Table of Contents
Installation Instructions
Gas Condensing Combi Boilers
Singular
Singular 4000 | Singular 5200
WARNING:
If the information in these instructions are not followed exactly, a fi re or explo-
sion may result causing property damage, personal injury or death.
WARNING:
Do not store or use gasoline or other fl ammable 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 qualifi ed 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
identifi ed 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.
Table of Contents
Related Manuals for Bosch Singular 4000
Summary of Contents for Bosch Singular 4000
- Page 1 Installation Instructions Gas Condensing Combi Boilers Singular Singular 4000 | Singular 5200 WARNING: If the information in these instructions are not followed exactly, a fi re or explo- sion may result causing property damage, personal injury or death. WARNING: Do not store or use gasoline or other fl ammable vapors and liquids in the vicinity of this or any other appliance.
- Page 2 Installation Instructions Singular Combi Boiler - BTC 439003301 B (2021/07)
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Page 3: Table Of Contents
Installation Instructions Table of Contents 1 Key to Symbols and Safety Instructions 6.5.2 Two-Pipe Sidewall Venting 6.5.3 Snorkel Flue 1.1 Key to Symbols 6.5.4 Non-Concentric Sidewall Venting 1.2 Safety 6.5.5 Concentric Sidewall Venting 2 General Information 6.5.6 Two-Pipe Vertical Venting 6.5.7 Concentric Roof Venting 2.1 Included Items 7 Setting the DIP Switches... -
Page 4: Key To Symbols And Safety Instructions
Installation Instructions 1 Key to Symbols and Safety Instructions 1.2 Safety Please read before proceeding 1.1 Key to Symbols Warnings WARNING: FIRE, EXPLOSION Vapors from flammable liquids can explode and/or catch fire Warnings in this document are identifi ed by a causing death or severe burns. - Page 5 Installation Instructions WARNING: FIRE, EXPLOSION WARNING: IMPROPER OR DANGEROUS OPERATION Do not store combustibles, such as papers or laundry, near Immediately call a qualified service technician to inspect the the boiler or venting system. appliance and replace any part of the control system and/or any gas control which has been immersed in water.
- Page 6 Installation Instructions 1.3 Important Note for the State of Massachusetts NOTICE BEFORE INSTALLATION This appliance must be installed by a licensed plumber or gas fi tter in accordance with the Massachusetts Plumbing and Fuel Gas Code 248 CMR Sections 4.00 and 5.00.
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Page 7: General Information
Installation Instructions 2 General Information 2.2 Optional Accessories The following optional accessory is not included with the boiler, but may be 2.1 Included Items necessary for the installation. Check the need for the following optional accessory The following items are included with the boiler. Check each of the following items before installation. -
Page 8: Specifi Cations
Installation Instructions 2.3 Specifi cations The following table shows the specifi cations for the boiler. Additional specifi cations about water, gas, electric, and air supplies (venting) appear in each installation section. Singular 4000 Singular 5200 Space Heating 19,900–80,000 BTU/H 19,900–140,000 BTU/H... -
Page 9: Rating Plate
Bosch Combination Boiler and Space Heater / Combiné Chaudière et Chauffe-Espace Bosch Thermotechnology Corporation 50 W entworth Ave, Londonderry , NH 03053 - 866-642-3198 For either direct vent installation or for installation using indoor combustion air... -
Page 10: Dimensions
Installation Instructions 2.4 Dimensions 5.26" 5.57" 1.8" (141.5 mm) (133.5 mm) (45.7 mm) 4.0" 6.1" 3.6" 2.7" 1.6" (40.6 mm) 18.11" (460 mm) (101.6 mm) (154.9 mm) (91.4 mm) (68.6 mm) Figure 4 Position Description Diameter Space heating Return 1" NPT Cold water inlet 3/4"... -
Page 11: Components
Installation Instructions 2.5 Components Flue connector Air intake connector Exhaust temperature sensor Burner hood Gas connector Heat Exchanger Cover Gas valve Pressure sensor Air vent Pump 3-way valve Condensate drain Space heating supply Gas inlet Space heating return Cold water inlet Hot water outlet Figure 5 | 11... - Page 12 Installation Instructions Turbo fan assembly Ignition transformer Primary heat TDR damper exchanger Secondary heat exchanger Water Pressure Sensor Air Pressure Sensor PCB assembly Flow sensor Front panel Figure 6 1 2 | Singular Combi Boiler - BTC 439003301 B (2021/07)
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Page 13: Boiler Installation
Installation Instructions 3 Boiler Installation 3.3.1 Access to Utilities Electricity – Close to where the electrical supply enters the building 3.1 Installer Qualifi cations Water – Close to where the domestic water supply enters the building A licensed professional must install and inspect the appliance. A licensed professional is a person who is licensed for the following: ... -
Page 14: Clearances
Installation Instructions 3.3.5 Clearances 3.3.6 Clean, Debris and Chemical-Free Combustion Air The boiler should be installed in an area that allows for service and maintenance Do not install the boiler in areas where dust and debris may accumulate or access to utility connections, piping, fi... -
Page 15: Mounting To The Wall
Installation Instructions 3.4 Mounting to the Wall CAUTION: BODILY INJURY, PRODUCT DAMAGE To mount the boiler to the wall: The boiler is heavy. Always lift the unit with assistance. Be 1. Check that the wall is level and can support the weight of the boiler. careful not to drop the boiler while lifting or handling it to 2. -
Page 16: System Piping
Before using freeze protection products, it is necessary to check if the amount of glycol use in the space heating water is appropriate and if the inhibitor level in such glycol is appropriate. Bosch recommends against exceeding a 35% concentration of glycol. Space heating Space heating ... -
Page 17: Space Heating Piping
If an additional water fi ll connection is necessary for special use, install NOTICE: PRODUCT DAMAGE the water fi ll connection at the same location as the expansion tank’s Bosch suggests the installation of a dirt/magnetic separator connection to the system. (boiler filter) on the system return line to help eliminate ... -
Page 18: Essential Elements In A Dhw System
Installation Instructions 4.2.3 DHW System Piping Bosch is not responsible for the blockage of the domestic system due to the accumulation of foreign matters or scaling. The installer or the user should take appropriate measures in order to avoid any CAUTION: PERSONAL INJURY, PROPERTY DAMAGE problem related to the quality of water. -
Page 19: Connecting The Condensate Drain
Installation Instructions 4.3 Connecting the Condensate Drain NOTICE: BOILER DAMAGE, PROPERTY DAMAGE All condensate must drain and be disposed of according to local codes. Do not cap or plug the integrated condensate line. If prevented from draining, condensate can damage the boiler. ... -
Page 20: Filling The Condensate Trap
Installation Instructions 4.4 System Filling 2. Place the free end of the drain line into an appropriate drain. 4.4.1 Built-In Water Filling NOTICE: The boiler is designed to fi ll the system with water. Therefore, additional water fi ll connection is not necessary in most cases. Filling the system with water should be ... -
Page 21: Test The Water System
Installation Instructions 4.5 Test the Water System 4.5.1 External Water Fill Connection Read and follow the guidelines below for system piping of the boiler. WARNING: PERSONAL INJURY, PROPERTY DAMAGE System application drawings are intended to explain the system piping concept only ... -
Page 22: Examples Of System Applications
Installation Instructions 4.6 Examples of System Applications Refer to the following examples to properly implement a system for space heating, DHW supply, or both. These examples are provided to suggest basic guidelines when you install the boiler system. However, the actual installation may vary depending on the circumstances, local building codes, or state regulations. -
Page 23: System Application - Single Zone System
Installation Instructions 4.6.2 System Application – Single Zone System Zone 1 System pump (optional) Purge Valve Air Separator Expansion tank Figure 19 | 23 Singular Combi Boiler - BTC 439003301 B (2021/07) -
Page 24: System Application - Zone System With Circulators
Installation Instructions 4.6.3 System Application – Zone System with Circulators Zone 1 Zone 2 Zone 3 Check Valve System pump Purge Valve Air Separator Expansion tank Not to exceed 4 pipe Dia or Max. 12 in Figure 20 2 4 | Singular Combi Boiler - BTC 439003301 B (2021/07) -
Page 25: Connecting The Gas Supply
Installation Instructions 5 Connecting the Gas Supply 5.1 Gas Pipe Sizing Tables Gas pipe sizing is based on the gas type, supplied gas pressure, pressure drop in the system, and gas line type. The tables below are for reference only (when the gas supply is piping straight to the boiler with no connections to any other gas appliances). -
Page 26: Gas Piping
8. Check for gas leaks at all joints. operating the boiler. Do not attempt a field conversion without a conversion kit. Use the Bosch conversion kit to convert from natural NOTICE: PRODUCT DAMAGE gas to propane or vice versa. Failure to do so may result in ... -
Page 27: Inlet Gas Pressure
Installation Instructions 5.3 Inlet Gas Pressure Gas Piping Examples: The following is a LP gas piping example for the single regulator system WARNING: Inlet gas pressure should be measured by a licensed professional only. The boiler cannot function properly without sufficient inlet gas pressure. - Page 28 Installation Instructions 8. When the boiler reaches its maximum fi ring rate, check the inlet gas pressure reading on the manometer. The gas pressure must fall within the ranges specifi ed in "Specifi cations" on page 8. Figure 27 9. Tighten the inlet gas pressure screw. 10.
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Page 29: Installing A Vent
Bosch recommends direct air vent installations whenever possible to avoid back Improper venting of the boiler can result in excessive levels drafting cold air through the boiler. Bosch recommends direct air vent installations of carbon monoxide, which can lead to severe personal when installing the boiler in your attic to get fresh air into the boiler. - Page 30 Installation Instructions IN S ID E D E T A IL C O R N E R F IX E D C L O S E D O P E R A B F IX E D C L O S E D O P E R A B VENT TERMINAL AIR SUPPLY INLET...
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Page 31: Non- Direct Venting
Singular 155,000 10"(W) x 4" (H) or 12 1/4" (W) x not be covered by the Bosch warranty. If there is any question about the possibility 4000 7" round" 12 1/4" (H) of back-drafting in the installation location, use a direct venting system for the boiler. - Page 32 Installation Instructions IN S ID E D E T A IL C O R N E R F IX E D C L O S E D O P E R A B F IX E D C L O S E D O P E R A B VENT TERMINAL AIR SUPPLY INLET...
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Page 33: Vent Pipe Materials
Installation Instructions 6.2 Vent Pipe Materials NOTICE: PCB DIP switch #1 is set to OFF as factory default WARNING: When you set PCB DIP switch #1 to ON, ensure that CPVC Venting requirements differ in the US and Canada. Consult piping shall be used for exhaust venting. -
Page 34: Vent Length
Installation Instructions 6.3 Vent Length 6.4 Connecting the Vent Clip The maximum vent length when using 2" exhaust ducts is 60’. The maximum vent length when using 3" vent ducts is 150’. The intake duct length can be of equal CAUTION: length to the exhaust duct length. -
Page 35: Vent Termination
Installation Instructions 6.5 Vent Termination 6.5.2 Two-Pipe Sidewall Venting Internal view WARNING: Air intake must be protected from any debris. Exhaust gas When connecting to the air intake connector and exhaust Intake air flue connector, all connecting parts must be installed properly. -
Page 36: Snorkel Flue
Installation Instructions 6.5.3 Snorkel Flue 6.5.4 Non-Concentric Sidewall Venting 10" (254 mm) min. Schedule 40 PVC pipe 10" (254 mm) min. 12" (300 mm) min. Figure 40 Figure 41 WARNING: NOTICE: Install a bird screen at the end of the intake air pipe and ... -
Page 37: Two-Pipe Vertical Venting
Installation Instructions 6.5.6 Two-Pipe Vertical Venting 6.5.7 Concentric Roof Venting 36" (900 mm) min. Vent Exhaust gas Combustion air Maintain 12" (300 mm) min. Intake air 12" (300 mm) min. From any obstruction (above, below, left, or right) Combustion air Vent Figure 44 Figure 43... -
Page 38: Setting The Dip Switches
Installation Instructions 7 Setting the DIP Switches The boiler has a DIP switch on the main circuit board (PCB) Set the DIP switch appropriately, depending on the installation environment. Switch Function ON: No temperature limit for exhaust gas Temperature limit switch for exhaust gas OFF: Temperature limit for exhaust gas ON: Enable EEP ROM data change EEP ROM data change switch... -
Page 39: Connecting The Power Supply
Installation Instructions 8 Connecting the Power Supply WARNING: Improperly connecting the power supply can result in electrical shock and electrocution. Follow all applicable electrical codes of the local authority having jurisdiction. In the absence of such requirements, follow the latest edition of the National Electrical Code (NFPA 70) in the USA or the latest edition of CSA C22.1 Canadian Electrical Code Part 1 in Canada. -
Page 40: Installation Checklist
Installation Instructions 9 Installation Checklist After the boiler installation, examine the following checklist. If you are not able to answer "Yes" to all of the items in the checklist, review the appropriate sections. To troubleshoot any operational problems, refer to "Troubleshooting" in the User's Manual. - Page 41 Installation Instructions Connecting a Pressure Relief Valve Check Have you installed an approved pressure relief valve on the boiler? Does the rating of the pressure relief valve match or exceed the maximum BTU rating of the boiler? Is the pressure relief valve 3/4 in on the hot water outlet and 3/4 in at the pressure relief valve adapter? ...
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Page 42: Operating The Boiler
Installation Instructions 10 Operating the Boiler 10.3 Setting the Space Heating Temperature 10.1 Turning the Boiler On or Off WARNING: To turn the Boiler on or off , press the button. If your household includes children, or elderly or disabled individuals, consider using a lower temperature setting. -
Page 43: Setting The Dhw (Domestic Hot Water) Temperature
Installation Instructions 10.4 Setting the DHW (Domestic Hot Water) Temperature 10.5 Viewing Basic Information To turn the boiler on, press the button. WARNING: Water above 120°F (50°C) can cause instant scalding, severe burns, or death. To adjust the water temperature: 1. -
Page 44: H0 Mode
Installation Instructions 10.5.1 H0 mode 10.5.3 H2 mode This is the mode for checking the previous error. This is the mode for checking the current error. H0 and the previous error (example: A6) will be displayed repeatedly on ... -
Page 45: H4 Mode
Installation Instructions 10.5.5 H4 mode 10.5.7 H6 mode This is the mode for checking the current number of revolutions of the fan. This is the mode for checking the current exhaust gas temperature. H4 and the current number of revolutions of the fan (Example : 3600) will ... -
Page 46: H8 Mode
Installation Instructions 10.5.9 H8 mode 10.5.11 HA mode This is the mode for checking the current ambient temperature. This is the mode for checking the hot water and heating modes. H8 and the current ambient temperature (example: 25) will be displayed ... -
Page 47: Cd Mode
Installation Instructions 10.6 Setting the Heat Load for The Outdoor Reset Control Mode 10.5.13 Cd mode 1. Move No. 2 PCB DIP switch in the ON direction. This is the mode for setting the cascade function of the heat only boiler and is not available for the combi boiler product line. - Page 48 Installation Instructions When you set ON for C7 and press the MODE button, C8 and “1” will be By pressing the MODE button, the user can enter modes such as C9, CA, Cb, and displayed repeatedly. CC, and can set the temperature. The content of each mode is as follows: ...
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Page 49: Altitude Adjustment
Installation Instructions 10.7 Altitude Adjustment 4. Press and hold the buttonsfor 5 seconds. These instructions shall address derating at altitudes above 2,000 ft. Boiler input ratings are based on sea level operation. No adjustments needed on installations up to 2,000ft. Adjust the program data based on altitude. See Table 24 below. Program Data Altitude Setting 0 ~ 1,999 ft... -
Page 50: Gas Conversion
WARNING: This conversion kit shall be installed by a qualified service agency* in accordance with Bosch's instructions and all Cold water Hot water applicable codes and requirements of the authority having jurisdiction. - Page 51 Installation Instructions 3. Once the front cover is removed, place it in a safe location to prevent accidental damage. With the internal components exposed, locate the gas Packing connector and the gas valve. Orifice Gas connector Gas connector Gas valve Figure 78 Figure 80 4.
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Page 52: Combustion Analysis
Installation Instructions 9. Replace the gas connector and the gas inlet pipe to its original position and 3. Insert analyzer into the exhaust analyzer hole and measure the gas/air ratio secure all connections. (using combustion analyzer is recommended) 10. Turn on the gas and water supply to the boiler. High fi... - Page 53 Installation Instructions WARNING: Be sure to turn off the power before changing the DIP switch setting. This boiler was converted on / to with Kit No. 5. Set the DIP switch to maximum heat capacity operation. (name and address of organization ...
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Page 54: Wiring Diagram
Installation Instructions 12 Wiring Diagram 120VAC,5A White White White White Green Green Blue Blue SRW Red SRW Red Black Blue Blue Gray Gray Black Figure 86 5 4 | Singular Combi Boiler - BTC 439003301 B (2021/07) -
Page 55: Ladder Diagram
Installation Instructions 13 Ladder Diagram Figure 87 | 55 Singular Combi Boiler - BTC 439003301 B (2021/07) -
Page 56: Normal Operating Sequence
Installation Instructions 14 Normal Operating Sequence Power ON E: Error check System Initalization "EF" Error check "A3" Error check E: Error check "EE" Error check "A5" Error check Remote "A4" Error check "E8" Error check Control ON? "AB" Error check "A7"... - Page 57 Installation Instructions Heating operation DHW operation T1 < T2 T3 < T4 T1: Heating Temperature T3: DHW Temperature T2: Setting the heating T4: Setting the DHW Temperature Temperature Pre-purge Pre-purge PUMP ON PUMP ON FAN ON FAN ON Fan Motor Fan Motor "A2"...
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Page 58: Outdoor Temperature Sensor
Installation Instructions 15 Outdoor Temperature Sensor 15.2 Outdoor Temperature Sensor Installation Guidelines 15.1 Outdoor Temperature Sensor Installation (Optional) Avoid installing the temperature sensor in a location where the temperature may change due to direct sunlight or a location where the representative outdoor temperature is not indicated. -
Page 59: Outdoor Reset Control
Installation Instructions 15.3 Outdoor Reset Control (Available with Optional Outdoor Temperature Sensor) The outdoor reset control can be used in order to improve the energy effi ciency. With the Outdoor Reset Control, the space heating temperature setting automatically changes according to the outdoor temperature and the current space heating system application (system load). -
Page 60: Inspection And Maintenance
Installation Instructions 16 Inspection and Maintenance 16.1 Draining the Boiler To perform maintenance tasks or to prevent the boiler from freezing when it will not Annual service and maintenance is required for the safe and long service life of the be used for an extended period, the boiler must be drained. - Page 61 Installation Instructions 7. Remove the strainer from the bottom of the boiler. I f there is no water supply valve, turn off the water supply at the water main. 5. Remove the boiler front cover by loosening the 2 Phillips screws securing it to the case.
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Page 62: Cleaning The Cold Water Inlet Filter
Installation Instructions 16.2 Cleaning the Cold Water Inlet Filter To clean the cold water inlet fi lter: 1. Drain the boiler. Refer to Section 16.1 " Draining the Boiler " . 2. Remove the cold water inlet fi lter from the boiler. Figure 98 Figure 99 3. -
Page 63: Protecting The Boiler From Freezing
This is not a Frequency Task manufacturing defect, and therefore, Bosch will not warrant any damage due to freezing. The installer is responsible Check that the area where the boiler is installed is free of for ensuring that there is sufficient make-up air to avoid combustible/flammable material and air-contaminants. - Page 64 Installation Instructions WARNING: 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.
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Page 65: Troubleshooting
Installation Instructions 17 Troubleshooting 17.1 Basic Problems suggested below do not resolve the problem, contact an authorized technician, If there is a problem with the boiler, refer to the following table for possible licensed professional, or technical support at 1-866-642-3198. remedies. -
Page 66: Error Codes
17.2 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... - Page 67 Installation Instructions NOTES: | 67 Singular Combi Boiler - BTC 439003301 B (2021/07)
- Page 68 United States and Canada Bosch Thermotechnology Corp. 65 Grove St. Watertown, MA 02472 Tel: 866-642-3198 Fax: 603-965-7581 www.bosch-thermotechnology.us BTC 439003301 B / 07.2021 Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances.