Bosch T5600S 12 D 23 Training And Service Information Download Page 2 | Manualshive

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6 720 887 547 “SM FP_ErP MPP Europe 2018/08 en”

Contents

INTRODUCTION ..............................................................................................3

APPLIANCE DESCRIPTION ............................................................................3

...................................................................................................... 3

VAILABLE ACCESSORIES

..................................................................................................... 3

INSTALLATION ................................................................................................5

PPLIANCE FIXATION ON THE WALL

........................................................................................ 5

ATER CONNECTIONS

........................................................................................................... 6

AS CONNECTION

................................................................................................................. 6

PPLIANCE PERFORMANCE

.................................................................................................... 7

COMPONENTS OVERVIEW ............................................................................8

ONTROL PANEL

................................................................................................................... 9

EAT CELL WITH BURNER PIPES

........................................................................................... 12

AS MANIFOLD

................................................................................................................... 13

................................................................................................................................... 14

........................................................................................................................ 14

.............................................................................................................. 15

............................................................................................................ 17

ATER TEMPERATURE SENSORS

......................................................................................... 17

EMPERATURE SENSOR

............................................................................................... 18

..................................................................................................... 18

GNITION ELECTRODE

....................................................................................................... 19

ONIZATION ELECTRODE

.................................................................................................... 20

WORKING PRINCIPLE / ELECTRIC MEASUREMENTS ............................ 21

SERVICE ....................................................................................................... 29

MAINTENANCE ............................................................................................. 38

TROUBLE SHOOTING .................................................................................. 41

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Summary of Contents for T5600S 12 D 23

Page 1: ...GAS WATER HEATER ROOM SEALED 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: ... 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 15 4 7 WATER INLET ASSY 17 4 8 WATER TEMPERATURE SENSORS 17 4 9 BOX TEMPERATURE SENSOR 18 4 10 WATER FLOW SENSOR 18 4 11 IGNITION ELECTRODE 19 4 12 IONIZATION ELECTRODE 20 5 WORKING PRINCIPLE ELECTRIC MEASUREMENT...

Page 3: ...r after sales technicians Example of variants T5600S 12 15 17 D 23 31 T5700S 12 15 17 D 23 31 WTD 12 15 17 3 AME 23 31 WTD 12 15 17 4 AME 23 31 Bosch T Instantaneous gas water heater T 5600 Thermostatic control variable power through electronic control T 5700 Thermostatic control variable power through electronic control with water valve T S Room sealed operation indoor unit T S 12 15 17 Output fl...

Page 4: ...ease 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 pipes until 20ºC and to be used in cases where ambient temperature can be lower than 5ºC It is optional for indoor models but included from factory in outdoo...

Page 5: ...tion 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 water gas pipe positions using supplied accessories a...

Page 6: ...connection Requisite Confirmation The appliance is suitable for the available 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 ac...

Page 7: ...0 2 m 00 2 4 m 01 4 8 m 02 Table 6 Flue Configurations for MPP2 5700 Pict 5 Wall distance in mm required 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 ...

Page 8: ...2018 08 en Pict 7 Use of water flow meter and thermometer 4 Components Overview 1 Temperature limiter 2 Thermo fuse 3 Burner 4 Gas manifold 5 Gas valve 6 Fan 7 Gas pipe 8 Outlet Temperature sensor 9 Hot water 10 Flue collector 11 Heat Exchanger 12 HMI ...

Page 9: ...u de gaz 8 Sonde de température de soufflage 9 Eau chaude 10 Collecteur des fumées 11 Échangeur thermique 12 IHM 13 Tableau de régulation 14 Sonde de température d entrée 15 Vanne d eau avec detecteur de débit 16 Eau froide 17 Commande du débit 18 Entrée de gaz 19 Câble d alimentation électrique Pict 9 Internal layout example de MPP2 T5700 4 1Control panel The control panel allows the user install...

Page 10: ...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 Observatio...

Page 11: ...e 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 the ...

Page 12: ...or the burner Pict 11 Burner and gas valve view 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 t...

Page 13: ...ll always supply the 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 w...

Page 14: ...5 Gas Valve Over the control unit it is possible to control the gas flow to the burner by the modulating gas valve MV1 This valve controls the thermal load in order to ensure the correct hot water set temperature under water flow or temperature variations The gas valve is composed by other solenoids identified as safety valves SV SV1 SV2 releasing the modulated gas to and from the solenoid gas val...

Page 15: ...for MPP Pict 17 Schematic view of 3 power levels 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 SV1 SV SV2 MV1 Burner segment 1 Burner segment 2 ...

Page 16: ... a bimetallic thermostat in direct contact with the copper and one thermal fuse around the heat exchanger Pict 19 Temperature limiter activation at 85ºC The thermal fuse is located around the heat exchanger and for protection is insulated nevertheless is composed by 4 specific fuses that melt at 192 ºC in the event of an overheating Pict 20 Thermal Fuse with without insulation ...

Page 17: ...cs Flow rate valve Filter The inlet water valve contains the filter and is acessible removing screw nº1 and pulling out the valve with know nº2 Pict 22 Inlet flow restrictor with filter 4 8Water temperature sensors The outlet and inlet water temperature is measured by a 8 5 kΩ NTC outlet and 50 kΩ NTC inlet Both NTC measures temperature and are connected to different cable colors and connectors in...

Page 18: ... Water Flow Sensor Water flow is measured by a turbine flow sensor that is fed by a DC signal of 5 V and gives a proportional feedback to the measured water flow Flow rate to operate the appliance 2 8 l min Flow rate to shut off the appliance 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...

Page 19: ... l right MPP 15 17 l In order to prevent harder ignition processes and be sure of conditions of gas supply and burner stability following situation is verified during the so called safety time period 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 sequenc...

Page 20: ... Time 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 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 se...

Page 21: ...lectrodes position on the burner 5 Working Principle Electric Measurements Water Flow Detection and solar mode operation Water Flow Calculation procedure WF Power T set T in WF 2 8 l min Burner ON WF 2 4 l min Burner OFF Burner On Solar mode Operation Burner Off T in T set 1K T out 60ºC if T set 50ºC or T out Tset 10ºC if T set 50ºC ...

Page 22: ...rner and run in normal operation mode without the symbol in the display Operation Action Connection to the control unit Result Standby Inputs Signals must be within expected limits Main Switch in control unit Input ON Electrical plug connected Input 230 V AC Thermostat temperature limiter and Thermal fuse with continuity Input Contact closed Ionization reading Input 0 µA Temperature sensors OK Inp...

Page 23: ...r 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 29 Electric Diagram MPP circuit board ...

Page 24: ...e R Ω T ºC table 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 3...

Page 25: ... A Segment valve Green Black Remain open the valve 14VDC Close the valve 0VDC Resistance 151Ω MPP type Segment valve B Table 10 Electric Values Attention all connectors have specific connection or colour coded nevertheless modulation valve in gas valve are polarity sensitive and connector to be done as picture shows below Pict 30 Modulation solenoid with red and brown mark ...

Page 26: ...Page 26 from 43 6 720 887 547 SM FP_ErP MPP Europe 2018 08 en Air temperature sensor resistance value Table 11 NTC resistance values for Air Box NTC Temperature Index table ...

Page 27: ...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 180 ...

Page 28: ... 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 16...

Page 29: ...tion after any intervention on the appliance the installation manual must be read and instructions and main functions must be explained to the end 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 t...

Page 30: ...Page 30 from 43 6 720 887 547 SM FP_ErP MPP Europe 2018 08 en Pict 31 Main parameters configuration in MPP for user level ...

Page 31: ...iance Capacity 12 15 18 P7 Gas Type Selection 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 length configurati...

Page 32: ...tion 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 33: ...r Butane Following image indicates the measurement point to be used Pict 34 Gas Manometer Connection 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 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 needed to keep P1 in operation Att...

Page 34: ...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 Adjustment of air flow without change gas conditions See installation manual f...

Page 35: ...17 17 l model Outdoor Models 12o outdoor 12 l model 15o outdoor 15 l model 17o outdoor 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 30 Note spare part pre set value is 20 Maximum flue pipe configuration See installation manuals for details according model and capacity Table 16 Adjustments Paramet...

Page 36: ...ing 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 recommendation...

Page 37: ...ge 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 Fa...

Page 38: ...ditions 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 part...

Page 39: ...ease any remaining water pressure and drain the appliance over the water assy cover Pict 37 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 t...

Page 40: ...ops 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 39 heat exchanger descaling Re assemble the heat exchanger ensuring its correct position on the two support hooks in the ...

Page 41: ...ature sensor opened circuit If a short or open circuit is detected on the air temperature NTC the appliance 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 C...

Page 42: ...t of an overheating and malfunction of temperature limiter the appliance shuts down and goes to lockout Error is resolved by manual reset after replacement of thermal fuse and circuit close contact again Lock out EA No ionization during safety time safety timeout If no ionization signal is detected after start up sequence appliance locks Error is resolved by manual reset Lock out EE Gas valve wron...

Page 43: ...s resolved by manual reset If error persist replace control unit Lock out F6 MCU RAM DC micro controller internal error Error is resolved by manual reset Check if voltage is too low 70 v ac If voltage ok and error persist 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 Er...

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