Bosch Singular 4000 Service Manual

Bosch Singular 4000 Service Manual

Gas condensing combi boilers
Hide thumbs Also See for Singular 4000:
Table of Contents

Advertisement

Quick Links

Service Manual
Gas Condensing Combi Boilers
Singular
Singular 4000 | Singular 5200
WARNING:
If the information in these instructions are not followed exactly, a fi re or explo-
sion may result causing property damage, personal injury or death.
WARNING:
Do not store or use gasoline or other fl ammable vapors and liquids in the vicinity
of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
— 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.
WARNING:
Improper installation, adjustment, alteration, service or maintenance can cause
property damage, personal injury (exposure to hazardous materials)* or loss of
life. Refer to the user's information manual provided with this boiler. Installation
and service must be performed by a qualifi ed installer, service agency or the gas
supplier who must read and follow the supplied instructions before installing,
servicing, or removing this boiler. This boiler contains materials that have been
identifi ed as carcinogenic, or possibly carcinogenic, to humans.
This boiler must be installed in accordance with local, state, and federal codes.
In the absence of such requirements, then to the latest edition of the National
Fuel Gas Code, ANSI Z223.1./NFPA 54. In Canada, installation must be in
accordance with the requirements of CAN/CSA B149.1, Natural Gas and
Propane Installation Code.

Advertisement

Table of Contents
loading

Summary of Contents for Bosch Singular 4000

  • Page 1 Service Manual Gas Condensing Combi Boilers Singular Singular 4000 | Singular 5200 WARNING: If the information in these instructions are not followed exactly, a fi re or explo- sion may result causing property damage, personal injury or death. WARNING: Do not store or use gasoline or other fl ammable vapors and liquids in the vicinity of this or any other appliance.
  • Page 2 Service Manual Singular Combi Boiler - BTC 439002301 A (12.2021)
  • Page 3: Table Of Contents

    Service Manual Table of Contents 1 Key to Symbols and Safety Instructions 9 Components Replacement Instructions 1.1 Key to Symbols 9.1 Preparation Step 9.2 Control Board 1.2 Safety 9.3 Sensor, Heating/Return 9.4 Sensor, DHW 2 Key Components 9.5 Exhaust Temperature Sensor_T4 (Blue) 9.6 Gas Orifi...
  • Page 4: Key To Symbols And Safety Instructions

    Service Manual 1 Key to Symbols and Safety Instructions 1.2 Safety Please read before proceeding 1.1 Key to Symbols Warnings WARNING: FIRE, EXPLOSION  Vapors from flammable liquids can explode and/or catch fire Warnings in this document are identifi ed by a causing death or severe burns.
  • Page 5 Service Manual WARNING: FIRE, EXPLOSION WARNING: IMPROPER OR DANGEROUS OPERATION  Do not store combustibles, such as papers or laundry, near  Immediately call a qualified service technician to inspect the the boiler or venting system. appliance and replace any part of the control system and/or any gas control which has been immersed in water.
  • Page 6: Key Components

    Service Manual 2 Key Components Flue connector Air intake connector Exhaust temperature sensor Burner hood Gas connector/Orifice Heating temperature sensor (T2) Heat Exchanger Cover Gas valve Pressure sensor Return temperature sensor Air vent Pump 3-way valve DHW temperature sensor Condensate drain Space heating supply Gas inlet Space heating return...
  • Page 7 Service Manual Turbo fan assembly Ignition transformer High Limit Cutout HEX T2 (302°F) Electrode assembly Flame rod TDR damper Primary heat High Limit Cutout exchanger Supply T3 (203°F) Secondary heat exchanger Water Pressure Sensor Air Pressure Switch Condensate Trap Control Board Flow sensor Touch Pad Figure 2...
  • Page 8: Technical Data

    Service Manual 3 Technical Data Singular 4000 Singular 5200 Space Heating 19,900–80,000 BTU/H 19,900–140,000 BTU/H Heat Capacity (Input) Domestic Hot Water 19,900–155,000 BTU/H 19,900–199,000 BTU/H 45°F (25°C) Temp Rise 6.0GPM (23LPM) 7.7GPM (29LPM) Flow Rate (DHW) 67°F (37°C) Temp Rise 4.0GPM (15LPM)
  • Page 9: Dimensions

    Service Manual 4 Dimensions 5.57" 5.26" 1.8" (133.5 mm) (141.5 mm) (45.7 mm) 4.0" 6.1" 3.6" 2.7" 1.6" (40.6 mm) 18.11" (460 mm) (101.6 mm) (154.9 mm) (91.4 mm) (68.6 mm) Figure 3 Position Description Diameter Space heating Return 1" NPT Cold water inlet 3/4"...
  • Page 10: Setting The Dip Switches

    Service Manual 5 Setting the DIP Switches The boiler has a DIP switch on the main circuit board (PCB) Set the DIP switch appropriately, depending on the installation environment. Switch Function ON: No temperature limit for exhaust gas Temperature limit switch for exhaust gas OFF: Temperature limit for exhaust gas ON: Enable EEP ROM data change EEP ROM data change switch...
  • Page 11: Wiring Diagram

    Service Manual 6 Wiring Diagram 120VAC,5A White White White White Green Green Blue Blue SRW Red SRW Red Black Blue Blue Gray Gray Black Figure 4 Singular Combi Boiler - BTC 439002301 A (12.2021) | 11...
  • Page 12: Key Components Description

    Service Manual 7 Key Components Description 7.1 Pump 7738007283 Part No.  Carries out combustion by circulating the water in the pipe.  Circulates the water when the water temperature is 59°F (15°C) or Function below to prevent the boiler from freezing and bursting. Unable to detect or measure water pressure change when the pump Failure Event operates.
  • Page 13: Orifi Ce

    Service Manual 7.3 Orifi ce 7738007257 (NG) Part No. 7738007258 (LP) Control the gas pressure and provide the proper quantity of the gas. Function  Making combustion noise. Failure Event  Imperfect and lifting flame occurs.  Making a noise. Effects ...
  • Page 14: High Limit Cutout Hex T2 (302°F)

    Service Manual 7.6 High Limit Cutout HEX T2 (302°F) 7738007253 Part No. Due to the excessively high temperatureof the Heat Exchanger (HEX), it will Function trip and stop combusting. Unable to detect the excessively high temperature if the cutout fails. Failure Event Unable to stop combusting if the heat exchanger temperature exceeds Effects...
  • Page 15: Secondary Heat Exchanger

    Service Manual 7.9 Secondary Heat Exchanger 7738007256* Part No.  Main part for heat transfer from the burner  It has multiple paths of water tubes on the heat exchanger surface as Function well as inside the combustion chamber.  Water and/or exhaust gas leakage through a crack ...
  • Page 16: Electrode

    Service Manual 7.11 Electrode 7738007260 Part No. To ignite the gas, discharge the spark to the main burner repeatedly until Function igniting the gas. Unable to ignite during the ignition process. Failure Event  The unit cannot ignite during the ignition process and “A6” error code will be shown on the display panel.
  • Page 17: Burner

    Service Manual 7.14 Burner 7738007256* Part No. Combustion with a mixture of gas and air. Function  Unable to initialize/sustain combustion.  Foreign substance or soot deposit on the burner surface. Failure Event  Gas leakage from the burners.  Unexpected combustion. ...
  • Page 18: Control Board

    Service Manual 7.17 Control Board 7738007249 (Singular 5200) Part No. 7738007248 (Singular 4000) To control each component and performance of unit. Function  Malfunction of control board. Failure Event  Unit does not operate.  A component does not operate within the unit.
  • Page 19: Troubleshooting

    Service Manual 8 Troubleshooting 8.1 A2 Error (Abnormal Operation: Fan) Error Description Turbo fan RPM error Error occurs when the RPM is not measured due to no turbo fan operation or a defect of the hall sensor  Check the connection of the wire ...
  • Page 20 Service Manual A2 Error - Wire Check 1. Check the connection of the Fan Connector Wire (Red-Black). 2. Check the connection of the Hall IC Connector Wire (Yellow-White). Connector Hall IC Wire Connector Wire Figure 6 3. Check the connection of the control board Connector Wire (Red-Black). Figure 8 Applied Voltage Measurement Method Control...
  • Page 21: A3 Error (Abnormal Operation: Pump)

    Service Manual 8.2 A3 Error (Abnormal Operation: Pump) Error Description  Determine whether the pump is in operation when the boiler operation signal is activated Abnormal Pump Operation  Before operating the pump, check the change in the pressure sensor before and after to see whether there are any problems in the operation of the pump.
  • Page 22 Service Manual A3 Error - Wire Check A3 Error - Control Board Operation Voltage Check 1. Check the pump connector. 1. Check the output voltage when the pump operation signal is activated  Normal: Normal if the voltage is higher than the input voltage Figure 12 Figure 11 Singular Combi Boiler - BTC 439002301 A (12.2021)
  • Page 23: A4 Error (Overheating Of Heat Exchanger)

    Service Manual 8.3 A4 Error (Overheating of Heat Exchanger) Error Description  T2: Stop the combustion when the surface temperature of the exhaust gas hood becomes higher than 302 °F due to backfi re.  T3: Stop the combustion when the surface temperature of the heat exchanger supply pipe becomes higher than 203 °F High Limit Cutout Error due to abnormal overheating.
  • Page 24 Service Manual A4 Error - Wire Check A4 Error - High Limit Cutouts Check 1. Check the connection status of the wire. 1. Measure the resistance of the cutouts.  Normal: 1 Ω or less  Abnormal: O.L 2. If the resistance cannot be measured normally, replace the high limit cutout. Figure 14 Ω...
  • Page 25: A5 Error (Low Water Pressure)

    Service Manual 8.4 A5 Error (Low Water Pressure) Error Description Internal pipe pressure decrease error Low water pressure error Internal pressure in pipes <= 4.3PSI error occurs —  Check the input voltage of the pressure sensor Color: Red – Black (DC 5 V) —...
  • Page 26 Service Manual A5 Error - Input Voltage of the Pressure Sensor Check 1. Check the pressure sensor for abnormalities in the input voltage Normal: DC 5 V — Figure 17 A5 Error - Pipe Pressure Check 1. Check for water leaks from the pipes and check the pressure of the expansion tank Singular Combi Boiler - BTC 439002301 A (12.2021) 2 6 |...
  • Page 27: A6 Error (Ignition Error)

    Service Manual 8.5 A6 Error (Ignition Error) Error Description When it is judged that fl ame is not recognized in normal combustion condition, ignition is attempted 6 times repeatedly. Ifthe Ignition Failure fl ame is not recognized, ignition is not attempted again and an error is issued ...
  • Page 28 Service Manual 2. Check the input voltage of the igniter A6 Error - Main Gas Valve Check Wire color: Brown-Brown (AC 105 – 135 V) — 1. Check if the main gas valve is closed. A6 Error - Gas Valve Check 1.
  • Page 29: A7 Error (Abnormal Operation: Gas Valve Relay)

    Service Manual 8.6 A7 Error (Abnormal Operation: Gas Valve Relay) Error Description Gas valve relay error It occurs when the gas valve relay which is mounted on PCB is stuck closed. Checkpoint Replace the control board Figure 23 8.7 A8 Error (Abnormal Operation: Gas Valve) Error Description Flame after combustion...
  • Page 30 Service Manual A8 Error - Voltage Check A8 Error - Flame Rod Check 1. Check the input voltage of the gas valve while burner is turned off . 1. Remove fl ame rod and check condition. 2. Reassemble the fl ame rod, turn on the power supply and measure the ...
  • Page 31: A9 Error (Exhaust Temperature Sensor Error)

    Service Manual 8.8 A9 Error (Exhaust Temperature Sensor Error) Error Description  Freeze prevention error due to a temperature decrease of the heating water Exhaust temperature Heating water temperature <= 43 °F: Combustion in progress — sensor error Heating water temperature >= 104 °F: Combustion stopped —...
  • Page 32 Service Manual A9 Error - Wire Check 1. Check if the heating water sensor connector is disconnected Figure 29 A9 Error - Exhaust Temperature Sensor Check 1. Check if the heating water sensor is defective Defective: OL — Normal: 86 °F: 40 kΩ —...
  • Page 33: Aa Error (Overheating)

    Service Manual 8.9 AA Error (Overheating) Error Description Overheating of temperature sensor (Boiling superheat) An error is displayed when abnormal overheating caused by heating water sensor over 208 °F  Check the resistance of Heating water sensor (NTC method) Checkpoint (Measurement should be carried out after separating the sensor) Table 31 An error occurs when the...
  • Page 34: Ab Error

    Service Manual 8.10 AB Error (Abnormal Operation: Heat Exchanger Temperature Sensor Error Description Hex Thermistor_T2 error Error is displayed when the Heating water sensor has short-circuited or is disconnected  Check if the Hex Thermistor connector is connected normally. 1. Control board wire 2.
  • Page 35 Service Manual AB Error - Wire Check AB Error - Disconnection Check 1. Check the connection of the wire. 1. Check if the heat exchanger overheat sensor is disconnected. Disconnection: OL — Normal:      86 °F: 40 kΩ — 140 °F: 12.4 kΩ...
  • Page 36: Ac Error (Abnormal Operation: Dhw Sensor)

    Service Manual 8.11 AC Error (Abnormal Operation: DHW Sensor) Error Description DHW Sensor T3 error Error is displayed when the DHW sensor has short-circuited or is disconnected  Check if the DHW Thermistor connector is connected normally. 1. Control board wire 2.
  • Page 37 Service Manual AC Error - Wire Check AC Error - Disconnection Check 1. Check the connection of the wire. 1. Check if the sensor is disconnected. Disconnection: OL — Normal:      86 °F: 40 kΩ — 140 °F: 12.4 kΩ 185 °F: 3.9 kΩ...
  • Page 38: Ad Error (Clog Of Condensate Trap)

    Service Manual 8.12 AD Error (Clog of Condensate Trap) Error Description Clogging of the condensation trap Error displayed when the condensation trap is clogged by foreign material.  Check the connection (short circuit) of the wire connector. Checkpoint  Check if foreign material exists inside the condensation trap. ...
  • Page 39 Service Manual AD Error - Wire Check AD Error - Control Board Check 1. Check the connection of the condensation trap and the wire. 1. The condensation trap is not clogged and the condensation water is discharged normally, replace the control board. 2.
  • Page 40: Ae Error (Blockage Of Flue Pipe)

    Service Manual 8.13 AE Error (Blockage of Flue Pipe) Error Description Error displayed when air is not supplied smoothly due to foreign material in the air inlet or external factors of when the air Blockage of air inlet pressure switch is defective Error displayed when exhaust gas is not discharged normally due to foreign material in the fl...
  • Page 41 Service Manual AE Error - Wire Check AE Error - Air Pressure Switch Check 1. Check the connection of the air pressure switch and the wire. 1. Check the air pressure switch for abnormalities under combustion stop condition. Normal: under 1Ω —...
  • Page 42: Eo Error (Abnormal Operation: Outdoor Temperature Sensor)

    Service Manual 8.14 EO Error (Abnormal Operation: Outdoor Temperature Sensor) Error Description Outdoor Temperature Sensor Error Error is displayed when the ambient sensor has short-circuited or is disconnected  Check if the outdoor temperature sensor wire is connected correctly. 1. Control board wire 2.
  • Page 43 Service Manual EO Error - Wire Check EO Error - Disconnection Check 1. Check the connection of the wire. 1. Check if the outdoor air sensor is disconnected. kΩ Figure 55 Control Board Figure 57 EO Error - Short Circuit Check 1.
  • Page 44: E1 Error (Abnormal Operation: Exhaust Temperature Sensor)

    Service Manual 8.15 E1 Error (Abnormal Operation: Exhaust Temperature Sensor) Error Description Hot Water Thermistor_T3 Error Error is displayed when the Exhaust Thermistor has short-circuited or is disconnected  Check if the Exhaust Thermistor connector is connected normally. 1. Control board wire 2.
  • Page 45 Service Manual E1 Error - Wire Check E1 Error - Disconnection Check 1. Check the connection of the wire. 1. Check if the Exhaust Temp. Sensor is disconnected. Disconnection: OL — Normal:      86 °F: 7.05 kΩ — 140 °F: 2.5 kΩ 201 °F: 952 Ω...
  • Page 46: E2 Error (Exhaust Temperature Overheating)

    Service Manual 8.16 E2 Error (Exhaust Temperature Overheating) Error Description The system stops combustion and issues an error when the temperature on the exhaust temperature sensor is rising Exhaust Temperature Sensor Error abnormally (over 208 °F)  Exhaust temperature sensor error (Wire color: Blue-Blue) Checkpoint ...
  • Page 47 Service Manual E2 Error - Wire Check E2 Error - Disconnection Check 1. Check the connection of the wire. 1. Check if the Exhaust Temp. Sensor is disconnected. Disconnection: OL — Normal:      86 °F: 7.05 kΩ — 140 °F: 2.5 kΩ 201 °F: 952 Ω...
  • Page 48: E3 Error (Abnormal Operation: Return Sensor)

    Service Manual 8.17 E3 Error (Abnormal Operation: Return Sensor) Error Description Return Sensor Error Error is displayed when the Return sensor has short-circuited or is disconnected  Check if the Hot Water Thermistor connector is connected normally. 1. Control board wire 2.
  • Page 49 Service Manual E3 Error - Wire Check E3 Error - Disconnection Check 1. Check the connection of the wire. 1. Check if the Hot Water Thermistor is disconnected. Disconnection: OL — Normal:      86 °F: 40 kΩ — 140 °F: 12.4 kΩ 185 °F: 3.9 kΩ...
  • Page 50: E4 Error (Abnormal Operation: Pressure Sensor)

    Service Manual 8.18 E4 Error (Abnormal Operation: Pressure Sensor) Error Description Pressure Sensor Error Error is displayed when the pressure sensor has short-circuited or is disconnected  Check if the Hot Water Thermistor connector is connected normally. 1. PCB wire 2.
  • Page 51 Service Manual E4 Error - Wire Check E4 Error - Pressure Sensor Check 1. Check the connection of the wire. 1. Measure the resistance of the Pressure sensor. 2. Check the pressure sensor input voltage at the control board. Normal:      DC 5 V —...
  • Page 52: E7 Error (Abnormal Operation: Gas Valve Relay)

    Service Manual 8.19 E7 Error (Abnormal Operation: Gas Valve Relay) Error Description Gas valve relay error It occurs when the gas valve relay which is mounted on control board is stuck closed. Checkpoint  Replace the control board Table 39 8.20 EB Error (Hot Water Overheating) Error Description...
  • Page 53 Service Manual EB Error - Temperature Resistance Check 1. Check if the resistance matches the temperature on the following temperature resistance table. 86 °F: 40 kΩ — 140 °F: 12.4 kΩ — 185 °F: 3.9 kΩ — KΩ Figure 82 Singular Combi Boiler - BTC 439002301 A (12.2021) | 53...
  • Page 54: Components Replacement Instructions

    Service Manual 9 Components Replacement Instructions 9.1 Preparation Step 1. Shut off the gas supply valve. Cold water Hot water Figure 86 4. Loosen the 2 screws and open the case. Figure 83 2. Pull out the power supply line. Figure 84 3.
  • Page 55: Control Board

    Service Manual 9.2 Control Board 9.4 Sensor, DHW 1. Refer to 9.1 Preparation Step. 1. Refer to 9.1 Preparation Step. 2. Loosen the connection terminals in the control board. 2. Disconnect the temperature sensor terminal. 3. Loosen the 3 control board fi xing screws (circled in blue) assembled to the 3.
  • Page 56: Gas Orifi Ce

    Service Manual 9.6 Gas Orifi ce 9.7 Air Pressure Switch 1. Refer to 9.1 Preparation Step. 1. Refer to 9.1 Preparation Step. 2. Loosen the bottom part of the gas outlet pipe slightly using a wrench. 2. Separate the silicon hose from the air mixer. 3.
  • Page 57: Gas Valve

    Service Manual 9.8 Gas Valve 9.10 High Limit Cutout Supply T3 (203°F) 1. Refer to 9.1 Preparation Step. 1. Refer to 9.1 Preparation Step. 2. Disconnect the wire from the gas valve (Item 1). 2. Disconnect the wire from the high limit cutout (Item 2). 3.
  • Page 58: Electrode Assembly

    Service Manual 9.12 Electrode Assembly 9.13 Flame Rod 1. Refer to 9.1 Preparation Step. 1. Refer to 9.1 Preparation Step. 2. Separate the electrode assembly connection terminal (Item 1). 2. Separate the fl ame rod connection terminal.(Item 1). 3. Separate the electrode assembly cap (Item 2). 3.
  • Page 59: Touch Pad

    Service Manual 9.14 Touch pad 9.15 Condensation Trap 1. Refer to 9.1 Preparation Step. 1. Refer to 9.1 Preparation Step. 2. Separate the touch pad from the touch pad bracket by pushing it up (Item 1). 2. Drain the water using the drain valve and water fi lter (Item 2). Figure 104 Figure 107 3.
  • Page 60: Turbo Fan

    Service Manual 5. Remove fan and silencer from boiler by pulling out silencer end fi rst. 9.16 Turbo Fan 1. Refer to 9.1 Preparation Step. 2. Separate the fan connection terminal (Item 1), solenoid valve terminal (Item 2), overheat sensor wire (Item 3), and heat exchanger temperature sensor (Item 4).
  • Page 61: Solenoid Valve

    Service Manual 9.17 Solenoid Valve 1. Refer to 9.1 Preparation Step. 2. Remove the fan and then separate the silencer from the fan according to Section 9.16. 3. Separate the solenoid valve unit (Item 2) by removing the 2 fi xing screws (Item 1), Figure 116 4.
  • Page 62: Heat Exchanger

    Service Manual 9.18 Heat Exchanger WARNING: FIRE, EXPLOSION, PERSONAL INJURY  Prior to performing any work on the boiler, ensure the gas supply is turned off and power unplugged . 1. Refer to 9.1 Preparation Step. 2. Drain the water using the drain valve and water fi lter (Item 1). Figure 120 6.
  • Page 63 Service Manual 9. Remove four fl ue connector fi xing screws and separate from top of boiler. 12. Remove connecting clip and separate condensate hose from bottom of heat exchanger. Figure 123   Venting may need to be moved to make room for the fl ue connector to be Figure 126 removed.
  • Page 64 Service Manual 14. Remove phillips screws on upper and lower heat exchanger bracket located on right and left side of the heat exchanger (Fig.129). Figure 128 15. Remove heat exchanger/fan from boiler. 16. Install replacement heat exchanger in reverse order. Singular Combi Boiler - BTC 439002301 A (12.2021) 6 4 |...
  • Page 65: Flushing The Heat Exchanger

    Service Manual 10 Flushing the Heat Exchanger NOTICE: BOILER DAMAGE  Flushing the Heat Exchanger annually is a required maintenance. In hard water conditions, it needs to take a place more often. Flushing the Heat Exchanger is a somewhat complicated procedure. Read the following instruction carefully before attempting this procedure.
  • Page 66 Service Manual NOTES: Singular Combi Boiler - BTC 439002301 A (12.2021) 6 6 |...
  • Page 67 Service Manual NOTES: Singular Combi Boiler - BTC 439002301 A (12.2021) | 67...
  • Page 68 United States and Canada Bosch Thermotechnology Corp. 65 Grove St. Watertown, MA 02472 Tel: 866-642-3198 Fax: 603-965-7581 www.bosch-thermotechnology.us BTC 439002301 A / 12.2021 Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances.

This manual is also suitable for:

Singular 5200

Table of Contents