Bosch Condens 2000 W Bedienungsanleitung

6 720 644 062-00.1O

Condens 2000 W

Service Manual

ZWB24 - 1AR...

TT-RH/PRMM21 - 01.2017

2| Content

Content

1 Safety precautions and symbols 3

1.1 Safety precautions 3

1.2 Symbols 3

2 Service Function Adjustment 4

2.1 Service Function 4

2.2 Overview Service Function 4

2.2.1 1. Service Level 4

2.2.2 2. Service Level 5

3 Failures / Errors 6

3.1 Elimination of errrors 6

3.2 Failure / Error Codes Overview 7

3.3 Failure codes and corrections steps 8

3.4 Sensor (NTC) Values 24

3.4.1 Flow Temperature Sensor 24

3.4.2 Domestic Hot Water Temperature Sensor 24

3.4.3 Flue Gas Safety Temperature Sensor ( Behind

Burner) 24

3.5 Electrical Datas 25

3.6 Electrical Circuit Diagram 26

3.7 Structure 27

3.8 Function Diagram 29

4 Gas Values (CH and DHW) 30

Safety precautions and symbols | 3

1 Safety precautions and symbols

1.1 Safety precautions

If you smell gas

BTurn off gas service cook.

BOpen windows.

BDo not operate any electrical switches.

BExtinguish any naked flames.

BLeave the building and telephone the gas company and

authorized dealer from an outside phone.

If you smell fumes from the appliance

BSwitch off the appliance.

BOpen windows and doors.

BInform your heating engineer.

Fitting and Modifications

BFitting of the appliance or many modifications to be appli-

ance may only be carried out by a compotent perEND.

BFlue systens must not be modified in any way.

BIf the appliance has a type B.. flue system : Ventilation

openings in doors, windows and walls must not be sealed

or restricted. If draught-proof windows are installed, meas-

ures must be taken to ensure there is an adequate supply

of air to the appliance for combustion.

Inspection / Maintenance

BWe recommend take out a to have the system regulary

serviced in order to ensure that it functions reliably and

safely.

BOnly use original spare parts.

Combustible materials

BDo not store or use any combustible materials (paper, thin-

ners, paints etc.) in the vicinty of the appliance.

Combustion Air / Ambient Air

BKeep combustion air/ambient air free of corrosive sub-

stances (e. g. halogenated hydrocarbons which contain

chlorine or fluorine compounds). In this way corrosion can

be prevented.

Instructions to the customer

BExplain to the customer how the appliance works and how

to operate it.

BAdvise the customer that he / she must not make any mod-

ifications to the appliance or carry out any repairs on it.

1.2 Symbols

Signal words indicate the seriousness of the hazard in terms

of the consequences of not following the safety instructions.

•Caution indicates that minor damage to property could

result.

•Warning indicates that minor personal injury or serious

damage to property could result.

•Danger indicates that serious personal injury could result.

In particularly serious cases, lives could be at risk.

Notes contain important information in cases where there is

no risk of personal injury or damage to property.

Safety instructions in this document are identi-

fied by a warning-triangle symbol and are print-

ed on a grey background.

Notes are identified by the symbol shown on

the left. They are bordered by horizontal lines

above and below the text.

4| Service Function Adjustment

2 Service Function Adjustment

2.1 Service Function

Service functions are in divided in 2 level :

•1. Level (see page 4)

•2. Level (see page 5)

Fig. 1

1Stand by (On/off) Button

2„Up (+)“ Button

3„Down (-)“ Button

4Temparature Display (°C)

5Service Button

2.2 Overview Service Function

2.2.1 1. Service Level

Operation

Change or query of a service function :

BPress buttonfor5second.Theservicefunctionwillbe

shown on Display (e.g. 1.2.C).

BSelect the desired/requested service code with “+” or “-”

button.

BPress button again (for entering).

After that you will see the selected (default) value on Dis-

play.

Changing / Adjustment of Value:

BChange the values with “+” or “-” button.

Storage/Save of Value :

BPress button until [ ]symbol will be shown on Display.

Exit from Service Level :

BFor the exit from service level press the or Stand by

button.

The flow temperature will be shown again on display.

1. Level

bar

6 720 644 501-07.1O

Service Code Description Range Initial (Factory

setting)

1.2.C Automatical Air Purging (0 = offý, 1= active ) Total time : 2 min.

and 20 sec on/off intervall 0 - 1 0

1.2.F Operating Mode : (0 = Normal, 3= min. output, 4 = max. output) 0, 3 , 4 0

1.3.b Burner Anticycling 1 - 10 min. 3 min.

1.3.C Burner start hysterisis (for flow temp. NTC) 0 - 10 K 5 K

1.5.b Fan overrun 1 - 18 (x10) sec. 3 (=30 sec.)

1.6.A Last failure on memory 00 - FF -

1.6.d Display actual water flow rate by turbine ( l/min. ) 0 - 99

1.7.A Operating LED (1 = on, 0 = 30 off after 30 sec.) 0 - 1 1

Tab. 1 1. level service functions

Service Function Adjustment | 5

2.2.2 2. Service Level

Operating

Change or query of a service function :

BTo enter to 2. service level must be entered first in 1. level.

Press button for 5 second. The service function onf1.

level will be shown on Display (e.g. 1.2.C).

BTo enter to 2. level : Press both “+” and “-” buttons for 3

second. The service function of 2. level will be shown on

Display (e.g. 2.1.A).

BSelect the desired/requested service code with “+” or “-”

button.

BPress button again (for entering)..

After that you will see the selected (default) value on Dis-

play.

Changing / Adjustment of Value:

BChange the values with “+” or “-” button.

Storage/Save of Value :

BPress button until [ ]symbol will be shown on Display.

Exit from Service level :

BFor the exit from service level press the or Stand by

button.

The flow temperature will be shown again on display.

2. Level

Service

Code Description Range Initial (Factory Setting)

2.1.A CH max. heat output 30 - 100 % 100 %

2.1.b DHW max. heat output (in winter mode) 30 - 100 % 100 %

2.2.b CH max flow temperature 35 - 82°C 82°C

2.3.d CH min. heat output 30 - 100 % 30 %

2.3.F Delay time after DHW in winter mode (Heating mode is disabled for this

period of time) 0 - 5 min. 1 min.

2.8.A Software version number e.g.. 162 112 -

2.8.E Reset to factory (default) setting 0 0

2.9.A Operation mode permanent : (0 = Normal, 1= min. power, 2 = max.

power) 0 - 2 0

2.9.E Delay time for the turbine ( each unit = 0,5 sec.) 1 - 6 2

2.9.F Pump over run) (CH circuit) 0 - 10 min. 3

2.A.A Actual flow temperature ºC -

2.A.b Actual DHW temperatur ºC -

2.A.F Actual combustion chamber temperature ºC -

2.b.d Selection of flue length (MAP Value) (0 = off, 1 - 10 : fan speed accord-

ing flue pipe length, see flue manuel for details) 0 - 10 0

2.b.F Solar mode delay time (sec.) 1 - 50 1

2.c.F Pump "over run” (DHW mode) 0 - 30 sec. 5 sec.

2.0.A Gas Convertion (0 = NG, 1 = LPG) 0 -1 0

Tab. 2 2. level service functions

6| Failures / Errors

3 Failures / Errors

3.1 Elimination of errrors All regulation, control and safety equipment of appliance is

controlled by the control unit.

BIf any failure during operation occurs, symbol and

maybe will start to flash also. In additional the failure

code will be shown on display (e.g. EA).

BIf and symbol on display flash:

BForthe reset:Press and Standbybuttonuntil and

symbol expire on display.

The appliance will start up again and the flow temperature

will be displayed.

BIf only symbol flashes:

BSwitch the appliance first off and then on again by means

of the standby key.

The appliance will start up again and the flow temperature

will be displayed.

If a failure can not be eliminated :

BContact your approved installer or Customer Service for

assistance, providing details of the fault and the appliance.

Danger: Explosion !

BTurn off gas cock before working on gas-

bearing components.

BCheck for leaks before working on gasbear-

ing components.

Danger: Poisoning !

BCheck for leaks before working on gasbear-

ing components.

Danger: Risk of electric shock !

BAlways disconnect the power supply to the

appliance at the mains before carrying out

any work on the electrical systems and com-

ponents (fuse, circuit breaker).

Leaking water may damage the Cotronic mod-

ule.

BCover the Cotronic module before working

on any parts that carry water.

For an overview of faults, see page 7.

Failures / Errors | 7

3.2 Failure / Error Codes Overview

Failure Code

on Display Failure Descripton Steps

MAP not selected (Fan speed adjustment accord-

ing the flue pipe length). Check the adjustment /selection via service function

2.b.d).

A2 Combustion chamber NTC failure (behind burner) :

when the temperature by CC NTC reached to limit Check the and the heat exchanger surface, whether is

blocked or not. And check the sensor and the connec-

tions.

A6 1)

1) Failure codes is adapted to the EMS (>FD660)

Combustion chamber NTC failure (behind burner) :

when NTC not detected or open circuit Check the and the heat exchanger surface, whether is

blocked or not. And check the sensor and the connec-

tions.

A7 Domestic hot water temperature sensor not correct

installed or failure. Check the sensor and cable connection.

B3 --> d5 2)

2) Failure codes is adapted to the EMS (>FD660)

Short circuit / failure in water level switch. Check the condensate water drain and recuperator

(condens-heatexchanger).

CE --> d4 3)

3) Failure codes is adapted to the EMS (>FD660)

Gradient limit : Temperature rises too rapidly in

heating mode. Check the pump, system pressure and by-pass circuit.

C7 Fan sensor not detected. Check the fan.

C8 Fan speed can not reached to target speed. Check the fan for the blockage and the electrical supply.

d7 Modulator coil failure (regulator valve on gas valve) Check the cable connection.

EA Ignition lock-out (flame not detected) (pump is run-

ning). Check the gas cock, gas pressure, electrode and the

cable connection.

E2 Flow temperature sensor failure (pump is running). Check the flow temperature sensor and the connection.

E9 Overheat lock-out by temperatur limiters (STBs)

(Flue gas + prim. Heatexchanger). In this case ;

Heat demands is blocked and pump stops 3 min.

later.

Check the system presseure, temperature sensor, pump

and fuses on board. Discharge the air in system. Check

also the flue gas pipe and heatexchanger.

FA Safety valve leaks. Check the gas valve, the cable connection and electrode

set.

Tab. 3 Failure codes

8| Failures / Errors

3.3 Failure codes and corrections steps

A2and operating LED is flashing.

Combustion chamber NTC failure (behind burner) : when the temperature by CC NTC reached to limit 1)

Control Step Action

1. Check if combustion chamber NTC dam-

aged or not and the position.

BSwitch off the appliance.

BPull the NTC cables out.

BMeasure NTC resistance.

Are the values correct ? (see NTC val-

ues)

yes: BCheck the cable connection.

A2 failure still exist ? -->2.

no: BChange the NTC.

BConnect the cable.

BSwitch on the appliance.

A2 failure still exist ? -->2.

2. Check if cable damaged or not.

BSwitch off the appliance.

BIn case of NTC is cahnged :

- Pull the NTC cables out.

- Measure NTC resistance.

- Reconnect the NTC cable.

BPull out the 20 poled connector on

control unit.

BMeasure the NTC resistance directly

on 20 poled connector. Are the meas-

ured values on NTC and cocnector dif-

ferent ?

yes: BChange the cable harness.

BSwitch on the appliance.

A2 failure still exist ? -->3.

no: -->3.

3. Is there any blockage on flue gas pipe? yes: BRemove the blockage.

A2 failure still exist ? -->4.

no: -->4.

4. Is the correct MAP (fan speed) value

according flue gas pipe length choosen ? no: BAdjust correct MAP value according flue gas pipe

length and diameter. See capitel 7.2.

A2 failure still exist ? -->5.

yes: -->5.

5. Is fan running correct ? no: BChange the fan.

A2 failure still exist ? -->6.

yes: -->6.

Failures / Errors | 9

6. Check the burner gas pressure. Are the

values OK ? yes: BCorrect the gas pressure values. If not possible,

change the gas valve.

A2 failure still exist ? -->7.

no: -->7.

7. Is the heat exchanger and recuperator

surface dirty or damaged (blockage) ? yes: BRemove the blockage.

A2 failure still exist ? -->8.

no: -->8.

8. Electronic card is defect. BSwitch off the appliance.

BCut mains supply.

BChange the electronic card.

BConnect to main supply.

BSwitch on the appliance.

1) The sensor is activated after 1 minute. After 3. failure the boiler is blocked. By first 2. time it will be reseted automaticly after 15 min.

A2and operating LED is flashing.

Combustion chamber NTC failure (behind burner) : when the temperature by CC NTC reached to limit 1)

Control Step Action

10 | Failures / Errors

A6and operating LED is flashing.

Combustion chamber NTC failure (behind burner) : when NTC not detected or open circuit

Control Step Action

1. Check if combustion chamber NTC dam-

aged or not and the position.

BSwitch off the appliance.

BPull the NTC cables out.

BMeasure NTC resistance.

Are the values correct ? (see NTC val-

ues)

yes: BCheck the cable connection.

A6 failure still exist ? -->2.

no: BChange the NTC.

BConnect the cable.

BSwitch on the appliance.

A6 failure still exist ? -->2.

2. Check if cable damaged or not.

BSwitch off the appliance.

BIn case of NTC is cahnged :

- Pull the NTC cables out.

- Measure NTC resistance.

- Reconnect the NTC cable.

BPull out the 20 poled connector on

control unit.

BMeasure the NTC resistance directly

on 20 poled connector. Are the meas-

ured values on NTC and cocnector dif-

ferent ?

yes: BChange the cable harness.

BSwitch on the appliance.

A6 failure still exist ? -->3.

no: -->3.

3. Electronic card is defect. BSwitch off the appliance.

BCut mains supply.

BChange the electronic card.

BConnect to main supply.

BSwitch on the appliance.

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