Bosch GWH 635 ES, User Manual

Page 1: ... 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 ...

Page 2: ...e environment 34 11 Fifteen Year Limited Warranty 35 1 Warning 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 If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal inju...

Page 3: ...ause undesired operation Fig 1 Fig 2 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 servic...

Page 4: ...ity Maximum flow rate 6 35 GPM 24 l min at a 45 F 25 C rise Maximum output 142 968 Btu h 41 8 kW Maximum input 175 000 Btu h 51 2 kW Efficiency in Recovery efficiency 86 5 Min Output 31 131 Btu h 9 1 kW Temperature Control Selection range 100 F 38 C 140 F 60 C Default temperature 122 F 50 C Stability 2 F 1 C Gas Requirement Gas connection inches Inlet gas pressure under operation with a high hot w...

Page 5: ...tration card Energy Guide label Do not lose this manual Please complete and return the enclosed product registration card Before installing the unit be certain you have the correct heater for your type of Gas Propane or Natural Gas Identification labels are found on the shipping box and on the rating plate which is located on the right side panel of the cover To remove front cover Loosen the two P...

Page 6: ...installation clearances Fig 4 Dimensions 1 Cover 2 On Off switch 3 Reset button 4 LCD display 5 Program button 6 Temperature buttons Fig 5 Minimum clearances Model GWH 635 ES TOP A 12 FRONT B 1 BACK 0 SIDES 1 FLOOR C 12 VENT DIAMETER 3 Table 1 Minimum clearances ...

Page 7: ...hut off valve on the gas line Note manual gas shutoff valve is not supplied with the heater B 9 Do not use this appliance if any part has been underwater Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been underwater 2 5 Proper location for installing your heater Carefully select the location of t...

Page 8: ...e of Gas Propane or Natural Gas Identification labels are found on the shipping box and on the rating plate which is located on the right side panel of the cover Fig 6 Mounting the heater 2 8 Combustion air requirements The GWH 635 ES is a sealed water heater and it s recommended that outdoor combustion air be supplied to the unit TWIN PIPE SYSTEM The combustion air pipe system may be constructed ...

Page 9: ...ty shops barber shops or other facilities where chemicals that generate corrosive or flammable products such as aerosol sprays are routinely used shall be installed as sealed unit following the TWIN PIPE SYSTEM method of venting 2 9 Venting NOTE This appliance s exhaust must be vented to the outside1 with sealed stainless steel vent pipe AL29 4C the minimum vent length is 3 feet a 90 degree vent e...

Page 10: ...e Vent pipe clearances within an enclosed space Room sealed twin pipe 3 or 4 inch stainless steel AL29 4C sealed vent pipe 26 feet 8 m with one elbow Less 2 feet for each additional 90 elbow 3 feet 3 inch PVC aluminum or galvanized pipe 26 feet 8 m with one elbow Less 2 feet for each additional 90 elbow See vent manufacturer s specifications See vent manufacturer s specifications Open combustion s...

Page 11: ...hten 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 Use of the external condensate drain tube kit supplied with the heater on the exhaust collar B The condensate drain tube kit must be used for all installation types Failure t...

Page 12: ...ig 14 Exhaust vent pipe 26 ft 8 m Fig 15 Exhaust vent pipe A B C 23 ft 7 2 m The exhaust vent system must vent directly to the outside of the building and an adequate amount of indoor combustion air must be provided for this installation See chapter 2 8 Connecting a one piece 90 degree elbow pipe to the combustion air inlet adaptor is necessary this will prevent debris or objects from ever falling...

Page 13: ... From an opposing wall or structure facing the termination 24 in From any other building opening gas utility meter service regulator or the like 36 in F From a terminator facing a terminator 48 in G Vertically between two exhaust vent terminators on the same wall 60 in H Horizontally between two exhaust vent terminators on the same wall 12 in I Horizontally from combustion air inlet of GWH 635 ES ...

Page 14: ...wn B A condensate drain tube must be attached to the exhaust collar of the heater for all vent type applications see page 11 Fig 19 Vertical venting installation combustion air piping not being shown A condensate drain tube must be attached to the exhaust collar of the heater for all vent type applications see page 11 i The venting materials and accessories required to properly install the water h...

Page 15: ...uring 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 groun...

Page 16: ...11 inches Water Column Inlet Pressure Based on a Pressure Drop of 0 5 Inch Water Column Source National Fuel Gas Code NFPA 54 ANSI Z223 1 No Additional Allowance is necessary for an ordinary number of fittings 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 Coppe...

Page 17: ...t all joints Apply some soapy water to all gas fittings Soap bubbles are a sign of a leak 2 12 Measuring gas pressure 2 12 1 Connecting Manometer B Shut off gas B Remove front cover and locate inlet gas pressure measuring point see Fig 24 B Loosen screw inside test point fitting do not remove and connect manometer tube on test point 2 12 2 Static Pressure Test B Turn gas supply back on B Operate a...

Page 18: ...ld water supply and hot water outlet lines to facilitate servicing the heater see Fig 26 For installation on a private well system with the use of a pressure tank the lowest pressure range setting recommended is 30 50 psi 2 07 and 3 45bar Connecting the pressure relief valve PRV A listed pressure relief valve supplied with the heater must be installed at the time of installation No valve is to be ...

Page 19: ... 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 opera...

Page 20: ... 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 i NOTE on a first time initial instal lation or after gas line work has been done existence of air in the gas line will cause ignition delay when the hot water is turned on This will result in an error EA on the units display screen This is normal When this occurs leave the hot ...

Page 21: ...temperature outlet B Press buttons and in order to reach requested temperature Fig 29 If the outlet water temperature is set too high the heater can produce temperatures that are too hot A temperature balance shower valve can automatically mix in cold water to reduce such hot water temperature In the event of any temperature instability with the use of a temperature balance shower valve refer to s...

Page 22: ...perature charts Hot Water Flow and Temperature with Various Inlet Temperature lpm Celsius 0 00 4 00 8 00 12 00 16 00 20 00 24 00 35 40 45 50 55 60 65 Hot water temperature ºC Hot Water Flow l min Inlet ºC 4 Inlet ºC 10 Inlet ºC 16 Inlet ºC 21 Hot Water Flow and Temperature with Various Inlet Temperature gpm Fahrenheit 0 00 1 00 2 00 3 00 4 00 5 00 6 00 7 00 90 100 110 120 130 140 150 Hot water tem...

Page 23: ...sists contact your installer 3 6 Program button Program button can be used programmed in the appliance and in the remote control Programming Program function Programming actions are similar for both controls appliance control pad and wireless remote control Fig 35 Program key B Press buttons and to select temperature to be memorized B Hold Program button for 3 seconds to save temperature When LCD ...

Page 24: ...D 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 connect...

Page 25: ...he 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 val...

Page 26: ...y shows A9 flashing the appliance can be operated normally but performance may be affected Close water tap and allow 30 seconds for purging time Open water tap and wait for 2 minutes to see if A9 message is deleted from the display Check that the water temperature sensor receiver is properly assembled in the water pipe Check that the water temperature sensor receiver is in proper condition C1 FAN ...

Page 27: ...temperature sensor 2 Ionization sensor 3 Water flow sensor 4 Over heat protection 5 Temperature limiter 6 Gas valve 7 Fan 8 Water valve 9 AC Plug 10 Ignition electrode 11 Display PCB 12 ON OFF switch 13 Fuse T 2 5A 14 Fuse T 3 15A 15 Terminal block 16 Ground post 17 Outlet water temperature sensor ...

Page 28: ...6 720 607 072 28 GWH 635 ES Functional scheme 7 GWH 635 ES Functional scheme Fig 38 Functional scheme ...

Page 29: ... 8 1 Interior components Fig 39 Components 1 Cover 2 On Off switch 3 Reset button 4 LCD display 5 Program button 6 Temperature switches 7 Flue gas collector 8 Mixer 9 Heat exchanger 10 Observation window 11 Inlet air duct 12 Control unit 13 Exhaust fan 14 Water valve 15 Gas valve Fig 40 Appliance overview ...

Page 30: ...onents diagram and parts list 8 2 Components diagram Fig 41 Components Diagram 7 6720607072 34 3 JF 1 3 4 40 5 5 2 6 7 8 8 9 10 10 12 13 7 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 36 35 37 38 11 39 41 42 43 44 ...

Page 31: ... 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 8 705 504 137...

Page 32: ...ord the CO2 reading in P1 below P2 CO2 Reading CO2 P1 CO2 Reading CO2 Compare your readings to those found in table 9 under the With Front Cover column If CO2 readings are off make adjustments as outlined below Note The Without Front Cover column give approximate values with the cover off to ease the adjustment process Final readings should be taken with the cover on C Adjusting CO2 Note P1 adjust...

Page 33: ... to the OFF O position and then back to the ON I position 5 Heater is ready for normal operation Final Readings P2 CO2 Reading CO2 P1 CO2 Reading CO2 Fig 44 Fig 45 Without Front Cover With Front Cover Nat Gas Nat Gas max input P1 9 1 0 1 9 7 0 1 min input P2 9 4 0 1 9 7 0 1 LP Gas LP Gas max input P1 10 1 0 1 10 7 0 1 min input P2 10 4 0 1 10 7 0 1 Final reading must be confirmed with the front co...

Page 34: ...w 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...

Page 35: ...nd service delivery for these parts Expedited or upgraded shipping will be charged to the customer Service Labor Costs This warranty does not cover any labor costs associated with service removal or re installation of part s All such costs must be borne by the Purchaser Additionally this warranty does not cover any labor costs associated with service removal or re installation of the original wate...

Page 36: ...__ ___ ___ ___ ___ ___ ___ ___ 8 digit serial number is located on rating plate on right side panel Gas Pressure Reading Static__________ Operating__________ Building Water Pressure __________ Range if on Well system __________ Installing Company _____________________________________________ Installer name _____________________________________________ Address ______________________________________...