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BOSCH GWH C 800 ES Installation Instructions Manual

Temperature modulated with electronic ignition.
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GWH C 800 ES
(GWH C 800 CTDR EFS)
Temperature Modulated with Electronic Ignition
Suitable for heating potable water - Not approved for space heating purposes
(Intended for variable flow applications)
GWH C 800 ES - Natural Gas
GWH C 800 ES - Liquefied Petroleum (LP) Gas
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
vapors and liquids in the vicinity of this or any other
appliance.
Improper
installation,
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.
adjustment,
alteration,
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.
• Installation and service must be performed by a
qualified installer, service agency or the gas supplier.

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   Summary of Contents for BOSCH GWH C 800 ES

  • Page 1

    Suitable for heating potable water - Not approved for space heating purposes (Intended for variable flow applications) GWH C 800 ES - Natural Gas GWH C 800 ES - Liquefied Petroleum (LP) Gas Warning: If the information in this manual is not What to do if you smell gas followed exactly, a fire or explosion may result •...

  • Page 2: Table Of Contents

    Features Condensing heat exchanger unit GWH C 800 ES Specifications Adjusting CO2 (Technical data) Program values Unpacking the GWH C 800 ES heater Control board diagnostics General rules to follow for safe operation Dimensions and minimum installation clearances Troubleshooting Introduction...

  • Page 3: Warning

    Warning Warning For your safety FCC: This device complies with Part 15 of the FCC rules. Do not store or use gasoline or other flammable, Operation is subject to the following two conditions: (1) combustible or corrosive vapors and liquids in the This device may not cause harmful interference, and (2) vicinity of this or any other appliance.

  • Page 4: Appliance Details

    Appliance details Appliance details GWH C 800 ES Specifications (Technical data) Approved in US/Canada Features Capacity Parts Maximum flow rate: 8.0 GPM (30 l/min) at a 45°F • Key Pad interface control (25°C) rise. • High power pre-mix compact burner with low NOx...

  • Page 5: Unpacking The Gwh C 800 Es Heater

    • Product registration card • Energy Guide label. Please complete and return the enclosed product registration card. The GWH C 800 ES is not approved or designed for: • Manufactured (mobile) homes, boats or any mobile installation. • Use above 4500ft A.S.L. altitude.

  • Page 6: General Rules To Follow For Safe Operation

    Appliance details To remove front cover General rules to follow for safe operation B Loosen the two Philips head screws located on bottom rear of cover (see Fig. 3). B 1. You must 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.

  • Page 7: Dimensions And Minimum Installation Clearances

    Appliance details Dimensions and minimum installation clearances Fig. 6 Dimensions On/Off button Model GWH C 800 ES Reset button Program key TOP (A) 12” Power ON or stand-by LED LCD display FRONT (B) 1” Up button BACK 0” Down button SIDES 1”...

  • Page 8: Installation Instructions

    • Adjustable wrench other flammable vapors and liquids. • Level • Thermometer Heater placement and clearances • Standard plumbing tools The GWH C 800 ES design is approved for • Manometer. installation on a combustible wall (see chapter 3.5 Mounting installation) provided...

  • Page 9

    Installation instructions B Hang the appliance on the bracket, see Fig. 10, page Studs 16" (406mm) on center Fig. 10 Mounting the heater Fig. 8 Distance between support boards Warning: Appliance must be installed vertically. Fig. 9 Leveling wall mounting bracket 6 720 608 643...

  • Page 10: Gas Piping & Connections

    Installation instructions Gas piping & connections fittings. Bubbles are a sign of a leak. A combustible gas detector may also be used to detect for leaks. Before connecting the gas supply, check the rating plate on the right side of the heater to be sure that the Danger: If you have a leak, shut off the heater is rated for the same gas to which it will be gas.

  • Page 11

    0.3” in Water Column (0.75mbar).(Based on a 0.60 Specific Gravity Gas) Btu numbers given in thousands. Follow boxed numbers for piping just one GWH C 800 ES (example: ¾” B.I. Natural Gas pipe for 10 ft (3.0m). will handle 278,000 btu’s (81.5 kWh). For multiple appliances combine the total maximum btu input load and then refer to applicable chart below.

  • Page 12: Water Connections

    For water analysis data call your local water department, or if on a well, have well water analyzed periodically. If Fig. 14 water quality exceeds one or more of the values specified below, Bosch recommends installing a water conditioner or softener. Description Max. Levels 6.5 - 8.5...

  • Page 13: Recirculation Application

    Connecting the pressure relief valve (PRV) Recirculation application A listed pressure relief valve supplied with the heater The GWH C 800 ES Protankless water heater is must be installed at the time of installation. No valve is approved for domestic hot water recirculation. The to be placed between the PRV and the heater.

  • Page 14: Filling The Condensate Trap

    Installation instructions B Fill the condensate trap by pouring approx.14 oz. 3.10 Filling the condensate trap (400ml) of water into the top of the drain tube. To The condensate trap can be filled before or after avoid damage to the appliance use a funnel in this connecting the vent pipe.

  • Page 15: Combustion Air Requirements

    Twin pipe – 1000 Btu/hr (292.81 Watts) if all air is taken from The GWH C 800 ES is designed as a sealed inside the building combustion appliance. It is recommended that the – 2000 Btu/hr (585.62 Watts) if all air is taken from combustion air be provided by a dedicated 3”...

  • Page 16: Venting

    Vent Safety System B Attach the flue gas exhaust accessory to the top of The GWH C 800 ES will shut down if inadequate the unit Fig. 23 (position 1) using the 4 screws and exhaust venting is detected or a lack of combustion air gasket provided, and fully insert vent pipe into the is provided to the unit;...

  • Page 17

    Installation instructions 3.12.1 Vent material and specifications Note: All combustion air and vent pipe materials and fittings B For twin pipe a maximum combination must comply with the following: length: Item Material United States Canada 52 ft + two 90º elbows + two terminals. B For concentric solution a maximum combination length: PVC schedule 40...

  • Page 18

    Adjusting the minimum power (P2) based on the total combined vent length. Straight section length __ = ____ After installing the GWH C 800 ES, the minimum power 90° elbows (qty) __ x 5 = ____ fan speed must be selected to compensate for variation in vent pipe length.

  • Page 19

    Installation instructions Example Adjusting minimum power fan speed P2 Exhaust To select fan speed: • 7 - 3’ straight sections B Press ON/OFF button into OFF. B Press and hold "Program" • 1 - 1’ straight section button and press ON/OFF button to turn appliance ON.

  • Page 20

    Installation instructions Below are approved examples of vertical and hor- izontal venting installations 12” (300 mm) OVER MAXIMUM SNOW Warning: leaf debris LEVEL OR 24” (600 MM) WHICHEVER protection screens at the end of vent IS GREATER and inlet pipes. 12”...

  • Page 21

    Installation instructions MINIMUM 1” EXHAUST INTAKE VENT INTAKE EXHAUST 4” Min. COMBUSTION DRAIN TEE DRAIN TEE Fig. 29 Horizontal venting system (sealed combustion) Fig. 32 Horizontal venting system (room air only) Fig. 30 Horizontal parallel venting system (sealed combustion) Fig. 31 Horizontal parallel venting system (sealed combustion) 6 720 608 643...

  • Page 22

    Bosch Water Heating responsible for improperly installed Fig. 33 venting systems. Establish vent clearances that comply with the vent manufacturer's specifications. In all cases follow local codes.

  • Page 23

    Installation instructions 3.12.3 Connecting the condensate water drain to Warning: the appliance Failure to properly install condensate Use materials approved by the authority drain will void the warranty. having jurisdiction. In the absence of other authority, PVC, and CPVC pipe must comply with ASTM D1785, F441 or D2665.

  • Page 24

    Installation instructions Recommended exhaust vent terminator position Fig. 36 Ref. Description Minimum distance Directly below an opening; operable windows, doors and any non- 36 in (twin pipe installation) mechanical fresh air openings 48 in (single pipe installation) Below a gutter, sanitary pipework or eaves 24 in Below a gutter, sanitary pipework or eaves, protected by metal 12 in...

  • Page 25

    Installation instructions Attention residents of the Commonwealth of Massachusetts: In the Commonwealth of Massachusetts the following signage installed in accordance with the provisions of regulation went into effect on 12/30/2005: 248 CMR 5.08(2)(a)1 through 4. (a)For all side wall horizontally vented gas fueled (b)EXEMPTIONS: The following equipment is exempt equipment installed in every dwelling, building or from 248 CMR 5.08(2)(a)1 through 4:...

  • Page 26: Measuring Gas Pressure

    Installation instructions 3.13 Measuring gas pressure Gas pressures lower than 4" W.C. for Natural Gas or 9" W.C. for LPG will result in insufficient degree rise to the Confirm gas pressure upon installation. hot water being used, reduced hot water volume, possible error code faults and must be corrected.

  • Page 27: Electrical Connections

    Fig. 40, pos. 2. B Check the fuses in the printed circuit board, see Fig. The GWH C 800 ES requires an electrical power 40, pos. 3. supply from a 120VAC / 60Hz circuit (with a dedicated outlet) and must be properly grounded.

  • Page 28: Operation Instructions

    Operation instructions Operation instructions Fig. 41 On/Off button Reset button Program Key LCD display Up button Down button Power On or stand-by LED Description LCD Display Fig. 45 Locked condition indicator (only with remote Warning: Do not use any cleaning control) agressive or corrosive agents to clean the window.

  • Page 29: For Your Safety Read Before Operating Your Water Heater

    The GWH C 800 ES has an electronically controlled gas valve that modulates the burner input in response to B. Use only your hand to press the on/off control switch.

  • Page 30: Operation

    Operation instructions B press reset button firmly in order to return heater to Use of optional remote control normal operation. accessory (part no. TSTAT2) Fig. 55 Reset button If the problem persists, contact your installer. Fig. 52 Remote control Program button The wireless remote control accessory (Fig.

  • Page 31: Maintenance And Service

    Maintenance and service Maintenance and service Inlet Water Filter Warning: Always shut off the electrical • Verify the inlet filter screen is clean and undamaged. power supply, shut off the manual gas The inlet water filter is located between the ¾" cold valve and shut off the water valves water inlet fitting on the right side of the appliance, whenever servicing.

  • Page 32: Mineral Scale Build-up

    Maintenance and service 5. Disconnect inlet and outlet water pipes from the 13.Disconnect all lines and drain all solution from heat water heater. Place a small bucket underneath the exchanger. Properly discard of solution. water heater to catch residual water remaining inside 14.Position a container below the hot water outlet and the water heater.

  • Page 33: Condensing Heat Exchanger Unit

    If repairs are needed, the repairs should be done by a cer- B Assemble the condensate unit and all other parts in tified Bosch technician. reverse order of disassembly. Adjusting CO...

  • Page 34

    Maintenance and service B While holding the Program (P) button, press the ON/ B Loosen yellow painted philips screw (1) and cover OFF button to turn ON the heater (see Fig. 62). As should rotate down (2) revealing a recessed brass soon as ‘188’...

  • Page 35: Program Values

    3.12.2, page 18 Remote see chapter 5.5, page 30 Controls installed Access to see chapter 6.7, page 36 Diagnostic Mode Cascade Mode contact Bosch for details Temperature Unit °F °F °C Appliance Type Condensing / Non-condensing note: incorrect setting will cause errors.

  • Page 36: Control Board Diagnostics

    Maintenance and service Control board diagnostics Diagnostic menu 1. Press ON/OFF button to turn off the appliance. Entry/Exit into sub-modes 2. Press and hold "Program" button and press Set-point temperature ON/OFF button to turn appliance ON. Inlet water temperature (°F) 3.

  • Page 37: Troubleshooting

    Troubleshooting Troubleshooting single lever faucet mixing valves are common causes Warning: If you are unable to perform of plumbing crossovers. the tasks listed below, or need 8. With the power button pressed switch turned to OFF additional assistance please contact and the power supply cord unplugged, remove the your original installer or a licensed gas unit's front cover (See Page 6.

  • Page 38: Low Water Flow/pressure

    Troubleshooting Contact your original installer or a local certified gas coming outlet. Consult technician to obtain this reading. www.boschpro.com for a detailed service bulletin on overcoming temperature fluctuations. 7. Cold water is mixing into the hot water lines (plumbing crossover). A plumbing crossover can 2.

  • Page 39

    Troubleshooting specifications in Section 3.11, page 15 Combustion Air Requirements. 4. Cross contamination. Ensure that intake and exhaust terminations maintain required clearances as stated in chapter 3.12, page 16. Cross contamination between intake and exhaust may cause unstable burner flames and noise. 5.

  • Page 40: Problem Solving

    46 chapter 10 or in short circuit or appliance 2. Check sensor (ref. selection on “P7” mode is not 3. Check “P7” mode: GWH C 800 ES requires setting “Cd” for correct. condensing appliances Fig. 70 Backflow temperature sensor 1.

  • Page 41

    4. Check gas pressure Low gas pressure may cause the fan to change its speed to meet desired temperature. 5. Possible defective control unit call Bosch Water Heating for further instructions. Primary fan rotation too low in 1.

  • Page 42

    3.12 page 16 venting may cause this failure. See 4. Call Bosch Water Heating for further instructions. Overheat sensor (ECO) open 1. Disconnect power supply cord and check wire connections on Fig. 70...

  • Page 43

    Use the reset button ( ) to reset any error codes. 3. Possible defective control unit call Bosch Water Heating for further instructions. Ionization error at standby. 1. Loose connection to the flame ionization rod. Verify that the...

  • Page 44

    The voltage should measure 24VDC between the left pair of wires and 24VDC between the right pair of wires when the unit is operating. If voltage is not proper, contact Bosch Water Heating for further instruction. 3. Gas valve may be defective, contact Bosch Water Heating for further instrucation.

  • Page 45: Electrical Diagram

    Electrical diagram Electrical diagram Fig. 65 Electrical scheme Intlet water temperature sensor Outlet water temperature sensor Backflow temperature sensor Cascading output connection Cascading input connection Ionization sensor Water flow sensor Overheat sensor (ECO) Flue gas limiter Gas valve Exhaust temperature sensor Water valve Primary fan ON/OFF switch...

  • Page 46: Sensor Resistance Charts

    Sensor resistance charts Sensor resistance charts Outlet NTC characteristics 2 2 2 2 17 10 5 2 12 10 0 2 0 7 2 0 2 19 7 19 2 18 7 18 2 16 7 16 2 14 7 14 2 13 7 13 2...

  • Page 47

    Sensor resistance charts Back Flow and Exhaust NTC characteristics 3 0 2 2 9 7 2 9 2 14 5 2 8 7 2 8 2 14 0 2 7 7 2 7 2 13 5 2 6 7 2 6 2 13 0 2 5 7 12 5...

  • Page 48: Gwh C 800 Es Functional Scheme

    GWH C 800 ES Functional scheme GWH C 800 ES Functional scheme Fig. 69 Functional scheme 6 720 608 643...

  • Page 49: Interior Components Diagram And Parts List

    Interior components diagram and parts list Interior components diagram and parts list 12.1 Interior components Fig. 70 Components Exhaust temperature sensor Ignition electrodes Flue gas collector Observation window Heat exchanger Backflow temperature sensor Ionization sensor Secondary air fan Primary fan (Mixer) Gas valve Hot water temperature sensor Condensate trap...

  • Page 50

    Interior components diagram and parts list Fig. 71 Appliance overview 6 720 608 643...

  • Page 51: Components Diagram

    Interior components diagram and parts list 12.2 Components diagram 12.2.1 Group 1 13 15 6720902973.AB JF Fig. 72 Components Diagram Item Description Reference Item Description Reference Combustion cover clip 8 701 201 032 Front cover 8 705 431 264 Grommet set 8 710 203 039 Cover shield 8 705 506 857...

  • Page 52

    Interior components diagram and parts list 12.2.2 Group 2 6720902980.AA JF Fig. 73 Components Diagram 6 720 608 643...

  • Page 53

    Interior components diagram and parts list Item Description Reference Heat exchanger 8 705 406 369 Heat exchanger top gasket 8 704 701 052 Condensing exchanger inlet 8 705 700 159 Overheat sensor (ECO) 8 707 206 204 Heat exchanger bottom gasket 8 704 701 054 Site window 8 701 000 401...

  • Page 54

    Interior components diagram and parts list 12.2.3 Group 3 6720902975.AA JF Fig. 74 Components Diagram Item Description Reference Item Description Reference Air duct O-ring 8 700 205 149 Main burner 8 708 120 642 Venturi 8 700 306 226 Burner gasket 8 704 701 087 O-ring 8 700 205 224...

  • Page 55

    Interior components diagram and parts list 12.2.4 Group 4 6720902976.AA JF Fig. 75 Components Diagram Item Description Reference Item Description Reference Gas filter 8 700 507 002 0 Gas valve 8 707 021 019 0 Gasket 8 704 701 085 Pressure tapping 8 703 404 219 0 Gas / Fan connector...

  • Page 56

    Interior components diagram and parts list 12.2.5 Group 5 (optional) 6720902977.AA JF Fig. 76 Components Diagram Item Description Reference Item Description Reference Inlet fitting 8 703 305 348 Water valve with engine and 8 708 505 024 temperature sensor O-ring 8 700 205 157 O-ring 8 700 205 147...

  • Page 57

    Interior components diagram and parts list 12.2.6 Group 6 Fig. 77 Components Diagram Item Description Reference Item Description Reference Flue gas limiter 8 700 400 032 Control unit 8 707 207 257 Cascading kit (optional) 7 709 003 617 Fuse T2.5A 1 904 521 342 Anti freeze kit (optional) 7 709 003 665...

  • Page 58: Protecting The Environment

    Protecting the environment 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.

  • Page 59: Limited Warranty

    Limited Warranty Limited Warranty General Service Labor Costs BOSCH PRO tankless water heaters are warranted by This warranty does not cover any labor costs the Manufacturer (BOSCH) through BBT North associated with service, removal or re-installation of America. BBT North America (BBTNA) will furnish a part(s).

  • Page 60

    Installation manual should be left with the owner after the installation is tested and completed Replacement Parts available from: BBT North America Corporation Bosch Group BBT Termotecnologia Portugal, S.A. Bosch Water Heating Estrada de Cacia 50 Wentworth Avenue 3801 - 856 Aveiro - PORTUGAL Londonderry, NH 03053 Tel.

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