Bosch Singular 4000 Manuel utilisateur

Service Manual

Gas Condensing Combi Boilers

Singular

Singular 4000 | Singular 5200

BTC 439002301 A / 12.2021

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.

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Service Manual

Singular Combi Boiler - BTC 439002301 A (12.2021)

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Service Manual

Singular Combi Boiler - BTC 439002301 A (12.2021)

Table of Contents

1 Key to Symbols and Safety Instructions 4

1.1 Key to Symbols 4

1.2 Safety 4

2 Key Components 6

3 Technical Data 8

4 Dimensions 9

5 Setting the DIP Switches 10

6 Wiring Diagram 11

7 Key Components Description 12

7.1 Pump 12

7.2 Turn Down Ratio (TDR) Solenoid valve 12

7.3 Oriﬁ ce 13

7.4 Fan 13

7.6 High Limit Cutout HEX T2 (302°F) 14

7.7 High Limit Cutout Supply T3 (203°F) 14

7.8 Primary Heat Exchanger 14

7.9 Secondary Heat Exchanger 15

7.10 Sensor 15

7.11 Electrode 16

7.12 Flame Rod 16

7.13 Ignition Transformer & Wire 16

7.14 Burner 17

7.15 Gas Valve 17

7.16 Touch Pad 17

7.17 Control Board 18

7.18 Condensate Trap Assembly 18

7.19 Air Pressure Switch 18

8 Troubleshooting 19

8.1 A2 Error (Abnormal Operation: Fan) 19

8.2 A3 Error (Abnormal Operation: Pump) 21

8.3 A4 Error (Overheating of Heat Exchanger) 23

8.4 A5 Error (Low Water Pressure) 25

8.5 A6 Error (Ignition Error) 27

8.6 A7 Error (Abnormal Operation: Gas Valve Relay) 29

8.7 A8 Error (Abnormal Operation: Gas Valve) 29

8.8 A9 Error (Exhaust Temperature Sensor Error) 31

8.9 AA Error (Overheating) 33

8.10

AB Error (Abnormal Operation: Heat Exchanger Temperature Sensor 34

8.11 AC Error (Abnormal Operation: DHW Sensor) 36

8.12 AD Error (Clog of Condensate Trap) 38

8.13 AE Error (Blockage of Flue Pipe) 40

8.14 EO Error (Abnormal Operation: Outdoor Temperature Sensor) 42

8.15 E1 Error (Abnormal Operation: Exhaust Temperature Sensor) 44

8.16 E2 Error (Exhaust Temperature Overheating) 46

8.17 E3 Error (Abnormal Operation: Return Sensor) 48

8.18 E4 Error (Abnormal Operation: Pressure Sensor) 50

8.19 E7 Error (Abnormal Operation: Gas Valve Relay) 52

8.20 EB Error (Hot Water Overheating) 52

9 Components Replacement Instructions 54

9.1 Preparation Step 54

9.2 Control Board 55

9.3 Sensor, Heating/Return 55

9.4 Sensor, DHW 55

9.5 Exhaust Temperature Sensor_T4 (Blue) 55

9.6 Gas Oriﬁ ce 56

9.7 Air Pressure Switch 56

9.8 Gas Valve 57

9.9 High Limit Cutout HEX T2 (302°F) 57

9.10 High Limit Cutout Supply T3 (203°F) 57

9.11 Ignition Transformer 57

9.12 Electrode Assembly 58

9.13 Flame Rod 58

9.14 Touch pad 59

9.15 Condensation Trap 59

9.16 Turbo Fan 60

9.17 Solenoid Valve 61

9.18 Heat Exchanger 62

10 Flushing the Heat Exchanger 65

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Service Manual

Singular Combi Boiler - BTC 439002301 A (12.2021)

1 Key to Symbols and Safety Instructions

1.1 Key to Symbols

Warnings

Warnings in this document are identiﬁ ed by a

warning triangle printed against a grey background.

Keywords at the start of a warning indicate the type and seriousness

of the ensuing risk if measures to prevent the risk are not taken.

The following keywords are deﬁ ned and can be used in this document:

DANGER indicates a hazardous situation which, if not avoided, will result

in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could

result in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, could

result in minor to moderate injury.

NOTICE is used to address practices not related to personal injury.

Important information

This symbol indicates important information where

there is no risk to people or property.

1.2 Safety

Please read before proceeding

WARNING: FIRE, EXPLOSION

Vapors from flammable liquids can explode and/or catch fire

causing death or severe burns.

Keep flammable products far away from the boiler and store

them in approved containers. Keep the containers tightly

closed and out of the reach of children.

The boiler has a main burner flame that can come on at any

time and will ignite flammable vapors.

Vapors cannot be seen and are heavier than air. They can

travel long distances along the ground and can be carried

from other rooms to the boiler’s main burner flame by air

current.

WARNING: SCALD HAZARD

Water temperature over 125°F can cause severe burns or

death from scalding.

If it is necessary to set the water temperature above 125°F

(52°C), consider installing a thermostatically-controlled

mixing valve. Contact a licensed plumber or your local

plumbing authority for more information.

Children, the disabled and the elderly are at highest risk of

being scalded.

Test water before bathing or showering.

Temperature Time to Produce Serious Burn

120 °F (48 °C) More than 5 minutes

125 °F (51 °C) 1.5 to 2 minutes

130 °F (54 °C) Approx. 30 seconds

135 °F (57 °C) Approx. 10 seconds

140 °F (60 °C) Less than 5 seconds

145 °F (62 °C) Less than 3 seconds

150 °F (65 °C) Approx. 1.5 seconds

155 °F (68 °C) Approx. 1 second

Table 1

WARNING: RISK OF PERSONAL INJURY OR DEATH FROM EXPLOSION!

Work on gas components may only be carried out by a

trained and certified installer or service company.

Appliance installation, the connection of gas and vent

piping, initial commissioning, electrical connections, and

service and maintenance must only be carried out by a

trained and certified installer or service company.

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Service Manual

Singular Combi Boiler - BTC 439002301 A (12.2021)

WARNING: FIRE, EXPLOSION

Do not store combustibles, such as papers or laundry, near

the boiler or venting system.

 Do not store or use gasoline or other flammable liquids near

this boiler.

Do not store or use compressed gases, such as hair sprays

or spray paints, near the boiler or venting system, including

the vent termination.

WARNING: HAZARDOUS VOLTAGE

Do not remove the front cover unless the power to the boiler

is turned off or disconnected.

Do not touch the internal components of the boiler or the

power cord with wet hands.

WARNING: FIRE, CARBON MONOXIDE

Do not operate the boiler with the front cover opened.

Do not operate the boiler without proper venting.

Do not place anything in or around the vent terminals that

could obstruct the air ﬂ ow in or out of the boiler.

WARNING: FIRE, EXPLOSION

Have your installer or plumber show you the location of the

gas shut off valve and demonstrate how to close the valve. If

the boiler is damaged as a result of overheating, fire, flood,

or any other reason, close the manual shut off valve and do

not operate the boiler again until it has been inspected by a

qualified technician.

WARNING: FIRE, EXPLOSION

Should overheating occur or if the gas supply fails to shut

off, turn off the manual gas shut off valve.

WARNING: PERSONAL INJURY, PROPERTY DAMAGE

Do not allow children to operate or have access to the boiler.

WARNING: IMPROPER OR DANGEROUS OPERATION

Immediately call a qualified service technician to inspect the

appliance and replace any part of the control system and/or

any gas control which has been immersed in water.

WARNING:

This product can expose you to chemicals including Lead

and Lead components, which are known to the State

of California to cause cancer and birth defects or other

reproductive harm. For more information go to www.

P65Warnings.ca.gov.

WARNING: FIRE, CARBON MONOXIDE

After replacement of a gas related component, where a

gasket of seal has been disturbed or replaced, check for gas

tightness using a gas detector / analyzer.

On re-assembly check all affected seals for cracks hardness

and deterioration. If damaged or in any doubt the seal must

be replaced.

CAUTION: INTENDED USE

Do not use the boiler for anything other than its intended

purpose, as described in this manual.

CAUTION: IMPROPER OR DANGEROUS OPERATION

Do not use unapproved replacement or accessory parts.

When servicing the controls, label all wires prior to

disconnecting them to prevent wiring errors.

Do not attempt to repair or replace any part of the boiler,

unless it is specifically recommended in this manual. For all

other service, contact an authorized technician or licensed

professional. Improper adjustments, alterations, service, or

maintenance may lead to property damage, personal injury,

or death and will void your warranty.

NOTICE: BOILER DAMAGE

Do not turn on the boiler unless the water and gas supplies

are fully opened. Failure to do so may damage the boiler.

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Service Manual

Singular Combi Boiler - BTC 439002301 A (12.2021)

2 Key Components

Figure 1

Air intake connector

Gas connector/Orice

Gas valve

3-way valve

Pressure sensor

Space heating supply

Gas inlet

Hot water outlet

Burner hood

Heat Exchanger Cover

Pump

Air vent

Condensate drain

Space heating return

Cold water inlet

Exhaust temperature

sensor

Flue connector

Heating temperature

sensor (T2)

Return temperature

sensor

DHW temperature

sensor

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Service Manual

Singular Combi Boiler - BTC 439002301 A (12.2021)

Figure 2

Ignition transformer

Control Board

Touch Pad

Secondary heat

exchanger

Primary heat

exchanger

Flow sensor

Air Pressure Switch

TDR damper

Water Pressure Sensor

Turbo fan assembly

High Limit Cutout

Supply T3 (203°F)

High Limit Cutout

HEX T2 (302°F)

Condensate Trap

Flame rod

Electrode assembly

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Service Manual

Singular Combi Boiler - BTC 439002301 A (12.2021)

3 Technical Data

Singular 4000 Singular 5200

Heat Capacity (Input) Space Heating 19,900–80,000 BTU/H 19,900–140,000 BTU/H

Domestic Hot Water 19,900–155,000 BTU/H 19,900–199,000 BTU/H

Flow Rate (DHW) 45°F (25°C) Temp Rise 6.0GPM (23LPM) 7.7GPM (29LPM)

67°F (37°C) Temp Rise 4.0GPM (15LPM) 5.2GPM (20LPM)

AFUE Natural Gas (propane) 95.0% (95.0%) 95.0% (95.0%)

Dimensions (W x D x H) 18.1“ x 27.6” x 11.6“ (460 mm x 700 mm x 295 mm)

Installation Type Indoor wall-hung

Venting Type Forced draft direct vent

Ignition Electronic ignition

Water Pressure(Hydronic/DHW) 12~30psi /15~150 psi

Supply Pressure Natural Gas 3.5" – 10.5" WC

Propane 8" – 13" WC

Temperature Range Space Heating 82°F – 180°F(27°C – 82°C)

DHW 86°F – 140°F(31°C – 60°C)

Minimum Flow Rate (DHW) 0.5GPM(2.0LPM)

Power Supply Main Supply 120V AC, 60 Hz / uses less than 5 AMP

Connection Sizes

Space heating Supply/Return 1" NPT

Cold water Inlet 3/4" NPT

Hot Water Outlet 3/4" NPT

Gas Inlet 3/4" NPT

Materials Primary Heat Exchanger Stainless steel

Secondary Heat Exchanger Stainless steel

Venting

Exhaust/Intake "2"" or 3"" PVC, CPVC, Polypropylene

2"" or 3"" Special gas vent type BH (Class II, A/B/C)"

Length 2" 60ft(18.3m)

3" 150ft(45.7m)

Vent Clearances 0" to combustibles

Safety Devices Flame rod, APS, Over heat preventer, Low water cut oﬀ switch,

Exhaust temperature high limit sensor, Power surge fuse

Table 2

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Service Manual

Singular Combi Boiler - BTC 439002301 A (12.2021)

4 Dimensions

Figure 3

2.80"

(71.1 mm) 0.36" (9.2 mm)

18.11" (460 mm)

5.57"

(141.5 mm)

5.26"

(133.5 mm)

11.61" (295 mm)

4.0"

(101.6 mm)

3.6"

(91.4 mm)

2.7"

(68.6 mm)

1.6" (40.6 mm)6.1"

(154.9 mm)

2.8"

(71.1 mm)

3.4"

(86.4 mm)

4.7" (119.4 mm)

2.2"

(55.9 mm)

8.0" (203.2 mm)

A B C D E F 1.8"

(45.7 mm)

27.56" (700 mm)

31.87" (809.5 mm)

Position Description Diameter

A Space heating Return 1" NPT

B Cold water inlet 3/4" NPT

C Condensate Outlet 1/2" NPT

D Hot water Outlet 3/4" NPT

E Space heating Supply 1" NPT

F Gas Inlet 3/4" NPT

G Exhaust Vent 2"

H Air inlet 2"

Table 3

10 |

Service Manual

Singular Combi Boiler - BTC 439002301 A (12.2021)

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

Temperature limit switch for exhaust gas ON: No temperature limit for exhaust gas

OFF: Temperature limit for exhaust gas

EEP ROM data change switch ON: Enable EEP ROM data change

OFF: Disable EEP ROM data change

Long ﬂ ue Length 1 DIP S/W #3 DIP S/W #4

FLUE LENGTH

2” PVC 3” PVC

OFF OFF Up to 15' Up to 150'

Long ﬂ ue Length 2

OFF ON Up to 30'

N/AON OFF Up to 45'

ON ON Up to 60'

N/A N/A

Minimum heat capacity operation ON : Minimum operation

OFF : Normal operation

Maximum heat capacity operation ON : Maximum operation

OFF : Normal Operation

N/A N/A

Table 4 Dip Switches

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