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BOSCH GWH 635 ES User Manual

Temperature modulated with electronic ignition suitable for heating potable water only - not approved for space heating purposes (intended for variable flow applications).
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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)
GWH-635-ES-N - Natural Gas
GWH-635-ES-L - 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
vapor 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.
INDOOR MODEL
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.
• 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.

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   Summary of Contents for BOSCH GWH 635 ES

  • Page 1

    GWH-635-ES INDOOR MODEL Temperature Modulated with Electronic Ignition Suitable for heating potable water only - Not approved for space heating purposes (Intended for variable flow applications) GWH-635-ES-N - Natural Gas GWH-635-ES-L - 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

    Index Index Warning Warning Warning: If the information in this Appliance details manual is not followed exactly, a fire or Features explosion may result causing property GWH-635-ES Specifications (Technical data) damage, personal injury or death. Dimensions and Minimum installation clearances General rules to follow for safe operation Proper location for installing your heater Warning:...

  • Page 3

    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.

  • Page 4: Appliance Details

    • Vent termination kit. gas collar of the heater, the supplied condensate drain tube must be installed to it for proper removal of BOSCH is constantly improving its condensate from the trap. See chapter 2.9 for Venting. products, therefore specifications are Water subject to change without prior notice.

  • Page 5

    Appliance details Combustion Do not lose this manual. Please complete and return the enclosed product registration card. • NOx ≤ 55 ppm Before installing the unit, be certain you have the • CO ≤ 250 ppm correct heater for your type of Gas - Propane or •...

  • Page 6: Dimensions And Minimum Installation Clearances

    Appliance details Dimensions and Minimum installation clearances Fig. 4 Dimensions Cover On/Off switch Reset button LCD display Program button Temperature buttons Fig. 5 Minimum clearances Model GWH-635-ES 12” TOP (A) FRONT (B) 1” 0” BACK SIDES 1” FLOOR (C) 12” VENT DIAMETER 3”...

  • Page 7: General Rules To Follow For Safe Operation

    Appliance details General rules to follow for safe Proper location for installing your operation heater B 1. You should follow these instructions when you Carefully select the location of the water heater. For install your heater. In the United States: The your safety and for proper heater operation, you must installation must conform with local codes or, in the provide combustion air to the heater and a proper...

  • Page 8: Clearances

    Appliance details 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.

  • Page 9: Venting

    Appliance details Venting construction, infiltration air is normally adequate to provide air for combustion. Warning: Do not reduce the vent • Appliances located in confined spaces: (exhaust and combustion) pipe sizes The confined space must be provided with two and do not common vent with any other permanent openings, one commencing within 12 vented appliance or stove.

  • Page 10

    Appliance details The maximum flue gas exhaust temperature on the GWH-635-ES is 437°F (225°C) Venting Exhaust * Exhaust * Exhaust Combustion Combustion Vent pipe Vent pipe Options vent vent vent air pipe air pipe clearances clearances diameter maximum minimum diameter maximum within an within an...

  • Page 11

    Appliance details Note: reduce 2½ ft for each 90° elbow used after the Use of the external condensate drain tube kit first one, reduce 1 ¼ ft for each 45° elbow. (supplied with the heater) on the exhaust collar B The condensate drain tube kit must be used for all Vent Safety System installation types.

  • Page 12: Venting Options

    Appliance details 2.9.1 Venting options Open combustion installation (SINGLE PIPE SYSTEM) Installing this water heater as a room sealed (TWIN PIPE SYSTEM) is the recommended method. Contact Not recommended in cold climate areas, see BBTNA or dealer for available vent termination kits and Chapter 2.8.

  • Page 13

    Appliance details Recommended exhaust vent terminator position Fig. 16 Ref. Description Minimum distance Directly below an opening; operable windows, doors and any non- 36 in mechanical fresh air openings Below a gutter, sanitary pipework or eaves 24 in Below a gutter, sanitary pipework or eaves, protected by metal 12 in shielding From any internal corner...

  • Page 14

    Appliance details Supporting the exhaust vent system The venting materials and accessories required to properly install the water heater are available from BBTNA 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) A condensate drain tube must be attached to the exhaust collar of the heater for all vent type applications,...

  • Page 15: Gas Piping & Connections

    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.

  • Page 16

    Appliance details FOR NATURAL GAS Maximum Capacity of pipe in Cubic Feet of Gas per Hour for Gas Pressure of 0.5 Psig or less and a Pressure drop of 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 635-ES (example: ¾”...

  • Page 17: Gas Line Sizing

    Appliance details 2.11 Gas line sizing 2.12 Measuring gas pressure B It is strongly recommended that the Natural Gas pipe 2.12.1 Connecting Manometer be Black Iron pipe the entire distance from the B Shut off gas. outside meter to the inlet of the gas connection. ¾” B Remove front cover and locate inlet gas pressure Black Iron pipe up to 20 feet (6.1m) and 1”...

  • Page 18: Water Connections

    Appliance details local codes if more stringent). Never sweat any rigid Static Gas Pressure Reading (see Chapter 2.12) piping directly to or beneath the water connections, damage can occur to the internal water valve from enter here: ___________________ heating of the pipe. Plastics or other PEX type plumbing line materials are not suitable for connecting directly to Operating Gas Pressure Reading (see Chapter 2.12) the water heater.

  • Page 19: Electrical Connections

    Appliance details 2.14 Electrical connections 2.16 For your safety read before operating your water heater Warning: safety reasons, disconnect the power supply to the Warning: If you do not follow these heater before any service or testing is instructions exactly, a fire or explosion performed.

  • Page 20

    Appliance details 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.

  • Page 21: Operation Instructions

    Operation instructions Operation instructions Fig. 27 B Press buttons in order to reach On/Off switch Reset button requested temperature. Program Key Increasing temperature selector Decreasing temperature selector LCD display Power B To start the appliance switch the button to position (I).

  • Page 22

    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.

  • Page 23: Program Button

    Operation instructions Use of remote control accessory Fig. 34 Reset button If the problem persists, contact your installer. Program button Fig. 31 Remote control Program button can be used/programmed in the The wireless remote control accessory and the appliance and in the remote control. temperature selector buttons on the front of the water heater operate identically.

  • Page 24: Maintenance And Service

    Maintenance and service Maintenance and service unit, the heater will communicate the source by these Warning: Always turn off the electrical error codes. power supply, turn off the manual gas valve and turn off the manual water BURNERS DO NOT IGNITE WHEN HOT WATER IS control valves whenever servicing.

  • Page 25: Inlet (ºf)

    Troubleshooting • Cold water is mixing with the hot water outlet Adjustments should be made to the hottest setting in (crossover) the shower valve. Additionally the temperature Test by following 4th bullet under BURNERS DO control of the heater can be lowered to produce a NOT IGNITE WHEN HOT WATER IS TURNED ON.

  • Page 26: Inlet (ºf)

    Troubleshooting Display Cause Solution Temperature limiter opened circuit Check connections.* (overheat). Trips at 220F (104C). Check heat exchanger condition.* No ionization during safety time (safety time Check gas pressure.* out). Check that gas is not diluted with air, as a result Note: appliance makes 3 ignition attempts from recent gas pipeline rework.*.

  • Page 27: Electrical Diagram

    Electrical diagram Electrical diagram Fig. 37 Electrical scheme Intlet water temperature sensor Ionization sensor Water flow sensor Over heat protection Temperature limiter Gas valve Water valve AC Plug Ignition electrode Display PCB ON/OFF switch Fuse T 2,5A Fuse T 3,15A Terminal block Ground post Outlet water temperature sensor...

  • Page 28: Gwh-635-es Functional Scheme

    GWH-635-ES Functional scheme GWH-635-ES Functional scheme Fig. 38 Functional scheme 6 720 607 072...

  • Page 29: Inlet (ºc)

    Interior components diagram and parts list Interior components diagram and parts list Interior components Fig. 39 Components Cover On/Off switch Reset button LCD display Program button Temperature switches Flue gas collector Mixer Heat exchanger Observation window Inlet air duct Control unit Exhaust fan Water valve Gas valve...

  • Page 30: Components Diagram

    Interior components diagram and parts list Components diagram 6720607072-34.3 JF Fig. 41 Components Diagram 6 720 607 072...

  • Page 31: Parts List

    Interior components diagram and parts list 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...

  • Page 32: Levels

    Special adjustment for measuring and adjusting CO2 levels Special adjustment for measuring and adjusting CO levels The CO can only be adjusted by a certified gas B. Measuring CO (Cover Installed): technician with a calibrated CO analyzer. B Open hot water taps to achieve a flow rate of at least 4 gallons per minute.

  • Page 33

    Special adjustment for measuring and adjusting CO2 levels D. Returning to Service: 1. Return slotted cover to original position. 2. Reinstall Torx cover. 3. Remove CO analyzer probe and reinstall flathead screw in exhaust collar. 4. Turn ON/OFF switch to the OFF (O) position and then back to the ON (I) position.

  • Page 34: 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 35: Fifteen Year Limited Warranty

    General of the original water heater or a replaced water heater. Certain service labor allowances are available to PHCC BOSCH PRO water heaters are warranted by the member contractors, dependent on prior authorization Manufacturer (BOSCH) through BBT North America. by BBTNA.

  • Page 36

    Installation manual should be left with the owner after the installation is tested and completed Replacement Parts available from: BBT NORTH AMERICA Bosch Group Bosch Water Heating VULCANO Termodomésticos S.A. 340 Mad River Park Estrada de Cacia Waitsfield, VT 05673...

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