Bosch Appliances GWH-635-ES manual

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6 720 607 072 2 Index Index 1 Warn ing 2 2 Appli ance det ails 4 2.1 Featu res 4 2.2 GWH-6 35-ES S pecific ations (Te chnical data) 4 2.3 Dimens ions an d Minimu m installa tion cle arance s 6 2.4 Genera l rules to follow for safe o peration 7 2.5 Proper location for instal ling your heater 7 2.6 Clearan ces 8 2.7 Mountin g insta llation 8 2.8 Comb[...]

6 720 607 072 Warning 3 What to do if you smell g as • Close gas valve . Open windows. • Do not try to l ight any appliance . • Do n ot t ouch any e lectrical switch; do not use any phone in your bui lding. • Immediately ca ll yo ur gas supplier fro m a ne ighbor’s phone. Follow th e gas supplier’ s instructions. • If you cann ot reac[...]

6 720 607 072 4 Appliance de tails 2 Applia nce de tails 2.1 Features Parts • Touch Pad interf ace control • High po wer pre- mix comp act bu rner wi th low Nox emissions • Modulating Gas Valv e with constant gas: air ratio control • Modulating water valve for improved comfort and temperat ure control. Safety • Flame sensor (i onization) [...]

6 720 607 072 Appliance det ails 5 Combustio n • NOx ≤ 55 ppm • CO ≤ 250 ppm • CO 2 level set from fa ctory, see chapte r 9. Dimensio ns • Depth (in): 8 ½” (220 mm) • Width (in): 15 ¾ ” (400 mm) • Height (in): 23 ½ ” (600 mm) • Weight: 47 po unds (21 kg). Gas types Natural Gas. LP Gas. Converting the gas t ype can only be[...]

6 720 607 072 6 Appliance de tails 2.3 Dim ensions and Minimum installation clearances Fig. 4 Dimensions 1 Cover 2 On/Off s witch 3 Reset button 4 LCD d isplay 5 Program button 6 Tempe rature buttons Fig. 5 Minimum cleara nces Model GWH-635-ES TOP (A) 12” FRONT (B) 1” BACK 0” SIDES 1” FLOOR (C) 12” VENT DIAMETER 3” Table 1 Minim um clea[...]

6 720 607 072 Appliance det ails 7 2.4 General rules to follow fo r safe operation B 1. You should follow these instructions when you install your heater. In the United States: T he installation must con form with l ocal codes or, in the absence of local codes, the National Fuel Gas Code ANSI Z223.1/NF PA 54. In Canada: T he Installation should con[...]

6 720 607 072 8 Appliance de tails 2.6 Clearances The GWH-6 35-ES is design certifie d for installation on a c ombustible wa ll ( see 2.7 Mou nting installatio n) provided the floor cover ing b elow t he heater is noncombustibl e. For in stallations in an alcove or closet, maintain the minimum clearances to combustible and non-combusti ble ma teria[...]

6 720 607 072 Appliance det ails 9 construct ion, infiltration air is normally ad equate to provide air fo r combustion. • Appliances lo cated in confine d spaces: The con fined s pace m ust be pro vided wit h two permanent o penings, one com mencing within 1 2 inches (304.8mm ) of the top and one comm encing within 12 in ches (304.8m m) of the b[...]

6 720 607 072 10 Appliance de tails The applianc e should be located as close to the poin t of termination as p ossible. The maxim um vent length is 26 feet (8 m) with on e 90 de gree elbow . Subtrac t 2½ feet from t he total vent l ength f or e ach ad ditional 9 0° elbow used (a maximum of thr ee 9 0° elbows are permitted in th e tot al vent le[...]

6 720 607 072 Appliance det ails 11 Note: red uce 2½ ft for each 90° elbow used after the first one, r educe 1 ¼ ft for ea ch 45° elbow. Vent Safe ty System The GWH-635-ES will sh ut dow n if inadequate exhaust venting i s detected or a lack of combus tion air is provided to the uni t; see tro ubleshooting section on page 2 4. See error co de t[...]

6 720 607 072 12 Appliance de tails 2.9.1 Venting o ptions Installing this water heater as a room sealed (TWIN PIPE SYSTEM) is the recomme nded method. Contac t BBTNA or dealer for a vailable ve nt termin ation kits and vent materia ls for this water he ater. Room seale d installation (TWIN PIPE SYST EM) Fig. 12 Combustion air pipe: ≤ 26 ft (8 m)[...]

6 720 607 072 Appliance det ails 13 Recommen ded exhaust v ent terminator position Fig. 16 * Subj ect to loc al codes and an ticipate d snow lev el ** Oth er equipm ent that operat es with a m echan ical air i nlet may r equire greater dis tances, r eferenc e manu facturer's instruct ions Ref. Description Minimum distance A Directl y below an [...]

6 720 607 072 14 Appliance de tails Supporting t he exhaust v ent system Fig. 17 Horizontal side w all venting in stallation (combustion air piping not be ing shown) Fig. 18 Above the roof cleara nce requirements from rain cap (c ombustion air piping not be ing shown) B A c ondensate drain tube must be attached t o th e exhaust collar of the heater[...]

6 720 607 072 Appliance det ails 15 Fig. 20 Vertical vent ing ins tallation - Masonry Chimney (c ombustion air piping not being shown) A conden sate drain tu be must be attached to the exhaust c ollar o f the heater for all vent type applicati ons, see page, s ee page 11. 2.10 Gas pi ping & conn ection s Before connecting the gas suppl y, check[...]

6 720 607 072 16 Appliance de tails FOR NA TU R AL GAS Maximum Cap acity of pipe in Cu bic Feet of Gas pe r Hour for Ga s Pressure of 0.5 Psig or less and a Pressure drop of 0.3 in Wate r Column (0.75 mbar).(Based on a 0.60 Specific Gravity Gas) B tu numbers give n in thousands. Fig. 22 Follow boxed numbers f or piping just one 635- E S ( examp le:[...]

6 720 607 072 Appliance det ails 17 2.11 Gas line sizing B It is strongly recomm ended that th e Nat ural G as pip e be Black Iron p ipe the entire distance from the outside met er to th e inlet of the gas co nnection. ¾” Black Iron pip e up to 20 fee t (6 .1m) and 1” B lack Iron pipe up to 70 feet ( 21.34m) distance s. Flex l ine is NOT recom[...]

6 720 607 072 18 Appliance de tails HIGH ALTIT UDE OPERATI ON 2.13 W ater connections When faci ng the hea ter, the ¾ ” cold wat er inlet i s on the bottom right a nd the hot wate r outlet is on the bottom left. Install the heater c entrally i n the b uilding i f possible and make hot water piping r uns as short as possible. Fig. 25 B THE USE OF[...]

6 720 607 072 Appliance det ails 19 2.14 Electrical connections The GWH -635-ES requires a n electrical po wer supply from a 120VAC 60Hz circuit and must be properly grounded. A means for swi tching off the 120VA C p ower supply must be prov ided. The he ater is w ired as shown in the wiring diagram (chapter 6, Fig. 37). 2.15 Operating instructions[...]

6 720 607 072 20 Appliance de tails When the heater is i n ope ration you will hear i ts pow er vent f an a nd burne r opera ting. Up on turni ng of f the hot water flow t he power v ent fan will c ontinue to op erate for up to 60 s econds to exhaust a ll flue gases. Th e power ve nts fan speed is variable d epending on the rate of hot water u sed [...]

6 720 607 072 Operation in structions 21 3 Opera tion in structi ons Fig. 27 1 On/O ff switch 2 Reset button 3 Prog ram Key 4 Incre asing tem perature selector 5 Decre asing tem peratur e selec tor 6 LCD d isplay 3.1 Power On B T o s tart t he a ppliance switch the butto n to position ( I ). LCD d isplay the d efault temperature - temperature facto[...]

6 720 607 072 22 Operation i nstructions Setting the water temperatu re The desired temperature of the hot water ca n be adjusted on the front control panel of the he ater. The GWH-635-ES has an e lectronically controlled gas valve that modulates the burner input i n resp onse to both varying hot w ater flow rates a nd/or changes in any incoming an[...]

6 720 607 072 Operation in structions 23 3.3 Use of remote control accessory Fig. 31 Remote control The wireless re mote control a ccessory and the temperature selector b uttons on the front o f the wa ter heater op erate identic ally. Contact your dist ributor or BBTNA to order if the remote control accessory is preferred. Modifi cation of t he w [...]

6 720 607 072 24 Maintenance and service 4 Mainte nance and ser vice The unit should be checked once a year by a gas technician. If re pairs are needed, t he re pairs should be done by a ga s technician To remove front cover B Remove plastic dec als on f ront p anel ( Page 5, Fig. 3). B Loosen th e two Philips h ead screws locat ed behind decals. B[...]

6 720 607 072 Troubleshooti ng 25 • Cold w ater i s mix ing wi th th e hot water outlet (crossover) Test by following 4th bullet under BURNER S DO NOT IGNITE WHEN HOT WATER IS TURNED ON. LOW WAT ER FLOW/PRE SSURE • Too m any hot wa ter applications are being used simultaneously or too much flow is being demanded The G WH-635-ES will e ffectivel[...]

6 720 607 072 26 Troubleshoot ing Display Caus e Solution E9 Temperature limiter opened circuit (overheat). Trips at 220F (104C). Check connections.* Check heat exchanger condition.* EA No ioniz ation during sa fety time (safety time out). Note: appliance makes 3 ignition attempts before entering error mode “EA”. Check gas pressure.* Check that[...]

6 720 607 072 Electrical d iagram 27 6 Elect rical dia gram Fig. 37 Electrical sch eme 1 Intlet w ater temp eratur e sensor 2 Ionizat ion sens or 3 Water flow sen sor 4 Over h eat prote ction 5 Tempe rature limiter 6 Gas v alve 7 Fan 8 Water valve 9 AC Pl ug 10 Ign ition el ectrode 11 D isplay PC B 12 O N/OFF sw itch 13 F use T 2,5A 14 F use T 3,15[...]

6 720 607 072 28 GWH-635-E S Functional sc heme 7 GWH -635-ES Functio nal sch eme Fig. 38 Functional schem e[...]

6 720 607 072 Interior compon ents diag ram and parts lis t 29 8 Inter ior com ponents diagra m and p arts lis t 8.1 Interior components Fig. 39 Components 1 Cover 2 On/O ff switch 3 Reset button 4 LCD d isplay 5 Prog ram button 6 Tempe rature switches 7 Flue ga s colle ctor 8 Mixe r 9 Heat exchang er 10 O bservation windo w 11 Inle t air du ct 12 [...]

6 720 607 072 30 Interior co mponents diag ram and parts li st 8.2 Co mponents diagram Fig. 41 Components Dia gram[...]

6 720 607 072 Interior compon ents diag ram and parts lis t 31 8.3 Parts list Item Description Referenc e 1 Front cover 8 7 05 42 1 83 7 2 Shield 8 705 506 66 1 3 Heat exc hanger 8 705 406 285 4 Heat exc hanger top gasket 8 7 04 7 0 1 05 2 5 Clip 8 7 1 6 1 02 607 6 Heat exc hanger bottom gasket 8 70 4 70 1 054 7 O-ring 8 7 0 0 205 1 4 7 8 Temperatu[...]

6 720 607 072 32 Special adj ustment for mea suring and ad justing CO2 l evels 9 Special adjus tment for mea suring and adjus ting CO 2 levels The CO 2 c an only be adju sted by a certified gas technician w ith a calibrate d CO 2 analyzer. Static Gas Pres sure: “ WC P1 Operating Pressure: “ W C The P1 minimum operating pressure is 5" WC fo[...]

6 720 607 072 Special ad justment for measuring and a djusting CO2 levels 33 D. Returni ng to Service: 1. Return slot ted cover to origi nal position. 2. Reinstall Torx cover. 3. Remove CO 2 analyzer probe an d reinstall flathea d screw in exha ust collar. 4. Turn ON /OFF switch to t he OFF (O) positi on and then back to the ON (I) posi tion. 5. He[...]

6 720 607 072 34 Protecting t he environment 10 Prot ecting the enviro nmen t Packing The packing b ox m ay be fully recycled as confirm ed by the recycling symbol . Components Many parts i n the h eater can be fully recycled in the e nd of the product life. Contact your city authorities for information about the dispos al of recyclable products. S[...]

6 720 607 072 Fifteen Y ear Limited Warra nty 35 11 Fiftee n Yea r Limited Warr anty General BOSCH PRO w ater h eaters are warranted by t he Manufactu rer (B OSCH) through BBT North America. BBT N orth America (B BTNA) will fur nish a replacement heat exchanger and will furnish a replacement of any other p art which fails in no rmal use a nd servi [...]

Replac ement P arts a vailable fro m: VU L C AN O T ermod omésticos S.A . Estrada de Caci a 38 0 1 - 856 Aveiro - P O RTUG AL Recycled pa per © 200 5 B BT NO RTH AM E R I CA , W aitsfield , V T all rights re serve d BBT NORTH AMERICA Bosch Group Bosch Water Heating 340 Mad River Park Waitsfield, VT 05673 Phone 866-330-2730 Fax (802) 426-6924 www.[...]