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Bosch SRS4002GB Repair Instruction

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42
Diagnosis Aids
42
Repair
1
SAFETY ........................................................ 3
2
INSTALLATION ............................................ 4
2.1
Aligning the appliance........................................................ 4
2.2
Electrical connection .......................................................... 4
2.3
Water connection................................................................ 4
3
OPERATION ................................................. 5
3.1
Function............................................................................... 5
3.2
Programme reset ................................................................ 6
3.3
Special functions ................................................................ 6
3.4
General information on control ......................................... 7
3.5
Function............................................................................. 10
3.6
Programme reset .............................................................. 10
3.7
Special functions .............................................................. 11
3.8
General information on control ....................................... 11
3.9
Function............................................................................. 14
3.10
Programme reset .............................................................. 15
3.11
Special functions .............................................................. 15
3.12
General information on control ....................................... 15
3.13
Function............................................................................. 18
3.14
Terminating the programme ............................................ 18
4
COMPONENTS........................................... 19
4.1
Actuator ............................................................................. 19
4.2
Aqua sensor (optional) ..................................................... 20
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Dishwasher
4.3
Aqua Stop valve................................................................ 21
4.4
Worktop (optional)............................................................ 23
4.5
NTC .................................................................................... 23
4.6
Salt and rinse-aid indicators (optional) .......................... 24
4.7
Hinge.................................................................................. 25
4.8
Safety temperature controller.......................................... 26
4.9
Dispenser .......................................................................... 27
4.10
Water softening system ................................................... 28
4.11
Regeneration / drainage valve......................................... 29
4.12
Filter system ..................................................................... 30
4.13
Rinsing and pumping system.......................................... 31
4.14
Door spring ....................................................................... 32
4.15
Circulation pump .............................................................. 33
4.16
Detergent-solution pump ................................................. 34
4.17
Level sensor with safety function ................................... 35
4.18
Spray system .................................................................... 36
4.19
Water inlet without heat exchanger ................................ 37
4.20
Water inlet with heat exchanger ...................................... 39
5
FUNCTIONS................................................41
6
REPAIR .......................................................42
6.1
Diagnosis aids .................................................................. 42

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  Summary of Contents for Bosch SRS4002GB

  • Page 1: Table Of Contents

    Dishwasher Aqua Stop valve..............21 SAFETY ............3 Worktop (optional)............23 INSTALLATION ..........4 NTC ..................23 Salt and rinse-aid indicators (optional) ......24 Aligning the appliance............4 Hinge.................. 25 Electrical connection ............4 Safety temperature controller.......... 26 Water connection..............4 Dispenser ................
  • Page 2 FAULT DIAGNOSTICS....... 43 Controller / module ............43 Controller / module ............44 Draining ................45 Odour ................. 46 Noises ................47 Rinsing result ..............48 Drying result..............56 Circulation pump .............. 57 TECHNICAL SPECIFICATIONS ....58 General technical specifications ........58 Consumption rates ............

  • Page 3: Safety

    SAFETY WARNING DANGER Comply with the following instructions: Repairs may be carried out by a qualified electrician only! If conducting the test in accordance with VDE 0701 via the connector, The user may be put at risk and injured by improper repairs! the heater (instantaneous water heater) must be tested directly for insulation faults due to all-pole disconnection (relays;...

  • Page 4: Installation

    water line with a water pressure of at least 0.5 bar (0.5 at.) (when the INSTALLATION tap is turned on, the water flow rate must be more than 8 l/min.). If the water pressure is more than 10 bar (10 at.), a pressure reducing valve Aligning the appliance must be installed.

  • Page 5: Operation

    3.1.2 Push buttons / Programme selection OPERATION Timer programming (ZVW) The electronic control consists of two modules, fitted in a housing. The control / power module is connected to the control / display module by The timer preselection button is used to delay the programme start by a ribbon cable.

  • Page 6: Programme Reset

    3.1.3 Display Special functions A 2½-digit 7-segment display enables programme run times, etc., over 3.3.1 Setting the hardness range 99 min. to be displayed. The remaining running time is recalculated at the end of the heating positions. If deviations occur on account of the Hold down the S3 button and switch on the appliance.

  • Page 7: General Information On Control

    3.4.4 Memory electronics General information on control The electronics module has its own memory which remembers the 3.4.1 Tap turned off programme last selected. If no new selection is made at the start of the programme, the programme last selected will run. The appliance stops in the programme 6 minutes after the start of programme (scan filling position).
  • Page 8 Front: 3.4.8 Listing of triacs If replacing a module due to a defective triac, ensure that the actuated component is also checked. R5 = Filling level R6 = Filling level TY6 = Heat exchanger outlet valve TY7 = Dispenser actuator TY8 = Regeneration valve TY9 = Filler valve TY11 = Actuator for top basket valve / water points...
  • Page 9 Programme sequence during the initial start-up with heat exchanger 3.4.9 Initial start-up / Replacing the electronics The following programme sequence must be taken into consideration PZ>0 during the initial start-up or when replacing the electronics. Programme ( Programme counter = 0 ! ) counter Programme sequence during the initial start-up without heat PZ=0...

  • Page 10: Function

    The electronic control consists of two modules, fitted in a housing. The 3.5.2 Push buttons / Programme selection control / power module is connected to the control / display module by a ribbon cable. Intensive 70 The programme consists of a prerinse at 50°, wash cycle at 70°, two Function intermediate rinse cycles, final rinse at 70°...

  • Page 11: Special Functions

    3.8.2 Regeneration electronics Special functions The electronics determine, in comparison with the water hardness set 3.7.1 Setting the hardness range on the appliance, the number of rinse cycles which are possible until the softening system is exhausted. Hold down the S3 button and switch on the appliance. The low salt LED flashes.
  • Page 12 Front: 3.8.6 Sensors All outgoing signals from the door switch, the level switch, the NTC sensor and the refill switches are recorded and evaluated by the microprocessor at the required time. 3.8.7 Components The components such as the drainage pump, the valves, the detergent and rinse aid dosage are controlled by triacs.
  • Page 13 3.8.8 Initial start-up / Replacing the electronics The following programme sequence must be taken into consideration during the initial start-up or when replacing the electronics. ( Programme counter = 0 ! ) PZ>0 Programme counter PZ=0 Pump 15 sec. Salt refill indicator Salt refill Salt refill...

  • Page 14: Function

    3.9.2 Pushbuttons / Programme selection Intensive 70 The programme consists of a prerinse at 50°, wash cycle at 70°, two intermediate rinse cycles, final rinse at 70° and a drying cycle. Normal 65 The programme consists of a prerinse, a wash cycle at 65°, two intermediate rinse cycles, final rinse at 69°...

  • Page 15: Programme Reset

    3.12.2 Regeneration electronics (optional) 3.10 Programme reset The electronics determine, in comparison with the water hardness set When the appliance is switched on, simultaneously press the S2 and on the appliance, the volume of water which is possible until the the S4 buttons for 3 sec.
  • Page 16 3.12.5 Memory electronics The electronics module has its own memory which remembers the programme last selected. If no new selection is made at the start of the programme, the programme last selected will run. 3.12.6 Power failure The electronics module has a power failure memory function which ensures that the current rinse programme continues in the event of a power failure or programme interruption.
  • Page 17 Programme sequence during the initial start-up without heat Programme sequence during the initial start-up with heat exchanger exchanger PZ>0 Programme counter PZ=0 PZ>0 Programme counter Pump 15 sec. PZ=0 Pump 15 sec. Salt refill indicator Salt refill Salt refill = ON = OFF Salt refill Prefill heat...

  • Page 18: Function

    The programme is selected via the programme selector. 3.14 Terminating the programme Switch off the main switch; to drain residual water from inside the appliance, rotate the programme selector in a clockwise direction to the drying position; switch on the main switch; wait until the residual water has been drained;...

  • Page 19: Components

    COMPONENTS Actuator The thermo hydraulic system consists of a metal cylinder with plunger. The cylinder is filled with a substance which expands greatly when heated. The heat source is a PTC (positive temperature coefficient) which is in direct contact with the metal cylinder. A strong pressure spring returns the plunger back to its original position when the heat source is switched off.

  • Page 20: Aqua Sensor (Optional)

    Aqua sensor (optional) The infrared light-emitting diode and the photodiode are located opposite each other in a U-shaped translucent housing on a board. The infrared diode transmits infrared light through the water flowing between the U to the light-sensitive base of the photodiode which then becomes conductive.

  • Page 21: Aqua Stop Valve

    Aqua Stop valve The valve system consists of two valves in series, which are actuated electrically parallel, and the filler valve and safety valve. The safety function may be actuated via the safety level chamber or electrically via the float in the base pan. The water flow is then stopped mechanically.
  • Page 22 Removal Open the housing; disconnect the inlet hose; sever the electrical connection cables; strip the insulation from the ends of the wires; push the shrink-fit hose over the cable; connect the wires to the insulating sleeves (1). After fitting, warm the connectors until the shrinkage process occurs and the hot-melt adhesive comes out of the ends of the connectors (2).

  • Page 23: Worktop (Optional)

    Worktop (optional) Catch tappets are located on the rear right and left hand sides of the The utilised temperature safety switch (>85 °C) is combined with the worktop. To remove the worktop, press up the catch tappets, push the NTC sensor. If a fault occurs, the heater is switched off at a water worktop back and lift off.

  • Page 24: Salt And Rinse-Aid Indicators (Optional)

    Salt and rinse-aid indicators (optional) The dispenser contains a float with an integrated permanent magnet. The magnetic field actuates a reed switch on the outside of the dispenser. The lamps of the refill indicators in the control panel are switched on via this reed switch. = Permanent magnet = Reed switch open = Reed switch closed...

  • Page 25: Hinge

    Hinge Unscrew the outer door, the base, the angle strip and the side panels; disengage the tension cord from the hinge lever; unscrew the hinge lever from the inside door; unscrew the hinge plate from the container frame. Unscrew the fixing screw which connects the hinge to the base pan; lever the hinge plate off the frame;...

  • Page 26: Safety Temperature Controller

    Safety temperature controller The utilised temperature safety switch (>85 °C) is combined with the temperature controller (65 °C). If a fault occurs, the heater is switched off at a water temperature of 85 °C (operates in switching mode). 58300000002393_ara_en_a.doc – 31.07.07 Seite 26 von 60...

  • Page 27: Dispenser

    Dispenser The release mechanism is actuated via an actuator. When the actuator is actuated for the first time, the detergent-dispenser cover is opened. At the same time the release pawl engages with the switching core of the rinse-aid lever so that when the actuator is actuated again, the dosing plunger is lifted off the rinse aid.

  • Page 28: Water Softening System

    4.10 Water softening system Unscrew the outside door, the base panel, the angle strip and the side Salt container: panels; unfasten the tension cords on the hinge levers; unscrew the Capacity: Finely ground salt approx. 1.3 kg screws which connect the base pan to the hinge plates; unscrew the rinsing tank from the rear panel of the base pan;...

  • Page 29: Regeneration / Drainage Valve

    4.11 Regeneration / drainage valve The regeneration valve and the drainage valve are situated in the water softening system. If the regeneration valve is actuated, the water stored in the regeneration chamber is conveyed through the water softening system. If the drainage valve is actuated, the water stored in the heat exchanger (HE) is conveyed into the rinsing tank via the water softening system.

  • Page 30: Filter System

    4.12 Filter system The filter system consists of four-fold filtration (coarse filter, fine filter cylinder, surface fine filter, microfine filter). The pump sump, which houses the microfine filter, is covered by the surface fine filter. The surface fine filter is attached with the combined coarse and fine filter cylinders to the base of the pump sump via a bayonet catch.

  • Page 31: Rinsing And Pumping System

    4.13 Rinsing and pumping system The circulation and drainage pumps as well as the instantaneous water heater are connected to the pump sump via plug-and-socket connections. The instantaneous water heater is also screwed securely to the pump sump. The filter system consists of four-fold filtration (coarse filter, fine filter cylinder, surface fine filter, microfine filter).

  • Page 32: Door Spring

    4.14 Door spring If the furniture doors are very heavy (e.g.: marble), the tensile force of The door spring compensates for the weight of the furniture front. the standard installed springs and maximum pretension of the spring tensioner is no longer adequate. The door springs are situated on the right and left under the base pan.

  • Page 33: Circulation Pump

    4.15 Circulation pump The circulation pump consists of a single-phase alternating current motor. Removal: Remove the side panels and base plate, release the stainless steel container / plastic base pan, consisting of 4 screws (front and back). Place the container on its back and fold down the base module. Note: Disconnect the level sensor housing from the base module.

  • Page 34: Detergent-Solution Pump

    4.16 Detergent-solution pump Remove the base panel and base plate; the detergent-solution pump is locked in position at the front left side of the pump sump. To remove the detergent-solution pump, disengage the lever (1), then rotate the pump forwards (2). The pump can be removed by rotating it through approx.

  • Page 35: Level Sensor With Safety Function

    4.17 Level sensor with safety function If the dishwasher controller or components malfunction, causing the machine to overfill, the valve combination is closed via the safety system, shutting off the water supply. The drainage pump is switched on via the safety level switch. Pumping continues until the safety level switch switches back again.

  • Page 36: Spray System

    4.18 Spray system The rotor spray system consists of three spraying levels, the lower and upper spray arms and a roof shower head. Water is supplied to the upper spray arm and the roof shower head via the supply pipe attached to the inside of the tank rear panel.

  • Page 37: Water Inlet Without Heat Exchanger

    4.19 Water inlet without heat exchanger When the filler valve has been opened, the water flows towards the integrated inlet via a free flow channel and into the regeneration chamber. When the regeneration chamber has been filled, the water flows through the water softening system via the overflow channel and then flows as soft water into the level sensor and pump sump.
  • Page 38 4.19.1 Filling procedure for appliances without a heat exchanger When the static level has been reached, the module is actuated by the level switch, moves to the next position and the circulation pump is switched on. When the circulation pump starts up, the level pressure switch switches back.

  • Page 39: Water Inlet With Heat Exchanger

    4.20 Water inlet with heat exchanger When the filling valve has been opened, the water flows towards the integrated inlet via the free flow channel and into the water softening system and as soft water into the heat exchanger. When the regeneration chamber has filled up, the water flows into the restricting funnel of the level sensor via the overflow channel.
  • Page 40 4.20.1 Filling process for appliances with heat exchanger During the initial water inflow for the rinse programme this volume of The electronics measure the time between the opening command of water compensates for the loss of water which is used to wet the dry the filling valve and the closing of the level switch (f1).

  • Page 41: Functions

    FUNCTIONS See Components 58300000002393_ara_en_a.doc – 31.07.07 Seite 41 von 60...

  • Page 42: Repair

    REPAIR Diagnosis aids Transparent door: Material no.: 21 7116 – appliance dimension 81 cm Test prod: Material no.: 340730 (remove the components from the module before measuring the resistance) Protective gloves: Material no.: size 9 = 340728 size 10 = 340729 58300000002393_ara_en_a.doc –...

  • Page 43: Fault Diagnostics

    FAULT DIAGNOSTICS Controller / module Customer complaint Cause Remedial action Running time too long Alternate rinsing technology, energy saving Advise customer, See Consumption rates Alternate rinsing technology Component is not actuated Triac on the module does not switch properly, smoke traces Before replacing the module, always measure may be visible on the module the connected consumers (valves, actuators, etc.).

  • Page 44: Controller / Module

    Controller / module Customer complaint Cause Remedial action Running time too long Alternating rinse technology, energy saving Advise customer, See Consumption rates Alternate rinsing technology Component is not actuated Triac on the module does not switch properly, smoke traces Before replacing the module, always measure may be visible on the module the connected consumers (valves, actuators, etc.).

  • Page 45: Draining

    Draining Customer complaint Cause Remedial action Pump is running audibly, but Filter system blocked Advise customer, conveying no or little water see operating instructions for cleaning the filter. Clean the filter. Trap in the inlet spigot (pump sump) dirty. Advise customer. Clean the trap in the intake spigot of the pump. Non-return flap is stuck in the outlet Remove non-return flap.

  • Page 46: Odour

    Odour Customer complaint Cause Remedial action Smell of burning Connection cable improperly extended Advise customer, follow safety instructions in the operating instructions Socket to which the appliance is connected is charred Advise customer; socket and connection cable must be (cause: socket has bad contact) replaced Damaged windings or insulation fault on the consumers Measure consumers (test programme) and check...

  • Page 47: Noises

    Noises Customer complaint Cause Remedial action Striking noises on the water inlet in the pipe Installation or cross-section of the water line Advise customer and refer to plumber system (usually occurs on appliances which feature (have pressure reducing valve fitted). Aqua Stop valve because the valve is connected directly to the tap) Rattling noises during the rinse cycle...

  • Page 48: Rinsing Result

    Rinsing result Food remnants or sandy residue Limescale (Analyse with diagnosis case 340070 / 10 % hydrochloric acid) Starch deposits (Analyse with diagnosis case 340070 / iodine solution) Water-soluble or regeneration salt residue (Analyse with diagnosis case 340070 / dest. water) Discoloration / colour residue (e.g.
  • Page 49 Food remnants or sandy residue (see additional information in general repair instructions) Customer complaint Cause Remedial action Food remnants or sandy Rough, micro or fine sieve blocked, sieve not locked in the Advise customer, sieve insert and care residue pump sump –...
  • Page 50 Customer complaint Cause Remedial action Food remnants or sandy Snorkel noises; circulation pump does not run uniformly, Check level sensor function (implement filling residue insufficient water in the appliance (note: intervals approx. process) 1 min if using alternate rinsing technology) Non-return valve leaking, dirty water flows back into the Remove non-return valve, check valve and seat for appliance...
  • Page 51 Limescale (see additional information in the general repair instructions) Customer complaint Cause Remedial action Limescale on the utensils Hardness range incorrectly set or untreated water hardness > Adjusting hardness range 50 °dH, check residual hardness in the wash and final rinse Advise customer, use phosphatic detergent.
  • Page 52 Starch deposits (see additional information in the general repair instructions) Customer complaint Cause Remedial action Starch deposits on the Underdosing of detergent (wrong detergent) Advise customer, use enzyme detergent utensils Wrong programme selected Advise customer, select correct programme (too weak programme selected) Appliance connected to hot water, water inlet temperature too Check hot water connection (setpoint: lower than high...
  • Page 53 Water-soluble or regeneration salt residue on the dishes (see additional information in the general repair instructions) Customer complaint Cause Remedial action Water-soluble residue Regeneration salt on the utensils – Leaking salt dispenser cover (check screw-fitting, Advise customer, eliminate leaks regeneration dispenser is dispensing slowly) –...
  • Page 54 Discoloration / colour residue (see additional information in the general repair instructions) Customer complaint Cause Remedial action Colour residue Insufficient detergent used Advise customer, increase amount of detergent Plastic discoloration by, e.g.: tomato remnants, tea, Use detergent containing chlorine bleach. coffee, etc.
  • Page 55 Detergent residue (see additional information in the general repair instructions) Customer complaint Cause Remedial action Detergent residue Detergent cover blocked by utensils Advise customer, dishwasher not loaded properly (does not open fully) Detergent cover does not open fully Replace spring of dispensing device Wrong programme selected Advise customer Tablets used in quick or short programme...

  • Page 56: Drying Result

    Drying result Customer complaint Cause Remedial action Not drying correctly No rinse aid in the dispensing device Advise customer Appliance connected to hot water, appliance is suitable Advise customer, refer to function of the heat for hot-water connection, but not recommended. exchanger;...

  • Page 57: Circulation Pump

    Circulation pump Customer complaint Cause Remedial action Circulation pump does not After a prolonged idle time the seal set may stick to The seal set must be replaced, start the pump wheel. 58300000002393_ara_en_a.doc – 31.07.07 Seite 57 von 60...

  • Page 58: Technical Specifications

    TECHNICAL SPECIFICATIONS General technical specifications Voltage / frequency 230–240 V / 50 Hz Connected load 2.3 kW Heat output 2.15 kW Fuse 10 / 13 A 58300000002393_ara_en_a.doc – 31.07.07 Seite 58 von 60...

  • Page 59: Consumption Rates

    Consumption rates 8.2.1 Appliance with water points and heat exchanger Intensive 70° auto 55–65° Normal 65° Eco 50° Gentle 40° Quick 35° Prerinse Duration in min. 100–140 Current consumption in kWh 1.35 0.75–1.05 1.15 0.65 Water consumption in litres 12–18 8.2.2 Appliance with water points without heat exchanger Intensive 70°...

  • Page 60: Seite 1 Von

    Consumption rates 8.3.1 Appliance with water points without heat exchanger Intensive 70° auto 55–65° Normal 65° Eco 50° Gentle 40° Quick 35° Prerinse Duration in min. 100–135 Current consumption in kWh 1.4 1.0–1.3 Water consumption in litres 12–18 8.3.2 Appliance without water points without heat exchanger Intensive 70°...