Bosch T2400S 11 ND 23 Training And Service Information For After Sales Download Page 1

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6 720 887 546 “SM FP_ErP LPP/MPP Europe 2018/05 en”

LOW NOX INSTANTANEOUS

GAS WATER HEATER

ROOM SEALED FAN ASSISTED / PRESSURIZED

GAS WATER HEATER

FOR INDOOR INSTALLATION

TRAINING AND SERVICE INFORMATION FOR AFTER SALES

This document is restricted to exclusive use by the official service partners. Each

country should adapt the manual and its contents to the available range.

Summary of Contents for T2400S 11 ND 23

Page 1: ...ATER HEATER ROOM SEALED FAN ASSISTED PRESSURIZED GAS WATER HEATER FOR INDOOR INSTALLATION TRAINING AND SERVICE INFORMATION FOR AFTER SALES This document is restricted to exclusive use by the official service partners Each country should adapt the manual and its contents to the available range ...

Page 2: ...AS CONNECTION 6 3 4 APPLIANCE PERFORMANCE 7 4 COMPONENTS OVERVIEW 8 4 1 CONTROL PANEL 9 4 2 HEAT CELL WITH BURNER PIPES 12 4 3 GAS MANIFOLD 13 4 4 FAN 14 4 5 GAS VALVE 14 4 6 HEAT EXCHANGER 16 4 7 WATER INLET ASSY 17 4 8 WATER TEMPERATURE SENSORS 18 4 9 BOX TEMPERATURE SENSOR 18 4 10 WATER FLOW SENSOR 19 4 11 IGNITION ELECTRODE 20 4 12 IONIZATION ELECTRODE 21 5 WORKING PRINCIPLE ELECTRIC MEASUREME...

Page 3: ...s needed through call centre or after sales technicians Example of variants T2400S 8 11 ND 23 31 T5600S 12 15 18 D 23 31 T5700S 12 15 18 D 23 31 W 8 10 AME 23 31 WD 8 11 AME 23 31 WTD 12 15 18 3 AME 23 31 WTD 12 15 18 4 AME 23 31 Bosch T Instantaneous gas water heater T 2400 Fixed power with electronic ignition and power steps T 5600 Thermostatic control variable power through electronic control T...

Page 4: ...remote control The kit includes 10 m of cable which needs to be connected to the remote by opening the back cover rotation and then removing 3 screws to release the circuit board and make the connection in the available connection Pict 1 Wired remote scope of delivery Pict 2 Remote Control View and connection Anti Freeze Allows the protection of the appliance against water freezing inside of its p...

Page 5: ...optimize and leave the appliance in correct operation conditions 3 1Appliance fixation on the wall Requisite Confirmation Appliance is levelled and in the vertical position Delivered accessories are used accordingly Appliance is supported exclusively by the wall fixation and not by hydraulic and or gas connections Table 2 Check List for Fixation Installer must ensure correct wall fixation and wate...

Page 6: ...vailable gas type Pressure reducer and gas pipe are adequate for the required pressure and gas flow Accessories for gas connection are adequate and according to the country specification standards Table 4 Check list for gas connections 3 4Flue Exhaustion The correspondent appliance manual have indicated the maximum flue length according model and flue type orientation nevertheless there is with th...

Page 7: ...ed in horizontal termination Pict 6 Example of wall terminations in 80 110 and 60 100 type 3 5Appliance performance Measure water flow and temperature increase to check temperature and instantaneous water flow assuring correct operation of the appliance Pict 7 Use of water flow meter and thermometer ...

Page 8: ...Heat Exchanger 4 Burner 5 Gas manifold 6 Gas valve 7 Outlet NTC 8 Hot water 9 Electrical supply cable 10 Pressure switch 11 Transformer 12 Control Unit 13 Ignition Ionization Electrode 14 Display 15 Power switch 16 Flow sensor 17 Flow rate control 18 Cold water 19 Gas inlet Pict 8 Internal layout of T2400 WD versions ...

Page 9: ...collector 11 Heat Exchanger 12 HMI 13 Control Unit 14 Inlet Temperature sensor 15 Flow sensor 16 Cold water 17 Flow rate control 18 Gas inlet 19 Electrical supply cable Pict 9 Internal layout of T5600 WTD version 4 1Control panel The control panel allows the user installer or technician to perform all different operations needed User manual explain how to access and use the HMI human machine inter...

Page 10: ...e mode to access service parameters which can be used by the user installer technician Program Button Used to Scroll back in the service mode menu when navigating menus OK Button Save value or adjust set values Save a temperature setting user Selection button Used to scroll inside menu ensuring navigation on parameters inside the diagnostic mode Table 6 Control Panel Buttons Symbol Description Obs...

Page 11: ...ote In case symbol is displayed decrease or increase flow accordingly Excessive water flow symbol is ON when the setpoint 3ºC cannot be reached at maximum power because there is too much water going through the water heater or at minimum power because there is not enough water going through the water heater Solar application Indication that the automatic solar function is activated meaning that th...

Page 12: ...1 Burner and gas valve view example from LPP MPP Primary air plate In the burner there is a primary air plate assembled between the gas manifold with injectors and the burner itself in order to ensure the correct mixture of air and gas according to the specific appliance model The plate has indexation pins that ensure the correct assembly on the heat cell and must be always replaced together with ...

Page 13: ...complete manifold The stamp indicates the size of injectors used for reference The Burner design allows to have on the same burner surface One primary rich flame oxygen enriched combustion for stabilization which corresponds to the injectors with smaller diameter in top of manifold One primary lean flame lack of oxygen for low NOx emissions which corresponds to the injectors with bigger diameter i...

Page 14: ...onsists on a square wave with a frequency proportional to the speed of the fan Pict 15 DC Fan WTD 3 4 T5600 T5700 In order to simplify the after sales stock of parts the modes share same type of fan according Low Power Fan MPP1 12 15 shares same fan of MPP2 12 High Power Fan MPP1 17 shares same fan of MPP2 15 17 The Fan in the LPP range is AC powered and have fix speed The safety element that cont...

Page 15: ...t and second burner segments respectively acting as safety and segmentation valves Pict 17 Gas Valve in LPP version The burner is composed by 2 segments which are fed according to the solenoid valves activation SV2 and or SV3 which can be switched over according to the different thermal load in order to obtain a stable combustion These valves ensure the most suitable condition under the control of...

Page 16: ... ON SV1 SV2 Pict 19 Schematic view of 3 power levels in LPP 4 6 Heat Exchanger The copper heat exchanger has a special configuration to ensures sealed combustion and optimized heat transfer from the flame heat to the water that flows through the copper pipes Pict 20 Heat exchanger For its protection and ensuring maximum life time there is over heating protection ensured by a bimetallic thermostat ...

Page 17: ...c fuses that melt at 192 ºC in the event of an overheating Pict 22 Thermal Fuse with without insulation Pict 23 Thermal Fuse detail 4 7Water Inlet Assy The inlet water valve contains the water connection of that integrates also the filter and the flow restrictor according country characteristics Flow rate valve Filter The inlet water valve contains the filter and is acessible removing screw nº1 an...

Page 18: ...nd 50 kΩ NTC inlet Both NTC measures temperature and are connected to different cable colors and connectors in the control unit Pict 25 Cold Hot Temperature sensor 4 9Box Temperature sensor The Box air temperature is measured by a 10 kΩ NTC See table with characteristic values and is assembled inside the room sealed box in order to monitor the temperature inside of the cabinet Pict 26 Box air temp...

Page 19: ...ce 2 4 l min Water flow characteristic curve formula f 6 9 x Q Note f is output frequency Hz Q is water flow rate L min Flow L min Frequency Hz 15 103 5 14 96 6 13 89 7 12 82 8 11 75 9 10 69 9 62 1 8 55 2 7 48 3 6 41 4 5 34 5 4 27 6 3 20 7 2 13 8 Table 8 Water flow sensor values Pict 27 Water Flow Sensor In case Q 2 8l min following Pout verification occurs If Pout Minimum Power the appliance will...

Page 20: ... In each of the attempts the system monitors the ionisation signal this signal drives the start of normal operation however and in case the ionization signal is not detected during the ignition sequence the failure indication EA will be displayed In this case a non volatile lock out is activated and only a manual reset can lead the system back to normal operation If the ionisation signal is interr...

Page 21: ...er than 8 µA Pict 29 Ionization electrode and its sealing element 2nd Ignition Sequence Safety Time of 31 sec 1st Attempt 5 sec Purge Period 3 sec 2nd Attempt 5 sec Purge Period 3 sec 3rd Attempt 5 sec Pos Purge 10 sec 3rd and last Ignition Sequence Safety Time of 41 sec 1st Attempt 5 sec Purge Period 3 sec 2nd Attempt 5 sec Purge Period 3 sec 3rd Attempt 5 sec Pos Purge 20 sec EA Error Code ...

Page 22: ... able to go into solar mode burner off when water flow is detected if inlet water temperature is higher than Setpoint 1ºC or expected outlet temperature calculated with minimum power is higher than Setpoint 10ºC or 60ºC whichever is higher When the conditions disappear the unit must be able to start up the burner and run in normal operation mode without the symbol in the display Water Flow Calcula...

Page 23: ...id scalding hazard the water heater perform as follows If the power selector is in level 2 or 3 and the outlet temperature is expected to be higher than 70ºC the control unit must automatically decrease the power level E1 warning code must be shown blinking with a frequency of 2Hz so the user is aware that the water heater has automatically decreased power After this even if the water flow is incr...

Page 24: ...of ECU electronic control unit MPP 1 Flame detection 10 Water flow sensor 2 Ignition needle 11 Water inlet temperature sensor 3 Power plug 12 Water outlet temperature sensor 4 Fan 13 Thermal fuse 5 Remote controller 14 Thermostat 6 Water proportional vale 15 Gas valve 7 HMI 16 On off valve 8 Wifi modulate 17 Segment valve A 9 Ambient temperature sensor 18 Segment valve B Pict 31 Electric Diagram M...

Page 25: ...ection 10 APS air pressure switch 2 Ignition electrode 11 Segment valve B 3 Transformer 12 Segment valve A 4 Power supply 13 Gas valve solenoid 5 Fan 14 Safety solenoid valve 6 Water flow sensor 15 Temperature limiter thermostat 7 Water inlet temperature sensor 8 Water outlet temperature sensor 9 HMI Pict 32 Electric Diagram LPP circuit board ...

Page 26: ... is for reference Outlet water temperature sensor NTC The R Ω T ºC table is for reference Inlet water temperature sensor NTC The R Ω T ºC table is for reference Flame sensor Yellow wire Use the multi meter to test the ion current which should be 8 μA The multimeter for current should be in series between the flame sensor and the ECU wire DC fan variable speed in MPP Red black GND 36V DC Input Powe...

Page 27: ...valve 0VDC Resistance 151Ω MPP type Segment valve A Green Black Remain open the valve 16 18 VDC Close the valve 0VDC Resistance 136 5Ω LPP type Segment valve A Segment valve Green Black Remain open the valve 14VDC Close the valve 0VDC Resistance 151Ω MPP type Segment valve B Yellow black Remain open the valve 16 18 VDC Close the valve 0VDC Resistance 136 5Ω LPP type Segment valve B Table 10 Electr...

Page 28: ...Page 28 from 45 6 720 887 546 SM FP_ErP LPP MPP Europe 2018 05 en Air temperature sensor resistance value Table 11 NTC resistance values for Air Box NTC Temperature Index table ...

Page 29: ...8 6 5783 126 1 5205 174 0 4633 222 0 1745 17 378 93 31 38 500 79 6 3543 127 1 4784 175 0 4528 223 0 1716 16 359 06 32 36 560 80 6 1393 128 1 4384 176 0 4425 224 0 1690 15 340 30 33 34 903 81 5 9331 129 1 3999 177 0 4326 225 0 1664 14 322 63 34 33 644 82 5 7356 130 1 3629 178 0 4231 226 0 1631 13 306 00 35 32 560 83 5 5467 131 1 3274 179 0 4140 227 0 1601 12 290 35 36 31 547 84 5 3657 132 1 2929 18...

Page 30: ...24 47 3 855 89 1 071 36 144 7 6 18 43 48 3 727 90 1 042 35 136 9 7 17 67 49 3 604 91 1 014 34 129 5 8 16 93 50 3 485 92 0 9872 33 122 5 9 16 23 51 3 371 93 0 9611 32 116 0 10 15 56 52 3 262 94 0 9357 31 109 8 11 14 93 53 3 156 95 0 9111 30 104 0 12 14 32 54 3 054 96 0 8872 29 98 61 13 13 74 55 2 956 97 0 8640 28 93 48 14 13 19 56 2 861 98 0 8417 27 88 66 15 12 66 57 2 770 99 0 8200 26 84 10 16 12 ...

Page 31: ...user 6 Service When replacing the control unit configurations need to be checked and set accordingly The parameters accessible to the user installer are as indicated in following pictures Procedure to enter in Service Mode Press and hold menu for more than 5 seconds From this position and using the selection buttons and different service modes can be assessed Note In the LPP versions W WD T2400 an...

Page 32: ...ters accessible with external remote in LPP versions PP Enter Menu Outlet temperature Normal Mode P0 Ignition Burner Pressure AP Appliance capacity 08 8l 11 11l P1 level 1 right side Min Burner Pressure P2 level 2 left side Intermed Burner Pressure P3 level 3 both sides Max Burner Pressure P8 Backlight control AS Altitude Selection E Save and Exit ...

Page 33: ...Appliance Capacity 12 15 17 P7 Gas Type Selection 20 30 31 Set point Normal Mode AS Altitude selection sea level until 2500 m CA Combustion Adjustment F5 Reset to factory default Only for certification purposes if required LP min power mode HP Max power mode See next table with parameters P3 Connectivity Wifi P5 Start up delay P6 Units Setting C Metric F Imperial P8 Backlight control F9 Flue lengh...

Page 34: ...mation DH Data History H2 Operating Hours 1D Inlet Temperature 2D Outlet Temperature 3D Water Flow 4D Output power 1F 10F Last recent failures C0 Operating Cycles H1 Operating Hours Setpoint Normal Mode C2 Operating Cycles C1 Operating Cycles H0 Operating Hours OD Operation Data FH Failure History 5D Box air temperature ...

Page 35: ...ndicates the measurement point to be used Pict 39 Gas Manometer Connection left for LPP right for MPP To keep the appliance in P1 maximum power adjustment is important to assure a minimum water flow otherwise the appliance will jump automatically to P2 minimum power 8 10 l model Flow 3 l min 11 12 l Model Flow 4 l min 15 l model Flow 5 l min 17 l model Flow 6 l min Table 14 Minimum water flow need...

Page 36: ... Adjustment of air flow without change gas conditions See installation manual for recommended setting Adjustment of gas flow without change air conditions See installation manual for recommended setting Minimum power burner adjustment after repairs maintenance gas conversions P2 contains the fan speed setting A2 and gas power L2 at minimum power depends on gas type model depends on gas type model ...

Page 37: ...l unit adaptation according appliance model modulation range 12 12 l model 15 15 l model 17 17 l model 20 Natural Gas G20 30 Butane G30 31 Propane G31 25 Natural Gas G25 NG models will have from factory 20 LPG models will have from factory 31 Note spare part pre set value is 20 Table 16 Adjustments Parameters for control unit configuration To change the gas type enter first into the service mode a...

Page 38: ...lling to the parameter P4 of the adjustment mode Diagnostic mode and visualization mode Installer Level Technician Level Comments This mode helps the installer in the startup to check parameters such as water flow through the appliance and inlet outlet temperatures This mode helps the technician to find some information useful to adjust and to check functionality of the appliance Main recommendati...

Page 39: ...tage as complement to power bar indicator Temperature of air in room sealed box Temperature read by outlet sensor ºC or ºF Table 19 Visualization mode parameters with readings of sensors until Last 10 Failures for diagnostic purposes Failure 1 is last failure occurred Failure 2 occurred before Failure1 Failure 3 occurred before Failure2 Failure 4 occurred before Failure3 Failure 5 occurred before ...

Page 40: ...onditions and use profile but in general once a year should be adequate Any intervention service work in the appliance must be carried out by a competent person such as registered and competent technician or brand service agent Before any service operation turn off the gas supply at the main gas service cock upstream and service operation to be carried out as described in the manual The service pa...

Page 41: ...elease any remaining water pressure and drain the appliance over the water assy cover Pict 42 Heat exchanger fins cleaning Take care not to damage the seals that ensure tightness between the heat exchanger the heat cell and collector and ensure correct clearing and alignment of the fins For this units maintenance kits were created in order than when disassembling unbit for maintenance and cleaning...

Page 42: ...stops bubbling Drain and thoroughly wash out the exchanger with clean water Warning Acid water solutions must be used with extreme caution Take care not to splash on to the skin or into the eyes Wash any affected areas with large amounts of cold water and seek medical advice Pict 44 heat exchanger descaling Re assemble the heat exchanger ensuring its correct position on the two support hooks in th...

Page 43: ...ance shuts down and goes to lockout Error is resolved by manual reset Lock out A7 Outlet water temperature sensor defective If a short or open circuit is detected on the outlet water NTC sensor a warning is shown Error is resolved when the sensor open or short circuit is repaired Self resolving C7 Signal from fan not received When no feedback signal is received from the fan the unit goes to lock E...

Page 44: ...eset Lock out EE Gas valve wrong connection If a safety solenoid from the gas valve is disconnected the appliance must lock Error is resolved by manual reset Lock out EF Wrong gas type If an output higher than expected is obtained the appliance shuts down Error is resolved by manual reset Lock out F7 Ionization error If ionization is detected without heat demand an error is shown and the appliance...

Page 45: ...ist replace control unit Lock out FP APS I O short circuit error Error is resolved by manual reset If error persist replace control unit Lock out F8 MCU ROM micro controller error Error is resolved by manual reset If error persist replace control unit Lock out F9 MCU registration DC micro controller error Error is resolved by manual reset If error persist replace control unit Lock out EH Remote co...

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