat e f o r u p t o 6 0 s e c o n d s t o e x h a u s t a l l f l u e g a s e s . T h e power ve nts fan sp eed is varia ble depen ding on th e [...]

6 720 607 072 Operat ion inst ructions 21 3 Operation in structions Fig. 26 1 On/O ff switch 2 Reset button 3 Progr am Ke y 4 Increasing temperature se lector 5 Decreasing temper a ture se lector 6 LCD displ ay 3.1 Power On B T o st art the a pplia nce switch the bu tton to pos ition ( I ). LCD displa y the def ault tempe rature - temp erature fact[...]

6 720 607 072 22 Operat ion ins tructi ons Setting the w ater tempera ture The desire d temp erature o f the hot w ater can be adjuste d on t he front control p anel of t he heater. The GWH-635 -ES has a n e lectronica lly con trolled gas valve tha t modul ates the burner input in response to both varyin g hot wate r flow rates and/or changes in an[...]

6 720 607 072 Operat ion inst ructions 23 3.3 Use of remote co ntrol accessory Fig. 30 R emote control The wirel ess re mote control a ccessory and the tempera ture sel ector b uttons on th e front of the water heate r operat e ident ically. Cont act your distr ibutor or CEC to o rder if t he re mote control access ory is prefer red. Modifica tion [...]

6 720 607 072 24 Maint enance and se rvice 4 Maintenance and service The unit shoul d be checked once a year by a gas technic ian. If rep airs are need ed, the re pairs sho uld be done b y a ga s tech nician To r emov e fron t cov er B R e m o v e p l a s t i c d e c a l s o n f r o n t p a n e l ( P a g e 5 , F i g . 4). B Lo o se n t he tw o P hi[...]

6 720 607 072 Troubleshooting 25 Test by following 4th bullet under BURNERS DO NOT IGNITE WHEN HOT WATER IS TURNED ON. LOW WATER FLOW/PRESSURE • T o o m a n y h o t w a t e r a p p l i c a t i o n s a r e b e i n g us ed si m u lt an e ou s ly or to o mu c h fl o w i s be in g demande d The G WH-635 -ES will e ffectively su pport two 2.0 - 2.5 gp[...]

6 720 607 072 26 Troubleshooting Display Cause Solu tion E9 Temperature limiter opened circuit (over heat). Tri ps at 22 0F (104C) . Check connections.* Check heat exchanger con dition.* EA No ionization during safety time (safety t i me out). Check gas pr essure.* Check that gas is not diluted with air, as a result from recent gas pipel ine rework[...]

6 720 607 072 Electr ical diag ram 27 6 Electrica l diagram Fig. 36 Electrical scheme 1 Intlet water temp erature sensor 2 Ioniz ation sensor 3 Water flow sensor 4 Over heat protection 5 Temperature limiter 6 Gas val ve 7 Fan 8 Water valve 9 AC Plug 10 Ignit ion ele ctrode 11 Dis play PCB 12 ON/OFF switch 13 Fuse T 1,25 A 14 Fuse T 3,15 A 15 Ter mi[...]

6 720 607 072 28 GWH-6 35-ES Func tional s cheme 7 GWH -635-ES F unction al sch eme Fig. 37 Func tional scheme[...]

6 720 607 072 Inte rior c ompo nent s dia gram an d parts list 29 8 Interior components diagram and parts list 8.1 Interi or compo nents Fig. 38 C omponents 1 Cover 2 On/O ff switch 3 Reset button 4 LCD displ ay 5 Program b utton 6 Temperature sw itches 7 Flue gas c ollector 8 Mi xer 9 Heat e xchanger 10 Obs erva tio n win dow 11 Inle t ai r duct 1[...]

6 720 607 072 30 Inte rior c omponent s dia gram a nd pa rts lis t 8.2 Comp onents diag ram Fig. 40 Comp onents Diagram[...]

6 720 607 072 Inte rior c ompo nent s dia gram an d parts list 31 8.3 Parts list Item Descri ption Reference 1 Front cover 8 7 05 42 1 83 7 2 Shield 8 7 05 506 66 1 3 Heat exc hanger 8 7 05 406 285 4 Heat exc hanger top gask et 8 7 04 70 1 052 5 Clip 8 7 1 6 1 02 60 7 6 Heat exc hanger bottom gasket 8 7 04 70 1 054 7 O-ring 8 700 205 1 4 7 8 Temper[...]

6 720 607 072 32 Specia l adjust ment for measur ing and ad justin g CO2 level s 9 Special adjustment for measuring and adjusting CO 2 levels The CO 2 can only be adjuste d by a certif ied gas techni cian w ith a calibrat ed CO 2 ana lyzer . 9.1 Adjust ing the uni t Fact ory set tings of this applian ce are listed in table 7. Further adju stment is[...]

6 720 607 072 Specia l adjus tment for mea suring and adju sting CO2 lev els 33 Fig. 43 Adjusting Leave “Program” mod e B Turn ON/OFF switc h in position OFF and then ON again . i NOTE: turn ing screw clockw ise decreases CO 2 lev el, turning coun terclock wise inc reases it. Caution: Faulty igniti on or noisy operation ma y occ ur if CO 2 leve[...]

6 720 607 072 34 Protect ing the environ ment 10 Protecting t he environment Packin g Th e p ack ing box may b e fu lly rec yc led as c onf ir med by the rec ycling symb ol . Component s Many parts in the he ater can be fully rec ycled in the en d o f t h e p r o d u c t l i f e . C o n t a c t y o u r c i t y a u t h o r i t i e s f o r inform ati[...]

6 720 607 072 Fifteen Year Limit ed Warr anty 35 11 Fifteen Year Limited Warranty Gene ral BOSCH PRO w ater h eaters are wa rranted by t he Manufa cturer (BO SCH) through Co n tro lled Energy Corp. Contro lled Energy Corp. (CEC) will furnish a replac ement heat excha nger and w ill furni sh a repla cement of any oth er par t whi ch fails in nor mal[...]

Replacemen t Parts available from North Americ an Distributor CONT RO L LE D E N ERG Y CORP . 340 Mad Ri ver Park W aitsfie ld, V ermont 0 567 3 Phone 86 6-330- 27 30 Fax (802) 496-6924 www .protan kless.co m techsupport@protankle ss.com VU L CAN O T e rmodomésticos S.A . Estra da de Cacia 380 1 - 856 Aveir o - PO RTUGAL Recyc led paper © 2004 Co[...]