Bosch Condens 2000 W Service Manual Download Page 1

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6 720 644 062-00.1O

Condens 2000 W

Service Manual

ZWB24 - 1AR...

-RH

MM21 - 01

.2017

Summary of Contents for Condens 2000 W

Page 1: ...6 720 644 062 00 1O Condens 2000 W Service Manual ZWB24 1AR TT RH PRMM21 01 2017 ...

Page 2: ...evel 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...

Page 3: ...aterials B Do not store or use any combustible materials paper thin ners paints etc in the vicinty of the appliance Combustion Air Ambient Air B Keep 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 B Explain to the customer how the appliance works a...

Page 4: ... Change the values with or button Storage Save of Value B Press button until symbol will be shown on Display Exit from Service Level B For the exit from service level press the or Stand by button The flow temperature will be shown again on display 1 Level 1 0 2 3 4 bar 4 5 2 3 1 6 720 644 501 07 1O Service Code Description Range Initial Factory setting 1 2 C Automatical Air Purging 0 offý 1 active...

Page 5: ...wn 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 ...

Page 6: ...ey The appliance will start up again and the flow temperature will be displayed If a failure can not be eliminated B Contact your approved installer or Customer Service for assistance providing details of the fault and the appliance Danger Explosion B Turn off gas cock before working on gas bearing components B Check for leaks before working on gasbear ing components Danger Poisoning B Check for l...

Page 7: ...itch 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...

Page 8: ...ged or not B Switch off the appliance B In case of NTC is cahnged Pull the NTC cables out Measure NTC resistance Reconnect the NTC cable B Pull out the 20 poled connector on control unit B Measure the NTC resistance directly on 20 poled connector Are the meas ured values on NTC and cocnector dif ferent yes B Change the cable harness B Switch on the appliance A2 failure still exist 3 no 3 3 Is ther...

Page 9: ...ge A2 failure still exist 8 no 8 8 Electronic card is defect B Switch off the appliance B Cut mains supply B Change the electronic card B Connect to main supply B Switch 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 burn...

Page 10: ... the cable B Switch on the appliance A6 failure still exist 2 2 Check if cable damaged or not B Switch off the appliance B In case of NTC is cahnged Pull the NTC cables out Measure NTC resistance Reconnect the NTC cable B Pull out the 20 poled connector on control unit B Measure the NTC resistance directly on 20 poled connector Are the meas ured values on NTC and cocnector dif ferent yes B Change ...

Page 11: ...3 Check if cable damaged or not B In case of NTC is cahnged Pull the NTC cables out Measure NTC resistance Reconnect the NTC cable B Switch off the appliance B Pull out the 20 poled connector on con trol unit B Measure the NTC resistance directly on 20 poled connector Are the measured values on NTC and cocnector different yes B Change the cable harnness B Switch on the appliance A7 failure still e...

Page 12: ...in recuperaotr or switch contacts are wet B It can be blockage at recuperator drain Correct it B Is the siphon connection adapter in right position It should be in vertical position B Leakage in water level switch If yes change it B3 d5 failure still exist 3 no B Short circuit in connection cable If necessary change it B3 d5 failure still exist 3 3 Electronic card is defect B Notice the changed pa...

Page 13: ...em pressure 0 5 bar yes 2 no B Fill the system with water CE d4 failure still exist 2 2 B Is there air in the system yes 3 no B Remove the air in system CE d4 failure still exist 3 3 B Check if water is circulated yes 4 no B Check and clean pump filters and return and flow valves CE d4 failure still exist 4 4 Electronic card is defect B Switch off the appliance B Cut mains supply B Change the elec...

Page 14: ...nce B Change the cables B Switch on the appliance C7 failure still exist 2 no 2 2 Is there any problem at fan sensor and cable B Switch off the appliance B Check the sensor and cable yes B Change the cable and sensor B Switch on the appliance C7 failure still exist 3 no 3 3 Electronic card is defect B Switch off the appliance B Cut mains supply B Change the electronic card B Connect to main supply...

Page 15: ...r voltage supply Is voltage below 160 V AC yes B Switch off the appliance B Inform related persons company B Switch on the appliance C8 failure still exist 3 no 3 3 Check the fan it self Is there any block age or others problems no 4 yes B Switch off the appliance B Change the fan B Switch on the appliance C8 failure still exist 4 4 Electronic card is defect B Switch off the appliance B Cut mains ...

Page 16: ...e B Pull out the 20 poled connector on con trol unit B Measure the resistance Is deviation of resistance values yes B Change the cable harness B Switch on the appliance d7 failure still exist 3 no 3 3 Check the resistance from regulator valve B Voltage current on reg valve B Measure the resistance directly on gas valve Is there deviation of resistance values between two messurements yes B Change t...

Page 17: ...uccesful B Switch off the appliance B Cut mains supply B Drain the water from appliance B Change the pump B Fill with water and bleed the system again B Connect to main supply B Switch on the appliance B Press RESET button and restart again E9 failure still exist 3 no 3 3 Check the flue gas pipe line Is there any blockage yes B Check the flue gas pipe and remove the blockage B Switch on the applia...

Page 18: ...ronic card is defect B Switch off the appliance B Cut mains supply B Change the electronic card B Connect to main supply B Switch on the appliance B END 1 If the air inside not removed discharged can be also used the manuel air vent valve in recuparator E9and operating LED is flashing Overheat lock out by temperatur limiters 2 x STB Flue gas prim Heatexchanger In this case Heat demands is blocked ...

Page 19: ...e any gas pressure regulator at the house entrance yes B Check if the montage of the gas pressure regulator assembly is correct or not If necessory correct it B Measure the gas inlet pressure If there is a deviation inform the gas distributor company B Press RESET button and restart again EA failure still exist 6 no 6 LPG liquid gas Is there sufficient gas flow in the LPG line to operate appliance...

Page 20: ...ce B Make sure there is no gas leakage leaking B Press RESET button and restart again EA failure still exist 8 8 Is the ignition correct yes 12 no 9 9 Check connection of ignition cable and electrode is correct or not yes 10 no B Connect the cable B Press RESET button and restart again EA failure still exist 10 10 Is the ignition cable assembled correctly yes 11 no B Switch off the appliance B Cor...

Page 21: ...B Press RESET button and restart again EA failure still exist 13 13 Cable harness is damaged B Switch off the appliance B Cut mains supply B Change the cable harness B Connect to main supply B Switch on the appliance B Press RESET button and restart again EA failure still exist 14 14 Electronic card is defect B Switch off the appliance B Cut mains supply B Change the electronic card B Connect to m...

Page 22: ...e appliance E2 failure still exist 2 2 Check if the cables are damaged or not B Switch off the appliance B If NTC changed disassemble the NTC cable from NTC measure the sensor resistance assemble the NTC to NTC cable again B Pull out the 20 poled main socket connector from the electronic card B Measure the electrical resistance of NTC on socket Are the measured resistance values at at NTC and sock...

Page 23: ...ep Action 1 Gas valve is defect B Switch off the appliance B Change the gas valve B Switch on the appliance B Check the leakage B Press RESET button and restart again FA failure still exist 2 2 Electronic card is defect B Switch off the appliance B Cut mains supply B Change the electronic card B Connect to main supply B Switch on the appliance ...

Page 24: ... run The I I symbol will be shown on display alternately Control Step Action 1 MAP value is according the flue gas pipe length not selected yes B Adjust the MAP value via service fonction 2 b d for details see flue gas instruction manuel I I symbol still exist 2 no 2 2 Electronic card is defect B Switch off the appliance B Cut mains supply B Change the electronic card B Connect to main supply B Sw...

Page 25: ...786 35 8 047 40 6 653 45 5 523 50 4 608 55 3 856 60 3 243 65 2 744 70 2 332 75 1 990 80 1 704 85 1 464 90 1 262 95 1 093 100 950 Tab 4 DHW Temperature Sensor C Resistance Ω 0 33 242 10 19 947 20 12 394 30 7 947 40 5 242 50 3 548 60 2 459 70 1 740 80 1 256 90 923 Tab 5 Temperature C Measure Tolerance 10 Resistance Ω 0 27 936 20 12 136 40 5 774 60 2 967 80 1 629 100 947 120 578 140 387 160 244 180 1...

Page 26: ... 2 9 kOhm 0 5 kOhm Pump 230 VAC I 495 Ohm II 355 Ohm III 220 Ohm 10 Ohm Ionisation Electrode ca 3 5 µA Gas Safety Valve 1 230 VAC 1 55 kOhm 10 Ohm Gas Safety Valve 2 230 VAC 8 kOhm 20 Ohm common neutral black cable Gas Regulator 0 24 VDC ca 80 Ohm min 25 mA max 130 LPG 165 mA 5 Ohm Fan 230 VAC 38 Ohm 5 Ohm Fan Sensor 1 Vcc 5VDC supply 2 GND 3 Vout Signal 5 VDC check physical 2 ad Fuse T 1 6 A 230 ...

Page 27: ...W temperatur regulator 10 Flow temperatur regulator 11 Transformer 12 Controller room thermostat connection 13 Diagnostic connection 14 Igniton transformer 15 Supply cable 16 DHW temperature sensor NTC 17 Gas valve 18 Ignition electrode 19 Temperatur limiter STB 20 Flow temperature sensor 21 Flue gas safety combustion chamber sensor 6 720 644 501 04 1O 15 1 5 13 12 17 5 2 6 20 18 4 19 2 3 14 16 3 ...

Page 28: ...28 Failures Errors 3 7 Structure reset 6 720 644 501 03 1O 17 26 29 30 27 33 34 36 35 2 3 6 8 1 9 10 11 12 13 14 5 32 15 7 28 31 4 25 23 24 21 19 18 22 20 16 ...

Page 29: ...ump 12 Pump speed switch 13 Condensate siphon 14 Turbine 15 Condensate water hose 16 Cotronic3 control unit 17 Manometer 18 Button 19 DHW temperature regulator 20 Operating LED 21 Flow temperature regulator 22 Service Button 23 Button 24 Display 25 Stand by On off Button 26 Water filling valve 27 Gas Valve 28 Type lable 29 DHW temperature sensor 30 Ignition electrode 31 Flue gas safety sensor Comb...

Page 30: ...r 14 Combustion chamber 15 Fan 16 Condensate Heatexchanger Recuperator 17 Flue gas pipe 18 Expansion vessel 19 Autom air vent valve 20 Circulation pump 21 CH safety valve 22 Siphon 23 Turbine 24 DHW water flow rate limiter Filter 25 Manometer 26 Gas valve 27 Siphon trichtersiphon ops 28 Regulator valve 29 Gas filter 30 Measurement point Inj pressure 31 Measurement point Gas inlet pressure 32 Safet...

Page 31: ... m 10 5 34 9 Display Output kW 30 7 3 1 2 2 2 13 0 0 6 53 9 5 2 0 3 7 16 9 0 7 56 10 7 2 6 4 7 19 1 0 8 59 11 9 3 2 5 7 21 2 0 9 61 12 6 3 5 6 4 22 5 1 0 66 14 4 4 6 8 2 25 8 1 1 69 15 6 5 3 9 5 27 9 1 2 72 16 8 6 1 10 9 30 1 1 3 75 18 0 7 0 12 4 32 3 1 4 78 19 2 7 9 13 9 34 5 1 5 80 20 4 8 9 15 5 36 7 1 6 83 21 6 9 9 17 2 38 9 1 7 86 22 8 11 0 19 0 41 1 1 8 90 100 24 0 12 2 21 0 43 3 1 9 Tab 8 ...

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