Bosch Termotecnologia 8708300123 Remote Control User Manual 6720607072 0401 GWH635ES 16 January

Bosch Termotecnologia S.A. Remote Control 6720607072 0401 GWH635ES 16 January

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8708300123 User Manual

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Water heaters for use with Natural and L.P.G.GWH-635-ESTemperature Modulated with Electronic IgnitionSuitable for heating potable water only - Not approved for space heating purposes(Intended for variable flow applications with multiple tapping points)GWH-635-ES-NGWH-635-ES-L6 720 607 072 (16 January) JSPRO TANKLESSWarning: If the information in this manual is notfollowed exactly. A fire or explosion may resultcausing property damage, personal injury or death.Do not store or use gasoline or other flammablevapor and liquids in the vicinity of this or any otherappliance.Improper installation, adjustment, alteration,service or maintenance can cause injury orproperty damage. Refer to this manual. Forassistance or additional information consult aqualified installer, service agency or the gassupplier.In the Commonwealth of Massachusetts thisproduct must be installed by a licensed plumber orgas fitter.Upon completion of the installation, theseinstructions should be handed to the user of theappliance 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 anyphone in your building• If you cannot reach your gas supplier, call the firedepartment.• Immediately call your gas supplier from a neighbor’sphone. Follow the gas supplier’s instructions• Installation and service must be performed by aqualified installer, service agency or the gas supplier.

6 720 607 072 (16 January)2IndexIndex1 Warning 22 Appliance details 42.1 Features 42.2 GWH-635-ES Specifications (Technical data) 42.3 Dimensions and Minimum installation clearances 62.4 General rules to follow for safe operation 72.5 Proper location for installing your heater 72.6 Clearances 82.7 Mounting installation 82.8 Combustion air requirements 82.9 Venting 92.9.1 Venting options 122.10 Gas piping & connections 152.11 Gas line sizing 172.12 Measuring gas pressure 172.13 Water connections 182.14 Electrical connections 202.15 Operating instructions 202.16 For your safety read before operating your water heater 202.17 Lighting and operating instructions 203 Operation instructions 223.1 Power 223.2 Temperature selection 223.3 New remote control registration 243.4 Operation 243.5 Reset button 243.6 Program button 243.7 Locked condition 254 Maintenance and service 255 Troubleshooting 256 Electrical diagram 287 GWH-635-ES Functional scheme 298 Interior components diagram and parts list 308.1 Interior components 308.2 Components diagram 318.3 Parts list 329 Special adjustment for measuring and adjusting CO2 levels 339.1 Adjusting the unit 339.1.1 CO2 measuring port 339.1.2 Selecting adjustment mode 3310 Protecting the environment 3511 Fifteen Year Limited Warranty 361WarningFeaturingElectronic Ignition and Power VentingFor your safetyDo not store or use gasoline or other flammable,combustible or corrosive vapors and liquids in thevicinity of this or any other appliance.Warning: If the information in thismanual is not followed exactly. A fire orexplosion may result causing propertydamage, personal injury or death.Warning: Improper installation,adjustment, alteration, service ormaintenance can cause injury orproperty damage. Refer to this manual.For assistance or additional informationconsult a qualified installer, serviceagency or the gas supplier.Upon completion of the installation,these instructions should be handed tothe user of the appliance for futurereference.Warning: Carefully plan where youinstall the heater. Correct combustionair supply and flue pipe installation arevery important. If a gas appliance is notinstalled correctly, fatal accidents canresult from lack of air, carbon monoxidepoisoning or fire.Warning: Exhaust gas must be ventedto outside using proper vent materialsuitable for category III vent systemsand temperatures up to 480°F. Ventand combustion air connector pipingmust be sealed gas-tight to preventpossibility of flue gas spillage, carbonmonoxide emissions and risk of fire,resulting in severe personal injury ordeath.Warning: Place the heater in a locationwhere water leaks will do NO DAMAGEto adjacent areas or lower floors.

6 720 607 072 (16 January)Warning3What 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 anyphone in your building.• Immediately call your gas supplier from a neighbor’sphone. Follow the gas supplier’s instructions.• If you cannot reach your gas supplier, call the firedepartment.• Installation and service must be performed by aqualified installer, service agency or the gas supplier.Fig. 1Fig. 2Warning: Field wiring connections andelectrical grounding must comply withlocal codes, or in the absence of localcodes, with the latest edition of theNational Electric Code, ANSI/NFPA 70,or in Canada, all electrical wiring mustcomply with the local codes and theCanadian Electrical Code, CSA C22.1Part 1.Warning: Shock hazard line voltage ispresent. Before servicing the waterheater, turn off the electrical power tothe water heater at the main disconnector circuit breaker. Failure to do so couldresult in severe personal injury or death.Warning: The heater must bedisconnected from the gas supplypiping system during any pressuretesting of that system at test pressuresequal to or more than 0.5 psig.FCC: This device complies with Part 15 of the FCCrules. Operation is subject to the followingtwo conditions: (1) This device may not causeharmful interference, and (2) this device mustaccept any interference received, includinginterference that may cause undesiredoperation.Caution:Any changes or modifications not expresslyapproved by the party responsible forcompliance could void the user's authority tooperate the equipment.

6 720 607 072 (16 January)4Appliance details2 Appliance details2.1 FeaturesParts• Touch Pad interface control• High power pre-mix compact burner with low Noxemissions• Modulating Gas Valve with constant gas:air ratiocontrol • Modulating water valve for improved comfort andtemperature control.Safety• Flame sensor (ionization) rod• Overheat sensor• Temperature limiter• Fan speed monitoring.High Quality Materials for Long Working Life• Copper heat exchanger• Ceramic Burner output• Automatic overheating protection shut-off sensor• Compact space saver: mounts on a wall with asupplied 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 tooperate with the appliance• Vent termination kit.2.2 GWH-635-ES Specifications (Technical data)Approved in US/CanadaCapacityMaximum flow rate: 6.35 GPM (24 l/min) at a 45°F(25°C) rise.Maximum output142,968 Btu/h (41.8 kW)Maximum input175,000 Btu/h (51.2 kW)Efficiency in %Recovery efficiency 86.5%Min. Output31,131 Btu/h (9.1 kW)Temperature ControlSelection range: 100°F (38°C) - 140°F (60°C)Default temperature: 122°F (50°C)Stability: +/- 2°F (+/- 1°C)Gas RequirementGas connection (inches) - ¾”Inlet gas pressure under operation (with a high hotwater flow rate)*• Propane: 11” - 14” water column• Natural Gas: 5” - 14” water column• Gas pressure measuring point inside the applianceat the gas valve inlet.* Testing with a manometer, operate other gasequipment on the same gas supply. Gas pressureslower than 5" W.C. for Natural Gas or 11" W.C. forLPG will result in insufficient degree rise to the hotwater being used. See Measuring Gas Pressure,chapter 2.12.Fig. 3 Gas pressure measuring pointVentingSee chapter 2.9 for Venting on page 9.Water• Hot water connection (inches) - ¾”• Cold water connection (inches) - ¾”• Water valve material: Polymer (PPS) (PolypropyleneSulfid)• Minimum water flow: 0.8 gallon/minute (3 l/m)iBOSCH is constantly improving itsproducts, therefore specifications aresubject to change without prior notice.

6 720 607 072 (16 January)Appliance details5• Minimum recommended water pressure range: 30PSI (2.07 bar)• Connections:– Bottom of heaterCombustion•NOx ≤ 55 ppm•CO ≤ 200 ppm•CO2 level set from factory, see chapter 9.1.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 typesNatural Gas.LP Gas.Converting the gas type can only be done by a certifiedgas technician with a calibrated CO2 analyzer. CallCEC for conversion instructions.Voltage120 V AC (60 Hz)AmperageIDLE - 40 mAOperation - ≤ 2,5 ANoise≤ 50 db (A)Safety devices• Flame failure device (ionization flame rod sensor)• Pressure relief valve (supplied with heater)• Over heat prevention (temperature limiter).Water resistantIP X4 (protection against water drops)UNPACKING THE GWH-635-ES HEATERThis heater is packed securely. The box includes:• Pressure relief valve• Bracket for wall hanging the heater• Exhaust vent adaptor (with 4 screws and gasketprovided)• Combustion air inlet adaptor (with 3 screws andgasket provided)• Installation manual• Product registration card.Do not lose this manual. Please complete and returnthe enclosed product registration card.Before installing the unit, be certain you have thecorrect heater for your type of Gas - Propane orNatural Gas. Identification labels are found on theshipping box, and on the rating plate which is located onthe right side panel of the cover.To remove front cover• Remove plastic decals on front panel• Undo two Philips head screws located behind decals• Lift front cover panel upward and remove.Fig. 4 Remove front coverPlastic decals

6 720 607 072 (16 January)6Appliance details2.3 Dimensions and Minimum installation clearancesFig. 5 Dimensions1Cover2On/Off switch3Reset button4LCD display5Program button6Temperature buttonsFig. 6 Minimum clearancesModel GWH-635-ESTOP (A) 12”FRONT (B) 4”BACK 0”SIDES 4”FLOOR (C) 12”VENT DIAMETER 3”Table 1 Minimum clearances

6 720 607 072 (16 January)Appliance details72.4 General rules to follow for safeoperationB1. You should follow these instructions when youinstall your heater. In the United States: Theinstallation must conform with local codes or, in theabsence of local codes, the National Fuel Gas CodeANSI Z223.1/NFPA 54.In Canada: The Installation should conform withCGA B149.(1,2) INSTALLATION CODES and /orlocal installation codes.B2. Carefully plan where you install the heater. Correctcombustion air supply and vent pipe installation arevery important. If not installed correctly, fatalaccidents can be caused by lack of air, carbonmonoxide poisoning or fire.B3. When the unit is installed indoors and ROOMSEALED (twin pipe) it is permitted to be located inbathrooms, bedrooms and occupied rooms that arenormally kept closed. See chapter 2.9. If the unit willbe installed indoors and use indoor combustion air,the place where you install the heater must haveenough ventilation. The National Fire Codes donot allow UNSEALED gas fired water heaterinstallations in bathrooms, bedrooms or anyoccupied rooms normally kept closed. Seechapter 2.5 and 2.8.B4. You must vent your heater. See section onVENTING.B5. The appliance must be isolated from the gassupply piping system by closing its individual manualgas shutoff valve (not supplied with heater) duringany pressure testing at pressures in excess of ½ Psig(3.5 kPa).The appliance and its gas connection must be leaktested before placing the appliance in operation.B6. Keep water heater area clear and free fromcombustibles and flammable liquids. Do not locatethe heater over any material which might burn.B7. Correct gas pressure is critical for the optimumoperation of this heater. Gas piping must be sized toprovide the required pressure at the maximum outputof the heater, while all the other gas appliances are inoperation. Check with your local gas supplier, andsee the section on connecting the gas supply.B8. Should overheating occur or the gas supply fail toshut off, turn off the gas supply at the manual gasshut off valve, on the gas line. Note: manual gasshutoff valve is not supplied with the heater.B9. Do not use this appliance if any part has beenunderwater. Immediately call a qualified servicetechnician to inspect the appliance and to replaceany part of the control system and any gas controlwhich has been underwater2.5 Proper location for installing yourheaterCarefully select the location of the water heater. Foryour safety and for proper heater operation, you mustprovide combustion air to the heater and a properexhaust vent system.Follow the guidelines below:B1. Locate the heater where venting, gas andplumbing connections are feasible and convenient.B2. It is strongly recommended that the heater beinstalled as a ROOM SEALED heater (twin pipe). Ifthe heater will be installed as an UNSEALED heater(single pipe) than National building codes requirethat you do not install this appliance in bathrooms,bedrooms or any occupied rooms normally keptclosed. Heaters that are UNSEALED require aconsiderable amount of combustion air, seechapter 2.8. If installing the heater UNSEALEDwithin a laundry room, be certain that the dryer isproperly vented. Failure to properly vent a dryer couldresult in a gradual accumulation of lint build up insidethe combustion chamber of the heater.B3. The hot water lines should be kept short to saveenergy. Centrally locating the water heater is best. Itis always best to have hot water lines insulated.Warning: The water in this waterheater is cold and always remains coldexcept for the times that hot water isbeing used DO NOT INSTALL IN ANAREA WHERE IT COULD FREEZE.Drain the heater entirely if freezingtemperatures are anticipated in areawhere heater is installed bydisconnecting both the inlet and outletconnections at the bottom of heater.To prevent any freeze damage,introduce short bursts of compressedair (20-40psi) through theseconnections to remove the residualwater in the horizontal pipes and watervalve.Warning: Flammable materials,gasoline, pressurized containers, or anyother items or articles that are potentialfire hazards must NOT be placed on oradjacent to the heater. The appliancearea must be kept free of allcombustible materials, gasoline andother flammable vapors and liquids.

6 720 607 072 (16 January)8Appliance details2.6 ClearancesThe GWH-635-ES is design certified for installation ona combustible wall (see 2.7 Mounting installation)provided the floor covering below the heater isnoncombustible. For installations in an alcove or closet,maintain the minimum clearances to combustible andnon-combustible materials listed below. See also Fig. 6.A. Top 12 inches (306 mm)B. Front 4 inches (102 mm)C. 0 inchesD. Sides 4 inches (102 mm)E. Bottom 12 inches (306 mm)Clearances from any exhaust vent pipe are dependentupon the clearance requirements of the stainless steelvent pipe manufacturer. Single wall stainless steel(AL29-4C) vent pipe (vent type rated for Category IIIappliances) must be used when exhaust venting thisappliance. See 2.9 Venting.2.7 Mounting installationThe GWH-635-ES is design certified for mounting on awall. Secure the wall mounting bracket provided withthe heater to a wall surface. See Fig. 7.Do not install this appliance on a carpeted wall or overfloor covering which is combustible, such as carpet.The heater must be mounted on a wall usingappropriate anchoring materials.If the mounting bracket is unable to line up on two wallstuds it is recommended that support board(s), either1x4's or ½" (minimum) plywood first be attached acrossa pair of studs and then the heater should be attachedto the support boards. The heater should be kept levelon the wall surface. See Fig. 7.Expansion and contraction of piping due to changingwater temperature in the pipes imparts movement to theheater which, if mounted directly to a brittle, friableboard, such as plasterboard, can cause failure ofmounting.Before installing the unit, be certain you have thecorrect heater for your type of Gas - Propane orNatural Gas. Identification labels are found on theshipping box, and on the rating plate which is located onthe right side panel of the cover.Fig. 7 Mounting the heater2.8 Combustion air requirementsThe GWH-635-ES is a sealed water heater and it isrecommended that outdoor combustion air be piped tothe unit. When combustion air is piped to the unit(TWIN PIPE SYSTEM) the combustion air pipe systemmay be constructed of either 3" PVC, aluminum orgalvanized pipe. See Fig. 11, 12 and 13. Select a pointfor building penetration being sure that the necessaryclearance on the outside of the building, between thecombustion air pipe and the exhaust vent terminator ofthe appliance, can be maintained, see Fig. 16. NOTE:Observe all local building codes when penetrating abuilding wall.The heater has the ability to operate withoutcombustion air being piped to it from the outside,provided there is an adequate amount of combustion airavailable in the room area. Observe the followinginstructions concerning combustion air when followingthe SINGLE PIPE (exhaust venting only) SYSTEM onlyand follow Fig. 14 and 15 for proper setup.• Appliances located in unconfined spaces:–a) An unconfined space is one whose volume isgreater than 50 cubic feet (1.42 cubic meter) per1000 Btu per hour (292.81 Watts) of thecombined rating of all appliances installed in thespace. That would be 8250 cubic feet (233.6cubic meter) for the GWH-635-ES alone.–b) In unconfined spaces in buildings ofconventional frame, masonry, or metalconstruction, infiltration air is normally adequate toprovide air for combustion.Warning: before starting installation:Bcheck that there are no loose partsinside the applianceBensure that gas pipe, gas valve, mixer,fan and burner have no damage and areproperly fitted.iFront cover should be removed (seeinstructions on page 4) in order to inspectcomponents visually.

6 720 607 072 (16 January)Appliance details9• Appliances located in confined spaces:The confined space must be provided with twopermanent openings, one commencing within 12inches (304.8mm) of the top and one commencingwithin 12 inches (304.8mm) of the bottom of theenclosure. Each opening must have a minimum freearea of one square inch per:– 1000 Btu/hr (292.81 Watts) if all air is taken frominside the building– 2000 Btu/hr (585.62 Watts) if all air is taken fromthe outside by horizontal ducts– 4000 Btu/hr (1171.24 Watts)if all air is taken fromthe outside by direct openings or vertical ductsOr the confined space must be provided with onepermanent opening or duct that is within 12 inches(304.8mm) of the ceiling of the enclosure. This openingmust have a minimum free area of one square inch per:– 3000 Btu/hr (878.43 Watts) if all air is taken fromthe outside by a direct opening or vertical duct.Louvers, grills and screens have a blocking effect. If theeffective free area is not known, increase the sizes ofyour openings by 75% if your louvers are wood and by30% if your louvers are metal. Refer to the National FuelGas Code for complete information. In buildings of tightconstruction all air should be taken from outside.2.9 Venting NOTE: This appliance's exhaust must be ventedto the outside with a sealed 3" stainless steelvent pipe (AL29-4C). The appliance's flue gassesare under positive pressure and must travelthrough a stainless steel 3" pipe that is sealedgas tight. Stainless steel vent pipe is equippedwith sealing gaskets for ease of installation,proper safety and durability. The heater shall notbe vented in combination with any otherappliance; the appliance must only be ventedwith a dedicated sealed vent system.Establish vent clearances that comply with the ventmanufacturer's specifications. In all cases follow localcodes. See table 2.Warning: Do not reduce the vent(exhaust and combustion) pipe sizesand do not common vent with any othervented appliance or stove.Caution: The vent system must beinstalled by a qualified agency inaccordance with these instructions. Ifimproperly installed a hazardouscondition such as explosion or CarbonMonoxide poisoning could result. CECwill not be responsible for improperlyinstalled appliances.

6 720 607 072 (16 January)10Appliance detailsThe maximum flue gas exhaust temperature on the GWH-635-ES is 437°F (225°C)Venting OptionsExhaust vent diameter and material* Exhaust vent maximum length* Exhaust vent minimum lengthCombustion air pipe diameter and materialCombustion air pipe maximum lengthVent pipe clearances within an unenclosed spaceVent pipe clearances within an enclosed spaceRoom se a l ed (twin pipe)3 inch stainless steel (AL29-4C) sealed vent pipe26 feet (8 m) with one elbow. Less 2½ feet for each additional elbow1½ feet 3 inch PVC, aluminum or galvanized pipe 26 feet (8 m) with one elbow. Less 2½ feet for each additional elbow** See vent manufacturer's specifications** See vent manufacturer's specificationsOpen combustion(single pipe)3 inch stainless steel (AL29-4C) sealed vent pipe26 feet (8 m) with one elbow. Less 2½ feet for each additional elbow1½ feet See chapter 2.8See chapter 2.8** See vent manufacturer's specifications** See vent manufacturer's specificationsExhaust vent is always fan assisted. Installation of exhaust vent and combustion air piping may be run vertically or horizontallyand in separate directions if required.* A maximum of three 90 degree elbows are permitted in the total vent length.** Stainless steel (AL29-4C) vent pipe is manufacturerd by Z-Flex, Protech and Heat Fab. NOTE: clearance distances arevariable depending if the vent pipe is installed in an enclosed or unenclosed space, the exhaust flue gas temperature and theorientation of the vent pipe. Never reduce pipe diameter.Table 2

6 720 607 072 (16 January)Appliance details11The appliance should be located as close to the pointof termination as possible. The maximum vent length is26 feet (8 m) with one 90 degree elbow. Subtract 2½feet from the total vent length for each additional 90-degree elbow used (a maximum of three 90-degreeelbows are permitted in the total vent length). Horizontalsections of vent must pitch ¼" for every foot ofhorizontal length and be supported at 4 foot intervalswith overhead hangers. Any vent section greater than45 degrees is considered an elbow.Note: The stainless steel exhaust vent pipe should notbe used in concealed or unheated locations. Listedthimbles or collars are necessary to pass through walland ceiling partitions. If the vent system passes throughcombustible areas where the vent clearancerequirements cannot be maintained, it is permissible tochase straight sections of sealed 3 inch single wall ventthrough 4 inch (or greater) Type-B vent. The distance tocombustibles using this chase technique is 1 inch.Note: Type-B vent should never be used as theactual exhaust vent system for the appliance, asit is not gas tight.Minimum exhaust vent size and lengthFig. 8Maximum vent lengthsFig. 9Note: reduce 2½ ft for each elbow used after the firstoneVent Safety SystemThe GWH-635-ES will shut down if inadequate exhaustventing is detected or a lack of combustion air isprovided to the unit; see troubleshooting section onpage 25. See error code to confirm error, correct theproblem and then reset the heater before operating.Attaching the exhaust and air inlet connectionadaptors to the top of the heaterFig. 10Fig. 11BAttach the flue gas exhaust accessory (8 705 504114) to the top of the unit (position 1) using the 4screws and gasket provided, and fully insert 3"stainless steel vent pipe into the accessory andtighten the clamp (position 2).BAttach the combustion air inlet accessory (8 705504 115) to the top of the unit (position 3) using the3 screws and gasket provided, and fully insert 3"combustion air pipe into the accessory and tightenthe clamp (position 4). NOTE: The appliance has thepossibility to mount the combustion air inletaccessory on the top right or on the top left side ofthe heater. The combustion air inlet that is not usedmust be kept sealed.

6 720 607 072 (16 January)12Appliance details2.9.1 Venting optionsInstalling this water heater as a room sealed (TWINPIPE SYSTEM) is the recommended method. ContactCEC or dealer for available vent termination kits andvent materials for this water heater.Room sealed installation (TWIN PIPE SYSTEM)Fig. 12Combustion air pipe: ≤ 26 ft (8 m)Exhaust vent pipe: ≤ 26 ft (8 m)Fig. 13Combustion air pipe: ≤ 26 ft (8 m)Exhaust vent pipe: A+B+C ≤ 23½ ft (7.2 m)Note: reduce 2½ ft for each elbow used after the firstone.Open combustion installation (SINGLE PIPESYSTEM)Fig. 14Exhaust vent pipe: ≤ 26 ft (8 m)Fig. 15Exhaust vent pipe: A+B+C ≤ 23½ ft (7.2 m)The exhaust vent system must vent directly to theoutside of the building and an adequate amount ofindoor combustion air must be provided for thisinstallation. See chapter 2.8.Connecting a one piece 90 degree elbow pipe to thecombustion air inlet adaptor is recommended, this willprevent debris or objects from ever falling into the inletopening.Note: reduce 2½ ft for each elbow used after the firstone.iExhaust venting shall be done with 3”stainless steel (AL29-4C) vent pipe.iThe exhaust vent pipe and combustion airpipe can be run vertically or horizontally.Maximum length for each individual pipe is26 feet (8 m) with one elbow, for eachadditional elbow after the first elbow youmust reduce 2½ feet from the total ventlength.

6 720 607 072 (16 January)Appliance details13Recommended exhaust vent terminator positionFig. 16* Subject to local codes and anticipated snow level** Other equipment that operates with a mechanical air inlet may require greater distances, reference manufacturer's instructionsRef. Description Minimum distanceADirectly below an opening; operable windows, doors and any non-mechanical fresh air openings 36 inBBelow a gutter, sanitary pipework or eaves 24 inBelow a gutter, sanitary pipework or eaves, protected by metal shielding 12 inCFrom any internal corner 12 inD* Above ground 12 inAbove a paved sidewalk or driveway 7 ftEFrom an opposing wall or structure facing the termination 24 inFrom any other building opening, gas utility meter, service regulator or the like 7 ftFFrom a terminator facing a terminator 48 inGVertically between two exhaust vent terminators on the same wall 60 inHHorizontally between two exhaust vent terminators on the same wall 12 inI**Horizontally from combustion air inlet of 635-ES 36 inVertically above combustion air inlet of 635-ESFrom the combustion air inlet of any appliance or below the combustion air inlet of 635-ES 3 ftJFrom any external corner 12 inKHorizontally from an opening; operable windows, doors and any non-mechanical fresh air openings 12 inLVertically from a wall, roof slope, or obstruction (venting through a flat or pitched roof)see ABOVE THE ROOF requirements on following pageTable 3

6 720 607 072 (16 January)14Appliance detailsSupporting the exhaust vent system and the use of an external condensate trapExternal condensate trapsBA condensate trap must be used in any sidewallexhaust vent installations when the total vent lengthis ≥ 8 ft (2.5 m) OR the vent pipe passes through anunheated space (below 60F).BA condensate trap must be used for any verticalexhaust vent installations ≥ 2 ft.BWhen installing the condensate tube at the bottom ofthe drain tee, be sure to form a trap by means of a 3"(76.2 mm) loop filled with water. This tube must be3/8" ID high temperature silicone for at least the first6 inches (152 mm) and attached with a gear clampor hose clamp. The condensate must be disposed ofaccording to local regulations.Fig. 17 Horizontal side wall venting installation(combustion air piping not being shown)Fig. 18 Above the roof clearance requirements fromrain cap (combustion air piping not beingshown)Fig. 19 Vertical venting installation (combustion airpiping not being shown)iThe venting materials and accessoriesrequired to properly install the waterheater are available from CEC and theirdistributors.

6 720 607 072 (16 January)Appliance details15Fig. 20 Vertical venting installation - MasonryChimney (combustion air piping not beingshown)2.10Gas piping & connections Before connecting the gas supply, check the ratingplate on the right side of the heater to be sure that theheater is rated for the same gas to which it will beconnected.In the United States: The installation must conform withlocal codes or, in the absence of local codes, theNational Fuel Gas Code ANSI Z223.1/NFPA 54.In Canada: The Installation should conform with CGAB149 INSTALLATION CODES and/or local installationcodes.GAS LINE SIZINGThe gas supply piping should be sized according to theApplicable Plumbing Code for a maximum draw of175,000 BTUH. First determine the effective length ofthe gas supply line by measuring the actual length ofpiping, and then adding 5 ft. (1.52m) for every elbow or“T” to the actual length. Use the charts in Fig. 22 todetermine the pipe diameter necessary toaccommodate the BTU (Wh) demand of the unit. Ifthere are more gas drawing appliances on the line, sizeaccording 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;we recommend the use of non-corrugated flexible gasline when used. Consult the gas sizing specificationtables provided by the flexible gas line manufacturer.Fig. 21BInstall a manual gas shut off valve, on the gas supplyline.BThe use of a union when connecting gas pipe to thegas inlet connection is critical, this will facilitate anynecessary servicing and cleaning of the inlet gasparticle screen.BFlexible gas line connectors are not recommendedbecause they are commonly undersized and restrictgas flow. Oversize the diameter of any flexible gasline connector if one must be used.Gas pipingInlet gas particle screen

6 720 607 072 (16 January)16Appliance detailsFOR NATURAL GASMaximum Capacity of pipe in Cubic Feet of Gas perHour for Gas Pressure of 0.5 Psig or less and aPressure drop of 0.3 in Water Column(0.75mbar).(Based on a 0.60 Specific Gravity Gas) Btunumbers given in thousands.Fig. 22Follow boxed numbers for piping just one GWH-635-ES (example: ¾” B.I. Natural Gas pipe for 20 ft(6.1m). will handle 190,000 btu’s (55.7 kWh). Formultiple appliances combine the total btu input loadand then refer to applicable chart below.Maximum Capacity of Semi-Rigid (flexible, noncorrugated) Tubing in Thousands of BTU per Hourof Undiluted Liquefied Petroleum Gases (at 11inches Water Column Inlet Pressure).(Based on a Pressure Drop of 0.5 Inch WaterColumn)* Source National Fuel Gas Code NFPA 54, ANSIZ223.1 - No Additional Allowance is necessary for anordinary number of fittingsFOR LP GASMaximum Capacity of Pipe in Thousands of BTU perHour of Undiluted Petroleum Gases (at 11 inchesWater Column Inlet Pressure) (Based on a PressureDrop of 0.5 Inch Water Column).CopperOutside Length of Tubing, FeetDiameter,Inch 10 20 30 40 50 60 70 80 90 1003/8 39 26 21 19 _ _____1/2 9262 50 41 37 35312927265/819913110790 79 72676259553/4 329 216 181 145 131 121 112 104 95 907/8 501 346 277 233 198 187 164 155 146 138NominalIron Pipe Black Iron PipeSize,Length of Pipe, FeetInches10 20 30 40 50 60 70 80 90 100 125 1501/2 275 189 152 129 114 103 96 89 83 78 69 633/4 567 693 315 267 237 217 196 185 173 162 146 1321 107 732 590 504 448 409 378 346 322 307 275 2521 1/4 220 149 121 103 913 834 771 724 677 630 567 5111 1/2 330 229 185 155 141 127 118 108 102 976 866 7872 622 433 346 299 264 239 220 204 192 1811 1606 1496NominalIron Length of Black Iron Pipe, FeetPipe InternalSize, Diameterinches inches 10 20 30 40 50 60 70 80 90 100 125 150 175 2001/4 0.364 32 22 18 15 14 12 11 11 10 9 8 8 7 63/8 0.493 72 49 40 34 30 27 25 23 22 21 18 17 15 141/2 0.622 132 92 73 63 56 50 46 43 40 38 34 31 28 263/4 0.824 278 190 152 130 115 105 96 90 84 79 72 64 59 551 1.049 520 350 285 245 215 195 180 170 160 150 130 120 110 1001 1/4 1.380 1050 730 590 500 440 400 370 350 320 305 275 250 225 2101 1/2 1.610 1600 1100 890 760 670 610 560 530 490 460 410 380 350 3202 2.067 3050 2100 1650 1450 1270 1150 1050 990 930 870 780 710 650 6102 1/2 2.469 4800 3300 2700 2300 2000 1850 1700 1600 1500 1400 1250 1130 1050 9803 3.068 8500 5900 4700 4100 3600 3250 3000 2800 2600 2500 2200 2000 1850 17004 4.026 17,500 12,000 9,700 8,300 7,400 6,80 6,200 5,800 5,400 5,100 4,500 4,100 3,800 3500

6 720 607 072 (16 January)Appliance details172.11 Gas line sizingBIt is strongly recommended that the Natural Gas pipebe Black Iron pipe the entire distance from theoutside meter to the inlet of the gas connection. ¾”Black Iron pipe up to 20 feet (6.1m) and 1” Black Ironpipe up to 70 feet (21.34m) distances. Flex line isNOT recommended, but if used, then oversize thediameter of the flex pipe, keep the length to aminimum and try to keep the flex line as straight aspossible.BIt is strongly recommended that the LP Gas pipe besemi-rigid copper or Black Iron pipe from the outsideregulator to the inlet of the gas connection. For semi-rigid copper piping: 5/8” up to 10 feet (3.05m) and¾” up to 30 feet (9.14m) distances. For Black Ironpiping: 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 flexpipe, keep the length to a minimum and try to keepthe flex line as straight as possible.National Fuel Gas Code requires that a sediment trap(drip leg) be installed on gas appliances not soequipped. Also, a manual gas shut off valve must beinstalled on the gas supply line within close proximity ofthe water heater and be visible from the water heater.The water heater must not be piped with gas supplypressures in excess of 0.5 psig. If overpressure hasoccurred, such as through improper testing of the gaslines or malfunction of the supply system, the gas valvemust be checked for safe operation.When connections are made, check for gas leaks at alljoints. Apply some soapy water to all gas fittings. Soapbubbles are a sign of a leak.2.12 Measuring gas pressureTo measure and verify if adequate gas pressure is beingdelivered to the water heater, first run a high hot waterflow rate and operate other gas equipment on the sameload. Using a manometer, then measure the inlet gaspressure at the inlet gas pressure test port. See Fig. 23.Gas pressures lower than 5" W.C. for Natural Gas or11" W.C. for LPG will result in insufficient degree riseto the hot water being used. See Gas Connections,chapter 2.10.Fig. 23 Gas pressure measuring (left tapping)HIGH ALTITUDE OPERATIONDue to the lower density of air at high altitudes, outputmust be reduced in installations above 4000 ft (1219m).Burner output at altitudes greater than 4000 ft (1219m) will be electronically reduced once the control boardhas been properly adjusted. Follow instruction below.High altitude adjustmentBDisconnect power supply to heater.BRemove front cover of heater.BRemove control box auxiliary cover (Fig. 24, pos. 4).Fig. 24iTHESE FIGURES ARE FOR GWH-635-ES SUPPLY ONLY, ALL OTHERAPPLIANCES IN THE BUILDING MUSTBE INCLUDED IN THE PIPE SIZING.Warning: The heater must bedisconnected from the gas supplypiping system during any pressuretesting of that system at test pressuresequal to or more than 0.5 psig.Danger: If you have a leak, shut off thegas. Tighten appropriate fittings to stopleak. Turn the gas on and check againwith a soapy solution. Never test for gasleaks using a match or flame.Altitude Natural Gas: Liquid Propane:0 - 4,000 ft(0 - 1,219 m)no modificationno modification4,000 ft - 8,000 ft(1,219 m - 2,438 m)insert jumper JP3insert jumper JP3Table 4

6 720 607 072 (16 January)18Appliance detailsBRemove the 5 screws on the front retaining bar (seeFig. 24, pos. 1 and 2) being careful not to damagethe foam sealant material on it.BRemove the two electrical strip connectors inside theboard (Fig. 25) and then loosen the 120V powersupply cord retaining nut located underneath theheater. Once loosened, the power cord can bepulled up through the heater to provide sufficientslack.Fig. 25 Electrical strip connectorsBAt the ignition electrodes, pull off the 2 yellow igniterwires that come from the top of the control board(Fig. 24, pos. 3). Then pull the complete controlboard forward and out of the heater, pull up thepower supply cord further if more slack is needed.BWhile holding the board in one hand or resting it ona flat surface, remove the front cover of the controlboard by removing its 4 screws.BOnce open, locate JP3 on the printed circuit board(see Fig. 26). The board is supplied with a jumperplaced on one JP3 pin, this means that one of thejumper sockets is connected to a JP3 pin and theother socket of the jumper is in the air. To make thehigh altitude adjustment complete, the jumper mustbe connected to both pins.BRemove the jumper from the JP3 pin (see Fig. 26).BLine up the two jumper sockets with the two JP3pins.BInsert the jumper.BReplace the front cover to the control board and re-insert into heater and then proceed with previoussteps in reverse order. Be sure that the rubbergrommets of the electrical strip connectors are inplace and the 2 yellow igniter wires get re-connected.Fig. 26 Control board adjustment for high altitudes(above 4000 ft)2.13 Water connections When facing the heater, the ¾” cold water inlet is on thebottom right and the hot water outlet is on the bottomleft. Install the heater centrally in the building if possibleand make hot water piping runs as short as possible.Fig. 27BThe use of a union when connecting both waterpipes to the inlet and outlet connections isrecommended, this will facilitate any necessaryservicing and required cleaning of the inlet waterparticle screen.Although water piping throughout the building may beother than copper, we recommend that copper,galvanized or suitably rated stainless steel flex linepiping be used for the water heater connections (followlocal codes if more stringent). Plastics or other PEXtype plumbing line materials are not suitable forconnecting directly to the water heater. Keep water inletand outlet pipes to no less than ¾” (19.05mm) diameterto allow the full flow capacity.If the cold and hot connections to the heater areOnce auxiliary cover isoff, pull off the twoelectrical strip connec-tors inside the board.Once off, the wiringstrands can be removedfrom the area of theboard by pulling theirrubber grommetsoutward.Rubbergrommets iFor altitudes greater than 8000 ft (2438 m),a special adjustment and CO2measurement needs to be done. Pleasecontact CEC for detailed instructions.High altitude adjustment(above 4 000 ft)HOT COLDINLET FILTER SCREEN

6 720 607 072 (16 January)Appliance details19reversed, the heater will not function. Be certain thereare no loose particles or dirt in the piping. Blow out orflush the lines before connecting to the water heater.Full port valves should be installed on both the coldwater supply and hot water outlet lines to facilitateservicing the heater (see Fig. 28). For installation on aprivate well system with the use of a pressure tank, thelowest pressure range setting recommended is 30-50psi (2.07 and 3.45bar).Connecting the pressure relief valve (PRV)A listed pressure relief valve supplied with the heatermust be installed at the time of installation. No valve isto be placed between the PRV and the heater. Noreducing coupling or other restriction may be installedin the discharge line. The discharge line must be aminimum of 4” above a drain and installed such that itallows complete drainage of both the PRV and the line.The location of the PRV must be readily accessible forservicing or replacement, and be mounted as close tothe water heater as possible. See Fig. 28. To install thePRV, a suitable fitting connected to an extension on a“T” fitting can be sweated to the hot water line.Support all piping.Fig. 28 Plumbing Connections and Pressure ReliefValve

6 720 607 072 (16 January)20Appliance details2.14 Electrical connectionsThe GWH-635-ES requires an electrical power supplyfrom a 120VAC 60Hz circuit and must be properlygrounded.A means for switching off the 120VAC power supplymust be provided.The heater is wired as shown in the wiring diagram(chapter 6, Fig. 39).2.15 Operating instructionsBBefore proceeding with the operation of the heatermake sure that the system is filled with water.BTurn off power supply to heater.BOpen the cold water inlet supply to the heater fully.BOpen a hot water faucet to permit the water to fill theheater and the piping and to eliminate the air trappedin the system.BClose the hot water faucet after the water flows freelyand all the air has escaped from the system. Turn onpower supply to heater. The water heater is nowready to operate.2.16 For your safety read beforeoperating your water heaterA. This appliance is equipped with electronic ignition forlighting the main burners. When turning the heater on,follow these instructions exactly.B. Before operating the unit, set the On/Off switch tothe On ( I ) position.WHAT TO DO IF YOU SMELL GASBDo not try to light any appliance.BDo not touch any electric switch; do not use anyphone in your building.BImmediately call your gas supplier from a neighborsphone. Follow the gas supplier’s instructions.BIf you cannot reach your gas supplier, call the firedepartment.C. Use only your hand to turn the on/off control switch.Never use tools. Follow these instructions exactly. Ifcontrol switch is jammed, close the gas supply and calla qualified service technician. Attempted forceful repairmay result in a fire or explosion.D. Do not use this appliance if any part has been underwater. Immediately call a qualified service technician toinspect the appliance and to replace any part of thecontrol system and any gas control which has beenunder water.2.17 Lighting and operating instructionsB1. STOP! Read the previous safety information.B2. The gas valve must be shut off by putting the ON/OFF switch to position (0). Wait five (5) minutes toclear out any gas. If you smell gas, STOP! Follow “B”in the safety information above. If you do not smellgas, go to the next step.B3. This appliance is equipped with electronic ignitionfor lighting the main burners. When turning theheater on, follow these instructions exactly.B4. Set the ON/OFF switch to the (I) position. In thisposition, the water heater is ready to use.B5. Open a hot water tap.B6. The burners will remain on until the hot water tapis turned off.Warning: For safety reasons,disconnect the power supply to theheater before any service or testing isperformed.Warning: This heater must beelectrically grounded in accordancewith the most recent edition of theNational Electrical Code. NFPA 70. InCanada, all electrical wiring to theheater should be in accordance withlocal codes and the Canadian ElectricalCode, CSA C22.1 Part 1. Do not relyon the gas or water piping to ground themetal parts of the heater.iNOTE: when the heater is turned on itsmotorized water valve will check itsposition at minimum and maximumsettings and rest, this process lasts about10 seconds and the noise of it will stopafterwards. Additionally a defaulttemperature setting of 122 F will appearon the display screen.Warning: If you do not follow theseinstructions exactly, a fire or explosionmay result causing property damage,personal injury or loss of life.

6 720 607 072 (16 January)Appliance details21When the heater is in operation you will hear its powervent fan and burner operating. Upon turning off the hotwater flow the power vent fan will continue to operatefor up to 60 seconds to exhaust all flue gases. Thepower vents fan speed is variable depending on the rateof hot water used and the burner output.TO TURN OFF GAS TO APPLIANCEBTurn off the manual gas shut off on the supply line tothe heater and set the ON/OFF switch to the OFF (0)position. Note: a manual gas shut off valve is notsupplied with the heater.iNOTE: on a first time initialinstallation, existence of air in thegas supply line will cause someignition delay when the hot wateris turned on and result in an error(EA) on the display screen. This isnormal. You must turn off theflow of hot water, reset the unit(Fig. 28, pos. 2), wait for (EA) todisappear, and then re-open thehot water tap again. Repeat thesesteps if the error (EA) repeatsitself until all air has been bledfrom the gas line.

6 720 607 072 (16 January)22Operation instructions3 Operation instructionsFig. 291On/Off switch2Reset button3Program Key4Increasing temperature selector5Decreasing temperature selector6LCD display3.1 PowerOnBTo start the appliance switch the button to position(I).LCD display the default temperature - temperaturefactory setting 122°F (50°C).Fig. 30OffBTo shut down the appliance switch the button toposition (0).3.2 Temperature selectionTo select water temperature outlet:BPress buttons and in order to reachrequested temperature.Fig. 31If the outlet water temperature is set too high, the heatercan produce temperatures that are too hot. Atemperature balance shower valve can automaticallymix in cold water to reduce such hot water temperature.In the event of any temperature instability with the useof a temperature balance shower valve, refer to showervalve manufacturer's instructions for internal adjustmentsetting. Adjustments should be made to the hottestsetting in the shower valve. Additionally the temperaturecontrol of the heater can be lowered to produce a morecomfortable hot water temperature.

6 720 607 072 (16 January)Operation instructions23Setting the water temperatureThe desired temperature of the hot water can beadjusted on the front control panel of the heater.The GWH-635-ES has an electronically controlled gasvalve that modulates the burner input in response toboth varying hot water flow rates and/or changes in anyincoming and outgoing water temperatures.Fig. 32 Flow/temperature chartsHot Water Flow and Temperature with Various Inlet Temperature (lpm/Celsius)0.004.008.0012.0016.0020.0024.0035 40 45 50 55 60 65Hot water temperature (ºC)Hot Water Flow (l/min) Inlet (ºC) 4 Inlet (ºC) 10 Inlet (ºC) 16 Inlet (ºC) 21Hot Water Flow and Temperature with Various Inlet Temperature (gpm/Fahrenheit)0.001.002.003.004.005.006.007.0090 100 110 120 130 140 150Hot water temperature (ºF)Hot Water Flow (GPM) Inlet (ºF) 40 Inlet (ºF) 50 Inlet (ºF) 60 Inlet (ºF) 70

6 720 607 072 (16 January)24Operation instructions3.3 New remote control registrationFig. 33 Remote controlRemote control registrationON/OFF switch in OFF position (Fig. 29, pos. 1).BPress and hold key (Fig. 29, pos. 5) while at thesame time turn the main switch (Fig. 29, pos. 1) to“ON” position (I).LCD shows one number and one rotating digit.The number represents the remote control which is tobe registered, the first remote control will be registeredwith number “0”, the second with number “1” and so on.The rotating digit shows that the electronics isexpecting a registration.BHold remote control in front of the control panel onthe heater and press simultaneously remote controlbuttons and until the temperature indicationis shown on the remote control LCD.BSwitch ON/OFF switch (Fig. 29, pos. 1) to “OFF”position (0) and then back on (I).BPress buttons and in order to reachrequested temperature.New remote control is programmed.3.4 OperationBWhen a hot water tap is opened, main burner ignitesand LCD displays indication .Fig. 34BLCD blinks until selected temperature is reached.3.5 Reset buttonIf the LCD shows the error symbol .See the error code on LCD and consult“Troubleshooting” section.Fig. 35After following instructions indicated in“Troubleshooting” sectionBpress reset button in order to make the applianceready-to-work.Fig. 36 Reset buttonIf the problem persists, contact your installer.3.6 Program buttonProgram button can be used/programmed in theappliance and in the remote control.Programming “Program” functionProgramming actions are similar for both controls(appliance control pad and wireless remote control).BPress “Program” key (Fig. 29, pos. 3) for 3 seconds.Fig. 37 “Program” keyTemperature on LCD starts blinking, showing currentmemorized temperature.iNOTE: up to 8 remote controls can beprogrammed for one single appliance.iEach remote control program button canbe programmed with differenttemperature set points.

6 720 607 072 (16 January)Maintenance and service25BPress buttons and to select temperature tobe memorized.BHold “Program” button for 3 seconds to savetemperature.When LCD stops blinking. Temperature is saved on“Program”.Using “Program” functionIn order to select memorized temperatureBPress “Program” key.LCD shows pre-memorized temperature, which is nowthe hot water selected temperature.3.7 Locked conditionThis condition is only valid for appliances with morethen 1 controller (appliances with remote control).Fig. 38 Locked conditionWhenever LCD shows the temperature settingcannot be adjusted because the appliance is in use bya user which already selected a different temperature.Appliance will be automatically unlocked after closinghot water tap.4 Maintenance and serviceThe unit should be checked once a year by a gastechnician. If repairs are needed, the repairs should bedone by a gas technicianTo remove front coverBRemove plastic decals on front panel.BUndo two Philips head screws located behinddecals.BLift front cover panel upward and remove.Systems and parts that should be checked atleast once a yearReference diagrams on pages 30 and 31.• Venting system• Burners -see page 30 for observation window• Manual operation of the pressure relief valve to insurecorrect operation• Periodic cleaning of the water filter screen, see Fig.27, chapter 2.13.• Flushing the heat exchanger with a descalingsolution if mineral build up is evident. Scale build upwill shorten the life of the water heater, descale heatexchanger thoroughly and repeat annually dependingon mineral content of ground water.5 TroubleshootingIntroductionThe GWH-635-ES burner is activated by a water flowvalve. Numerous water related problems can cause thiswater valve to malfunction such as: Insufficient waterflow volume to activate the burners at its minimum flowrequirement; Dirt in the water flow valve causing it tomalfunction; Sediment build-up in faucet aerators, orshower heads; Uneven pressures between cold and hot(with single lever mix valves); and Plumbing crossovers.These water flow related problems can cause theheater to deliver less than its full output, or to fail toignite or to shut down completely.Problems stated below in upper case and in bold faceshould be investigated when there is a problem with theperformance of the water heater but there is NO errorcode on the heater's LCD display or wireless remotecontrol.Any failures that result in a displayed error code arereferenced on page 27. A Functional Scheme of theGWH-635-ES is detailed on page29. If there is aproblem with the installation, venting or operation of theunit, the heater will communicate the source by theseerror codes.BURNERS DO NOT IGNITE WHEN HOT WATER ISTURNED ON•Cold incoming water connection made towrong side of heaterMake sure cold water inlet connection is plumbed tothe right side of heater when facing unit•Water flow rate at hot water tap is too lowA minimum of 0.8 gallon/minute (3 l/m) is required toactivate the heater•Cold water inlet filter screen is dirtyRemove water inlet filter screen and clean. Thescreen is located at the inlet connection to the waterheater, disconnecting the main cold supply line at theheater is required. Check and clean faucet aeratorscreens too.•Crossover in plumbingThe heater activates when there is sufficient waterflow through its water valve, a minimum of 0.8 gallon/minute (3 l/m) is required. If there is a crossover in theplumbing, the necessary hot water flow rate throughthe unit may not be reached, even though the flow atthe hot water tap is sufficient. A plumbing crossovercan be caused by a failed washer at a single leverfaucet, incorrect plumbing or a faulty mixing valve inthe piping. The crossover will create a back pressureWarning: Always turn off the electricalpower supply, turn off the manual gasvalve and turn off the manual watercontrol valves whenever servicing.

6 720 607 072 (16 January)Troubleshooting27Display Cause SolutionE9 Temperature limiter opened circuit (overheat).Check connections.*EA No ionization during safety time (safety time out).Check gas pressure.Check that gas is not diluted with air, as aresult from recent gas pipeline rework.*.Check if vent terminal is blocked (speciallywhen the appliance starts up for someseconds and then looses ionization signal).Check ionization electrode.*Check for a proper ground.*FA Leakage error (gas valves do not close gas circuit)Check gas valve and electronic controller.*F7 Ionization error (flame sensing at stand-by)Check electronic controller.*E0 Internal software/hardware failure. Check electronic controller.*A7 Hot water temperature sensor/receiver defect (from main controller)Check water temperature sensor/receiver and connections.*A9 Hot water temperature sensor/receiver mis-assembled (from main controller)Check that the water temperature sensor/receiver is properly assembled in the water pipe.*E1 Over-temperature detected (from main controller)Check heat exchanger sealings.*Check heat exchanger and flue gas collector.*Check over temperature fuse.*C1 FAN rotation too low at start-up (from main controller)Check supply voltage.*Check fan and connections.*Check electronic controller.*C6 FAN rotation too low at operation (from main controller)Check supply voltage.*Check fan and connections.*Check electronic controller.*C7 No rotational speed sensor signal from FANCheck fan and connections.*Check electronic controller.*CA Water flow signal over specifiedmaximum valueCheck water valve and flow sensor.E2 Inlet temperature sensor fault Check water temperature sensor/receiver and connections.*Table 5* By installer or service technician only.

6 720 607 072 (16 January)28Electrical diagram6 Electrical diagramFig. 39 Electrical scheme1Intlet water temperature sensor2Ionization sensor3Water flow sensor4Over heat protection5Temperature limiter6Gas valve7Fan8Water valve9AC Plug10 Ignition electrode11 Display PCB12 ON/OFF switch13 Fuse T 1,25A14 Fuse T 3,15A15 Terminal block16 Ground post17 Outlet water temperature sensor

6 720 607 072 (16 January)GWH-635-ES Functional scheme297 GWH-635-ES Functional schemeFig. 40 Functional scheme

6 720 607 072 (16 January)30Interior components diagram and parts list8 Interior components diagram and parts list8.1 Interior componentsFig. 41 Components1Cover2On/Off switch3Reset button4LCD display5Program button6Temperature switches7Flue gas collector8Mixer9Heat exchanger10 Observation window11 Inlet air duct12 Control box13 Exhaust fan14 Water valve15 Gas valveFig. 42 Appliance overview

6 720 607 072 (16 January)Interior components diagram and parts list318.2 Components diagramFig. 43 Components Diagram

6 720 607 072 (16 January)32Interior components diagram and parts list8.3 Parts listItem Description Reference1 Front cover 8 705 421 8372 Shield 8 705 506 6613 Heat exchanger 8 705 406 2854 Heat exchanger top gasket 8 704 701 0525 Clip 8 716 102 6076 Heat exchanger bottom gasket 8 704 701 0547 O-ring 8 700 205 1478 Temperature sensor 8 700 400 0159 Washer 1/2" 8 710 103 04510 Wireform spring 8 714 606 00211 Air inlet duct 8 705 700 09712 Water filter 8 700 507 00113 O-ring 8 700 205 13414 Water valve with engine 8 708 505 01615 Main burner 8 708 120 51516 Fan / Burner gasket 8 704 701 05017 Set of electrodes 8 708 107 02018 Exhaust Fan 8 707 204 03919 Gas / Air Mixer 8 705 700 11520 Mixer / Fan gasket 8 704 701 05921 Gas valve washer 8 704 701 06222 Gas valve 8 707 021 01923 Gas valve washer 8 700 103 01424 Remote control 8 707 207 15325 Control unit 8 707 207 13326 Ignition cable 8 704 401 22027 Cables / 24V 8 704 401 21428 Cables 8 704 401 23929 Power supply cord 8 704 401 22130 Overheat cutoff fuse 8 700 400 01931 Flue gas exhaust accessory 8 705 504 11432 Combustion air inlet accessory 8 705 504 11533 Flue gas collector 8 705 700 10034 Flue gas collector collar 8 705 700 11435 Cold water pipe 8 700 715 15636 Hot water pipe 8 700 715 15537 Air inlet screen 8 700 507 06938 Crossover tube 8 700 715 24739 Overheat sensor (ECO) 8 707 206 204Table 6

6 720 607 072 (16 January)Special adjustment for measuring and adjusting CO2 levels339 Special adjustment for measuring and adjusting CO2 levelsThe CO2 can only be adjusted by a certified gastechnician with a calibrated CO2 analyzer.9.1 Adjusting the unitFactory settings of this appliance are listed in table 7.Further adjustment is only needed if optimal CO2 levelis required in order to assure the minimum possibleCO2 emissions. In this case a CO2 analyzer is required.9.1.1 CO2 measuring portBLoosen screw 1 (Fig. 44).BInsert CO2 analyzer into measuring port (Fig. 44,pos. 1).Fig. 441Measuring point9.1.2 Selecting adjustment modeBON/OFF switch in position OFF (0).CO2 adjustment at minimum gas flow (P1) - Seetable 7.BPress “Program” key and turn ON/OFF switch toposition ON.Fig. 45LCD shows “P1” and the appliance is ready to beadjusted.BOpen hot water tap.The appliance will run constantly at minimum poweroutput and minimum water flow. This program step canalso be used to measure minimum output and minimumwater flow.BTurn the screw in order to regulate the air-gas mixtureinside the ventilator until the CO2 level required isreached (Fig. 46, pos. 3).CO2 adjustment at maximum gas flow (P2) - Seetable 7.BPress , until “P2” appears.BOpen water tap.The appliance will run constantly at maximum poweroutput and maximum water flow. This program step canalso be used to measure maximum output and maximumwater flow.BTurn the screw in order to regulate the air-gas mixtureinside the ventilator until the CO2 level required isreached (Fig. 46, pos. 3).Caution: Converting the gas type canonly be done by a certified gastechnician with a calibrated CO2analyzer. Call CEC for conversioninstructions.Caution: Adjustments must only becarried out by authorized servicepersonnel only.Caution: The appliance should alwaysbe disconnected from the power supplybefore any maintenance is carried out.Factory settingField settings acceptable rangeNat. Gas Nat. Gasmin. input P1 9.00 % 7.65 % to 10.35 %min. input P2 9.00 % 8.1 % to 9.9 %LP Gas LP Gasmin. input P1 10.80 % 9.18 % to 12.42 %min. input P2 10.80 % 9.72 % to 11.88 %* Final reading must be confirmed with the front coveron, CO2 levels increase when the cover is installed.Table 7

6 720 607 072 (16 January)34Special adjustment for measuring and adjusting CO2 levelsFig. 46 AdjustingLeave “Program” modeBTurn ON/OFF switch in position OFF and then ONagain.iNOTE: turning screw clockwisedecreases CO2 level, turningcounterclockwise increases it.Caution: Faulty ignition or noisyoperation may occur if CO2 levels areadjusted outside the indicated range.

6 720 607 072 (16 January)Protecting the environment3510 Protecting the environment PackingThe packing box may be fully recycled as confirmed bythe recycling symbol .ComponentsMany parts in the heater can be fully recycled in the endof the product life. Contact your city authorities forinformation about the disposal of recyclable products.Saving water resources:BMake sure you close all the taps after any use. Avoidleaving the taps dripping. Repair any leaking tap.BWhenever possible use taps with built-in water flowlimiters. They will give you the same comfort levelwhile saving water.BDefine the temperature you want, in the appliance orwith the remote control. This way you have theprecise water flow needed (mixing cold water toregulate temperature will increase the water flow withconsequent waste of water).For increased safety shut off the appliance fromthe main water supply if your are staying awayfrom home for a considerable time.At below freezing temperatures, disconnect theplumbing connections to the heater and allowthe heater to drain.To prevent any freeze damage, introduce shortbursts of compressed air (20-40 psi) throughthese connections to remove the residual waterin the horizontal pipes and water valve.

6 720 607 072 (16 January)36Fifteen Year Limited Warranty11 Fifteen Year Limited WarrantyGeneralBOSCH PRO water heaters are warranted by theManufacturer (BOSCH) through Controlled EnergyCorp. Controlled Energy Corp. (CEC) will furnish areplacement heat exchanger and will furnish areplacement of any other part which fails in normal useand service within the applicable periods specifiedbelow, in accordance with the terms of this warranty.The CEC replacement will be warranted for theunexpired portion of the original warranty. This warrantywill be valid only for water heaters in possession of theoriginal purchaser as recorded on the warranty card.The Heat ExchangerIf the heat exchanger fails within fifteen (15) years afterthe original installation and operation, CEC will furnisha replacement heat exchanger. However, if the waterheater is installed in other than a single family dwelling,this heat exchanger warranty is limited to two (2) yearsfrom date of original installation and operation.ExceptionsThis warranty will not apply:•1. to defects or malfunctions resulting from failure toproperly install, operate or maintain the unit inaccordance with the printed instructions provided;•2. to damage or abuse, accident, neglect or freezingand other acts of nature;•3. to damage resulting from operation with either theflame sensor rod or overheat sensor removed;•4. to failure of the heat exchanger resulting from theoperation of the water heater in a corrosiveatmosphere or at water temperatures exceeding themaximum rating, or if the water heater is not suppliedwith potable water;•5. to defects or damage cause by any attachmentor modification, including any energy-saving device.All Other PartsIf any other part fails within two (2) years after originalinstallation and operation, CEC will furnish areplacement part free of charge.Extended warranty is available to PHCC membercontractors; however, all replacements are madesubject to validation by CEC of in-warranty coverage.Shipping costsIn addition to supplying the replacement part(s), CECwill provide ground service delivery for these parts.Expedited or upgraded shipping will be charged to thecustomer.Service Labor CostsThis warranty does not cover any labor costsassociated with service, removal or re-installation ofpart(s). All such costs must be borne by the Purchaser.Additionally, this warranty does not cover any laborcosts associated with service, removal or re-installationof the original water heater or a replaced water heater.Certain service labor allowances are available to PHCCmember contractors, dependent on prior authorizationby CEC.How to Make a ClaimAny claim for warranty parts should be made to yourlocal dealer, distributor or to CEC. If CEC, pleasecontact the Technical Support Department:Controlled Energy Corp.340 Mad River ParkWaitsfield, VT 05673Phone: 866-330-2730www.protankless.comIn most cases, the dealer or distributor will be able topromptly honor your claim and subsequently notifyCEC. However, all replacements are made subject tovalidation by CEC of in-warranty coverage. Thedamaged or defective item must be made available inexchange for the replacement.MiscellaneousNo one is authorized to make any other warranties onbehalf of CEC. It is expressly understood that thereplacement warranty of CEC shall be in lieu of any andall other warranties, express or implied, includingwarranties of merchantability or fitness for a particularuse or purpose, and further that CEC shall not be liablefor any loss or damage directly or indirectly arising fromthe use of the hot water heater, or for any consequentialdamages arising from such use (including damagesfrom water leakage). CEC’s sole liability with respect toany defect shall be for the replacement of the defectivepart(s). Some states do not allow such limitations andexclusions, so the above may not apply to you.This warranty gives specific legal rights. You may alsohave other rights which vary from state to state.iNOTE: the water heater must be free ofdamaging scale deposits and not subjectto gas pressures greater than thoseshown on the rating plate, which must notbe altered, defaced or removed.

6 720 607 072 (16 January)Fifteen Year Limited Warranty37

Replacement Parts available from North American DistributorCONTROLLED ENERGY CORP.340 Mad River ParkWaitsfield, Vermont 05673Phone 866-330-2730Fax (802) 496-6924www.protankless.comtechsupport@protankless.comVULCANO Termodomésticos S.A.Estrada de Cacia3801 - 856 Aveiro - PORTUGALRecycled paper © 2004 Controlled Energy Corporation, Waitsfield, VT all rights reserved

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