BOSCH 4000 Singular Combi Boiler User Manual

July 30, 2024
Bosch

4000 Singular Combi Boiler

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Gas Condensing Combi Boilers Singular

Specifications:

  • Models: Singular 4000, Singular 5200
  • Model Number: BTC 439003302 D / 02.2024
  • Compliance: Local, state, and federal codes
  • Gas Code Compliance: ANSI Z223.1/NFPA 54 (USA), CAN/CSA B149.1
    (Canada)

Product Information:

The Gas Condensing Combi Boilers Singular models include
Singular 4000 and Singular 5200. These boilers are designed for
efficient heating and hot water supply in residential settings. The
boilers must be installed following specific guidelines to ensure
safe operation and compliance with regulations.

Installation Instructions:

Boiler Installation:

Qualified installers should follow local codes for proper
installation. Ensure the boiler is mounted securely on a wall with
adequate clearances and access to utilities. Venting, drainage, and
combustion air requirements must be met.

System Piping:

Properly install space heating and domestic hot water systems as
per guidelines provided. Connect the condensate drain and fill the
system with water. Test the water system for leaks.

Connecting the Gas Supply:

Refer to gas pipe sizing tables for correct sizing. Install gas
piping, check inlet gas pressure, and ensure proper connections for
safe operation.

Installing a Vent:

Select the appropriate vent type and materials. Install vent
pipes according to guidelines and ensure proper termination for
effective venting.

Setting Up:

Configure DIP switches, connect the power supply, and follow an
installation checklist to ensure all steps are completed
correctly.

Operating Instructions:

Operating the Boiler:

Learn how to turn the boiler on or off, check the ignition
system, set space heating and hot water temperatures, and view
basic information modes for monitoring.

Zone Control Wire:

Understand the TT connections for zone control wire and set the
heat load for outdoor reset control mode if applicable.

FAQ:

Q: What should I do if I encounter a gas leak?

A: If you suspect a gas leak, immediately turn off the gas
supply, open windows for ventilation, evacuate the premises, and
contact your gas provider and emergency services.

Q: How often should I service my boiler?

A: Regular maintenance is essential. It is recommended to have
your boiler serviced annually by a qualified technician to ensure
optimal performance and safety.

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User Manual
Gas Condensing Combi Boilers Singular
Singular 4000 | Singular 5200
WARNING: If the information in these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
WARNING: Do not store or use gasoline or other flammable 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 qualified 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 identified 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.

BTC 439003302 D / 02.2024

User Manual

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Singular 4000-5200 Combi Boiler – BTC 439003302 D (02.2024)

Table of Contents

1 Key to Symbols and Safety Instructions

4

1.1 Key to Symbols

4

1.2 Safety

4

2 General Information

7

2.1 Included Items

7

2.2 Optional Accessories

7

2.3 Specifications

8

2.4 Rating Plate

9

2.4 Dimensions

10

2.5 Components

11

3 Boiler Installation

13

3.1 Installer Qualifications

13

3.2 Compliance Requirements

13

3.3 Location

13

3.3.1 Access to Utilities

13

3.3.2 Humidity and Contact with Water

13

3.3.3 Drainage

13

3.3.4 Venting and Ventilation

13

3.3.5 Clearances

14

3.3.6 Clean, Debris and Chemical-Free Combustion Air

14

3.3.7 Position

14

3.4 Mounting to the Wall

15

4 System Piping

16

4.1 Installing a Space Heating System

16

4.1.1 Guidelines for a Space Heating System

16

4.1.2 Essential Elements in a Space Heating System

16

4.1.3 Space Heating Piping

17

4.2 Installing a Domestic Hot Water(DHW) System

17

4.2.1 Guidelines for a DHW System

17

4.2.2 Essential Elements in a DHW System

18

4.2.3 DHW System Piping

18

4.3 Connecting the Condensate Drain

19

4.3.1 Filling the Condensate Trap

20

4.4 System Filling

20

4.4.1 Built-In Water Filling

20

4.4.2 External Water Fill Connection

20

4.5 Test the Water System

21

4.5.1 External Water Fill Connection

21

4.6 Examples of System Applications

22

4.6.1 System Application ­ Zone System with Zone Valves

22

4.6.2 System Application ­ Zone System with Circulators

23

5 Connecting the Gas Supply

24

5.1 Gas Pipe Sizing Tables

24

5.2 Gas Piping

25

5.3 Inlet Gas Pressure

26

6 Installing a Vent

28

6.1 Vent Type

28

6.1.1 Direct Venting

28

6.1.2 Non- Direct Venting

30

6.2 Vent Pipe Materials

32

6.3 Vent Length

33

6.4 Connecting the Vent Clip

33

6.5 Vent Termination

34

6.5.1 Single-Pipe Sidewall Venting

34

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6.5.2 Two-Pipe Sidewall Venting

34

6.5.3 Snorkel Flue

35

6.5.4 Non-Concentric Sidewall Venting

35

6.5.5 Concentric Sidewall Venting

35

6.5.7 Concentric Roof Venting

36

7 Setting the DIP Switches

37

8 Connecting the Power Supply

38

9 Installation Checklist

39

10 Operating the Boiler

41

10.1 Turning the Boiler On or Off

41

10.2 Checking the Ignition System

41

10.3 Setting the Space Heating Temperature

41

10.4 Setting the DHW (Domestic Hot Water) Temperature

42

10.5 Viewing Basic Information

42

10.5.1 H0 mode

43

10.5.2 H1 mode

43

10.5.3 H2 mode

43

10.5.4 H3 mode

43

10.5.5 H4 mode

44

10.5.6 H5 mode

44

10.5.7 H6 mode

44

10.5.8 H7 mode

44

10.5.9 H8 mode

45

10.5.10 H9 mode

45

10.5.11 HA mode

45

10.5.12 Hb mode

45

10.5.13 Cd mode

46

10.6 Zone Control Wire ( TT Connections)

46

10.7 Setting the Heat Load for The Outdoor Reset Control Mode

46

10.8 Altitude Adjustment

48

11 Gas Conversion

49

11.1 Combustion Analysis

51

12 Wiring Diagram

53

13 Ladder Diagram

54

14 Normal Operating Sequence

55

15 Outdoor Temperature Sensor

57

15.1 Outdoor Temperature Sensor Installation (Optional)

57

15.2 Outdoor Temperature Sensor Installation Guidelines

57

15.3 Outdoor Reset Control

58

16 Inspection and Maintenance

59

16.1 Draining the Boiler

59

16.2 Cleaning the Cold Water Inlet Filter

61

16.3 Cleaning the Air Intake Filter

61

16.4 Protecting the Boiler from Freezing

62

16.5 Maintenance Schedules

62

16.5.1 Owner Maintenance

62

16.5.2 Service Technician Maintenance

62

17 Troubleshooting

64

17.1 Basic Problems

64

17.2 Error Codes

65

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1 Key to Symbols and Safety Instructions 1.1 Key to Symbols
Warnings In warnings, signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimizing danger are not taken. The following keywords are defined and can be used in this document:
DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor to moderate injury.
NOTICE NOTICE is used to address practices not related to personal injury.
Important information
The info 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. · Children, the disabled and the elderly are at highest risk of being scalded. · Test water before bathing or showering.

Temperature 120 °F (48 °C) 125 °F (51 °C) 130 °F (54 °C) 135 °F (57 °C) 140 °F (60 °C) 145 °F (62 °C) 150 °F (65 °C) 155 °F (68 °C)
Table 1

Time to Produce Serious Burn More than 5 minutes 1.5 to 2 minutes Approx. 30 seconds Approx. 10 seconds Less than 5 seconds Less than 3 seconds Approx. 1.5 seconds Approx. 1 second

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.

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Singular 4000-5200 Combi Boiler – BTC 439003302 D (02.2024)

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 flow 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 Personal injury · 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.
CAUTION Intended use · Do not use the boiler for anything other than its intended purpose, as
described in this manual.

User 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.
WARNING Carbon monoxide
· This product burns gas to produce heat. The appliance must be properly installed, operated, and maintained to avoid exposure to appreciable levels of carbon monoxide and the installer is required to confirm that at least one carbon monoxide alarm is installed in the living space before the appliance is put into operation. It is important for the carbon monoxide alarms to be installed, maintained, and replaced following the alarm manufacturer’s instructions and applicable local codes.
NOTICE Product damage!
· Do not turn on the boiler unless the water and gas supplies are fully opened. Failure to do so may damage the boiler.
This boiler has been approved for use in the USA and Canada only. Using the boiler in any other country will void the manufacturer’s warranty.

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2 Front Panel 2.1 Digital Display and Icons
The digital display and icons on the front panel provide important information required for the operation of the boiler. Refer to the table below for detailed information.

2.2 Buttons
Using the buttons on the front panel, you can turn the boiler on or off, adjust the water temperature, and change modes to monitor the operation status. Refer to the table below for detailed information.

A

B

I

C

H

G

D

F

A

D

E

B

C

Figure 1 Icon
A B C D E F G H I Table 2

Description
Digital display Displays water temperature, error codes, etc.
Space heating mode Indicates space heating set point/ system temperature.
DHW mode Indicates DHW set point.
Pressure Indicates the pressure in the boiler.
RPM Indicates fan revolutions per minute (RPM).
Freeze protection mode Indicates freeze protection mode operation.
Outdoor reset mode Indicates temperature sensor connected.
Combustion Indicates gas burner operation.
Error Indicates error.

Figure 2 Icon
A B C D Table 3

Description
Power Turns the boiler on or off.
Mode Changes the mode.
UP Increases the temperature.
Down Decreases the temperature.

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Singular 4000-5200 Combi Boiler – BTC 439003302 D (02.2024)

3 Operating the Boiler 3.1 Turning the Boiler On or Off
To turn the Boiler on or off, press the button.

User Manual
2. Press the or buttons until the desired temperature appears on the digital display.

Figure 3 When the boiler is on, the water temperature which has been set recently will appear on the digital display.
3.2 Setting the Space Heating Temperature
WARNING Scald hazard
· If your household includes children, or elderly or disabled individuals, consider using a lower temperature setting.
To set the space heating water temperature: 1. Press the MODE button until the icon turns on.

Figure 5
Temperature range 82­180°F (Fahrenheit mode)
27­82°C (Celsius mode) Table 4

Adjusting the water temperature 2°F increments 1°C increments

Figure 4

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User Manual

3.3 Setting the DHW (Domestic Hot Water) Temperature
WARNING Scald hazard · Water above 120°F (50°C) can cause instant scalding, severe burns, or
death.

To adjust the water temperature: 1. Press the Mode button until the

icon turns on.

3.4 Viewing Basic Information
To turn the boiler on, press the button.

Figure 8
To view information about the boiler, press the MODE and seconds.

buttons for 5

Figure 6
2. Press the or buttons until the desired temperature appears on the display.

Figure 7
Temperature range 86-120°F (Fahrenheit mode)
31­49°C (Celsius mode) 121-140°F 50-60°C
Table 5

Adjusting the water temperature
2°F increments 1°C increments
10°F increments 5°C increments

Figure 9 Press the MODE button to switch between the information types.

To change the temperature over 120°F, hold down plus button for 5 seconds to unlock.
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Singular 4000-5200 Combi Boiler – BTC 439003302 D (02.2024)

3.4.1 H0 mode · This is the mode for checking the previous error. · H0 and the previous error (example: A6) will be displayed repeatedly on
the screen.

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3.4.3 H2 mode · This is the mode for checking the current error. · H2 and the current error (Example : A3) will be displayed repeatedly on the screen.

Figure 10

Figure 12

3.4.2 H1 mode · This is the mode for checking the most recent error. · H1 and the most recent error (Example : A2) will be displayed repeatedly
on the screen.

3.4.4 H3 mode · This is the mode for checking the current pressure in the system. · H3 and the current pressure in the boiler (Example : 25) will be displayed repeatedly on the screen. · The pressure unit is PSI.

Figure 11

Figure 13

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User Manual
3.4.5 H4 mode · This is the mode for checking the current number of revolutions of the fan. · H4 and the current number of revolutions of the fan (Example : 3600) will
be displayed repeatedly on the screen. · The unit is rpm.

3.4.7 H6 mode · This is the mode for checking the current exhaust gas temperature. · H6 and the current exhaust gas temperature (example: 120) will be displayed repeatedly on the screen. · The unit is °F.

Figure 14

Figure 16

3.4.6 H5 mode · This is the mode for checking the output voltage of the fan. · H5 and the output voltage (Example : C5) will be displayed repeatedly on
the screen.

3.4.8 H7 mode · This is the mode for checking the current hot water temperature. · H7 and the hot water temperature (example: 100) will be displayed repeatedly on the screen. · The unit is °F.

Figure 15 10 |

Figure 17 Singular 4000-5200 Combi Boiler – BTC 439003302 D (02.2024)

3.4.9 H8 mode · This is the mode for checking the current ambient temperature. · H8 and the current ambient temperature (example: 25) will be displayed
repeatedly on the screen. · The unit is °F.

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3.4.11 HA mode · This is the mode for checking the hot water and heating modes. · HA and the heating mode or the hot water mode (example: FF or 00) will be displayed repeatedly on the screen. · FF is the current hot water mode, and 00 is the heating mode.

Figure 18
3.4.10 H9 mode · This is the mode for checking the return temperature of the boiler. · H9 and the return temperature (example: 120) will be displayed
repeatedly on the screen. · The unit is °F.

Figure 20
3.4.12 Hb mode · This is the mode for checking the current PCB version (example: 1.0). · HB and the PCB version will be displayed repeatedly on the screen.

Figure 19

Figure 21

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User Manual

4 Inspection and Maintenance
Annual service and maintenance is required for the safe and long service life of the appliance, for efficient and economical operation, and to keep the environmental impact as low as possible. Owners/operators are encouraged to sign a service and maintenance contract with a trained and certified installer for annual servicing and maintenance of the boiler.
WARNING Electric shock hazard · Always disconnect the appliance from the main power supply before
performing any work. Disconnect the emergency shutoff switch or disengage the heating system circuit breaker. Take measures to prevent accidental re- connection.

4.1 Draining the Boiler
To perform maintenance tasks or to prevent the boiler from freezing when it will not be used for an extended period, the boiler must be drained. To drain the boiler:
1. Press the button to turn off the boiler.
2. Disconnect the power supply to the boiler.
3. Turn of the gas valve.

WARNING Scald hazard · The boiler may remain hot for few minutes after it is turned off. Wait until
the boiler has cooled down before cleaning to prevent burns.
WARNING Explosion! · Close the gas supply shutoff valve prior to working on the gas train. · Check for gas leaks after carrying out work on the gas train.
WARNING Risk of flue gas poisoning · Check for leaks after carrying out work on the venting system.

Gas
Figure 22 4. Turn off the water supply valve on the inlet to the boiler.

NOTICE Product damage! · Insufficientantifreeze canaccelerate corrosion. · Frost protection level has to be checked annually during the regular
scheduled maintenance of the condensing boiler.

Figure 23

Cold DHW water supply supply

If there is no water supply valve, turn off the water supply at the water main.

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Singular 4000-5200 Combi Boiler – BTC 439003302 D (02.2024)

5. Remove the boiler front cover by loosening the 2 Phillips screws securing it to the case.

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2 2
1 1
Figure 24 6. Open the drain valve.

Figure 26 8. Close the drain valve when the water is completely drained. 9. Remove the cold water inlet filter. 10. Allow the residual water to drain from the boiler. 11. When the water is completely drained, reinsert the cold water inlet filter and close the drain valve.
Follow the steps in reverse order to refll the boiler. Be careful not to lose the drain plug.

Figure 25 7. Remove the strainer from the bottom of the boiler.

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4.2 Cleaning the Cold Water Inlet Filter
To clean the cold water inlet filter: 1. Drain the boiler. Refer to “Draining the Boiler” on page 12. 2. Remove the cold water inlet filter from the boiler.

2 2

Figure 27
3. Rinse the cold water inlet filter with clean running water. 4. Reinsert the cold water inlet filter. 5. Refill the boiler. Refer to “Draining the Boiler” on page 12.

1 1
Figure 28 4. Remove the air intake filter located under the air intake connector.

4.3 Cleaning the Air Intake Filter
To maintain the boiler properly, clean the air intake filter every 2­3 months. If the air intake filter is clogged by dust or lint, the boiler will cease to operate or error can occur. To clean the air intake filter:
1. Press the button to turn off the boiler.
2. Disconnect the power supply to the boiler.
3. Remove the boiler front cover by loosening the 2 Phillips screws securing it to the case.

Air intake filter
Figure 29 5. Rinse the air intake filter with clean running water. 6. Dry the air intake filter completely. 7. Reinsert the air intake filter and replace the front cover.

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4.4 Protecting the Boiler from Freezing
NOTICE
Product damage, property damage
· To protect the boiler from freezing, recommend the use of a direct vent exhaust and intake system. Ensure that the exhaust vent pipe and the air intake pipe are both connected directly from the collars on the top of the boiler to the outdoors. This type of vent system minimizes air movement within the boiler.
· Freezing damage usually occurs due to back-drafting caused by negative pressure in the building. This is not a manufacturing defect, and therefore, Bosch will not warrant any damage due to freezing. The installer is responsible for ensuring that there is sufficient make-up air to avoid such a situation, and the owner is responsible for ensuring protection against freezing.

4.5 Maintenance Schedules
WARNING Improper operation, product damage, personal injury
· A qualified technician must inspect the boiler at the beginning of every heating season and/or when there is a problem.

4.5.1 Owner Maintenance

Frequency

Task

· Check that the area where the boiler is installed is free of

Daily

combustible/flammable material and air-contaminants.

· Visually inspect the exterior of the boiler.

To protect the boiler from freezing, follow these guidelines: · Do not unplug the power supply cord, except for routine maintenance. The boiler has a freeze protection function that warms up the boiler. The freeze protection function will operate regardless of whether or not the front panel isturned on or off, as long as the power supply is still connected.
· If the power or gas supply must be disconnected for an extended period, drain the boiler.
· Protect and insulate all water pipes, including the condensate trap drain line, from freezing.
· If the boiler will not be used for an extended period of time, drain the boiler.

Monthly

· Inspect the condensate trap and the PVC fittings. · Visually inspect the piping (water and gas) for leaks. · Visually inspect the vent piping for signs of leakage and
blockage.

Every 6 Months

· Inspect the piping (water and gas) for leaks. · Inspect the vent piping for leakage and blockage. · Test to make sure the pressure relief valve is operating
properly.

Table 6

If you suspect that the boiler is frozen, contact an authorized technician or licensed professional.

4.5.2 Service Technician Maintenance
WARNING Personal injury or death
· Failure to inspect and properly maintain and repair the boiler can result in severe personal injury or death.

Frequency

Task

Every Year

· Inspect the interior of the boiler. · Clean the condensate trap and fill with fresh water. · Clean the air intake filter. · Check for leaks (gas, water, flue, and condensate). · Check the system pressure (gas, and water). · Check ignition and flame rod. · Check wiring connections. · Combustion analysis.

Table 7

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WARNING Shock hazard, improper operation, personal injury, product damage
· Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system.
· Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.
· The boiler must be inspected annually by a qualified service agency. In addition, the maintenance and care of the boiler must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.
· Electrical shock hazard ­ Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death..
Addressing the Reported Problems 1. Inspect any problems reported by the owner and correct before proceeding.
Inspecting the Installation Area 1. Verify that boiler area is free of any combustible materials, gasoline and
other flammable vapors and liquids. 2. Verify that air intake area is free of any of the contaminants listed in
Installation Manual. If any of these are present in the boiler intake air vicinity, they must be removed (pg. 28 of the Installation Manual, “Installing Venting”). If they cannot be removed, reinstall the air and vent lines per the Installation Manual.
Inspecting the Boiler Interior 1. Remove the front cover and inspect the interior of the boiler. 2. Vacuum any sediment from inside the boiler and components. Remove any
obstructions.
Cleaning the Condensate Trap 1. Inspect the condensate drain line, condensate fittings, and condensate
trap. 2. Remove any sediment in the trap. 3. Fill
Checking the Flue Vent System and Air Piping 1. Visually inspect the entire flue gas venting system and air piping for
blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed (if installed). 2. Verify that boiler vent discharge and air intake are clean and free of obstructions.

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5 Troubleshooting 5.1 Basic Problems
If there is a problem with the boiler, refer to the following table for possible remedies. For minor problems, turning the boiler off and then turning back on may resolve the situation. If turning the boiler off and on and attempting the remedies

suggested below do not resolve the problem, contact an authorized technician, licensed professional, or technical support at 1-866-642-3198.

Category

Problem Boiler does not ignite.

Possible Cause(s) · Are the gas and water pipes connected properly?

What to Do 1. Check for correct plumbing or crossed piping to the unit.

Initial operation

Unit attempts to ignite but fails

· Is there air in the gas line? · Is the gas supply pressure sufficient?

1. Turn off the boiler and then turn it back on. 2. Have your installing contractor check the gas supply pressure. 3. Ensure the boiler is powered by 120 V-1 PH-60 Hz.

Space heating side malfunction

· Is the setting temperature too low?

1. Check the boiler’s temperature setting. See “Operating the Boiler” on page 7.

· Is there power to the system, or is the system in stand by?

1. Make sure the power is on, and plugged into the outlet with the correct voltage. Press the Power button and raise the setting temperature. Make sure the boiler is turned on.

Hot water is not produced when a faucet is opened.

· Are the gas and water supply valves fully open? · Is the water supply cut off to the household? · Is gas being provided by the gas meter? · Is there enough gas (for LP) in the tank? · Is the water inlet filter clogged? · Is the power button turned on?

1. Fully open the gas and water supply valves. 2. Check the water inlet filter for debris. 3. Check the power status of the boiler.

No water is available when a faucet is opened.

· Is the water supply cut off? · Is the boiler frozen? · Are the pipes frozen?

Temperature

The hot water is not at the correct temperature.
Water takes a long time to become hot after opening
the hot water faucet.

· Is the hot water faucet sufficiently open?
· Have you allowed enough time for the cold water in the pipes to drain out?

1. Open the cold water supply. 2. Check if the boiler and/or the pipes are frozen.
1. Fully open the hot water faucet.
1. Even though the unit may be operating properly, the cold water contained in the piping will need to flow through the faucet before the hot water can reach the faucet. Wait for several minutes.

The water is too hot.

· Are the gas and cold water supply valves fully open? · Is the water temperature setting appropriate?

1. If the cold water supply temperature is too high, it is possible for the temperature to be higher than the temperature set on the front panel. Decrease the water temperature on the front panel.
2. If only a small amount of hot water is required, it is possible for the temperature to be higher than the temperature set on the front panel. Decrease the water temperature on the front panel.
3. If the cold water supply passes through a solar preheating system, it passes for the delivered water temperature to be higher than the temperature set on the front panel.

Table 8

The water is not hot enough.
Fluctuation in hot water temperature.

· Are the gas and cold water supply valves fully open? · Is the water temperature setting correct?”
· Is the water inlet filter clogged?

Singular 4000-5200 Combi Boiler – BTC 439003302 D (02.2024)

1. Fully open the gas and cold water supply valves. 2. Check the water temperature setting. 1. Clean the water inlet filter for debris.
| 17

User Manual

5.2 Error Codes
If an error code appears on the digital display, refer to the following chart for the reason, and a possible remedy for the situation. If the situation requires more support please contact Bosch at 866-642-3198.

Error Code

Cause

A2

· Abnormal operation: FAN

A3

· Abnormal operation: Pump

A4

· Overheating of heat exchanger

A5

· Low water pressure

A6

· Ignition error

A7

· Abnormal operation: gas valve relay “open”

A8

· Abnormal operation: flame detection

AA

· Overheating

AB

· Abnormal operation: heat exchanger temperature sensor

AC

· Abnormal operation: DHW temperature sensor

AD

· Clog of condensate trap

AE

· Blockage of flue Pipe

E0

· Abnormal operation: Outdoor temperature sensor

E1
E2 E3 E4 E7 EB EE EF Table 9

· Abnormal operation: Exhaust temperature sensor
· Abnormal operation: Exhaust temperature overheating · Abnormal operation: Return water temperature sensor · Abnormal operation: Pressure sensor · Abnormal operation: gas valve relay “Close” · Overheating of DHW temperature sensor · Abnormal operation:Data Communication · Abnormal operation: eep-rom error

Self-diagnosis/Action 1. Clean the intake air filter. 2. Check the fan connector. 3. Contact original installer or licensed professional. 1. Contact original installer or licensed professional.
1. Turn off the system for at least 30 minutes, and then restart it. 2. Contact original installer or licensed professional.
1. Water supplementation of manual 2. Contact original installer or licensed professional.
1. Ensure that the main gas supply valve is open. 2. Contact original installer or licensed professional.
1. Turn off the main gas valve. 2. Contact original installer or licensed professional.
1. Turn off the main gas valve. 2. Contact original installer or licensed professional.
1. Contact original installer or licensed professional. 1. Contact original installer or licensed professional. 1. Contact original installer or licensed professional. 1. Contact original installer or licensed professional.
1. Clean the vent terminal. 2. Contact original installer or licensed professional.
1. Check the outdoor temperature sensor wiring connection. 2. Contact original installer or licensed professional.
1. Check the exhaust temperature sensor wiring connection. 2. Contact original installer or licensed professional.
1. Contact original installer or licensed professional. 1. Contact original installer or licensed professional. 1. Contact original installer or licensed professional. 1. Contact original installer or licensed professional. 1. Contact original installer or licensed professional. 1. Contact original installer or licensed professional. 1. Contact original installer or licensed professional.

18 |

Singular 4000-5200 Combi Boiler – BTC 439003302 D (02.2024)

Online Help Resources Alternatively, please visit our Service & Support webpage to find FAQs, videos, service bulletins, and more; www.boschheatingcooling.com/service or use your cellphone to scan the code below.
Figure 30

User Manual

Singular 4000-5200 Combi Boiler – BTC 439003302 D (02.2024)

| 19

United States and Canada Bosch Thermotechnology Corp. 65 Grove St. Watertown, MA 02472
Tel: 866-642-3198 Fax: 954-776-5529 www.bosch-homecomfort.us
BTC 439003302 D / 02.2024
Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances.

References

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