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

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Water heaters for use with Natural and L.P.G.
GWH-635-ES
Temperature Modulated with Electronic Ignition
Suitable for heating potable water only - Not approved for space heating purposes
(Intended for variable flow applications with multiple tapping points)
PRO TANKLESS
GWH-635-ES-N
GWH-635-ES-L
6 720 607 072 (16 January) JS
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
Warning
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.9.1
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
Appliance details
Features
GWH-635-ES Specifications (Technical data)
Dimensions and Minimum installation clearances
General rules to follow for safe operation
Proper location for installing your heater
Clearances
Mounting installation
Combustion air requirements
Venting
Venting options
Gas piping & connections
Gas line sizing
Measuring gas pressure
Water connections
Electrical connections
Operating instructions
For your safety read before operating your water heater
Lighting and operating instructions
12
15
17
17
18
20
20
20
20
3.1
3.2
3.3
3.4
3.5
3.6
3.7
Operation instructions
Power
Temperature selection
New remote control registration
Operation
Reset button
Program button
Locked condition
22
22
22
24
24
24
24
25
Maintenance and service
25
Troubleshooting
25
Electrical diagram
28
GWH-635-ES Functional scheme
29
8.1
8.2
8.3
Interior components diagram and parts list
Interior components
Components diagram
Parts list
9.1
9.1.1
9.1.2
Special adjustment for measuring and adjusting CO2
levels
33
Adjusting the unit
33
33
CO2 measuring port
Selecting adjustment mode
33
10
Protecting the environment
35
11
Fifteen Year Limited Warranty
36
30
30
31
32
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.
6 720 607 072 (16 January)
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.
Fig. 1
• 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. 2
6 720 607 072 (16 January)
Appliance details
Appliance details
2.1
Features
Maximum input
175,000 Btu/h (51.2 kW)
Parts
• Touch Pad interface control
Efficiency in %
• High power pre-mix compact burner with low Nox
emissions
Recovery efficiency 86.5%
• Modulating Gas Valve with constant gas:air ratio
control
Min. Output
31,131 Btu/h (9.1 kW)
• Modulating water valve for improved comfort and
temperature control.
Temperature Control
Safety
Default temperature: 122°F (50°C)
• Flame sensor (ionization) rod
Stability: +/- 2°F (+/- 1°C)
• Overheat sensor
Gas Requirement
• Temperature limiter
Gas connection (inches) - ¾”
• Fan speed monitoring.
Inlet gas pressure under operation (with a high hot
water flow rate)*
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 a
supplied bracket.
• Easily removable one-piece cover.
Features
• LCD Display
• On/Off and Temperature control switches
Selection range: 100°F (38°C) - 140°F (60°C)
• Propane: 11” - 14” water column
• Natural Gas: 5” - 14” water column
• Gas pressure measuring point inside the appliance
at the gas valve inlet.
* Testing with a manometer, operate other gas
equipment on the same gas supply. 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. See Measuring Gas Pressure,
chapter 2.12.
• 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.
BOSCH is constantly improving its
products, therefore specifications are
subject to change without prior notice.
Fig. 3
Gas pressure measuring point
Venting
2.2
GWH-635-ES Specifications
(Technical data)
See chapter 2.9 for Venting on page 9.
Water
Approved in US/Canada
• Hot water connection (inches) - ¾”
Capacity
• Cold water connection (inches) - ¾”
Maximum flow rate: 6.35 GPM (24 l/min) at a 45°F
(25°C) rise.
• Water valve material: Polymer (PPS) (Polypropylene
Sulfid)
Maximum output
• Minimum water flow: 0.8 gallon/minute (3 l/m)
142,968 Btu/h (41.8 kW)
6 720 607 072 (16 January)
Appliance details
• Minimum recommended water pressure range: 30
PSI (2.07 bar)
UNPACKING THE GWH-635-ES HEATER
• Connections:
– Bottom of heater
The box includes:
Combustion
• Bracket for wall hanging the heater
• NOx ≤ 55 ppm
• Exhaust vent adaptor (with 4 screws and gasket
provided)
• 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 types
Natural Gas.
LP Gas.
Converting the gas type can only be done by a certified
gas technician with a calibrated CO2 analyzer. Call
CEC for conversion instructions.
This heater is packed securely.
• Pressure relief valve
• Combustion air inlet adaptor (with 3 screws and
gasket provided)
• Installation manual
• Product registration card.
Do not lose this manual. Please complete and return
the enclosed product registration card.
Before installing the unit, be certain you have the
correct heater for your type of Gas - Propane or
Natural Gas. Identification labels are found on the
shipping box, and on the rating plate which is located on
the right side panel of the cover.
To remove front cover
• Remove plastic decals on front panel
Voltage
• Undo two Philips head screws located behind decals
120 V AC (60 Hz)
• Lift front cover panel upward and remove.
Amperage
IDLE - 40 mA
Operation - ≤ 2,5 A
Noise
Plastic decals
≤ 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)
Fig. 4
6 720 607 072 (16 January)
Remove front cover
Appliance details
2.3
Dimensions and Minimum installation clearances
Fig. 5
Dimensions
Cover
On/Off switch
Reset button
LCD display
Program button
Temperature buttons
Fig. 6
Minimum clearances
Model GWH-635-ES
TOP (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 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 must be isolated from the gas
supply piping system by closing its individual manual
gas shutoff valve (not supplied with heater) during
any pressure testing at pressures in excess of ½ Psig
(3.5 kPa).
The appliance and its gas connection must be leak
tested before placing the appliance in operation.
B 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
6 720 607 072 (16 January)
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.
Appliance details
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. 6.
A. Top 12 inches (306 mm)
B. Front 4 inches (102 mm)
C. 0 inches
D. Sides 4 inches (102 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
Fig. 7
Mounting the heater
B ensure that gas pipe, gas valve, mixer,
fan and burner have no damage and are
properly fitted.
2.8
Combustion air requirements
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. 7.
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. 7.
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.
The GWH-635-ES is a sealed water heater and it is
recommended that outdoor combustion air be piped to
the unit. When combustion air is piped to the unit
(TWIN PIPE SYSTEM) the combustion air pipe system
may be constructed of either 3" PVC, aluminum or
galvanized pipe. See Fig. 11, 12 and 13. Select a point
for building penetration being sure that the necessary
clearance on the outside of the building, between the
combustion air pipe and the exhaust vent terminator of
the appliance, can be maintained, see Fig. 16. NOTE:
Observe all local building codes when penetrating a
building wall.
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 8250 cubic feet (233.6
cubic meter) for the GWH-635-ES alone.
– b) In unconfined spaces in buildings of
conventional
frame,
masonry,
or
metal
construction, infiltration air is normally adequate to
provide air for combustion.
6 720 607 072 (16 January)
Appliance details
• 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. If the
effective free area is not known, increase the sizes of
your openings by 75% if your louvers are wood and by
30% if your louvers are metal. Refer to the National Fuel
Gas Code for complete information. In buildings of tight
construction all air should be taken from outside.
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 outside with a sealed 3" stainless steel
vent pipe (AL29-4C). The appliance's flue gasses
are under positive pressure and must travel
through a stainless steel 3" pipe that is sealed
gas tight. 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.
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. CEC
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 2.
6 720 607 072 (16 January)
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)
3 inch
stainless
steel
(AL29-4C)
sealed vent
pipe
26 feet (8
m) with one
elbow. Less
2½ feet for
each
additional
elbow
1½ 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
specifications
Open
combustion
(single
pipe)
3 inch
stainless
steel
(AL29-4C)
sealed vent
pipe
26 feet (8
m) with one
elbow. Less
2½ feet for
each
additional
elbow
1½ feet
See
chapter 2.8
See
chapter 2.8
** 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.
* 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 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.
Never reduce pipe diameter.
Table 2
10
6 720 607 072 (16 January)
Appliance details
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 90degree elbow used (a maximum of three 90-degree
elbows are permitted in the total vent length). Horizontal
sections of vent must pitch ¼" for every foot of
horizontal length and be supported at 4 foot intervals
with overhead hangers. Any vent section greater than
45 degrees is considered an elbow.
Note: The stainless steel exhaust vent pipe should not
be used in concealed or unheated locations. 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.
Note: reduce 2½ ft for each elbow used after the first
one
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 25. 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
Minimum exhaust vent size and length
Fig. 10
Fig. 8
Maximum vent lengths
Fig. 11
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).
Fig. 9
6 720 607 072 (16 January)
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.
11
Appliance details
2.9.1
Venting options
Installing this water heater as a room sealed (TWIN
PIPE SYSTEM) is the recommended method. Contact
CEC or dealer for available vent termination kits and
vent materials for this water heater.
Exhaust venting shall be done with 3”
stainless steel (AL29-4C) vent pipe.
Room sealed installation (TWIN PIPE SYSTEM)
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 elbow after the first elbow you
must reduce 2½ feet from the total vent
length.
Open combustion installation (SINGLE PIPE
SYSTEM)
Fig. 14
Fig. 12
Exhaust vent pipe: ≤ 26 ft (8 m)
Combustion air pipe: ≤ 26 ft (8 m)
Exhaust vent pipe: ≤ 26 ft (8 m)
Fig. 15
Exhaust vent pipe: A+B+C ≤ 23½ ft (7.2 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 elbow used after the first
one.
12
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 recommended, 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.
6 720 607 072 (16 January)
Appliance details
Recommended exhaust vent terminator position
Fig. 16
Ref.
Description
Minimum distance
Directly below an opening; operable windows, doors and any nonmechanical fresh air openings
36 in
Below a gutter, sanitary pipework or eaves
24 in
Below a gutter, sanitary pipework or eaves, protected by metal
shielding
12 in
From any internal corner
12 in
Above ground
12 in
D*
Above a paved sidewalk or driveway
From an opposing wall or structure facing the termination
7 ft
24 in
From any other building opening, gas utility meter, service regulator
or the like
7 ft
From a terminator facing a terminator
48 in
Vertically between two exhaust vent terminators on the same wall
60 in
Horizontally between two exhaust vent terminators on the same wall
12 in
Horizontally from combustion air inlet of 635-ES
I**
36 in
Vertically above combustion air inlet of 635-ES
From the combustion air inlet of any appliance or below the
combustion air inlet of 635-ES
3 ft
From any external corner
12 in
Horizontally from an opening; operable windows, doors and any
non-mechanical fresh air openings
12 in
Vertically from a wall, roof slope, or obstruction (venting through a
flat or pitched roof)
see ABOVE THE ROOF
requirements on following page
Table 3
* 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
6 720 607 072 (16 January)
13
Appliance details
Supporting the exhaust vent system and the use
of an external condensate trap
External condensate traps
B A condensate trap must be used in any sidewall
exhaust vent installations when the total vent length
is ≥ 8 ft (2.5 m) OR the vent pipe passes through an
unheated space (below 60F).
B A condensate trap must be used for any vertical
exhaust vent installations ≥ 2 ft.
B When installing the condensate tube at the bottom of
the drain tee, be sure to form a trap by means of a 3"
(76.2 mm) loop filled with water. This tube must be
3/8" ID high temperature silicone for at least the first
6 inches (152 mm) and attached with a gear clamp
or hose clamp. The condensate must be disposed of
according to local regulations.
Fig. 18 Above the roof clearance requirements from
rain cap (combustion air piping not being
shown)
The venting materials and accessories
required to properly install the water
heater are available from CEC and their
distributors.
Fig. 17 Horizontal side wall venting installation
(combustion air piping not being shown)
Fig. 19 Vertical venting installation (combustion air
piping not being shown)
14
6 720 607 072 (16 January)
Appliance details
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
Applicable Plumbing 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;
we recommend the use of non-corrugated flexible gas
line when used. Consult the gas sizing specification
tables provided by the flexible gas line manufacturer.
Fig. 20 Vertical venting installation - Masonry
Chimney (combustion air piping not being
shown)
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
line connector if one must be used.
6 720 607 072 (16 January)
15
Appliance details
FOR NATURAL GAS
Pressure drop of 0.3 in Water Column
(0.75mbar).(Based on a 0.60 Specific Gravity Gas) Btu
numbers given in thousands.
Maximum Capacity of pipe in Cubic Feet of Gas per
Hour for Gas Pressure of 0.5 Psig or less and a
Follow boxed numbers for piping just one GWH635-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
Length of Black Iron Pipe, Feet
Pipe
Internal
Size,
Diameter
inches inches
10
20
30
40
50
60
70
80
90
100
125
150
175
200
32
22
18
15
14
12
11
11
10
1/4
0.364
3/8
0.493
72
49
40
34
30
27
25
23
22
21
18
17
15
14
1/2
0.622
132
92
73
63
56
50
46
43
40
38
34
31
28
26
3/4
0.824
278
190
152
130
115
105
96
90
84
79
72
64
59
55
1.049
520
350
285
245
215
195
180
170
160
150
130
120
110
100
1 1/4
1.380
1050
730
590
500
440
400
370
350
320
305
275
250
225
210
760
670
610
560
530
490
460
410
380
350
320
1270 1150 1050
990
930
870
780
710
650
610
980
1 1/2
1.610
1600
1100
890
2.067
3050
2100
1650 1450
2 1/2
2.469
4800
3300
2700 2300
2000 1850 1700 1600 1500 1400 1250
1130 1050
3.068
8500
5900
4700 4100
3600 3250 3000 2800 2600 2500 2200
2000 1850 1700
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
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).
Nominal
Black Iron Pipe
Iron Pipe
Length of Pipe, Feet
Size,
10
Inches
20
30
40
of Undiluted Liquefied Petroleum Gases (at 11
60
70
80
90
96
89
100
150
275 189 152
129 114 103
83
78
69
63
3/4
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
622 433 346
299 264 239 220 204 192 1811 1606 1496
Copper
Length of Tubing, Feet
Outside
Diameter,
Inch
10
20
30
40
50
60
70
80
90 100
inches Water Column Inlet Pressure).
3/8
39
26
21
19
(Based on a Pressure Drop of 0.5 Inch Water
Column)
1/2
92
62
50
41
37
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
7/8
501 346
277 233
198
187 164 155 146 138
* Source National Fuel Gas Code NFPA 54, ANSI
Z223.1 - No Additional Allowance is necessary for an
ordinary number of fittings
125
1/2
Maximum Capacity of Semi-Rigid (flexible, non
corrugated) Tubing in Thousands of BTU per Hour
50
Fig. 22
16
6 720 607 072 (16 January)
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.
THESE FIGURES ARE FOR GWH-635ES 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.
load. Using a manometer, then measure the inlet gas
pressure at the inlet gas pressure test port. See Fig. 23.
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. See Gas Connections,
chapter 2.10.
Fig. 23 Gas pressure measuring (left tapping)
HIGH ALTITUDE OPERATION
Due to the lower density of air at high altitudes, output
must be reduced in installations above 4000 ft (1219
m).
Altitude
Natural Gas:
Liquid
Propane:
0 - 4,000 ft
(0 - 1,219 m)
no
modification
no modification
4,000 ft - 8,000 ft
(1,219 m - 2,438 m)
insert jumper
JP3
insert jumper
JP3
Table 4
Burner output at altitudes greater than 4000 ft (1219
m) will be electronically reduced once the control board
has been properly adjusted. Follow instruction below.
High altitude adjustment
B Disconnect power supply to heater.
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.
B Remove front cover of heater.
B Remove control box auxiliary cover (Fig. 24, pos. 4).
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
To measure and verify if adequate gas pressure is being
delivered to the water heater, first run a high hot water
flow rate and operate other gas equipment on the same
6 720 607 072 (16 January)
Fig. 24
17
Appliance details
B Remove the 5 screws on the front retaining bar (see
Fig. 24, pos. 1 and 2) being careful not to damage
the foam sealant material on it.
B Remove the two electrical strip connectors inside the
board (Fig. 25) and then loosen the 120V power
supply cord retaining nut located underneath the
heater. Once loosened, the power cord can be
pulled up through the heater to provide sufficient
slack.
Rubber
grommets
Once auxiliary cover is
off, pull off the two
electrical strip connectors inside the board.
Once off, the wiring
strands can be removed
from the area of the
board by pulling their
rubber
grommets
outward.
Fig. 25 Electrical strip connectors
B At the ignition electrodes, pull off the 2 yellow igniter
wires that come from the top of the control board
(Fig. 24, pos. 3). Then pull the complete control
board forward and out of the heater, pull up the
power supply cord further if more slack is needed.
High altitude adjustment
(above 4 000 ft)
Fig. 26 Control board adjustment for high altitudes
(above 4000 ft)
For altitudes greater than 8000 ft (2438 m),
a special adjustment and CO2
measurement needs to be done. Please
contact CEC for detailed instructions.
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.
B While holding the board in one hand or resting it on
a flat surface, remove the front cover of the control
board by removing its 4 screws.
INLET FILTER
SCREEN
B Once open, locate JP3 on the printed circuit board
(see Fig. 26). The board is supplied with a jumper
placed on one JP3 pin, this means that one of the
jumper sockets is connected to a JP3 pin and the
other socket of the jumper is in the air. To make the
high altitude adjustment complete, the jumper must
be connected to both pins.
B Remove the jumper from the JP3 pin (see Fig. 26).
B Line up the two jumper sockets with the two JP3
pins.
B Insert the jumper.
B Replace the front cover to the control board and reinsert into heater and then proceed with previous
steps in reverse order. Be sure that the rubber
grommets of the electrical strip connectors are in
place and the 2 yellow igniter wires get reconnected.
18
HOT
COLD
Fig. 27
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
local codes if more stringent). 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
6 720 607 072 (16 January)
Appliance details
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. 28). 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. 28. 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.
Fig. 28 Plumbing Connections and Pressure Relief
Valve
6 720 607 072 (16 January)
19
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. 39).
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.
NOTE: when the heater is turned on its
motorized water valve will check its
position at minimum and maximum
settings and rest, this process lasts about
10 seconds and the noise of it will stop
afterwards.
Additionally
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.
20
6 720 607 072 (16 January)
Appliance details
NOTE: on a first time initial
installation, existence of air in the
gas supply line will cause some
ignition delay when the hot water
is turned on and result in an error
(EA) on the display screen. This is
normal. You must turn off the
flow of hot water, reset the unit
(Fig. 28, pos. 2), wait for (EA) to
disappear, and then re-open the
hot water tap again. Repeat these
steps if the error (EA) repeats
itself 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.
6 720 607 072 (16 January)
21
Operation instructions
Operation instructions
Fig. 29
On/Off switch
Reset button
Program Key
Increasing temperature selector
Decreasing temperature selector
LCD display
3.1
B Press buttons
and
requested temperature.
in order to reach
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).
Fig. 31
If the outlet water temperature is set too high, the heater
can produce temperatures that are too hot. A
temperature balance shower valve can automatically
mix in cold water to reduce such hot water temperature.
In the event of any temperature instability with the use
of a temperature balance shower valve, refer to shower
valve manufacturer's instructions for internal adjustment
setting. Adjustments should be made to the hottest
setting in the shower valve. Additionally the temperature
control of the heater can be lowered to produce a more
comfortable hot water temperature.
Fig. 30
Off
B To shut down the appliance switch the button to
position (0).
3.2
Temperature selection
To select water temperature outlet:
22
6 720 607 072 (16 January)
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
Hot Water Flow (GPM)
6.00
5.00
4.00
3.00
2.00
1.00
0.00
90
100
110
120
130
140
150
Hot water temperature (ºF)
Inlet (ºF) 40
Inlet (ºF) 50
Inlet (ºF) 60
Inlet (ºF) 70
Hot Water Flow and Temperature with Various Inlet Temperature (lpm/Celsius)
Hot Water Flow (l/min)
24.00
20.00
16.00
12.00
8.00
4.00
0.00
35
40
45
50
55
60
65
Hot water temperature (ºC)
Inlet (ºC) 4
Inlet (ºC) 10
Inlet (ºC) 16
Inlet (ºC) 21
Fig. 32 Flow/temperature charts
6 720 607 072 (16 January)
23
Operation instructions
3.3
New remote control registration
Fig. 35
Fig. 33 Remote control
After
following
instructions
“Troubleshooting” section
Remote control registration
ON/OFF switch in OFF position (Fig. 29, pos. 1).
B Press and hold
key (Fig. 29, pos. 5) while at the
same time turn the main switch (Fig. 29, pos. 1) to
“ON” position (I).
indicated
in
B press reset button in order to make the appliance
ready-to-work.
LCD shows one number and one rotating digit.
The number represents the remote control which is to
be registered, the first remote control will be registered
with number “0”, the second with number “1” and so on.
The rotating digit shows that the electronics is
expecting a registration.
B Hold remote control in front of the control panel on
the heater and press simultaneously remote control
buttons
and
until the temperature indication
is shown on the remote control LCD.
Fig. 36 Reset button
If the problem persists, contact your installer.
B Switch ON/OFF switch (Fig. 29, pos. 1) to “OFF”
position (0) and then back on (I).
3.6
B Press buttons
and
requested temperature.
Program button can be used/programmed in the
appliance and in the remote control.
in order to reach
New remote control is programmed.
3.4
NOTE: up to 8 remote controls can be
programmed for one single appliance.
Program button
Each remote control program button can
be
programmed
with
different
temperature set points.
Programming “Program” function
Programming actions are similar for both controls
(appliance control pad and wireless remote control).
Operation
B When a hot water tap is opened, main burner ignites
and LCD displays indication
B Press “Program” key (Fig. 29, pos. 3) for 3 seconds.
Fig. 34
B LCD blinks until selected temperature is reached.
3.5
If the LCD shows the error symbol
See the error code on LCD and
“Troubleshooting” section.
24
Fig. 37 “Program” key
Reset button
Temperature on LCD starts blinking, showing current
memorized temperature.
consult
6 720 607 072 (16 January)
Maintenance and service
B Press buttons
be memorized.
and
to select temperature to
B Hold “Program” button for 3 seconds to save
temperature.
• 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.
When LCD stops blinking. Temperature is saved on
“Program”.
Using “Program” function
In order to select memorized temperature
Introduction
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. 38 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.
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.
B Undo 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 30 and 31.
• Venting system
• Burners -see page 30 for observation window
• Manual operation of the pressure relief valve to insure
correct operation
• Periodic cleaning of the water filter screen, see Fig.
27, chapter 2.13.
6 720 607 072 (16 January)
Troubleshooting
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 27. A Functional Scheme of the
GWH-635-ES is detailed on page 29. 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
25
Troubleshooting
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
• 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 2.02.5 gpm shower heads simultaneously or multiple
sink applications. Greater draws will result in
increased pressure drop and reduced flow at taps.
See flow/temperature chart on page 23.
screen is located at the inlet connection to the water
heater, disconnecting the main cold supply line at the
heater is required. Check and clean faucet aerator
screens too.
HOT WATER TEMPERATURE FLUCTUATES /
UNIT DEACTIVATED
• Unbalanced pressure in water lines
Any restriction caused by the water heater in the hot
water system can result in uneven pressures
between the cold and the hot. In such cases when
mixing cold water at the tap (manually or
automatically through a mix-type shower valve) the
lower hot water pressure may be overpowered by the
higher cold water pressure in the building and cause
the hot water flow rate to fall below the minimum rate
required. A pressure balance valve will help to
resolve this symptom.
• Temperature balance valves
If the outlet water temperature is set too high, the
heater can produce temperatures that are too hot. A
temperature balance shower valve can automatically
mix in cold water to reduce such hot water
temperature. In the event of any temperature
instability with the use of a temperature balance
shower valve, refer to shower valve manufacturer's
instructions for internal adjustment setting.
Adjustments should be made to the hottest setting in
the shower valve. Additionally the temperature
control of the heater can be lowered to produce a
more comfortable hot water temperature.
• Inlet water pressure is erratic due to
fluctuating supply water pressure
For installation on a private well system with the use
of a pressure tank, the lowest pressure range setting
recommended is 30-50 psi (2.07-3.45 bar). The use
of a pressure reducing valve after the pressure tank
is also an effective way to maintain a constant water
pressure to the water heater. Watts brand 25AUB¾” or N35B-¾” pressure relief valves or equivalent
are suggested.
• 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 23.
• Cold water inlet filter screen is dirty
Remove water inlet filter screen and clean. The
26
6 720 607 072 (16 January)
Troubleshooting
Display
Cause
Solution
E9
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 a
result from recent gas pipeline rework.*.
Check if vent terminal is blocked (specially
when the appliance starts up for some
seconds 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 standby)
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
FAN
Check fan and connections.*
Check electronic controller.*
CA
Water flow signal
maximum value
Check water valve and flow sensor.
E2
Inlet temperature sensor fault
over
specified
Check water temperature sensor/receiver and
connections.*
Table 5
* By installer or service technician only.
6 720 607 072 (16 January)
27
Electrical diagram
Electrical diagram
Fig. 39 Electrical scheme
10
11
12
13
14
15
16
17
28
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 1,25A
Fuse T 3,15A
Terminal block
Ground post
Outlet water temperature sensor
6 720 607 072 (16 January)
GWH-635-ES Functional scheme
GWH-635-ES Functional scheme
Fig. 40 Functional scheme
6 720 607 072 (16 January)
29
Interior components diagram and parts list
Interior components diagram and parts list
8.1
Interior components
Fig. 41 Components
10
11
12
13
14
15
Cover
On/Off switch
Reset button
LCD display
Program button
Temperature switches
Flue gas collector
Mixer
Heat exchanger
Observation window
Inlet air duct
Control box
Exhaust fan
Water valve
Gas valve
Fig. 42 Appliance overview
30
6 720 607 072 (16 January)
Interior components diagram and parts list
8.2
Components diagram
Fig. 43 Components Diagram
6 720 607 072 (16 January)
31
Interior components diagram and parts list
8.3
Parts list
Item
Description
Reference
Front cover
8 705 421 837
Shield
8 705 506 661
Heat exchanger
8 705 406 285
Heat exchanger top gasket
8 704 701 052
Clip
8 716 102 607
Heat exchanger bottom gasket
8 704 701 054
O-ring
8 700 205 147
Temperature sensor
8 700 400 015
Washer 1/2"
8 710 103 045
10
Wireform spring
8 714 606 002
11
Air inlet duct
8 705 700 097
12
Water filter
8 700 507 001
13
O-ring
8 700 205 134
14
Water valve with engine
8 708 505 016
15
Main burner
8 708 120 515
16
Fan / Burner gasket
8 704 701 050
17
Set of electrodes
8 708 107 020
18
Exhaust Fan
8 707 204 039
19
Gas / Air Mixer
8 705 700 115
20
Mixer / Fan gasket
8 704 701 059
21
Gas valve washer
8 704 701 062
22
Gas valve
8 707 021 019
23
Gas valve washer
8 700 103 014
24
Remote control
8 707 207 153
25
Control unit
8 707 207 133
26
Ignition cable
8 704 401 220
27
Cables / 24V
8 704 401 214
28
Cables
8 704 401 239
29
Power supply cord
8 704 401 221
30
Overheat cutoff fuse
8 700 400 019
31
Flue gas exhaust accessory
8 705 504 114
32
Combustion air inlet accessory
8 705 504 115
33
Flue gas collector
8 705 700 100
34
Flue gas collector collar
8 705 700 114
35
Cold water pipe
8 700 715 156
36
Hot water pipe
8 700 715 155
37
Air inlet screen
8 700 507 069
38
Crossover tube
8 700 715 247
39
Overheat sensor (ECO)
8 707 206 204
Table 6
32
6 720 607 072 (16 January)
Special adjustment for measuring and adjusting CO2 levels
Special adjustment for measuring and adjusting CO2 levels
The CO2 can only be adjusted by a certified gas
technician with a calibrated CO2 analyzer.
Caution: Converting the gas type can
only be done by a certified gas
technician with a calibrated CO2
analyzer. Call CEC for conversion
instructions.
Caution: Adjustments must only be
carried out by authorized service
personnel only.
Caution: The appliance should always
be disconnected from the power supply
before any maintenance is carried out.
9.1
Adjusting the unit
CO2 adjustment at minimum gas flow (P1) - See
table 7.
Factory
setting
Field settings
acceptable range
Nat. Gas
Nat. Gas
min. input
P1
9.00 %
7.65 % to 10.35 %
min. input
P2
9.00 %
8.1 % to 9.9 %
LP Gas
LP Gas
min. 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 cover
on, CO2 levels increase when the cover is installed.
Table 7
B Press “Program” key and turn ON/OFF switch to
position ON.
Factory settings of this appliance are listed in table 7.
Further adjustment is only needed if optimal CO2 level
is required in order to assure the minimum possible
CO2 emissions. In this case a CO2 analyzer is required.
9.1.1
CO2 measuring port
B Loosen screw 1 (Fig. 44).
B Insert CO2 analyzer into measuring port (Fig. 44,
pos. 1).
Fig. 45
LCD shows “P1” and the appliance is ready to be
adjusted.
B Open hot water tap.
The appliance will run constantly at minimum power
output and minimum water flow. This program step can
also be used to measure minimum output and minimum
water flow.
B Turn the screw in order to regulate the air-gas mixture
inside the ventilator until the CO2 level required is
reached (Fig. 46, pos. 3).
CO2 adjustment at maximum gas flow (P2) - See
table 7.
Fig. 44
B Press
, until “P2” appears.
Measuring point
B Open water tap.
9.1.2
Selecting adjustment mode
B ON/OFF switch in position OFF (0).
The appliance will run constantly at maximum power
output and maximum water flow. This program step can
also be used to measure maximum output and maximum
water flow.
B Turn the screw in order to regulate the air-gas mixture
inside the ventilator until the CO2 level required is
reached (Fig. 46, pos. 3).
6 720 607 072 (16 January)
33
Special adjustment for measuring and adjusting CO2 levels
NOTE:
turning
screw
clockwise
decreases
CO2
level,
turning
counterclockwise increases it.
Caution: Faulty ignition or noisy
operation may occur if CO2 levels are
adjusted outside the indicated range.
Fig. 46 Adjusting
Leave “Program” mode
B Turn ON/OFF switch in position OFF and then ON
again.
34
6 720 607 072 (16 January)
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.
6 720 607 072 (16 January)
35
Fifteen Year Limited Warranty
11
Fifteen Year Limited Warranty
General
BOSCH PRO water heaters are warranted by the
Manufacturer (BOSCH) through Controlled Energy
Corp. Controlled Energy Corp. (CEC) 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 CEC 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.
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 CEC.
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.
The Heat Exchanger
If the heat exchanger fails within fifteen (15) years after
the original installation and operation, CEC 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 two (2) years after original
installation and operation, CEC will furnish a
replacement part free of charge.
Extended warranty is available to PHCC member
contractors; however, all replacements are made
subject to validation by CEC of in-warranty coverage.
Shipping costs
How to Make a Claim
Any claim for warranty parts should be made to your
local dealer, distributor or to CEC. If CEC, please
contact the Technical Support Department:
Controlled Energy Corp.
340 Mad River Park
Waitsfield, VT 05673
Phone: 866-330-2730
www.protankless.com
In most cases, the dealer or distributor will be able to
promptly honor your claim and subsequently notify
CEC. However, all replacements are made subject to
validation by CEC 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 CEC. It is expressly understood that the
replacement warranty of CEC 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 CEC 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). CEC’s 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.
In addition to supplying the replacement part(s), CEC
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
36
6 720 607 072 (16 January)
Fifteen Year Limited Warranty
6 720 607 072 (16 January)
37
Replacement Parts available from North American Distributor
CONTROLLED ENERGY CORP.
340 Mad River Park
Waitsfield, Vermont 05673
VULCANO Termodomésticos S.A.
Phone 866-330-2730
Estrada de Cacia
3801 - 856 Aveiro - PORTUGAL
Fax (802) 496-6924
www.protankless.com
techsupport@protankless.com
Recycled paper
© 2004 Controlled Energy Corporation,
Waitsfield, VT all rights reserved

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